Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

Table of Contents

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Table of Contents

Summary of Contents for jcb JS300

Page 1 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 2 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 3 Section 1 - General Information Notes: 9813/5100-1...
Page 4 Section 1 - General Information Contents Page No. Introduction Identifying Your Machine ................1-1 Safety Introduction ....................1-3 Introduction ....................1-5 Scope ......................1-6 Format ....................... 1-7 Left Side, Right Side .................. 1-8 Hydraulic Schematic Codes ..............1-9 Routine Maintenance Maintenance Schedules ................
Page 5 Section 1 - General Information Contents Page No. 1-ii 1-ii...
Page 6 Section 1 - General Information Introduction Identifying Your Machine For information about identifying your machine and its main components, refer to Section 2, About the Machine, Machine and Component Identification. 9813/5100-1...
Page 7 Section 1 - General Information Introduction Identifying Your Machine Page left intentionally blank 9813/5100-1...
Page 8 Section 1 - General Information Safety Introduction In this manual and on the machine there are safety notices. The safety notices have different signal words as follows: – DANGER – WARNING – CAUTION – Notice For an explanation of the safety notice signal words, refer to Section 2, Introduction, Safety.
Page 9 Section 1 - General Information Safety Introduction Page left intentionally blank 9813/5100-1...
Page 10 Section 1 - General Information Introduction This topic contains information about the structure of the manual and how to use the manual. K Scope ( T 1-6) K Personnel ( T 1-6) K Applications ( T 1-6) K Newest Data ( T 1-6) K Format ( T 1-7) K Left Side, Right Side ( T 1-8) K Hydraulic Schematic Codes ( T 1-9)
Page 11 Section 1 - General Information Scope Scope Personnel This manual 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...
Page 12 Section 1 - General Information Format Format The manual is compiled in sections, the first two are numbered and contain information as follows: General Information - The section includes general information such as torque settings and service tools. Operator Manual - The section contains a copy of the applicable machine Operator Manual.
Page 13 Section 1 - General Information Left Side, Right Side Left Side, Right Side In this manual, 'left' A and 'right' B mean your left and right when you are seated correctly in the machine. C017280 Fig 1. 9813/5100-1...
Page 14 The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications. Full Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and LSRV operating pressure.
Page 15 Section 1 - General Information Hydraulic Schematic Codes Page left intentionally blank 1-10 9813/5100-1 1-10...
Page 16 Section 1 - General Information Routine Maintenance Maintenance Schedules This publication contains procedures for carrying out the routine maintenance tasks listed on the maintenance schedules. Refer to Section 2, Maintenance Schedules. Operator tasks are given in Section 2, Maintenance. Additional service engineer tasks are given in the related sections of this publication.
Page 17 Section 1 - General Information Routine Maintenance Maintenance Schedules Page left intentionally blank 1-12 9813/5100-1 1-12...
Page 18 Section 1 - General Information General Procedures Introduction When work is done on the machine it is important that the correct care is taken. This will help to prevent personal injury and reduce the risk of component failure. As part of the procedures in this manual you will need to do some general procedures. Two examples of these general procedures are;...
Page 19 Section 1 - General Information General Procedures Parking the Machine and Making it Safe Parking the Machine and Making it Safe For the correct procedures to park and make the machine safe, refer to Section 2, Maintenance, Maintenance Positions. 1-14 9813-5100-1 1-14...
Page 20 Section 1 - General Information General Procedures Venting the Hydraulic Pressure Venting the Hydraulic Pressure 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 21 Section 1 - General Information General Procedures Connecting/Disconnecting Hydraulic Hoses Connecting/Disconnecting Hydraulic Hoses 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 22 Section 1 - General Information General Procedures Battery Disconnection/Connection Battery Disconnection/Connection For the correct procedures to disconnect/connect the battery, refer to Section 2, Maintenance, Electrical System, Battery. 1-17 9813-5100-1 1-17...
Page 23 Make sure that the correct new components are installed. Do not substitute components from another machine. Components may look the same but may not be interchangeable. Refer to the JCB parts systems. Torques and Fixings When replacing components always tighten the applicable fixings to the correct torque.
Page 24 Section 1 - General Information General Procedures Battery Charging System Precautions Battery Charging System Precautions Obey the procedures below to prevent damage to the alternator and battery. – Ensure that the battery negative terminal is connected to the earthing cable. –...
Page 25 Section 1 - General Information General Procedures Gas Hydraulic Bladder Accumulators Gas Hydraulic Bladder Accumulators Some hydraulic circuits and valve blocks are fitted with gas WARNING hydraulic bladder type accumulators. Use only nitrogen gas to charge accumulators. The Before removing accumulators make sure hydraulic use of any other gas can cause the accumulators to K Venting pressure...
Page 26 Section 1 - General Information General Procedures Gas Hydraulic Bladder Accumulators Connect the accumulator adaptor 1 (from kit 892/ 00239) to the accumulator. Connect the charging unit 6 to the accumulator adaptor. Connect the charging hose to the pressure regulator 3 using the correct adaptor.
Page 27 Section 1 - General Information General Procedures Gas Hydraulic Bladder Accumulators Page left intentionally blank 1-22 9813-5100-1 1-22...
Page 28 Section 1 - General Information Service Consumables Introduction Consumables such as sealing and retaining compounds are necessary to complete some procedures. Before you start work make sure that the consumables show in the tables are available. K Sealing and Retaining Compounds ( T 1-24) 1-23 1-06-00 Issue 01 1-23...
Page 29 A medium strength sealant suitable for all sizes of 4102/1212 50 ml gasket flanges, and for hydraulic fittings of 25-65 mm diameter. JCB High Strength Threadlocker A high strength locking fluid for use with threaded 4102/0551 50 ml components. Gasketing for all sizes of flange where the strength of the joint is important.
Page 30 Section 1 - General Information Torque Settings Introduction This topic contains information about torques. Torque values are given for types and sizes of bolts and hydraulic connectors and adaptors. Where a torque is given as a single figure it may be varied by plus or minus 3%. Torque figures are given for fasteners with different surface treatments.
Page 31 For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt. Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
Page 32 Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 kgf m lbf ft kgf m lbf ft 7/16 11.2 10.0 5/16 22.3...
Page 33 Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. Metric Grade 10.9 Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 ISO Metric Thread kgf m lbf ft kgf m lbf ft 13.9 10.2 12.5 34.0 25.0...
Page 34 Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. Torque Settings - Rivet Nut Bolts/Screws Bolt Size ISO Metric Thread kgf m lbf ft 10.0 24.0 18.0 48.0 35.5 82.0 60.5 Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc) Bolt Size ISO Metric Thread...
Page 35 Section 1 - General Information Torque Settings Hydraulic Connections Hydraulic Connections T11-003 'O' Ring Face Seal System Adaptors Screwed into Valve Blocks Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45° seat machined into the face of the tapped port.
Page 36 Section 1 - General Information Torque Settings Hydraulic Connections Hoses Screwed into Adaptors Fig 2. Hoses 2-B screwed into adaptors 2-A seal onto an `O' ring Note: Dimension 2-D will vary depending upon the torque 2-C which is compressed into a 45° seat machined into the applied.
Page 37 Section 1 - General Information Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 11. BSP Adaptors with Bonded Washers - Torque Settings BSP Size kgf m lbf ft 20.0 15.0 34.0 25.0 75.0 55.0 102.0 10.3 75.0 122.0 12.4...
Page 38 Section 1 - General Information Torque Settings Hydraulic Connections 'Torque Stop' Hose System Fig 3. `Torque Stop' Hoses 3-B screwed into adaptors 3-A seal Stop' Hoses have an additional shoulder 3-D, which acts onto an 'O' ring 3-C which is compressed into a 45° seat as a physical stop.
Page 39 Note: The dimensions and shore hardness of the `O' ring is critical. Should it become necessary to replace the `O' ring, ensure that only JCB Genuine Parts are used. Screw the adaptor into the port of the hydraulic component as far as possible, so that ALL the threads engage and the `O' ring is correctly seated against the sealing face.
Page 40 Tool Detail Reference, Section 1. These tools are available from JCB Service. Note: Tools other than those listed will be required. It is Some tools are available as kits or sets, the part numbers expected that such general tools will be available in any for parts within such kits or sets are not listed here.
Page 41 Section 1 - General Information Service Tools Numerical List Part Description See Section Number Female Blanking Caps K Male Cone Blanking Caps ( T 1-44) Male Cone Blanking Caps. K Female Connectors ( T 1-44) Female Connectors. K Bonded Washers ( T 1-44) Bonded Washers.
Page 42 Section 1 - General Information Service Tools Numerical List Part Description See Section Number K Bush Removal Jig ( T 1-57) Bush Removal Jig. K Bush Fitting Jig ( T 1-57) Bush Fitting Jig. K Wiper Ring Fitting Jig ( T 1-57) Wiper Ring Fitting Jig.
Page 43 Section 1 - General Information Service Tools Tool Detail Reference Tool Detail Reference Section B - Body and Framework Note: Not all service tools are illustrated. Fig 6. 993/68100 Slide Hammer Kit 993/68101 Slide Hammer 993/68107 Bar - M20 x M20 X 800 mm 993/68102 End Stops 993/68108...
Page 44 Section 1 - General Information Service Tools Tool Detail Reference Fig 12. 892/00847 Nylon Spatula General tool used for smoothing sealants - also used to re-install glass in rubber glazing because metal tools will Fig 9. 892/00843 Folding Stand chip the glass edge. Essential for preparing new glass prior to installation.
Page 45 Consumable heavy duty cut-out wire used with the glass supplied. extraction tool. Approx 25 m length. Note: 110V models available upon request - contact JCB Technical Service. Fig 15. 926/15500 Rubber Spacer Blocks Used to provide the correct set clearance between glass edge and cab frame.
Page 46 Section 1 - General Information Service Tools Tool Detail Reference Fig 20. 4104/1310 Hand Cleaner Special blend for the removal of polyurethane adhesives (454g; 1 lb tub). 1-41 9813/5100-1 1-41...
Page 47 Section 1 - General Information Service Tools Tool Detail Reference Section C - Electrics Note: Not all service tools are illustrated. Fig 21. 892/00298 Fluke Meter Fig 24. 892/01174 Interconnecting cable, DLA to machine ECU diagnostics socket. Interconnecting cable, DLA to machine ECU diagnostics socket.
Page 48 Section 1 - General Information Service Tools Tool Detail Reference Section E - Hydraulics Note: Not all service tools are illustrated. Male Adapters - BSP x BSP 1606/2052 3/8 in. x 1/4 in. 1604/0003A 3/8 in. x 3/8 in. 892/00071 3/8 in.
Page 49 Section 1 - General Information Service Tools Tool Detail Reference 892/00047 3/8 in. BSP (A) x 1/4 in. BSP (B) 892/00048 1/2 in. BSP (A) x 1/4 in. BSP (B) 892/00049 5/8 in. BSP (A) x 1/4 in. BSP (B) 816/50043 3/4 in.
Page 50 Section 1 - General Information Service Tools Tool Detail Reference 892/01016 For 25 mm Rod Diameter 892/01017 For 30 mm Rod Diameter 892/01018 For 40 mm Rod Diameter 892/01019 For 50 mm Rod Diameter 892/01020 For 50 mm Rod Diameter (slew ram) 892/01021 For 60 mm Rod Diameter 892/01022...
Page 51 Section 1 - General Information Service Tools Tool Detail Reference Note: No longer available, refer to 998/11046 JCB 892/00268 Flow Monitoring Unit K Fig 38. ( T ServiceMaster Flow Test Kit. 1-46). 892/00269 Sensor Head 0 - 100 l/min (0 - 22 UK gal/min) 892/00273 Sensor Head 0 - 380 l/min (0 - 85.5 UK gal/min)
Page 52 Section 1 - General Information Service Tools Tool Detail Reference Note: No longer available, refer to 998/11051 JCB 892/00201 Replacement Gauge 0-20 bar (0-300 lbf/in ServiceMaster Digital Hydraulic Datalogger Pressure K Fig 40. ( T Test Kit. 1-47). 892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in...
Page 53 Section 1 - General Information Service Tools Tool Detail Reference 892/00223 Hand Pump 892/00137 Micro-bore Hose 1/4 in BSP x 3 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 Test Probe 892/00278...
Page 54 Section 1 - General Information Service Tools Tool Detail Reference 993/99512 Spanner 55 mm A/F 993/99513 Spanner 60 mm A/F 993/99514 Spanner 65 mm A/F 993/99515 Spanner 70 mm A/F 993/99516 Spanner 75 mm A/F 993/99517 Spanner 85 mm A/F 993/99518 Spanner 90 mm A/F 993/99519...
Page 55 Section 1 - General Information Service Tools Tool Detail Reference A408900 Fig 47. Socket Box Wrench Note: For disassembly and assembly of Swing motor gearbox. This tool can not be ordered from JCB. 1-50 9813/5100-1 1-50...
Page 56 Section 1 - General Information Service Tools Tool Detail Reference A408860 Fig 48. Nut Adaptor Note: For disassembly and assembly of Swing motor gearbox. This tool can not be ordered from JCB. 1-51 9813/5100-1 1-51...
Page 57 Section 1 - General Information Service Tools Tool Detail Reference A408880- C 1 Fig 49. Seal Ring Tool Note: For assembly and disassembly of Swing motor gearbox seal. This tool can not be ordered from JCB. 1-52 9813/5100-1 1-52...
Page 58 Section 1 - General Information Service Tools Tool Detail Reference A408890 Fig 50. Stopper Note: For assembly of Swing motor gearbox. This tool can not be ordered from JCB. 1-53 9813/5100-1 1-53...
Page 59 Section 1 - General Information Service Tools Tool Detail Reference A408870- C 1 Fig 51. Bearing Rig Note: For removal of Swing motor bearing. This tool can not be ordered from JCB. 1-54 9813/5100-1 1-54...
Page 60 Section 1 - General Information Service Tools Tool Detail Reference C118440 Fig 52. 892/00239 Accumulator Gas Charge Kit Use with Hydac bladder type accumulators Kit comprises the following: Pressure gauge Connection hose Mounting bracket (pressure gauge) Gas bottle adaptor (G2) Hydac bladder accumulator adaptor Testing and charging unit Spare seal (accumulator plug)
Page 61 Section 1 - General Information Service Tools Tool Detail Reference Ram Jigs Inserting Seal Ring and Correction Jig WDB 2052 Bucket 120mm Cylinder inner diameter WDB 2054 Boom 125mm Cylinder inner diameter WDB 2164 Boom 130mm Cylinder inner diameter WDB 2056 150mm Cylinder inner diameter Jig for Pulling Out, Press-fitting Bushing WDB 2166...
Page 62 Section 1 - General Information Service Tools Tool Detail Reference Bush Removal Jig WDB 2166 Bush removal jig WDB 2166-1 Retainer Note: The above Part no. is applicable to a rod diameter of 80mm Bush Fitting Jig WDB 2166 Bush press fitting jig WDB 2166-1 Retainer Note: The above Part no.
Page 63 Section 1 - General Information Service Tools Tool Detail Reference Page left intentionally blank 1-58 9813/5100-1 1-58...
Page 64 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 65 Section 2 - Operator’s Manual Notes: 9813/5100-1...
Page 66 Operator's Manual. You must understand and follow the instructions in the Operator's Manual. If you do not understand anything, ask your employer or JCB dealer to explain it. OPERATOR'S Do not operate the machine without an Operator's...
Page 67 Notes: 9831/1100-2...
Page 68 Table of Contents Contents Page No. Acronyms Glossary ............................viii Introduction About this Manual Model and Serial Number ........................1 Using the Manual ..........................1 Left-Hand Side, Right-Hand Side ......................1 Cross References ..........................1 Safety Safety - Yours and Others ........................2 Safety Warnings ............................
Page 69: Table Of Contents
Table of Contents Front Lower Window Wiper ........................ 18 Interior Switches Ignition Switch ............................. 19 Cab Interior Light ..........................19 Operation Introduction General ..............................21 Operating Safety General ..............................22 Worksite Safety ........................... 24 Risk Assessment ..........................25 Walk-Around Inspection General ..............................
Page 70 Table of Contents Travel Speed Selector ........................62 Instruments General ..............................64 Instrument Panel ..........................65 Getting the Machine Moving General ..............................91 Driving the Machine General ..............................94 Towing Other Equipment ........................95 Operating Levers/Pedals General ..............................96 Control Layouts ........................... 96 Excavator Arm Controls ........................
Page 71 Put into Storage ..........................166 During Storage ..........................166 Take out of Storage .......................... 167 Security General .............................. 168 JCB Plantguard ..........................168 Construction Equipment Security and Registration Scheme (CESAR) ..........168 LiveLink ............................. 168 Anti-Vandal Guards ........................... 168 Maintenance Introduction General ..............................
Page 72 Table of Contents How to Use the Maintenance Schedules ..................177 Maintenance Intervals ........................177 Pre-start Cold Checks, Service Points and Fluid Levels ..............179 Functional Tests and Final Inspection ....................182 Maintenance Positions General .............................. 184 Maintenance Position (Excavator Arm Lowered) ................184 Service Points General ..............................
Page 73 Table of Contents Tracks General ............................. 217 Steel ..............................218 Idler Wheels ............................219 Rollers ............................... 219 Track Gearbox Oil ..............................220 Hydraulic System General ............................. 221 Services ............................222 Oil ..............................222 Cylinder Rams ..........................223 Electrical System General ............................. 224 Battery ...............................
Page 74 Table of Contents Warranty Information Service Record Sheet ........................279 Engine Emissions ..........................285 9831/1100-2...
Page 75 Table of Contents Acronyms Glossary Auxiliary Relief Valve CESAR Construction Equipment Security and Registration DECU Display Electronic Control Unit Diesel Particulate Diffuser Electronic Control Unit Exhaust Gas Recirculation FOGS Falling Object Guard System FOPS Falling Object Protective Structure HVAC Heating Ventilation Air Conditioning Light Emitting Diode Mass Air Flow MECU...
Page 76 Particular attention must be given to all the safety aspects of operating and maintaining the product. If there is anything you are not sure about, ask your JCB dealer or employer. Do not guess, you or others could be killed or seriously injured.
Page 77 If you do not fully understand the warning messages, ask your employer or JCB dealer to explain them. Safety is not just a matter of responding to the warnings. All the time you are working on or with the product you must be thinking of what hazards there might be and how to avoid them.
Page 78 Lightning can kill you. Do not use the machine if there is lightning in your area. Machine Modifications This machine is manufactured in compliance with prevailing legislative requirements. It must not be altered in any way which could affect or invalidate its compliance. For advice consult your JCB dealer. 9831/1100-2...
Page 79 Introduction Safety Clothing and Personal Protective Equipment (PPE) Do not wear loose clothing or jewellery that can get caught on controls or moving parts. Wear protective clothing and personal safety equipment issued or called for by the job conditions, local regulations or as specified by your employer.
Page 80 Product Compliance Your JCB product was designed to comply with the laws and regulations applicable at the time of its manufacture for the market in which it was first sold. In many markets, laws and regulations exist that require the owner to maintain the product at a level of compliance relevant to the product when first produced.
Page 81 For more information, contact your JCB dealer. Optional Equipment and Attachments A wide range of optional attachments are available to increase the versatility of your machine. Only the JCB approved attachments are recommended for use with your machine. Contact your JCB dealer for the full list of approved attachments available.
Page 82 About the Product Description Before you do a maintenance task, make the product safe. Refer to: Maintenance > Maintenance Positions (Page 184). Main Component Locations Figure 3. Bucket Bucket link Bucket ram Dipper Dipper link Dipper ram Boom Boom ram Operators cab Counterweight Undercarriage...
Page 83 Digit Description 1 to 3 World manufacturer identification. For example, JCB = UK Build. 4 to 8 Machine type and model. For example, 8025 = 8025. Random check letter. The check letter is used to verify the authenticity of a machine's PIN.
Page 84 About the Product Product and Component Identification Figure 5. JCB HEAVY PRODUCTS LTD. MADE LAKESIDE WORKS, ROCESTER, UTTOXETER IN THE UNITED KINGDOM, ST14 5JP Product Identification Number PIN, ISO10261 WEIGHT (kg), ISO 6016 YEAR OF MANUFACTURE ENGINE SERIAL NUMBER TYPE...
Page 85 This must be done by a qualified person. For assistance, contact your JCB dealer. Failure to take precautions could result in death or injury to the operator.
Page 86 Any damage or modification to the structure may invalidate the ROPS certification. If damage has occurred then an authorised JCB dealer should be consulted. An excavator with a ROPS (Roll-Over Protective Structure) can be identified by referring to the identification plate.
Page 87 Keep all of the safety labels clean and readable. Replace a lost or damaged safety label. Make sure the replacement parts include the safety labels where necessary. Each safety label has a part number printed on it, use this number to order a new safety label from your JCB dealer. Safety Label Identification Figure 10.
Page 88 About the Product Safety Labels Figure 11. Table 3. Safety Labels Item Part No. Description Qty. 332/J2896 (Combination label) The coolant is under pressure. Risk of severing of hands/fingers in the rotating parts. Hot surfaces. Remove the ignition key and refer to the operator's manual and the service manual. 817/70005 Hot fluid under pressure.
Page 89 About the Product Safety Labels Item Part No. Description Qty. 817/70027 Crushing of whole body. Keep a safe distance. 817/70001 Falling hazard. Keep a safe distance from the edge. 333/J2439 Strike to the whole body (machine swing). Keep a safe distance from the machine.
Page 90 About the Product Operator Station Operator Station Component Locations Figure 12. Left hand track control, Refer to: Operation > Drive Controls > Track Controls (Page 61). DECU (Display Electronic Control Unit), Refer to: Operation > Instruments > Instrument Panel (Page 65). Right hand track control, Refer to: Operation >...
Page 91 About the Product Console Switches Console Switches General The installed switches and their positions can change according to the specification of the machine. Each switch has a graphic symbol to show the function of the switch. Before you operate a switch, make sure that you understand its function.
Page 92 About the Product Console Switches Seat Ventilation Two position rocker switch. The switch functions operate when the ignition is in the on position. Position : 1 = Seat ventilation off Position : 2 = Seat ventilation on Control Locks Controls isolation switch. Two position momentary rocker switch. The switch functions when the engine is running, and the controls isolation lever is lowered.
Page 93: Front Lower Window Wiper
About the Product Console Switches Cushion Two position rocker switch. The switch functions operate when the ignition switch is in the on position. Position : 1 = Off Position : 2 = On. Window Washer Two position momentary rocker switch. The switch functions when the ignition switch is in the on position.
Page 94: Interior Switches
About the Product Interior Switches Interior Switches Ignition Switch The ignition key operates the four-position ignition switch. The ignition key can only be inserted or removed in position 0. If the engine fails to start, the ignition key must be returned to position 0 before the starter motor is re-engaged. Do not operate the starter motor for more than 20s without the engine firing.
Page 95 About the Product Interior Switches Figure 15. Cab interior light 9831/1100-2...
Page 96: Operation Introduction General
Operation Introduction Operation Introduction General The aim of this part of the manual is to guide the operator step-by-step through the task of learning how to operate the machine efficiently and safely. Read the Operation section through from beginning to end. The operator must always be aware of events happening in or around the machine.
Page 97: Operating Safety
On a busy site, use a signalman. Before doing any job not covered in this manual, find out the correct procedure. Your local JCB distributor will be glad to advise you.
Page 98 This machine is designed for use in normal out door atmospheric conditions. It must 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 dealer. Regulations Obey all laws, worksite and local regulations which affect you and your machine.
Page 99: Worksite Safety
Operation Operating Safety Passengers Passengers in or on the machine can cause accidents. Do not carry passengers. Fires If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the correct machine location until you need to use it. Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical fire.
Page 100: Risk Assessment
It is essential that a risk assessment of the work to be done is completed and that the operator obeys any safety precautions that the assessment identifies. If you are unsure of the suitability of the machine for a specific task, contact your JCB dealer who will be pleased to advise you.
Page 101 Operation Operating Safety • How steep are any slopes, up/down/across? A cross slope is particularly hazardous, is it possible to detour to avoid them? Weather • How windy is it? High wind will adversely affect the stability of a loaded machine, particularly if the load is bulky.
Page 102: Walk-Around Inspection
Operation Walk-Around Inspection Walk-Around Inspection General WARNING Walking or working under a raised boom and dipper is hazardous. You could be crushed by the boom and dipper or get caught in the linkages. Lower the boom and dipper before doing these checks. The following checks must be made each time you return to the machine after leaving it for any period of time.
Page 103: Entering And Leaving The Operator Station
Operation Entering and Leaving the Operator Station Entering and Leaving the Operator Station General General WARNING For safety reasons, machines installed with single access canopies from new must not have the barrier removed. The machine must always be entered/exited with the left hand isolator raised via the left hand side.
Page 104 Operation Entering and Leaving the Operator Station 3. Stop the engine. 4. Turn the ignition key to the on position. 5. Operate the hydraulic controls several times to release any residual hydraulic pressure in the system. Refer to: Operation > Moving a Disabled Machine > Excavator Arm (Emergency Operation) (Page 133). 6.
Page 105: Emergency Exit
Operation Entering and Leaving the Operator Station Emergency Exit Standard Cab Figure 18. Glazing breaker In an emergency, if the door cannot be used: 1. Turn the backrest of the seat fully forward/down. 2. Use the glazing breaker to hit the rear window near the corner to shatter the window. 9831/1100-2...
Page 106: Doors
Operation Doors Doors Operator Door To open the door from the outside, unlock it with the key provided and pull the handle towards you to release the latch. To open the door from inside, pull the lever towards you. Figure 19. Lever Close the door from the inside by pulling it towards you, it will latch itself.
Page 107 Operation Doors Figure 20. Lever 9831/1100-2...
Page 108: Windows
Operation Windows Windows Front Window Depending on machine specification, windows are provided to function as guards. Damaged windows must be replaced with those of equivalent specification before the machine is used again. Is is the responsibility of the operator to assess whether the attachment they are using and/or the operation they are performing requires the protection offered by a screen.
Page 109: Side Window
Operation Windows To open the front lower window: 1. For a small amount of ventilation pinch the locks between finger and thumb and move the window down until the locks locate in the lower latch positions. 2. For a larger amount of ventilation the window can be removed. Pinch the locks between finger and thumb and pull the window out of the brackets at the bottom of the frame.
Page 110 Operation Windows To open the window, operate the latch and slide the window to the required position. To close the window, slide the window fully shut and check that the latch has located into position at one of the slots. Figure 24.
Page 111: Sun Visor/Sunblind
Operation Sun Visor/Sunblind Sun Visor/Sunblind Sunblind Standard Sunblind The sunblind is installed in the cab roof and can be secured in three positions: 1. Use the handle in the centre of the sunblind lower edge to pull the sunblind forward. Figure 25.
Page 112 Operation Sun Visor/Sunblind 3. To release the sunblind, hold the handle, release the bottom edge of the sunblind from the hooks and let the sunblind slowly rewind back into the stowed position. Figure 27. Handle Front hooks Upper hooks Optional Sunblind - Half Length The sunblind is installed at the top of the cab front window and can be secured in a position to suit the operator: 1.
Page 113: Before Starting The Engine
4.5. Remove or stow all loose articles in the cab, for example tools. 4.6. Examine the ROPS (Roll-Over Protective Structure), FOPS (Falling Object Protective Structure) and FOGS (Falling Object Guard System) for damage. Get your JCB dealer to repair any damage. Make sure all securing bolts are installed and correctly tightened.
Page 114 Operation Before Starting the Engine 7. Fasten the seat belt. 9831/1100-2...
Page 115: Operator Seat
Operation Operator Seat Operator Seat General CAUTION Position the seat so that you can comfortably reach the machine controls. Do not adjust the seat while the machine is moving. You could have an accident if you operate the machine with the seat in the wrong position.
Page 116 Operation Operator Seat Seat Options Mechanical Suspension Seat Figure 29. Cushion tilt lever Cushion slide lever Armrest adjuster Backrest lever Indicator Suspension adjuster Console fore/aft lever 9831/1100-2...
Page 117: Heated Seat Controls
Operation Operator Seat Heated Air Suspension Seat Figure 30. Cushion tilt lever Cushion slide lever Armrest adjuster Backrest lever Indicator Suspension adjuster Console fore/aft lever Lumbar adjuster Heated Seat Controls A switch on the left console operates the heated seat. Refer to: About the Product >...
Page 118: Seat Belt
Operation Seat Belt Seat Belt General WARNING Operating the machine without a seat belt can be dangerous. Before starting the engine, make sure your seat belt is fastened. Check the tightness and condition of the seat belt securing bolts regularly. WARNING When a seat belt is installed on your machine replace it with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident.
Page 119: Static Seat Belt
Operation Seat Belt Figure 32. Seat belt Button Release the Seat Belt WARNING Release the seat belt only after safely stopping the machine, switching off the engine and engaging the park brake (if applicable). 1. Push the button and pull the tongue from the latch. 2.
Page 120 Operation Seat Belt Figure 33. Tongue Latch Adjust 1. Move the toggle the required distance down the strap. 2. To make the strap longer, pull the end as far as it will go. 3. To make the strap shorter, pull the end as far as it will go. Figure 34.
Page 121 Operation Seat Belt Figure 35. Tongue Latch Button 9831/1100-2...
Page 122: Mirrors
Operation Mirrors Mirrors General Installation Introduction When they operate the machine, the operator must continually survey their field of vision. It is important that the mirrors are securely installed and give maximum vision around the machine. When a mirror is provided to supplement the operators direct field of vision, it must be adjusted to serve as an aid to the operator in seeing people or obstacles around the machine.
Page 123 Operation Mirrors Cab Mirrors - Position A and B Secure the mirror to the handrail: 1. Secure the mirror support to the handrail with the cap-screws and nuts. 2. Remove the protective cap from the back of the mirror and tighten the nut to secure the mirror to the support. 3.
Page 124 Operation Mirrors Figure 38. Protective cap Bolt Spring washer Washer Mirror support Adjusting the Mirrors 1. Adjust the seat to suit the operator. 2. Adjust the mirror(s) to suit your specific working requirements before you drive or operate the machine. 3.
Page 125 Operation Mirrors Figure 39. Side Mirror Field of vision Filament position centre point Outer borderline Inner borderline Measurement at ground level Measurement at 1m above ground level 3.5m 750mm 9831/1100-2...
Page 126 Operation Mirrors Rear Mirror 1. Adjust the seat to suit the operator. 2. Adjust the mirror. The field of vision shall be such that the operator can see, using the mirror the area of ground directly behind the machine. 9831/1100-2...
Page 127: Starting The Engine
Operation Starting the Engine Starting the Engine General WARNING Thoroughly warm the hydraulic oil before operating the excavator services. Before selecting boom up, check there are no overhead obstructions or electric power cables. CAUTION Do not use ether or other starting fluids to assist cold starting. Using these fluids may result in an explosion causing possible injury and/or damage to the engine.
Page 128: Immobiliser
Operation Starting the Engine Immobiliser Introduction If your machine has an immobiliser system installed, then your JCB dealer must enable the system as part of the standard machine installation. Coded Immobiliser System Introduction Before you try to disarm the immobiliser, make sure that the machine is ready to start and that you have your four digit security code available.
Page 129: Warming Up
Duration: 2min 3. If you restart the engine within the time, the system disarms automatically. Add/Change/Delete a Security Code Immobiliser codes can only be added, changed or deleted using JCB Servicemaster software. Contact your local JCB dealer. Warming Up Before starting work in temperatures below -15°C (5.0°F), the hydraulic fluid must be warmed.
Page 130 Operation Starting the Engine 3.2. Warm up the hydraulic oil by repeatedly selecting bucket crowd by moving the right hand lever to the left for: Duration: 5s 3.3. Repeat for several minutes. 3.4. Select dozer up (if installed) by moving the dozer control lever backwards, keep it selected for: Duration: 1min 4.
Page 131: Stopping And Parking
Operation Stopping and Parking Stopping and Parking General Stopping and Parking DANGER Before lowering the attachments to the ground, make sure that the machine and the area around it are clear of other people. Anyone on or close to the machine could fall and be crushed by the attachments, or get caught in the linkages.
Page 132: Preparing For Travel
Operation Preparing for Travel Preparing for Travel General When you travel on the road or on site there are usually local rules and safety regulations for the machine travel position. This publication contains recommendations that may help you meet the requirements of these regulations, they are not necessarily the applied law.
Page 133: Beacon
Operation Preparing for Travel Figure 47. Tracking strut Beacon In certain territories you will break the law if you do not install a beacon before you travel on site/public highways, make sure you comply with the local laws. Be careful when you operate the machine with a beacon. The total height of the machine is increased when the beacon is in the operating position.
Page 134: Locks
Operation Locks Locks General WARNING The slew lock must be engaged when travelling on road or trailer, otherwise the boom could slew to one side and cause injury or death. The requirement for controls isolation varies according to local legislation. You must comply with local legislation at all times.
Page 135 Operation Locks Figure 49. Controls isolation lever 9831/1100-2...
Page 136: Drive Controls
Operation Drive Controls Drive Controls Track Controls WARNING When the cab is swung around so that it is facing the track motor end of the undercarriage, the action of the track controls is reversed. Take extra care! The machine is fitted with hydrostatic track motors. The motors have a built-in spring-applied parking brake which is automatically applied shortly after the pressure feed is removed from the motor.
Page 137: Travel Speed Selector
Operation Drive Controls Figure 51. To turn the machine to the right, push the left travel lever forwards. To turn the machine to the left, push the right travel lever forwards. If the travel speed selector is set to fast speed and the travel levers are operated quickly, the machine will start quickly.
Page 138 Operation Drive Controls The travel speed selected is shown in the top left corner of the DECU (Display Electronic Control Unit): Figure 53. Fast (hare) Slow (tortoise) Creep (snail) 9831/1100-2...
Page 139: Instruments
Operation Instruments Instruments General Machine Power Band Controller The machine power band controller matches engine speed and hydraulic pump output dependant on the machine power selected by the operator. Machine power can be varied from Light (L), General (G), Heavy (H) and Heavy Plus (H+) using the rotary control.
Page 140: Instrument Panel
Operation Instruments Figure 55. AUTO n/min n/min Rotary control Automatic idle button H+ button Instrument Panel The DECU (Display Electronic Control Unit) is located at the front of the cab in the line of sight from the operator's seat. It provides the interface with the machines electronic system. 4 Inch Colour Display The display has mechanical gauges for fuel level and engine coolant temperature as well as a digital display.
Page 141 NOTICE Reverse as slowly as possible since higher speeds may limit your reaction time to stop the machine. If the rear of the machine is hit or damaged, ask your JCB dealer to check the camera system for correct coverage and operation.
Page 142 Operation Instruments 3. Press the home button. Figure 58. Camera one bottom of screen, normal. Camera two, top of screen. Figure 59. Camera one bottom of screen, mirrored Camera two, top of screen. If the back button is pressed whilst cameras one and two are displayed on the screen the home screen is shown for 3s.
Page 143 Start-Up Screen When the cab door is opened the JCB logo is displayed followed by a machine hours, hours to service and fuel level screen. The 7 Inch display shows a egg timer next to the JCB logo to indicate it is loading.
Page 144 15s. Figure 63. Immobilizer Screen If the JCB immobilizer option is enabled the operator must enter the 4 digit immobilizer code before the engine will start. Refer to: Operation > Starting the Engine > Immobiliser (Page 53).
Page 145 Operation Instruments Main Display Screens After the engine has been started the operator can select one of three main display screens using the control wheel. Turn the rotary control right or left to navigate the screens. Default Operating Screen (Home Screen) Displays the engine speed, inside and outside air temperature, selected travel speed, time, isolator status.
Page 146 Operation Instruments Machine Status Figure 66. Press the rotary control again to display machine status information. Turn the rotary control to switch between screen 1 and 2. Press the back button to return. Figure 67. Battery voltage Alternator voltage Coolant temperature Hydraulic temperature Figure 68.
Page 147 Operation Instruments Press the rotary control again to display service information. Turn the rotary control to switch between screen 1 and 2. Press the back button to return. Figure 70. Engine hours Machine type Vehicle identification number Time to next service Figure 71.
Page 148 Operation Instruments Figure 73. Time Date Units Display brightness Figure 74. Auto refuel maximum level Auto idle time Kerosene Overload warning system Figure 75. Slew/boom priority default Dipper arm limiter setup ISO/SAE controls selection Error Log Figure 76. 9831/1100-2...
Page 149 Operation Instruments Press the rotary control again to display a list of the machine faults recorded. Turn the rotary control to switch between screens 1 and 2. Press the back button to return. Figure 77. Figure 78. The fault log screen is used to provide information on the active and previously active faults on the machine. The fault log display screen displays the fault code, time, date, engine hours and number of times that the fault has been active.
Page 150 Operation Instruments Figure 80. Attachments- Basic Tool Select Figure 81. Press the rotary control again to change between hammer and auxiliary mode. A tick next to the hammer enables hammer. A cross next to the hammer enables auxiliary. Figure 82. Press the rotary control to access the auxiliary settings.
Page 151 Operation Instruments Figure 84. Turn the rotary control until the High flow auxiliary is selected then press the rotary control. Figure 85. Turn the rotary control to change the setting. Press the back button to return to the auxiliary settings. Machines can be equipped with Hydraulic High Flow Circuits in 3 types.
Page 152 Operation Instruments Figure 88. High Flow Auxiliary Single Direction Figure 89. High Flow Auxiliary Two Direction Figure 90. Super High Flow Auxiliary Two Direction Figure 91. Turn the rotary control until the flow rate is selected then press the rotary control. Figure 92.
Page 153 Operation Instruments Attachment- Advanced Tool Select Figure 93. From the home screen, Advanced Tool Select is accessed by selecting the attachment icon. Figure 94. In the attachment overview screen,turn the rotary control to scroll through the available attachments. Press the rotary control to set the highlight attachment as being active or inactive. If the attachment is active, it will shown in green.
Page 154 Operation Instruments Figure 96. The attachment settings can then be modified by selecting the attachment and entering the attachment detail screen using the rotary control. Figure 97. The attachment type can be changed from any of the icons as shown above. To edit the High-Flow settings: Figure 98.
Page 155 Operation Instruments Figure 100. • Two direction super high-flow Figure 101. • High-Flow operating flow- This is normally set according to the recommended flow rating on the attachment data sheet but can be adjusted lower to optimize attachment performance. • High-Flow operating pressure- This is set normally between 20–50bar (289.9–724.6psi) below the ARV (Auxiliary Relief Valve) pressure and can be adjusted to optimize attachment performance.
Page 156 Operation Instruments a service fault is active. The code will remain until it is acknowledged by pressing the enter button. The fault indicator remains on if the fault is acknowledged with the enter button. If multiple service faults are active, the fault screen (icon and fault code) shall alternate through the active faults.
Page 157 Operation Instruments Figure 106. Notification Symbols Table 6. Quickhitch entry Quickhitch hose reminder Quickhitch exit and confirm Boom and dipper not aligned Boom aligned, dipper not aligned Boom not aligned, dipper aligned Boom and dipper aligned Boom and dipper aligned, crowd pressed raised 9831/1100-2...
Page 158 Operation Instruments Boom and dipper aligned, crowd pressure raised, joystick unlock button pressed. Hammer engaged (green) Hammer overwork alarm (amber) Hammer overwork alarm (red) Engine automatic warm-up (blue) Cold Idle (blue) Engine pre-heat (amber) Engine stop (red) Work lights (amber). Warns that the work lights are on and the ignition is off. The buzzer will sound in this state after 15.
Page 159 They remain on even when the operator turns the ignition switch off and on. The service should be per- formed by your JCB dealer. The symbol and fault indicator can only be cancelled by your JCB dealer.
Page 160 Operation Instruments Water in fuel (amber) Hydraulics oil temperature high (red) Hydraulic oil temperature high (amber) Fuel level low (amber) Coolant temperature high (amber) Engine (amber) Engine (red) Engine oil pressure low (red) Engine oil level low (amber) Coolant temp high (red) CAN lost communications (red) 9831/1100-2...
Page 161 Operation Instruments Coolant level low (amber) Battery no charge (amber) Air filter blocked (amber) Livelink (amber) Livelink (red) Buzzer The buzzer is activated to notify the operator of a message or a fault. Some messages/faults are acknowledgeable and will silence the buzzer and some messages/faults are not acknowledgeable and the buzzer will continue until the message/fault clears.
Page 162 Operation Instruments During regeneration white smoke may be temporarily generated from the tail pipe as a result of particulate matter combustion. This does not indicate a failure. The engine speed may rise while idling, when this occurs the DPD (Diesel Particulate Diffuser) is in the process of automatic regeneration.
Page 163 Operation Instruments Figure 108. Figure 109. Deferring Regeneration If you are about to enter a hazard atmosphere (entering into an enclosed environment for example), it may be necessary to defer auto regeneration mode. To defer the auto regeneration mode, press the regeneration switch within 5s of the green regeneration symbol being displayed.
Page 164 Operation Instruments Figure 111. To perform a manual regeneration the operator must move the machine to a safe location so as not to cause an obstruction, away from any flammable materials. Position the excavator end on the ground and keep the engine running.
Page 165 Operation Instruments The machine can only be recovered from this mode using a service tool, contact JCB dealer, to initiate a fast forced regeneration. Figure 114. Figure 115. 9831/1100-2...
Page 166: Getting The Machine Moving
Operation Getting the Machine Moving Getting the Machine Moving General Moving the Machine 1. Prepare the machine. Refer to: Operation > Preparing for Travel (Page 57). 2. Select a general power band. Refer to: Operation > Instruments > General (Page 64). 3.
Page 167 Operation Getting the Machine Moving Figure 118. When a track comes off the ground, the track will loosen and the track rollers may come off their links. On hard surfaces the shock forces are larger and have an adverse effect on the undercarriage. Always keep the correct track tension.
Page 168 Operation Getting the Machine Moving Figure 122. When you travel over a mound, always support the chassis with the dig end to prevent shock loads. Figure 123. Figure 124. When the machine travels for long distances heat is generated in the undercarriage, which causes increased wear.
Page 169: Driving The Machine
Operation Driving the Machine Driving the Machine General WARNING When the cab is swung around so that it is facing the track motor end of the undercarriage, the action of the track controls is reversed. Take extra care! CAUTION Drive the machine smoothly. Spin turn manoeuvres, zig-zag driving or turning too fast can cause the vehicle to overturn.
Page 170: Towing Other Equipment
Operation Driving the Machine Towing Other Equipment A light duty tow eye is attached to the undercarriage. The maximum tow capacity of the tow eye is 25% of the machine weight. Do not exceed the maximum tow capacity of the tow eye. Use the minimum force to move the equipment slowly (not greater than 2km/h (1.2mph)) smoothly and without shocks.
Page 171: Operating Levers/Pedals
Operation Operating Levers/Pedals Operating Levers/Pedals General WARNING Make sure it is clear overhead before raising the boom. Keep an adequate safe distance from all electrical power lines. Contact your local power company for safety procedures. CAUTION Keep the machine controls clean and dry. Your hands and feet could slide off slippery controls. If that happens you could lose control of the machine.
Page 172 Operation Operating Levers/Pedals The boom will move within its limits for as long as you hold the joystick forward or backwards. It will stop automatically when you release the joystick. To raise the boom, pull the joystick backwards (position 1). To lower the boom, push the joystick forwards (position 2).
Page 173 Operation Operating Levers/Pedals Figure 130. Backward: Raise the boom Forward: Lower the boom Left: Fill the bucket Right: Empty the bucket Power boost Quickhitch One touch idle Proportional auxiliary control low flow (option) 9831/1100-2...
Page 174 Operation Operating Levers/Pedals Left Joystick The left hand joystick controls the slew of the superstructure and the movements of the dipper. When released, the joystick returns to the neutral position. The superstructure will slew within its limits for as long as you hold the joystick over to one side. It will stop automatically when you release the joystick due to the application of the slew brake.
Page 175 Operation Operating Levers/Pedals Figure 131. Left: Slew to the left Right: Slew to the right Forward: Move the dipper outwards Backward: Move the dipper inwards Auxiliary hold (proportional control only) Boom priority (if fitted) Horn Proportional auxiliary control high flow (option) SAE Pattern Right Joystick NOTICE In some instances it may be possible to hit the cab with the bucket or attachment.
Page 176 Operation Operating Levers/Pedals Press the one touch idle switch to instantly changes the engine rpm back and forth between that selected for working and a low idling speed. The proportional auxiliary control (low flow) switch is a variable position switch, spring loaded to the central off position, it provides bi-directional flow for the relevant attachments, for example weed cutter, grab rotate.
Page 177 Operation Operating Levers/Pedals Left Joystick The left hand joystick controls the slew of the superstructure and the movements of the boom. When released, the joystick returns to the neutral position. The superstructure will slew within its limits for as long as you hold the joystick over to one side. It will stop automatically when you release the joystick due to the application of the slew brake.
Page 178 Operation Operating Levers/Pedals Figure 133. Left: Slew to the left Right: Slew to the right Forward: Lower the boom Backward: Raise the boom Auxiliary hold (proportional control only) Boom priority (if fitted) Horn Proportional auxiliary control high flow (option) Triple Articulating Boom (Option) On a machine with a triple articulating boom, the boom is in two parts, as shown.
Page 179: Auxiliary Circuit Controls
Operation Operating Levers/Pedals Figure 134. Pedal Heel end of the pedal: Extend the ram Toe end of the pedal: Retract the ram Auxiliary Circuit Controls WARNING Before operating the auxiliary control system make sure that you are aware of all safety notices that apply to the attachment you are using.
Page 180 Operation Operating Levers/Pedals Rockbreaker Circuit This system supplies a one-way, regulated hydraulic flow to operate a rockbreaker. The flow to the rockbreaker is controlled by a pedal at the operator's feet. Automatic engine speed reduction is incorporated, to prevent damage to the rockbreaker because of excessive oil flow. Two-Way Auxiliary Circuit This system supplies a two-way flow, controlled by the pedal.
Page 181 Operation Operating Levers/Pedals 4. Put the isolator bar down. Do not operate the machine services. Let the engine idle for Duration: 10s 5. Stop the engine with the engine shutdown button. 6. Operate the two hand controllers to release the pressure in the hydraulic system. 7.
Page 182: Lifting And Loading
The owner and/or operator must make sure that they fully understand the laws and regulations concerning the use of the JCB machine as an earthmover and for lifting. Consult your JCB dealer for more information. In certain countries safety regulations in force call for the application of specific safety factors. Consult your JCB dealer for more information.
Page 183: Overload Warning System
Lifting and Loading All lifting operations must be done using the load charts in the cab. The load charts refer to the lift capacities relevant to the machine specification when equipped with an approved JCB tipping link, shackle and bucket ram.
Page 184 Operation Lifting and Loading Figure 138. If the safe operating lift limit is exceeded, the buzzer will sound and the icon in the lower section will turn red. A red hook notification symbol is also displayed in the right section of the DECU. When the buzzer sounds and the icon appears, the operator must take the necessary action to lower the lift.
Page 185: Working With The Excavator Arm
Operation Working with the Excavator Arm Working with the Excavator Arm General WARNING When using the boom and dipper fully extended, take the following precautions, otherwise the machine could get damaged or become unstable and become a danger to you and other people. Make sure you do not exceed the working capacity of the boom at maximum reach.
Page 186: Digging
Operation Working with the Excavator Arm 3. Attach a handline to the load. Make sure the person holding the handline stands clear of the load and machine. 4. Test the load by lifting it: Distance: 25–50mm 5. If the load is to be lifted to a height where it is not possible to prevent the bucket obstructing or deflecting the lifting chains then the lifting chains must only be guided by the back wall of the bucket and not by any other parts of the machine.
Page 187 Operation Working with the Excavator Arm If impact force is used to do a task, it will cause damage to the dig end. An impact force will also create high pressures inside the cylinders, which will cause the cylinders to swell. Figure 141.
Page 188 Operation Working with the Excavator Arm Figure 145. When the dig end is used, always keep the drive sprockets at the rear. The stability of the machine is improved and wear to the drive is decreased. Figure 146. Where practical work with the tracks pointing forwards, to improve the stability of the machine. When working with the tracks pointing to the sides exercise caution due to reduced stability.
Page 189 Operation Working with the Excavator Arm Figure 148. When you dig with the dipper, keep the dipper angle within a range of 45° to the front and 30° to the rear. In this range if the boom and bucket are also used, the efficiency of the operation is increased. Figure 149.
Page 190 Operation Working with the Excavator Arm 5. Important: All of the lifting equipment, including the hook and/or the shackle and any chains/slings/webs between the machine and the load, will need regular inspections and testing by a competent person to make sure they are fit for purpose. 6.
Page 191: Changing The Bucket Linkage
Operation Working with the Excavator Arm Figure 151. 1 2 3 Changing the Bucket Linkage It is possible to compensate for the lateral wear which causes the sideways play of the bucket. The regular use of this compensating procedure leads to less wear on the bucket swivel pin and the dipper bushes. Figure 152.
Page 192: Dipper Stroke Limiter
The dipper stroke limiter is factory set to 500mm For the dipper stoke limiter to operate it must be enabled by the JCB Service Master set up tool. When enabled, it is set up by the DECU (Display Electronic Control Unit).
Page 193 Operation Working with the Excavator Arm Figure 154. Clearance 3. Fully crowd the bucket and lower the boom until the bucket is on the ground. Do not retract or extend the dipper ram. 4. Stop the engine and remove the ignition key. 5.
Page 194 Operation Working with the Excavator Arm 9. Check the clearance. Check the Clearance 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 195: Slopes
Operation Slopes Slopes General WARNING Make sure that you have been trained and are familiar with the use of machines on slopes, and understand the adverse affects that slopes and site conditions can have on stability. Never use the machine on a slope if you do not understand the recommended practices for the use of machines in such applications.
Page 196 Operation Slopes Figure 157. Driving Up a Slope When you drive up a slope, make sure that the bucket is set 250 ± 50mm above the ground (in the position shown). Refer to Figure 158. Figure 158. When you drive up a steep slope, make sure that the bucket is set 250 ± 50mm above the ground (in the position shown).
Page 197: Working On Slopes
Operation Slopes Working on Slopes The illustrations show a typical model. Your machine may look different to the model shown. It is dangerous to operate the machine on a slope. Where possible, use a platform or a level cut-out to keep the machine horizontal when in use.
Page 198 Operation Slopes Figure 163. When you climb a ramp, it is easier and safer if the work equipment is used to help the machine. Figure 164. 9831/1100-2...
Page 199: Heating, Ventilating And Air-Conditioning (Hvac)
Operation Heating, Ventilating and Air-Conditioning (HVAC) Heating, Ventilating and Air-Conditioning (HVAC) General The operator must set the controls to obtain the best working environment in the operator station. Poor ventilated air can cause tiredness. Do not operate the machine for long periods without ventilation or with the operator station fully closed and the fan turned off.
Page 200 Operation Heating, Ventilating and Air-Conditioning (HVAC) Heater/Air Conditioning Controls Introduction Figure 166. Display Fan speed switch Temperature control switch Defrost/Demist switch Recirculation switch Auto mode switch On/Off switch The heater/air conditioning control panel is installed on the left console. Adjust the air vents to direct the hot air flow to the front window (for demisting) and/or the cab floor. To activate the control panel push the On/Off switch, the switch LED (Light Emitting Diode) and the panel will illuminate.
Page 201 Operation Heating, Ventilating and Air-Conditioning (HVAC) 1. Close the door and windows. 2. Push the defrost/demist switch. 3. Turn the fan speed switch clockwise fully clockwise and direct the air flow onto the front window. 4. Turn the temperature control switch fully clockwise to heat the dehumidified conditioned air, demist the screen and generally dehumidify the cab air.
Page 202: Power Sockets
Operation Power Sockets Power Sockets Auxiliary Power Socket Your machine may be fitted with one or more 12V auxiliary power sockets, which can be used for mobile phone chargers or other 12V powered devices. Refer to: About the Product > Operator Station > Component Locations (Page 15).
Page 203: Battery Isolator
Operation Battery Isolator Battery Isolator General NOTICE Before carrying out arc welding on the machine, disconnect the battery and alternator to protect the circuits and components. The battery must still be disconnected even if a battery isolator is installed. NOTICE Do not isolate the machine electrics when the engine is running, this may cause damage to the machine electrics.
Page 204: Fire Extinguisher
Operation Fire Extinguisher Fire Extinguisher General Location The fire extinguisher is stowed in a bracket behind the seat. Keep the fire extinguisher in the bracket until you need to use it. Figure 168. Fire extinguisher Operation WARNING Do not use the fire extinguisher in a confined space. Make sure that the area is well ventilated during and after using the fire extinguisher.
Page 205 Operation Fire Extinguisher Figure 169. Safety pin Trigger 9831/1100-2...
Page 206: Moving A Disabled Machine
If the machine becomes disabled, the machine must be made safe, lifted onto a transporter and moved to a location where it can be repaired. You must contact your nearest JCB dealer before you try to tow, winch or push the machine. Towing, winching or pushing the machine without following the correct procedure will damage parts of the hydraulic system.
Page 207: Jump-Starting The Engine
Using a higher voltage supply will damage your machine's electrical system. If you do not know the voltage of your booster (slave) supply, then contact your JCB dealer for advice. Do not attempt to jump-start the engine until you are sure of the voltage of the booster (slave) supply. The negative (-) terminal on the battery is connected to frame earth.
Page 208: Retrieval
Operation Moving a Disabled Machine 7. Disconnect the booster cables: 7.1. Disconnect the negative booster cable from the machine frame earth. Then disconnect if from the booster supply. 7.2. Disconnect the positive booster cable from the positive (+) terminal on the battery. Then disconnect it from the booster supply.
Page 209 Operation Moving a Disabled Machine If an emergency occurs: 1. Turn the ignition key to the on position. 2. Enable the controls. Refer to: Operation > Locks > Control Lock (Page 59). 3. Use the right and left control levers to move the dipper and lower the boom. 4.
Page 210: Lifting The Machine
Operation Lifting the Machine Lifting the Machine General Figure 173. Spacer bars Lifting platform Lifting-hook height Angle = 75° DANGER! Do not stand underneath the raised load during the lowering procedure. Stand clear and to one side until the load has been safely lowered. Make sure that the area is clear of other people before lowering the load.
Page 211 Operation Lifting the Machine 11. Lift the machine slightly to check the balance of the machine and the installation of the lifting equipment. If the machine does not lift horizontally, adjust the length of the slings. Proceed slowly and evenly until the lift is complete.
Page 212: Transporting The Machine
Operation Transporting the Machine Transporting the Machine General WARNING The safe transit of the load is the responsibility of the transport contractor and driver. Any machine, attachments or parts that may move during transit must be adequately secured. WARNING Make sure that the ramp incline does not exceed the machine's operational limits. CAUTION Before moving the machine onto the trailer, make sure that the trailer and ramp are free from oil, grease and ice.
Page 213 Operation Transporting the Machine 9. Lift the bucket/attachment. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 96). WARNING! The machine must be clean and free of any debris and the contact surfaces must be clean, undamaged, without frost, ice or snow covered. If this is not the case then special precautions may be taken to increase the friction contact with the loading surface through the addition of certified anti-slip matting.
Page 214 Operation Transporting the Machine Figure 176. JS330/JS370 34–39° 15–25° 1,275mm Chain wrapped around undercarriage Centre line of machine 9831/1100-2...
Page 215 27. Measure the maximum height of the machine from the ground. Make sure that the transporter driver knows the maximum height before he drives away. Table 7. Tie-Down Accessories Restraint Specification Lashing capacity 12500 (JS300), 13000 (JS330), 14500 (JS370) 9831/1100-2...
Page 216: Unloading The Machine From The Transporting Vehicle/Trailer
Operation Transporting the Machine Unloading the Machine from the Transporting Vehicle/Trailer WARNING If the dozer blade is to the rear, the track controls will be reversed. Use extreme caution when tracking off the trailer. 1. Stop the transport vehicle on solid, level ground. 2.
Page 217: Operating Environment
6. Protect the machine when its not in use. Park the machine inside a building or cover it with a tarpaulin. 7. Install a cold weather starting aid. In very low temperatures (less than the value shown) additional starting aids may be needed. Examples are fuel, oil and coolant heaters. Ask your JCB dealer for advice. Temperature: -20°C (-4.0°F) 8.
Page 218: Cab Filters
Operation Operating Environment 4. Keep the cooling pack and engine clean, regularly remove dirt and debris from the cooling pack and the engine. 5. Check the fan belt regularly. 6. Check the air vents. Make sure that the air vents to and from the engine compartment are not blocked. 7.
Page 219: Refuelling
Do not use fuel to clean the machine. When filling with fuel, choose a well aired and ventilated area. NOTICE Consult your fuel supplier or JCB dealer about the suitability of any fuel you are unsure of. Low Fuel Levels If you operate the machine on very low fuel levels, then air can enter the fuel system.
Page 220 Operation Refuelling Figure 180. Fuel filler cap Fuel Level The amount of fuel in the tank is shown on the fuel gauge. Be alert for the red warning indicator on the gauge. Refer to: Operation > Instruments > General (Page 64). You should fill the tank at the earliest opportunity when the red warning indicator comes on.
Page 221 Operation Refuelling Figure 181. Filler cap Fuel hose Close-off valve Switch 9831/1100-2...
Page 222: Attachments
An attachment which is not designed for use with the machine can cause damage and create a safety hazard for which JCB cannot be held responsible. Also the machines warranty and any other legislative compliance can be affected by the use of non JCB approved attachments.
Page 223: Connecting/Disconnecting Hydraulic Hoses
Attachments Working with Attachments Notice: Some attachments may contact parts of the machine when in the fully folded position. Take extra care to avoid damage to the machine. Connecting/Disconnecting Hydraulic Hoses WARNING Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear personal protective equipment.
Page 224 Attachments Working with Attachments 4.5. To allow for length changes when the hose is pressurised, do not clamp at the bend. The curve absorbs the change. Figure 184. 5. Check for leaks: 5.1. Start the engine. 5.2. Operate the related controls to increase the pressure in the hydraulic system. 5.3.
Page 225 Attachments Working with Attachments Figure 185. Female coupling Male coupling The quick release couplings will be trouble free and relatively easy to connect and disconnect, if they are kept clean and used correctly. The recommendations listed below must always apply when using flat face quick release couplings.
Page 226: Impact Protection
Make sure that the attachment, for example a hydraulic breaker is positioned in front of the cab before it is operated. Do not slew the boom to the side during operation of the attachment. Consult your JCB dealer for further information. Figure 187.
Page 227: Direct-Mounted Attachments
Attachments Direct-Mounted Attachments Direct-Mounted Attachments General Removal 1. Move the boom straight in front of the machine. Refer to: Operation > Operating Levers/Pedals (Page 96). 2. Put the bucket on level ground, with the dipper approximately vertical and the bucket flat. 3.
Page 228 Attachments Direct-Mounted Attachments 12. Use the boom rams to carefully lower the dipper nose until there is no load on the pivot pin in the dipper tipping-links. 13. Use the drift to remove the pivot pin. 14. Move the dipper nose away from the bucket, then remove the O-ring seals. Installation The installation procedure is not the reverse of the removal procedure.
Page 229 Attachments Direct-Mounted Attachments 11. Move the bucket to the dump position so that the dipper link and the bucket bores are closely aligned (as shown at position 'C'), with the bucket teeth/toe plate above the ground by the specified distance. Distance: 20mm 11.1.
Page 230: Quickhitch
Attachments Quickhitch Quickhitch Excavator Arm Quickhitch General CAUTION When the Quickhitch is installed and its attachment attached, there is a danger of the attachment hitting the machine. Operate the boom and dipper carefully when the Quickhitch and its attachment are attached.
Page 231 Attachments Quickhitch Refer to: Operation > Instruments > Instrument Panel (Page 65). 7. Align the boom and dipper so that the colour display displays the green boom and dipper symbols. A grey boom or dipper symbol signifies mis-alignment. When the boom and dipper are aligned, the Quickhitch is in the Quickhitch ready state.
Page 232 Attachments Quickhitch 5. Engage the tipping link: 5.1. Operate the controls to line up hole in the tipping link with hole in the Quickhitch. 5.2. Install the pivot pin and attach it with the nut and bolt. Removal The removal of the Quickhitch is a reversal of the installation procedure. Pay particular attention to safety notices.
Page 233: Buckets
Attachments Buckets Buckets General WARNING The bucket selected must be the correct width to suit the hole/trench to be excavated. However, if the hole width demands a larger bucket, consideration must be given to the density/weight of the material to be moved affecting the stability of the machine especially if working on a slope. If there is danger of the machine's stability being compromised, then select a smaller bucket or reposition the machine.
Page 234 ESCO Teeth Introduction This information only relates to the ESCO buckets supplied by JCB. If a bucket from another source is used, refer to the relevant manufacturer's manual. A wide range of Super V-teeth are available for your machine, which are suitable for all digging conditions. The Super V system consists of an adaptor, tooth and locking pin.
Page 235 Attachments Buckets Figure 198. 5. Remove the tooth from the adaptor. Refer to Figure 199. Figure 199. Installation 1. Install the tooth over the adaptor. (The reverse movement of step 5, in the Removal procedure. Refer to Figure 199. 2. Install a new locking pin. Make sure that the locking pin is the correct position, (the arrow points downwards on the outside edge).
Page 236 Attachments Buckets Figure 200. 3. Carefully hit the locking pin with a hammer until it is flush with its guide and locks in position. Refer to Figure 201. Figure 201. 9831/1100-2...
Page 237 Notes: 9831/1100-2...
Page 238: Preservation And Storage
Preservation and Storage Cleaning Preservation and Storage Cleaning General WARNING When using cleaning agents, solvents or other chemicals, you must adhere to the manufacturer's instructions and safety precautions. CAUTION To avoid burning, wear personal protective equipment when handling hot components. To protect your eyes, wear goggles when using a brush to clean components.
Page 239 Preservation and Storage Cleaning 2. Stop the engine and let it cool for at least one hour. Do not try to clean any part of the engine while it is running. 3. Make sure that all of the electrical connectors are correctly coupled. If the connectors are open, attach the correct caps or seal with water proof tape.
Page 240: Checking For Damage
Preservation and Storage Checking For Damage Checking For Damage General Refer to the individual condition checks throughout the Maintenance section. Refer to: Maintenance > Maintenance Schedules (Page 177). 9831/1100-2...
Page 241: Storage
Preservation and Storage Storage Storage General If the product will not be used for an extended period, you must store the product correctly. If you prepare the product carefully and apply on-going care you can prevent deterioration and damage to the product while it is in storage.
Page 242: Take Out Of Storage
Preservation and Storage Storage 3. Install a charged battery. 4. Start the engine. 5. Operate the hydraulic controls. Make sure that the hydraulic functions operate correctly. 6. Prepare the machine for storage. Take out of Storage 1. Examine the coolant condition. Replace if necessary. 2.
Page 243: Security
The Construction Equipment Association is managing the scheme, and Datatag are providing the security material and support. JCB is fully supportive of the CESAR initiative and will offer it as a factory option across the range.
Page 244 Preservation and Storage Security Unpacking the Guards Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 184). Unlock the cage and remove the guards. Leave the guards 2, 3 and 4 in the cage, they are installed from the top of the machine.
Page 245 Preservation and Storage Security Guard 7, Front top panel - position A Hook the guard onto the rail above the front window, make sure the top lip of the guard is correctly installed on the rail. Guard 6, Front bottom panel - position B Attach to the guard 7 and lock onto the two locking points on the cab front.
Page 246: Maintenance Introduction General
To maintain this condition and trouble free operation it is important that the routine services, as specified in this manual, are done by an approved JCB dealer at the recommended specified intervals and it is recommended that this is done by an approved JCB dealer using genuine JCB parts.
Page 247: Obtaining Spare Parts
If you use non-genuine JCB parts or consumables, then you can compromise the health and safety of the operator and cause machine failure. A parts book for your machine is available from your JCB dealer. The parts book will help you identify parts and order them from your JCB dealer.
Page 248: Maintenance Safety
The accumulators contain hydraulic fluid and gas at high pressure. Prior to any work being carried out on systems incorporating accumulators, the system pressure must be discharged by a JCB dealer, as the sudden release of the hydraulic fluid or gas may cause injury.
Page 249: Fluids And Lubricants
Chemicals Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such as Viton®, FluorelTM and Technoflon®. Fluoroelastomeric materials subjected to high temperatures can produce highly corrosive hydrofluoric acid.
Page 250 Maintenance Maintenance Safety Whenever you are handling oil products you must maintain good standards of care and personal and plant hygiene. For details of these precautions we advise you to read the relevant publications issued by your local health authority, plus the following. Storage Always keep lubricants out of the reach of children.
Page 251 Maintenance Maintenance Safety Figure 203. Keep away from children Shield eyes No smoking, no naked flames, no sparks Explosive gas Battery acid Note operating instructions First Aid - Oil Eyes In the case of eye contact, flush with water for 15min. If irritation persists, get medical attention. Swallowing If oil is swallowed do not induce vomiting.
Page 252: Maintenance Schedules
Maintenance Maintenance Schedules Maintenance Schedules General WARNING Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe, it must be correctly parked on solid, level ground. To prevent anyone starting the engine, remove the ignition key. Disconnect the battery when you are not using electrical power.
Page 253 The hydraulic oil must be sampled and checked for contamination and degradation at the intervals shown. Contact your JCB dealer who will have the facilities to do these tasks and make sure that the hydraulic system is correctly maintained.
Page 254: Pre-Start Cold Checks, Service Points And Fluid Levels
Maintenance Maintenance Schedules Table 13. Important Parts Replacement Interval Fuel hose (Fuel tank - engine) Every 2 years or every 4000 hours, whichever comes first. Fuel hose (Fuel filter - injection pump) Table 14. Important Parts Replacement Interval Pump exit hose (Pump - operation valve) Every 2 years or every 4000 hours, whichever comes first.
Page 255 Maintenance Maintenance Schedules Component Task 500 1,000 2,000 4,000 Engine Check (Leaks) Check (Level) Replace FEAD belt Check (Condition) Replace FEAD belt Fan belt Check (Condition) Replace Fan belt (10) Check (Condition) Valves Engine mounts Check (Condition) Air inlet security Check (Condition) Exhaust system security Check (Condition)
Page 256 Maintenance Maintenance Schedules Component Task 500 1,000 2,000 4,000 Gearbox Track gearbox security Check (Condition) Slew gearbox security Check (Condition) Check (Level) Track gearbox oil Check (Level) Slew gearbox oil Replace Track gearbox oil (3, 8) Replace Slew gearbox oil (3, 8) Tracks Track plate condition and bolt...
Page 257: Functional Tests And Final Inspection
(9) Replace every 3000 hours. (10) Replace every 5000 hours. (11) Replace every 8000 hours. (12) These procedures can only be performed with specialist equipment and by trained personnel. Contact your JCB dealer. Functional Tests and Final Inspection Table 17. Component...
Page 258 Maintenance Maintenance Schedules Component Task 500 1,000 2,000 4,000 Electrics General Check (Operation) Alternator - output Check (Condition) Miscellaneous Check (Operation) Fit for purpose test Optional Equipment Overload warning system Check (Operation) Refuel pump Check (Operation) (1) Dusty conditions only. (2) Tasks which must be done by a specialist.
Page 259: Maintenance Positions
Maintenance Maintenance Positions Maintenance Positions General DANGER Your machine may be fitted with a hydraulically raised cab. Do not, under any circumstances enter or work underneath an un-supported cab in the raised position. WARNING A machine can sink into soft ground. Never work under a machine on soft ground. WARNING Make the machine safe before getting beneath it.
Page 260: Service Points
Maintenance Service Points Service Points General CAUTION Make sure the steps, handrails, and your footwear soles are clean and dry before climbing onto the machine. Always face the machine when climbing on and off it. Upper Structure Figure 205. Diesel level indicator Fuel filler cap Hydraulic oil filler cap Hydraulic tank breather...
Page 261 Maintenance Service Points Access to the Upper Structure Figure 206. Figure 207. 9831/1100-2...
Page 262 Maintenance Service Points Figure 208. 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 184). 2. Hold the handrail with both hands, then use the step between the top and bottom tracks to climb onto the top of the track.
Page 263 Maintenance Service Points Battery Compartment Figure 209. Air intake Radiator(s) Batteries Window washer fluid bottle Battery isolator 9831/1100-2...
Page 264 Maintenance Service Points Hydraulic Compartment Figure 210. Main fuel filter/sedimenter Hydraulic oil level indicator Primary fuel filter/drain Engine fuel filter/sedimenter Engine oil filter 9831/1100-2...
Page 265 Maintenance Service Points Undercarriage Figure 211. Track rollers Track tensioner 9831/1100-2...
Page 266: Access Apertures
Maintenance Access Apertures Access Apertures General When moved to their maintenance position, the access panels give you access to parts or areas of the machine that are not required during machine operation. Before you operate the machine, make sure that all of the access panels are correctly in their closed or installed positions.
Page 267: Hydraulic Compartment Cover
Maintenance Access Apertures Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 184). 2. Use the ignition key to unlock the cover. 3. Pull the handle to release the latch. The cover opens automatically and is supported on a gas strut. 4.
Page 268: Radiator Cover
Maintenance Access Apertures Figure 214. Lock Handle Cover Close 1. To release the latch pull it up. 2. Close the cover. 3. Make sure the cover is closed correctly. 4. Use the ignition key to lock the cover. Radiator Cover Open 1.
Page 269 Maintenance Access Apertures Figure 215. Lock Handle Cover Cap Cover Close 1. To release the latch pull it up. 2. Close the covers. 3. Make sure the covers are closed correctly. 4. Use the ignition key to lock the cover. 9831/1100-2...
Page 270: Tools
Maintenance Tools Tools General When you carry tools onto the machine, you must keep three points of contact with the machine at all times. If necessary, lift the tools on to the machine in intervals. Put the tools down before you adjust your grips on the machine. Do not try to adjust your grips on the machine while holding tools.
Page 271: Lubrication
Maintenance Lubrication Lubrication General CAUTION Waxoyl contains turpentine substitute which is flammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin.
Page 272: Attachments
Maintenance Attachments Attachments General Lubricate Where applicable, refer to the specific manufacturers manual for instructions on the lubrication of optional attachments. Check (Condition) Where applicable, refer to the specific manufacturers manual for instructions on the maintenance of optional attachments. 9831/1100-2...
Page 273: Body And Framework
Maintenance Body and Framework Body and Framework General Clean Debris can collect under the boom. Remove all debris from under the boom. Thoroughly dry the piston rams and protect them with clean transmission or hydraulic oil if necessary. Check (Condition) 1.
Page 274: Pivot Pins
Maintenance Body and Framework Pivot Pins Lubricate Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 184). Grease the pivot pins. Figure 218. Boom base pin Boom ram, eye and pin Dipper ram, dump end pin Dipper ram, eye end pin Boom to dipper, connecting pin Bucket ram, dump end pin...
Page 275 Maintenance Body and Framework Figure 220. Bucket ram to bucket linkage pin Bucket linkage to bucket pin Dipper to bucket pin Dipper to bucket linkage pin Figure 221. Boom ram, eye and pin Dipper ram, dump end pin 9831/1100-2...
Page 276: Operator Station
FOGS (Falling Object Guard System) installed. It is the operators responsibility to identify the risk of an application. A failure to do these precautions can cause death or injury to the operator. For assistance, contact your JCB dealer.
Page 277 Maintenance Operator Station Figure 222. Cab Mounted FOGS Torque tightness is 104N·m Torque tightness is 60N·m Torque tightness is 259N·m Figure 223. Frame Mounted FOGS - XD machines Only Torque tightness is 259N·m Torque tightness is 104N·m Torque tightness is 104N·m Torque tightness is 259N·m 9831/1100-2...
Page 278: Seat
Maintenance Operator Station Figure 224. Frame Mounted ROPS (FOGS) Torque tightness is 874N·m Torque tightness is 506N·m Torque tightness is 506N·m Torque tightness is 104N·mFOGS Seat Check (Condition) Check that the seat adjustments operate correctly. Check the seat is undamaged. Check the seat mounting bolts are undamaged, correctly installed and tight.
Page 279: Controls
Maintenance Operator Station Check that the buckle assembly is undamaged and operates correctly. Controls Check (Operation) Check the operation of the non-hydraulic and non-electrical operator station controls. 9831/1100-2...
Page 280: Engine
3. Check the engine and the area below for oil leaks. 4. Close the engine cover (if applicable). 5. If necessary, contact your JCB dealer. Check (Level) WARNING Never check the oil level or add oil with the engine running. Be careful of hot lubricating oil.
Page 281 Maintenance Engine Refer to: Maintenance > Service Points (Page 185). 8.2. Add the recommended oil slowly through the filler point Refer to: Technical Data > Fluids, Lubricants and Capacities (Page 262). 8.3. Replace the dipstick. 8.4. Remove the dipstick. 8.5. Check the oil level, if necessary add more oil. 8.6.
Page 282: Drive Belt
Maintenance Engine 13. Close and secure the engine cover. 14. Operate the engine at idle speed until the oil pressure low warning light has extinguished and the new filter has primed before the engine speed is increased above idle speed. 15.
Page 283: Air Filter
Air Filter General Check (Condition) NOTICE Do not modify or fit non JCB approved components to the engine induction system, otherwise the engine emissions will be compromised. 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 184).
Page 284: Fuel System
Maintenance Fuel System Fuel System General Bleed CAUTION Running the engine with air in the system could damage the fuel injection pump. After maintenance, the system must be bled to remove any air. 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 285: Tank
2. Get access to the engine compartment (if applicable). Refer to: Maintenance > Access Apertures (Page 191). 3. Check the engine compartment (if applicable), fuel lines and the area below for leaks. 4. If necessary, contact your JCB dealer. Tank Clean Draining Fuel Tank Impurities 1.
Page 286: Fuel Filter
Maintenance Fuel System Refer to: Maintenance > Service Points > General (Page 185). 3. Clean the exterior of the cap with a clean cloth. 4. Remove the fuel filler cap. 5. Clean the interior of the fuel filler cap with a clean cloth. 6.
Page 287: Water Separator
Maintenance Fuel System 4. Use the filter wrench to remove the filter bowl from the filter head. 5. Remove seal and filter element. 6. Smear the new sealing ring with fuel oil and install with filter element into bowl. 7. Install bowl to filter head and tighten with filter wrench. 8.
Page 288 Maintenance Fuel System Figure 229. Bowl Main Fuel Filter The fuel filter housing contains a float which moves up and down in accordance with the amount of separated water. Drain any water in the bowl as follows: 1. Make the machine safe. Refer to: Maintenance >...
Page 289: Fuel Pump Filter
Maintenance Fuel System Priming pump Filter bowl Fuel Pump Filter Replace 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 184). 2. Get access to the fuel pump. Refer to: Maintenance > Service Points (Page 185). 3. Rotate cover counter clockwise and remove. 4.
Page 290: Cooling System
2. Get access to the cooling pack. Refer to: Maintenance > Access Apertures (Page 191). 3. Check the cooling system for leaks. 4. If necessary, contact your JCB dealer. Coolant Check (Condition) Refer to: Technical Data > Fluids, Lubricants and Capacities > Coolant (Page 264).
Page 291: Cooling Pack
Maintenance Cooling System Refer to: Operation > Heating, Ventilating and Air-Conditioning (HVAC) > Air-Conditioning Controls (Page 124). 8. Turn the slew lock on. Refer to: Operation > Operating Levers/Pedals (Page 96). 9. Stall the 'dipper in' service until the coolant reaches the specified temperature. Temperature: 90°C (193.9°F) Refer to: Operation >...
Page 292: General
8. When the track is clean, stop the movement. 9. Examine the track, roller sprockets and idler wheels for damage or oil leaks. Replace any damaged parts. If in doubt contact your JCB dealer. 10. Operate the controls slowly to lower the track to the ground.
Page 293: Steel
Steel Check (Operation) WARNING Recoil unit servicing must only be carried out by JCB dealers. You could be killed or injured if you tamper with it. NOTICE Always make sure that the track tension measurement is not less than specified or severe strain to the track will result.
Page 294: Idler Wheels
Refer to: Maintenance > Tracks > Steel > Check (Operation) (Page 218). 3. Check the top and bottom rollers for oil leaks. If leaks are found contact your JCB dealer 4. Repeat the steps 2 to 3 for the other track.
Page 295: Track Gearbox
Maintenance Track Gearbox Track Gearbox Check (Level) 1. Make the machine safe, with the fill/level and drain plugs in the positions shown. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 184). Figure 234. Fill\level plug Drain plug 2.
Page 296: Hydraulic System
4. Lower the boom. Stop the boom several metres from the ground. 5. Lower the boom to the ground. There must be sufficient pressure stored in the accumulator to lower the boom to the ground in two stages. If this is not possible, contact your JCB dealer. 9831/1100-2...
Page 297: Services
2. Look at the hydraulic fluid in the sight tube. If the hydraulic fluid is cloudy, water or air is in the system. Water or air in the system can damage the hydraulic pump. Contact your JCB dealer if the hydraulic fluid is cloudy.
Page 298: Cylinder Rams
Extend each ram fully, one at a time and visually examine for score marks, dents, leaks or similar defects. Make the machine safe before inspecting each ram. If a ram piston appears defective, contact your service engineer or JCB dealer. 9831/1100-2...
Page 299: Electrical System
Maintenance Electrical System Electrical System General Check (Operation) Make sure all of the electrical equipment operates correctly, for example: • Switches • Warning lights • Beacon • Alarms • Horn • Wipers • Hourmeter/display • Battery • Lights All defective equipment must be repaired before the machine is used. Check (Condition) WARNING Battery electrolyte is toxic and corrosive.
Page 300: Battery Isolator
Maintenance Electrical System Figure 235. 4. Apply a thin layer of petroleum jelly to the terminal posts. Connect CAUTION The machine is negatively earthed. Always connect the negative pole of the battery to earth. When connecting the battery, connect the earth (-) lead last. When disconnecting the battery, disconnect the earth (-) lead first.
Page 301: Fuses
1. Isolate the machine electrics. Refer to: Operation > Battery Isolator (Page 128). 2. Make sure that the machine electrics are isolated. A defective isolator must be repaired before the machine is used. For more information, contact your JCB dealer. Fuses Replace NOTICE Always replace fuses with ones of correct ampere rating to avoid electrical system damage.
Page 302: Relays
Maintenance Electrical System Figure 237. Cover Relays Replace Introduction For more information on the individual relays: Refer to: Technical Data > Electrical System > Relays (Page 275). Relays - Cab The relay are installed in the rear stowage area. Open the cover to get access to the relays. For relay identification, a label is attached to the rear of cover.
Page 303: Window Washer
Maintenance Electrical System Figure 239. Cover Window Washer Check (Level) 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 184). 2. Get access to the front window washer bottle. Refer to: Maintenance > Service Points > General (Page 185). 3.
Page 304: Miscellaneous
Maintenance Miscellaneous Miscellaneous Fire Extinguisher Check (Condition) In addition to the operator check the extinguisher must be serviced every 12 months by a suitably qualified person. 1. Examine the fire extinguisher for damage and leaks. 2. Make sure the fire extinguisher is correctly attached. 3.
Page 305 Notes: 9831/1100-2...
Page 306: Technical Data
Technical Data Static Dimensions Technical Data Static Dimensions General For: JS370 ..........................Page 231 For: JS330 ..........................Page 231 For: JS300 ..........................Page 231 (For: JS370) Lifting Dimensions Refer to: Operation > Lifting the Machine (Page 135). Table 18. Item Dimension Lifting angle 75°...
Page 307: Dimensions
Refer to: Operation > Working with the Excavator Arm > Lifting With the Excavator Arm (Page 110). Table 23. Lifting hook 12.5t Lifting lug Dimensions For: JS330 ..........................Page 232 For: JS300 ..........................Page 234 For: JS370 ..........................Page 235 (For: JS330) JS330 - Monoboom Figure 241. Table 24. Description...
Page 308 Technical Data Static Dimensions Table 27. Description Length Counterweight clearance 1,190mm Tailswing radius 3,413mm Width of superstructure 2,990mm Height over cab 3,170mm Height over grab rail 3,196mm Ground clearance 500mm Track height 1,026mm JS330 - Triple Articulated Boom Figure 242. Table 28.
Page 309 Width over tracks (700 shoes) 3,300mm Width over tracks (800 shoes) 3,400mm Width over tracks (850 shoes) Width over tracks (900 shoes) 3,500mm Transport length 16,772mm Transport height 4,103mm Track height 1,026mm (For: JS300) JS300 - Monoboom Figure 244. 9831/1100-2...
Page 310 Technical Data Static Dimensions Table 32. Description Track length on ground 3,990mm 3,990mm Undercarriage overall length 4,843mm 4,843mm Track gauge 2,390mm 2,600mm Width over tracks (600 shoes) 2,990mm 3,200mm Width over tracks (700 shoes) 3,090mm 3,300mm Width over tracks (800 shoes) 3,190mm 3,400mm Width over tracks (900 shoes)
Page 311 Technical Data Static Dimensions Description Length (LC) Length (NLC) Width over tracks (800 shoes) 3,400mm 3,190mm Width over tracks (900 shoes) 3,500mm 3,290mm Table 36. Dipper lengths 2,210mm 2,630mm 3,230mm 4,030mm Transport length 11,413mm 11,353mm 11,253mm 11,333mm Transport height 3,440mm 3,510mm 3,280mm 3,700mm...
Page 312: Weights
1,024mm Weights For: JS330 ..........................Page 237 For: JS370 ..........................Page 237 For: JS300 ..........................Page 238 (For: JS330) Shipping Weight An approximate weight when the machine has a monoboom, medium length dipper, bucket, operator and a full fuel tank.
Page 313 Table 43. LC Track shoe width Weight 600mm 37,720kg 700mm 38,165kg (For: JS300) Shipping Weight An approximate weight when the machine has a monoboom, medium length dipper, bucket, operator and a full fuel tank. Table 44. JS300LC Track shoe width Weight...
Page 314: Performance Dimensions
Technical Data Performance Dimensions Performance Dimensions Excavator Arm Dimensions and Performance For: JS330 ..........................Page 239 For: JS300 ..........................Page 248 For: JS370 ..........................Page 250 (For: JS330) Digging JS330 - Standard Monoboom Figure 247. Table 46. Boom length 6,450mm...
Page 315 Technical Data Performance Dimensions JS330 - Triple Articulated Boom Figure 248. Metres Table 47. Boom length 6,240mm Dipper length 2,210mm 2,630mm 3,230mm 4,030mm A Maximum digging reach 10,170mm 10,570mm 11,400mm 11,890mm B Maximum digging reach (on 9,960mm 10,370mm 10,950mm 11,710mm ground) C Maximum digging depth 5,760mm...
Page 316 Technical Data Performance Dimensions JS330 - ME Monoboom Figure 249. Table 48. Boom length 6,100mm Dipper length 2,210mm 2,630mm Maximum digging reach 9,780mm 10,190mm Maximum digging reach (on ground) 9,560mm 9,980mm Maximum digging depth 5,960mm 6,390mm Maximum digging height 9,450mm 9,720mm Maximum dumping height 6,620mm...
Page 317 Technical Data Performance Dimensions JS330 LR Figure 250. 45º 45º Table 49. Boom length 12,330mm Dipper length 9,500mm Maximum digging reach 21,660mm Maximum digging reach (on ground) 21,560mm Maximum digging depth 17,500mm Maximum digging height 15,500mm Maximum dumping height 13,320mm Minimum dumping height 3,140mm Bucket struck radius...
Page 318 Technical Data Performance Dimensions Lifting Figure 251. Figure 252. 9831/1100-2...
Page 319 Technical Data Performance Dimensions Figure 253. Figure 254. 9831/1100-2...
Page 320 Technical Data Performance Dimensions Figure 255. Figure 256. 9831/1100-2...
Page 321 Technical Data Performance Dimensions Figure 257. Figure 258. 9831/1100-2...
Page 322 Technical Data Performance Dimensions Figure 259. 9831/1100-2...
Page 323 Technical Data Performance Dimensions (For: JS300) Digging JS300 - Standard Monoboom Figure 260. Table 51. Boom length 6,200mm Dipper length 2,500mm 3,100mm 3,700mm A Maximum digging reach 10,091mm 10,655mm 11,291mm B Maximum digging reach (on 9,871mm 10,447mm 11,096mm ground) C Maximum digging depth...
Page 324 Technical Data Performance Dimensions Lifting Figure 261. Figure 262. 9831/1100-2...
Page 325 Technical Data Performance Dimensions (For: JS370) Digging Monoboom Figure 263. Met re s Feet Met re s Feet Table 52. Boom length 6,450mm Dipper length 2,210mm 2,630mm 3,230mm 4,030mm A Maximum digging reach 10,060mm 10,460mm 11,020mm 11,760mm B Maximum digging reach (on ground) 9,850mm 10,255mm 10,820mm...
Page 326 Technical Data Performance Dimensions ME Monoboom Figure 264. Met re s Met re s Feet Feet Table 53. Boom length 6,100mm Dipper length 2,210mm 2,630mm Maximum digging reach 9,782mm 10,190mm Maximum digging reach (on ground) 9,566mm 9,984mm Maximum digging depth 5,960mm 6,387mm Maximum digging height...
Page 327 Technical Data Performance Dimensions Figure 265. 45º 45º Table 54. Boom length 12,330mm Dipper length 9,500mm Maximum digging reach 21,100mm Maximum digging reach (on ground) 21,000mm Maximum digging depth 17,040mm Maximum digging height 15,830mm Maximum dumping height 14,350mm Minimum dumping height 2,440mm Bucket struck radius 1,300mm...
Page 328 Technical Data Performance Dimensions Lifting Figure 266. Figure 267. 9831/1100-2...
Page 329 Technical Data Performance Dimensions Figure 268. Figure 269. 9831/1100-2...
Page 330 Technical Data Performance Dimensions Figure 270. Figure 271. 9831/1100-2...
Page 331: Driving Performance
Technical Data Performance Dimensions Figure 272. Figure 273. Driving Performance The maximum travel speed of all JS Tracked Excavators is no more than 6 kph (3.7 mph). 9831/1100-2...
Page 332: Noise Emissions
The noise data values shown only apply to CE marked machines. For information relating to this machine when used with other JCB approved attachments, please refer to the literature accompanying the attachments. Table 56. Definition of terms...
Page 333: Vibration Emissions
Technical Data Vibration Emissions Vibration Emissions General To assist in compliance with the European Directive 2002/44/EC, the duty specific vibration emission values for this machine type have been provided on the following page(s) and may be used for the assessment of risks to exposure from vibration.
Page 334: Vibration Data
Technical Data Vibration Emissions Vibration Data For: JS330 ..........................Page 259 For: JS300 ..........................Page 259 For: JS370 ..........................Page 260 (For: JS330) The whole-body vibration emission under representative operating conditions (according to the intended use) are shown. Figure 275.
Page 335 Technical Data Vibration Emissions Figure 276. 0.37 0.25 0.15 Dominant axis Machine operating duty: Low idle Machine operating duty: Excavating Machine operating duty: Tracking (rough terrain) The whole-body vibration emission calculated in accordance with ISO 2631-1:1997 for this machine type is 0.25m/s²...
Page 336 Technical Data Vibration Emissions The whole-body vibration emission calculated in accordance with ISO 2631-1:1997 for this machine type is 0.25m/s² normalised to an 8h reference period [A(8)] and based upon a test cycle defined in SAE J1166. The hand-arm vibration calculated in accordance with the dynamic test conditions defined in ISO 5349-2: 2001 does not exceed 2.5m/s².
Page 337: Fluids, Lubricants And Capacities
Fluids, Lubricants and Capacities General JCB recommend that you use the JCB lubricants shown as they have been verified by JCB for use on JCB machines. However, you could use other lubricants that are equivalent to the JCB standards and quality or offer the same machine component protection.
Page 338 Technical Data Fluids, Lubricants and Capacities Use a type of extra-low-sulphur diesel fuel designated for general diesel vehicles which satisfies these requirements. • No fine dust is contained • Appropriate degree of viscosity is provided • High in cetane value •...
Page 339: Coolant
The correct concentration of antifreeze protects the engine against frost damage in winter and provides year round protection against corrosion. The protection provided by JCB High Performance Antifreeze and Inhibitor is shown below. Table 61. Concentration...
Page 340 Technical Data Fluids, Lubricants and Capacities If you use any other brand of antifreeze: • Make sure that the antifreeze complies with International Specification ASTM D6210 • Always read and understand the manufacturer's instructions • Make sure that a corrosion inhibitor is included. Serious damage to the cooling system can occur if corrosion inhibitors are not used •...
Page 341: Torque Values
Hydraulic pump Hydraulic oil tank Fuel tank Control valve Battery Rotary coupling 196/245 176/221 (1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed. Table 63. Bolt Diameter (size) Hex. bolt Wrench (mm) Tightening (N.m) 12.5...
Page 342 Technical Data Torque Values Bolt Diameter (size) Hex. socket Wrench (mm) head bolt Tightening (N.m) torque 9831/1100-2...
Page 343 Technical Data Torque Values Figure 278. (For: JS370) Before and after daily work, check for loose or missing nuts and bolts. Tighten if loose and replace if missing. 9831/1100-2...
Page 344 Hydraulic pump Hydraulic oil tank Fuel tank Control valve Battery Rotary coupling 196/245 176/221 (1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed. Table 65. Bolt Diameter (size) Hex. bolt Wrench (mm) Tightening (N.m) 12.5 torque Hex.
Page 345 Technical Data Torque Values Figure 279. 9831/1100-2...
Page 346 Hydraulic pump Hydraulic oil tank Fuel tank Control valve Battery Rotary coupling 196/245 176/221 (1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed. Table 67. Bolt Diameter (size) Hex. bolt Wrench (mm) Tightening (N.m) 12.5 torque Hex.
Page 347 Technical Data Torque Values Figure 280. 9831/1100-2...
Page 348: Electrical System
Technical Data Electrical System Electrical System General Table 68. Item Specification System voltage Fuses Fuses - Cab Figure 281. Table 69. Fuse Identification Fuse Circuit(s) Protected Rating Beacon Backlight Cushion solenoid 7.5A Ignition wakeup Livelink 2 ECU (Electronic Control Unit) ignition Auxiliary ignition supplies Spare 1 Heated/Suspension/Ventilated seat...
Page 349 12–24V connector Standard worklamps Horn Wash wipe Engine stop Refuelling pump Display ECU Fuses - Battery Bay Figure 282. Table 70. Fuse Identification Fuse Circuit(s) Protected Rating Fuse box battery supply Alternator JCB engine/pod box Ignition relay/fuse box ignition supply 9831/1100-2...
Page 350: Relays
Technical Data Electrical System Relays Relay - Cab Figure 283. Table 71. Relay Identification Relay Circuit(s) Engine crank Horn Wash wipe Engine stop Refuel pump Main engine relay Engine micro relay 9831/1100-2...
Page 351: Tracks
Technical Data Tracks Tracks General Refer to: Maintenance > Tracks (Page 217). Table 72. Track Tension Minimum Track Tension Maximum Track Tension 25mm 30mm 9831/1100-2...
Page 352: Declaration Of Conformity
Refer to: Technical Data > Declaration of Conformity > Data (Page 277). Data Table 73. JCB Heavy Products Limited, Lakeside Works, Rocester, Staffordshire, United Kingdom, ST14 5JP. Excavators, Rope Or Hydraulic (Hydraulic, Tracked). Refer to: Introduction > About this Manual > Model and Serial Number (Page 1).
Page 353 Technical Data Declaration of Conformity Figure 284. 9831/1100-2...
Page 354 Technical Data Warranty Information Warranty Information Service Record Sheet Table 74. Date Annual Insurance (Yes) Hours Signature and stamp Figure 285. Installation Checklist Figure 286. 500h/3 Month Figure 287. 1000h/6 Month 9831/1100-2...
Page 355 Technical Data Warranty Information Figure 288. 1500h/9 Month Figure 289. 2000h/12 Month Figure 290. 2500h/15 Month Figure 291. 3000h/18 Month 9831/1100-2...
Page 356 Technical Data Warranty Information Figure 292. 3500h/21 Month Figure 293. 4000h/24 Month Figure 294. 4500h/27 Month Figure 295. 5000h/30Month 9831/1100-2...
Page 357 Technical Data Warranty Information Figure 296. 5500h/33 Month Figure 297. 6000h/36 Month Figure 298. 6500h/39 Month Figure 299. 7000h/42 Month 9831/1100-2...
Page 358 Technical Data Warranty Information Figure 300. 7500h/45 Month Figure 301. 8000h/48 Month Figure 302. 8500h/51 Month Figure 303. 9000h/54 Month 9831/1100-2...
Page 359 Technical Data Warranty Information Figure 304. 9500h/57 Month Figure 305. 10000h/60 Month Figure 306. 10500h/63 Month Figure 307. 11000h/66 Month 9831/1100-2...
Page 360 Technical Data Warranty Information Engine Emissions Emission Control System Maintenance and Warranty Statement Emission Related System Defect Warranty Isuzu Motors America LLC warrants to the initial owner and subsequent owner of a certified non-road diesel engine (powering non-road machines and equipment), that such engine is: 1.
Page 361 Technical Data Warranty Information 3.1. EGR valve 3.2. EGR cooler 4. Thermal reactor system 4.1. Exhaust manifold 4.2. Diesel oxidation catalyst (build within DPD) 5. Particulate controls 5.1. Particulate filter (build within DPD) 5.2. Diesel oxidation catalyst 6. PCV (Positive Crankcase Ventilation) system 7.
Page 362 Technical Data Warranty Information This includes diagnosis and labour to remove and install the engine, if necessary. Owner Responsibilities During the emission warranty period, the owner is responsible for: • The performance of all required maintenance. A warranty claim will not be denied because the scheduled maintenance was not performed.
Page 363 Technical Data Warranty Information If any emission related part on your engine is defective, the part will be repaired or replaced by Isuzu Motors America LLC. Owner's Warranty Responsibilities • As the off road compression ignition engine owner, you are responsible for the performance of the required maintenance listed in your owner's manual.
Page 364 Technical Data Warranty Information Turbocharger Check for any unusual sound or vibration in the turbocharger. Inspect inlet and exhaust piping and connections. Check bearing condition and perform maintenance as described in the Maintenance Schedule. Slow engine response and low power may indicate a need for adjustment or repair. Your Isuzu engine dealer is equipped with the necessary tools, personnel, and perform this service.
Page 365 Notes: 9831/1100-2...
Page 366 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 367 Section B - Body and Framework Notes: 9813/5100-1...
Page 368 Section B - Body and Framework Contents Page No. Heater/Air Conditioning SYSTEM Introduction ....................B-1 Related Topics ..................B-2 Specifications ................... B-3 Operation Overview .................. B-4 Electrical Operation and Schematics ............B-12 Fault Finding ................... B-16 HVAC Unit Introduction ..................... B-21 Related Topics ..................
Page 369 Section B - Body and Framework Contents Page No. B-ii B-ii...
Page 370: Heater/Air Conditioning System
Section B - Body and Framework Heater/Air Conditioning SYSTEM Introduction Heater/Air Conditioning SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications K Related Topics ( T table.
Page 371: Related Topics
Section B - Body and Framework Heater/Air Conditioning SYSTEM Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 372: Specifications
Section B - Body and Framework Heater/Air Conditioning SYSTEM Specifications Specifications Table 2. Pressure Switch Setting lbf/in Low Pressure Cut In 1.4 (+/- 0.1) 20 (+/- 1.5) Low Pressure Cut Out 0.3 (+/- 0.1) 4 (+/- 1.5) High Pressure Cut In 17.2 (+/- 0.7) 250 (+/- 10) High Pressure Cut Out...
Page 373: Operation Overview
Section B - Body and Framework Heater/Air Conditioning SYSTEM Operation Overview Operation Overview 716480-C7.eps Fig 1. 9813/5100-1...
Page 374 Section B - Body and Framework Heater/Air Conditioning SYSTEM Operation Overview Item Description K Fig 2. ( T B-6) Evaporator Matrix Condenser Binary Switch Receiver/Drier Compressor Control Panel Low Pressure Recharge Point High Pressure Recharge Point ATC Electronic Control Module Pulse Width Modulation (PWM) Module Cab Air Sensor Thermal Expansion Valve (TXV)
Page 375 Section B - Body and Framework Heater/Air Conditioning SYSTEM Operation Overview C134900 Fig 2. Evaporator Matrix (A) 9813/5100-1...
Page 376 Section B - Body and Framework Heater/Air Conditioning SYSTEM Operation Overview Air Conditioning System Operation refrigerant is now considerably below that of the air being drawn across the evaporator matrix by the blowers. Heat is transferred from the ambient and re-circulated air to the To maintain optimum operator comfort in warm climates or refrigerant, causing the low pressure liquid to vaporise and during seasons of high ambient temperature, the air...
Page 377 Section B - Body and Framework Heater/Air Conditioning SYSTEM Operation Overview Heater/Air Conditioning Controls (ATC) Auto mode is activated by switch 2, the LED will illuminate and an `A' will appear on the display 7. The heater/air conditioning can be set for automatic Rotate control 5 to set the desired temperature.
Page 378 Section B - Body and Framework Heater/Air Conditioning SYSTEM Operation Overview ATC Control Panel T013670 Fig 4. The ATC system includes an electronic control system that Cab Temperature Sensor protects the system components if a problem occurs. The electronic control system also lets the operator control the The cab temperature sensor is on the inlet vent in the ATC cab temperature, fan speed and air flow direction at the unit in the cab.
Page 379 Section B - Body and Framework Heater/Air Conditioning SYSTEM Operation Overview change where the inlet air is drawn in from by moving a control flap. – Water valve (Actuator). The PWM module changes the signal to the Water valve as requested on the temperature dial on the ATC control panel.
Page 380 Section B - Body and Framework Heater/Air Conditioning SYSTEM Operation Overview Safety Procedures refrigerant system must be conducted in a well ventilated area. The air conditioning system includes a pressurised closed Containers of refrigerant should be stored in a cool circuit containing a non-CFC, environmentally friendly environment away from direct sunlight.
Page 381: Electrical Operation And Schematics
Section B - Body and Framework Heater/Air Conditioning SYSTEM Electrical Operation and Schematics Electrical Operation and Schematics ATC System K Fig 5. ( T B-13) ATC Control Panel Connector Low Pressure Switch Evaporator Temperature Sensor A Outlet Temperature Sensor A Cab Temperature Sensor A ATC Unit Connector Water Valve Actuator...
Page 382 Section B - Body and Framework Heater/Air Conditioning SYSTEM Electrical Operation and Schematics B-13 9813/5100-1 B-13...
Page 383 Section B - Body and Framework Heater/Air Conditioning SYSTEM Electrical Operation and Schematics B-14 9813/5100-1 B-14...
Page 384 Section B - Body and Framework Heater/Air Conditioning SYSTEM Electrical Operation and Schematics B-15 9813/5100-1 B-15...
Page 385: Fault Finding
Section B - Body and Framework Heater/Air Conditioning SYSTEM Fault Finding Fault Finding Preliminary Checks Before any checks are carried out on the refrigerant circuit the following checks should be made: Check the compressor drive belt is serviceable and correctly tensioned. Check the condenser and engine radiator are not blocked by debris, clean with compressed air or water if necessary.
Page 386 Section B - Body and Framework Heater/Air Conditioning SYSTEM Fault Finding Error Codes / Error Diagnosis (Automatic Temperature Control (ATC) System) Table 5. Error Code 1 - High Pressure Lock Out Effect Description Causes Remedy The unit cannot The high pressure switch The system is overcharged.
Page 387 Section B - Body and Framework Heater/Air Conditioning SYSTEM Fault Finding Table 7. Error Code 3 - Blower Potentiometer Error (User Interface / Control Panel) Effect Causes Remedy The Blower motor speed is irregular in Wiring Error (open or short-circuit). Check for 24V at blower motor.
Page 388 Section B - Body and Framework Heater/Air Conditioning SYSTEM Fault Finding Table 10. Error Code 8 - Evaporator Temperature Sensor Error Effect Causes Remedy The unit cannot cool the cab The There is no temperature signal from Check the continuity between pin1 on compressor disengages.
Page 389 Section B - Body and Framework Heater/Air Conditioning SYSTEM Fault Finding Page left intentionally blank B-20 9813/5100-1 B-20...
Page 390: Hvac Unit
Section B - Body and Framework HVAC Unit Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.
Page 391: Related Topics
Section B - Body and Framework HVAC Unit Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 392: Removal And Replacement
Section B - Body and Framework HVAC Unit Removal and Replacement Removal and Replacement Removal Note: Before removing the HVAC/Air Conditioning Unit, the system must be discharged. WARNING The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be disconnected until the system has been discharged by a refrigeration engineer or a suitably trained person.
Page 393 Section B - Body and Framework HVAC Unit Removal and Replacement C134850-C1.eps Fig 2. Remove the ventilation hoses A. Label the water hoses B and the air conditioning hoses C and remove. Remove the mounting screws D from both sides of the unit and lift the heater from the machine.
Page 394: Air Conditioning Condensor
Section B - Body and Framework Air Conditioning Condensor Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.
Page 395: Related Topics
Section B - Body and Framework Air Conditioning Condensor Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 396: Removal And Replacement
Section B - Body and Framework Air Conditioning Condensor Removal and Replacement Removal and Replacement C132060-C1.eps Fig 1. Note: Before removing the condenser matrix, discharge the cooling pack, this can be done without disconnecting the system. the air conditioning hoses i.e. with the system fully charged.
Page 397 Section B - Body and Framework Air Conditioning Condensor Removal and Replacement connected. Take care not to kink the hoses. Do not allow Disconnect the air conditioning hoses 5 and 6 from the condenser to hang on the hoses unsupported. the condenser.
Page 398: Air Conditioning Compressor
Section B - Body and Framework Air Conditioning Compressor Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.
Page 399: Related Topics
Section B - Body and Framework Air Conditioning Compressor Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 400: Removal And Replacement
Section B - Body and Framework Air Conditioning Compressor Removal and Replacement Removal and Replacement Removal Note: Before removing any of the hoses from the compressor, the system must be discharged. See Refrigerant Charging and Discharging. WARNING The air conditioning system is a closed loop system and contains pressurised refrigerant.
Page 401 Section B - Body and Framework Air Conditioning Compressor Removal and Replacement Page left intentionally blank B-32 9813/5100-1 B-32...
Page 402: Cab
Section B - Body and Framework Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.
Page 403: Related Topics
Section B - Body and Framework Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 404: Cab Structure
Reference is frame housing in one piece. made to the tools in the text. The majority of these tools can be obtained locally and the remainder from JCB b Toughened glass - remove as much of the Service (see Service Tools).
Page 405 Section B - Body and Framework Cab Structure ii Insert the braided cutting wire B down the centre of the steel tube. If necessary, from the outside, cut out local sealant at the point of the tube to gain access to the wire. iii Using suitable pliers, pull the cutting wire through the sealant to the outer side of the glass.
Page 406 Section B - Body and Framework Cab Structure K Fig 4. ( T d Craft Knife. B-37). The blades A are Preparing the Cab Frame Aperture replaceable. If damp or wet, dry the aperture area using a hot air Insert the knife blade into the sealant. gun (sourced locally).
Page 407 Section B - Body and Framework Cab Structure Fig 8. Make sure the glass is positioned on the stand the correct way up (i.e. with the black ceramic ink band upwards) ready for application of primer etc. Clean the glass Fig 6.
Page 408 Section B - Body and Framework Cab Structure a Remove the aluminium disc cover from the base Note: Once the pre-heated adhesive has been applied to of the cartridge and discard the 'dessicant the glass, install the glass in the aperture as soon as capsule'.
Page 409 Section B - Body and Framework Cab Structure minutes, but it must not be used during the curing period of 30 minutes. c Clean the glass using a purpose made glass cleaner On completion of the glass installation procedures tidy the work area: a Remove all broken glass from the cab area.
Page 410 Section B - Body and Framework Cab Structure Checks bolt torques. Tighten them to the correct torque if necessary. Failure to take these precautions could result in death or Table 2. Torque Settings injury to the operator. Item Kgf m lbf ft Check the structure for damage.
Page 411 Section B - Body and Framework Cab Structure Checking the FOGS Structure Torque Setting All excavators are designed so that an operator's protective structure can be fitted. In certain applications such as demolition, machines must be fitted with the optional Falling Objects Guard Structure (FOGS). It is the operator's responsibility to identify the risk of an application.
Page 412: Cab Panel Removal
Section B - Body and Framework Cab Panel Removal Cab Panel Removal The cab is fitted with five plastic trim panels. The panels K Fig 17. ( T B-45) LH ‘C’ Post Cover. are fixed to the cab frame with screws. Fixings - 4 x screws and nylon washers Components, such as electrical switches, locate in some Coat hook...
Page 413 Section B - Body and Framework Cab Panel Removal C130450 Fig 16. B-44 9813/5100-1 B-44...
Page 414 Section B - Body and Framework Cab Panel Removal C130490 Fig 17. B-45 9813/5100-1 B-45...
Page 415 Section B - Body and Framework Cab Panel Removal Page left intentionally blank B-46 9813/5100-1 B-46...
Page 416: Routine Maintenance Procedures
Section B - Body and Framework Routine Maintenance Procedures Scheduled Tasks The table below lists the Body and Framework related Note: Maintenance schedules can vary according to Scheduled tasks. The tasks are in addition to the tasks machine operating conditions and environments. Refer to detailed in Section 2.
Page 417: Doors And Locks
Section B - Body and Framework Routine Maintenance Procedures Doors and Locks Doors and Locks Check (Condition) Check the condition of the cab doors and locks as follows: – Check the operation of the latches and locks. Replace worn or defective components if the latches fail to latch, release, lock or unlock correctly.
Page 418: Excavator Lever And Pedal Locks
Section B - Body and Framework Routine Maintenance Procedures Excavator Lever and Pedal Locks Excavator Lever and Pedal Locks Check (Operation) Check the operation of the machine control locks. refer to Section 2, Operation, Machine Locks. If the control locks do not operate correctly, carry out the necessary procedures to repair them.
Page 419: Swing Ring Pinion And Gear Teeth
Section B - Body and Framework Routine Maintenance Procedures Swing Ring Pinion and Gear Teeth Swing Ring Pinion and Gear Teeth General Ensure Swing ring is kept full of grease. Always grease whenever the machine has been steam-cleaned. Lubricate Lubricate the Swing ring pinion and gear teeth as follows: Prepare machine Refer...
Page 420: Fit For Purpose Test
This may be needed every six months or at least annually in some countries to meet and comply with legislation and for insurance purposes. Check with your local JCB distributor for further advice. B-51 9813/5100-1 B-51...
Page 421: Cab Heater/Air-Conditioning Filter
Section B - Body and Framework Routine Maintenance Procedures Cab Heater/Air-Conditioning Filter Cab Heater/Air-Conditioning Filter General the Heating Ventilation and Air-Conditioning (HVAC) unit 1 inside the cab. The HVAC unit is located at the rear of the operator’s seat. There are two cab heater/air-conditioning filters. A fresh air filter 2 and a re-circulation filter 3.
Page 422 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 423 Section C - Electrics Notes: 9813/5100-1...
Page 424 Section C - Electrics Contents Page No. Overview and Schematics Circuit Symbols ..................C-1 Circuit Concepts ..................C-3 Using a Multimeter ..................C-6 Schematic Diagrams ................C-10 Fuses and Relays Introduction ..................... C-31 Related Topics ..................C-32 Introduction ..................... C-33 Cab Fuse and Relay Box - Connector Identification .......
Page 425 Section C - Electrics Contents Page No. 24 to 12 Volt Converter ................. C-141 Charging System Introduction ................... C-145 Related Topics ..................C-146 Description .................... C-147 Alternator ....................C-149 Test Procedures ..................C-150 Harness Systems Installation and Interconnections ............C-153 Earth Points ..................
Page 426: Overview And Schematics Circuit Symbols
Section C - Electrics Overview and Schematics Circuit Symbols Overview and Schematics Circuit Symbols TC-013 The following notations are used in the description circuit, drawings. C005310GB-2 Fig 1. Inputs and Outputs The letters i/p and o/p refer to input and output. The letters in brackets i.e.
Page 427 Section C - Electrics Overview and Schematics Circuit Symbols Page left intentionally blank 9813/5100-1...
Page 428: Circuit Concepts
Section C - Electrics Overview and Schematics Circuit Concepts Circuit Concepts Inputs There are two main types of input, Digital and Analogue. Digital type inputs are on/off type inputs (i.e. switches) and can be Low side inputs or High side inputs. Low side inputs are inputs that provide a ground to the ECU.
Page 429 Section C - Electrics Overview and Schematics Circuit Concepts Analogue input (i.e. sensor type inputs) C045960GB-2 Fig 5. 9813/5100-1...
Page 430 Section C - Electrics Overview and Schematics Circuit Concepts Outputs There are three main types of outputs Low side output, High side output and Modulated output. In the Low side output circuit the actuator (solenoid, relay etc.) which is being driven already has a positive feed available, the ECU then provides the ground side of the circuit.
Page 431: Using A Multimeter
Section C - Electrics Overview and Schematics Using a Multimeter Using a Multimeter TC-002 In order to obtain maximum benefit from the fault finding information contained in Section C it is important that the technician fully understands the approach to fault finding and the use of the recommended test equipment, in this case a FLUKE 85 or AVO 2003 digital multimeter, or a moving pointer (analogue) multimeter.
Page 432 Section C - Electrics Overview and Schematics Using a Multimeter plugged into the black socket (sometimes, this socket Measuring Resistance is also marked by a "-", or "E" or marked as "COMMON" or "COM"). The red test lead should be Make sure there is no power to the part of the circuit plugged into the red socket marked with "+", "V"...
Page 433 Section C - Electrics Overview and Schematics Using a Multimeter Measuring Continuity Measuring Frequency Make sure there is no power to the part of the circuit The AVO 2003 and the analogue meter are not capable of you are checking for continuity. measuring frequency, therefore a Fluke 85 digital multimeter must be used.
Page 434 Section C - Electrics Overview and Schematics Using a Multimeter Testing a Diode or a Diode Wire c On an analogue meter. Select the Ohms 1000s (1k) range. A diode wire is a diode with male connector fitted on one end and a female connector fitted on the other end.
Page 435: Schematic Diagrams
Section C - Electrics Overview and Schematics Schematic Diagrams C-10 9813/5100-1 C-10...
Page 436 Section C - Electrics Overview and Schematics Schematic Diagrams C-11 9813/5100-1 C-11...
Page 437 Section C - Electrics Overview and Schematics Schematic Diagrams C-12 9813/5100-1 C-12...
Page 438 Section C - Electrics Overview and Schematics Schematic Diagrams C-13 9813/5100-1 C-13...
Page 439 Section C - Electrics Overview and Schematics Schematic Diagrams C-14 9813/5100-1 C-14...
Page 440 Section C - Electrics Overview and Schematics Schematic Diagrams C-15 9813/5100-1 C-15...
Page 441 Section C - Electrics Overview and Schematics Schematic Diagrams C-16 9813/5100-1 C-16...
Page 442 Section C - Electrics Overview and Schematics Schematic Diagrams C-17 9813/5100-1 C-17...
Page 443 Section C - Electrics Overview and Schematics Schematic Diagrams C-18 9813/5100-1 C-18...
Page 444 Section C - Electrics Overview and Schematics Schematic Diagrams C-19 9813/5100-1 C-19...
Page 445 Section C - Electrics Overview and Schematics Schematic Diagrams C-20 9813/5100-1 C-20...
Page 446 Section C - Electrics Overview and Schematics Schematic Diagrams C-21 9813/5100-1 C-21...
Page 447 Section C - Electrics Overview and Schematics Schematic Diagrams C-22 9813/5100-1 C-22...
Page 448 Section C - Electrics Overview and Schematics Schematic Diagrams C-23 9813/5100-1 C-23...
Page 449 Section C - Electrics Overview and Schematics Schematic Diagrams C-24 9813/5100-1 C-24...
Page 450 Section C - Electrics Overview and Schematics Schematic Diagrams C-25 9813/5100-1 C-25...
Page 451 Section C - Electrics Overview and Schematics Schematic Diagrams C-26 9813/5100-1 C-26...
Page 452 Section C - Electrics Overview and Schematics Schematic Diagrams C-27 9813/5100-1 C-27...
Page 453 Section C - Electrics Overview and Schematics Schematic Diagrams C-28 9813/5100-1 C-28...
Page 454 Section C - Electrics Overview and Schematics Schematic Diagrams C-29 9813/5100-1 C-29...
Page 455 Section C - Electrics Overview and Schematics Schematic Diagrams Component Keys Refer to Section C - Harness Data for connector details. C-30 9813/5100-1 C-30...
Page 456: Fuses And Relays
Section C - Electrics Fuses and Relays Introduction Fuses and Relays Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications K Related Topics ( T table.
Page 457: Related Topics
Section C - Electrics Fuses and Relays Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 458: Introduction
Section C - Electrics Fuses and Relays Introduction Introduction CAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5 For details of the machine fuses and relays refer to Section 2, Technical Data. C-33 9813/5100-1 C-33...
Page 459: Cab Fuse And Relay Box - Connector Identification
Section C - Electrics Fuses and Relays Cab Fuse and Relay Box - Connector Identification Cab Fuse and Relay Box - Connector Identification C100 - X3 C100 - X1 3 5 7 2 4 6 8 C100 - X4 C100 - X2 C129520.eps Fig 1.
Page 460: Electronic Controllers
Section C - Electrics Electronic Controllers Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.
Page 461: Related Topics
Section C - Electrics Electronic Controllers Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 462: Canbus System
Section C - Electrics Electronic Controllers CANbus System CANbus System Modern machines use Electronic Control Units (ECU’s) to control machine systems such as hydraulics, transmission and engine. In much the same way as office computers can be ‘networked’ to communicate with each other the machine ECU’s can be ‘networked’.
Page 463 Section C - Electrics Electronic Controllers CANbus System CANbus Communications System An electronic communications system that connects all the machine ECU’s to one pair of data wires called the CANbus. Coded data is sent to and from the ECU’s on the Controller CANbus.
Page 464 – Bound ECU’s must be unlocked from the CANbus before removal of ECU’s or installation of operating software. For security reasons an unlock code must be obtained from JCB Service to enable completion of procedure. Refer Servicemaster documentation and JDS Technical Information for the correct procedures.
Page 465: Machine Electronic Control Unit (Mecu
Section C - Electrics Electronic Controllers Machine Electronic Control Unit (MECU) Machine Electronic Control Unit (MECU) Location The MECU 2 is located inside the cab on the rear bulkhead 3. To get access to the MECU remove the rear access panel 1.
Page 466 Section C - Electrics Electronic Controllers Machine Electronic Control Unit (MECU) Wires and Connectors C015 C016 C128270 Fig 3. Harness Connectors C015, C016 Not used Harness Connector C015 - J1 (black) Power signal - wake up (door open, refuel) Pins Details CAN shield Output - cooling fan solenoid High side output - travel speed solenoid...
Page 467 Section C - Electrics Electronic Controllers Machine Electronic Control Unit (MECU) Digital input - boom overload pressure switch Harness Connector C016 - J2 (grey) Pins Details Low side output - cooling fan PWM return Digital input - coolant level switch Digital input - boom up pressure switch High side output - travel alarm High side output - MRV boost solenoid...
Page 468 The MECU is bound on the CANbus system. Do not remove or disconnect the MECU unless you have access to the applicable JCB Servicemaster software tools. Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2, Maintenance.
Page 469: Hydraulic Electronic Control Unit (Hecu
Section C - Electrics Electronic Controllers Hydraulic Electronic Control Unit (HECU) Hydraulic Electronic Control Unit (HECU) Location The HECU 2 (if fitted) is located inside the cab on the rear bulkhead 3. To get access to the HECU remove the rear access panel 1.
Page 470 Section C - Electrics Electronic Controllers Hydraulic Electronic Control Unit (HECU) Wires and Connectors C153 C154 C128270-C1 Fig 6. Harness Connectors C153, C154 Not used Harness Connector C153 - J1 (black) Not used Pins Details Digital input - arm limit proximity switch High side output - proportional solenoid - high flow Not used Battery (+ 24V)
Page 471 Section C - Electrics Electronic Controllers Hydraulic Electronic Control Unit (HECU) Digital input - quickhitch pressure switch Harness Connector C154 - J2 (grey) Pins Details Low side output - high flow auxiliary proportional solenoids return Not used Digital input - quickhitch switch Not used High side output - merge flow A solenoid High side output - merge flow B solenoid...
Page 472 Section C - Electrics Electronic Controllers Hydraulic Electronic Control Unit (HECU) Removal and Replacement Guide – Connect the harness connectors at the correct sockets on the HECU. The HECU is a reliable and robust component. Before – If the HECU is a replacement unit refer to the ECU K ECU Set-up ( T C-39) removing and replacing the HECU carry out all the relevant Set-up instructions.
Page 473: Display Ecu (Decu
Section C - Electrics Electronic Controllers Display ECU (DECU) Display ECU (DECU) Location The DECU is part of the LCD monitor mounted in the cab. C128570 Fig 8. Operation Overview The DECU 3 controls the information shown on the LCD monitor 4.
Page 474 Section C - Electrics Electronic Controllers Display ECU (DECU) Wires and Connectors K Fig 10. Circuit ( T C-50) C109 J1 C128580 Fig 9. Harness Connectors C109 Harness Connector C109 - J1 (grey) Pins Details Digital input - work lights switch Wake up signal (+ 24V ignition) Not used Not used...
Page 475 Section C - Electrics Electronic Controllers Display ECU (DECU) C-50 9813/5100-1 C-50...
Page 476 The DECU is bound on the CANbus system. Do not Replacement remove or disconnect the DECU unless you have access to the applicable JCB Servicemaster software tools. Replace the DECU as follows: Park the machine and make it safe. Obey the care and safety procedures.
Page 477 Section C - Electrics Electronic Controllers Display ECU (DECU) Note: Do not replace the DECU with a unit from another machine. ECU’s may look the same but have different software installations. C-52 9813/5100-1 C-52...
Page 478: Engine Ecu
Section C - Electrics Electronic Controllers Engine ECU Engine ECU Location The engine ECU 1 is located inside the cab at the bottom rear LH corner. C146620 Fig 12. C-53 9813/5100-1 C-53...
Page 479 Section C - Electrics Electronic Controllers Engine ECU Description functions are also given in the applicable engine documentation. For details about the engine ECU refer to the applicable K Fig 14. ( T C-55) engine documentation. For more information about the engine ECU and connected devices refer to Section K, The machine harnesses connect to a dedicated engine Electrical Components and Connections.
Page 480 Section C - Electrics Electronic Controllers Engine ECU C250 C251 IC18 IC19 IC20 IC21 IC33 P030610-C1 Fig 14. Typical Engine Wiring Interface C-55 9813/5100-1 C-55...
Page 481 Section C - Electrics Electronic Controllers Engine ECU Removal and Replacement Guide The engine ECU is a reliable and robust component. Before removing and replacing the engine ECU carry out all the relevant diagnostic and fault finding procedures. Most faults are usually due to damaged wires, connectors or connected devices such as switches or sensors.
Page 482: Testing Of Ecu Inputs + Outputs
Section C - Electrics Electronic Controllers Testing of ECU Inputs + Outputs Testing of ECU Inputs + Outputs Care should be taken when testing the inputs + outputs of Testing Low Side Output the ECU to ensure that correct test method is used to determine if the ECU is functioning normally.
Page 483 Section C - Electrics Electronic Controllers Testing of ECU Inputs + Outputs Solenoid connected output off = 0.1 V approx. Solenoid connected output on = battery voltages nominal. Solenoid disconnected output off = reduced voltage (15 V - 22 V). Solenoid disconnected output on = battery voltage nominal.
Page 484: Engine And Power Control
Section C - Electrics Engine and Power Control Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.
Page 485: Related Topics
Section C - Electrics Engine and Power Control Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures.
Page 486: Battery Power Supply And Distribution
Section C - Electrics Engine and Power Control Battery Power Supply and Distribution Battery Power Supply and Distribution Overview enables isolation of the complete machine electrical system during maintenance procedures. The machine has two 12V batteries 4 connected in series Power from the batteries connects directly to four primary to give a 24V power supply.
Page 487 Section C - Electrics Engine and Power Control Battery Power Supply and Distribution Wires and Connectors Primary Fuse B Main feed from the alternator (C042) to the batteries K Fig 2. Batteries and Primary Fuses ( T C-63) K Fig 3. Main PCB Fuses and Circuits - Sheet 1 of 2 Primary Fuse C ( T C-64) Glow plugs relay (C250)
Page 488 Section C - Electrics Engine and Power Control Battery Power Supply and Distribution 2000 C-63 9813/5100-1 C-63...
Page 489 Section C - Electrics Engine and Power Control Battery Power Supply and Distribution C-64 9813/5100-1 C-64...
Page 490 Section C - Electrics Engine and Power Control Battery Power Supply and Distribution C-65 9813/5100-1 C-65...
Page 491: Ignition Power Supply And Distribution
Section C - Electrics Engine and Power Control Ignition Power Supply and Distribution Ignition Power Supply and Distribution Overview When the engine stop switch is set to engine stop, power When the ignition switch 1 is set to position I power from connects to an input on the the batteries connects to pins 5 and 6 of the switch MECU.
Page 492 Section C - Electrics Engine and Power Control Ignition Power Supply and Distribution C-67 9813/5100-1 C-67...
Page 493: Engine Start/Stop
Section C - Electrics Engine and Power Control Engine Start/Stop Engine Start/Stop Engine Run K Fig 7. Circuits ( T C-69) When the ignition switch is set to position I, there is a +24 V supply at the engine stop switch C119. The fuel lift pump K Ignition energises.
Page 494 Section C - Electrics Engine and Power Control Engine Start/Stop C-69 9813/5100-1 C-69...
Page 495: Engine Cranking
Section C - Electrics Engine and Power Control Engine Cranking Engine Cranking Overview running. When the low side input at C251 pin 92 turns ON the starter cut relay (2) C321B energises. The contacts open and the starter relay C262 de-energises. The starter K Fig 9.
Page 496 Section C - Electrics Engine and Power Control Engine Cranking C146660-C1 Fig 8. C-71 9813/5100-1 C-71...
Page 497 Section C - Electrics Engine and Power Control Engine Cranking C-72 9813/5100-1 C-72...
Page 498: Engine Throttle And Power Mode Control
Section C - Electrics Engine and Power Control Engine Throttle and Power Mode Control Engine Throttle and Power Mode Control Overview C128310-C2.eps Fig 10. The machine power output setting can be selected by the The MECU transmits the required engine rpm to the operator by means of the hand throttle control 1.
Page 499 The engine rpm and hydraulic pump output change within 1900 (max) the power bands, depending on the rotation of the hand throttle control knob. L1 L2 L3 G1 G2 G3 H H+ Table 3. Power map - JS300 Power No Load Engine Pump Current (mA) Band...
Page 500 Section C - Electrics Engine and Power Control Engine Throttle and Power Mode Control H+ Button Pressing the H+ button 2 selects the H+ power band. Pressing the H+ button again de-selects the H+ power band. The H+ button sends and input to the MECU. The MECU will not select the H+ power band unless the hand throttle knob 1 is first set to the H power band.
Page 501 Section C - Electrics Engine and Power Control Engine Throttle and Power Mode Control Engine Speed Sensing a pre-set value the power output to the pump proportional solenoid valve starts to reduce. When the load from the hydraulic pump is high the engine The graph shows an example of the control function.
Page 502 Section C - Electrics Engine and Power Control Engine Throttle and Power Mode Control Engine Idle Control By use of the one touch idle control button 1. The button is located in the RH joystick control lever 2. When the operator selects this function the MECU switches off the output to the pump proportional solenoid valve (set to 0 mA) and requests the engine idle rpm setting from the engine ECU by means of a CAN message.
Page 503 Section C - Electrics Engine and Power Control Engine Throttle and Power Mode Control Hand Throttle Control Unit simply detects falling or rising voltage from the potentiometer. The output from the hand throttle potentiometer is shown on the graph. The hand throttle control knob 1 operates a potentiometer 2 which gives and analogue output between 0 and 4.5V.
Page 504 Section C - Electrics Engine and Power Control Engine Throttle and Power Mode Control Wires and Connectors C128400 Fig 16. Harness connectors C123, C094 The 5V reference voltage is also connected to the cooling Harness connector C123 - Mode switches K Electro control module...
Page 505 Section C - Electrics Engine and Power Control Engine Throttle and Power Mode Control C-80 9813/5100-1 C-80...
Page 506 Section C - Electrics Engine and Power Control Engine Throttle and Power Mode Control Removal and Replacement Guide If the engine throttle and power mode control unit 1 is faulty it must be replaced. C128400 Fig 18. Removal Park the machine and make it safe. Obey the care and safety procedures.
Page 507: Engine Cold Idle
Section C - Electrics Engine and Power Control Engine Cold Idle Engine Cold Idle The engine cold idle function restricts the engine to idle speed for different periods of time when the engine coolant or ambient air temperatures are less than pre-set values. The MECU uses pre-set data to calculate the cold idle time period depending on the engine coolant and ambient air temperature values.
Page 508: Engine Fuel Lift Pump
Section C - Electrics Engine and Power Control Engine Fuel Lift Pump Engine Fuel Lift Pump Location The fuel lift pump 1 is located on the revolving frame, below the main fuel filter 2 inside the hydraulic pump compartment. C146700 Fig 19.
Page 509: Barometric Air Pressure Sensor
Section C - Electrics Engine and Power Control Barometric Air Pressure Sensor Barometric Air Pressure Sensor Location The barometric air pressure sensor 1 is located inside the cab at the bottom rear LH corner. C129150 Fig 20. Overview The barometric air pressure sensor transmits a signal to the engine ECU.
Page 510: Fuel Filter Pressure Sensor
Section C - Electrics Engine and Power Control Fuel Filter Pressure Sensor Fuel Filter Pressure Sensor Location The fuel filter pressure sensor 3 is located on the main fuel filter 1. C146710 Fig 21. Overview The fuel filter pressure sensor transmits a signal to the engine ECU.
Page 511: Tmaf Sensor
Section C - Electrics Engine and Power Control TMAF Sensor TMAF Sensor Location The Temperature Mass Air Flow (TMAF) sensor 1 is located in the induction hose between the air filter and turbocharger. C146690 Fig 22. Overview Note: Do not use a TMAF sensor which has been dropped or damaged.
Page 512: Ambient Air Temperature Sensor
Section C - Electrics Engine and Power Control Ambient Air Temperature Sensor Ambient Air Temperature Sensor Location Overview The ambient air temperature sensor 1 is located on a The ambient air temperature sensor transmits a signal to bracket on the LH side of the boom. the MECU.
Page 513: Engine Exhaust After Treatment
Section C - Electrics Engine and Power Control Engine Exhaust After Treatment Engine Exhaust After Treatment Overview Sensors on the DPD are connected to the engine ECU. This enables monitoring of the DPD status. The engine ECU responds to the inputs to ensure effective engine The engine exhaust system is fitted with a Diesel emission control.
Page 514 Section C - Electrics Engine and Power Control Engine Exhaust After Treatment DPD Filter Regeneration operator interaction required during auto regeneration. The DPD contains a filter which traps exhaust particle When regeneration is completed successfully the green matter. After a period of time the filter starts to become regeneration symbol will be replaced by the fan speed saturated.
Page 515 Section C - Electrics Engine and Power Control Engine Exhaust After Treatment The MECU responds as follows: – The maximum pre-set time period of 13.5 machine hours between complete regeneration cycles has – Energises the load assist solenoid valve. The valve been exceeded.
Page 516 Section C - Electrics Engine and Power Control Engine Exhaust After Treatment Servicemaster T4i DPD Diagnostics Tool The T4i DPD diagnostics tool is part of the applicable machine tools suite. Refer to Servicemaster Tools Set in this section. C148690 Fig 32. Item Description Diagnostic Display DPD Amber symbol...
Page 517 Section C - Electrics Engine and Power Control Engine Exhaust After Treatment Item Description Diagnostic Display DPD Amber symbol - manual regeneration required Green LED - On or Off (stage 2 warning) DPD Amber symbol - regeneration ON Green LED - On or Off DPD Green symbol - automatic regeneration mode Green LED - On or Off DPD Saturation level...
Page 518 Section C - Electrics Engine and Power Control Engine Exhaust After Treatment Using the DPD Status Table C148690-C1 Fig 33. The table indicates the regeneration cycle that is Initiating Regeneration Using Servicemaster applicable for the status of the DPD. The status is shown as a combination of elapsed time between regeneration Before using the forced regeneration or slow forced (axis X) and particle matter accumulation (axis Y).
Page 519 Section C - Electrics Engine and Power Control Engine Exhaust After Treatment Set the engine RPM to between 1000 and 1050. Select the required regeneration by clicking the Forced Regen or Slow Forced Regen button on the diagnostics screen. Wait for the regeneration symbol to show on the DECU display and then press the regeneration console switch.
Page 520 Section C - Electrics Engine and Power Control Engine Exhaust After Treatment DPD Devices via the regeneration switch. In this state the engine ECU will initiate automatic regeneration. DPD Filter When the engine is running and the switch is pressed for 3 to 6s the engine ECU responds as follows: DPD filter regeneration turns the soot accumulation on the filter to ash.
Page 521 Section C - Electrics Engine and Power Control Engine Exhaust After Treatment DPD Pressure Differential Sensor The DPD pressure differential sensor 1 is located on a bracket 2 mounted on the DPD. The sensor measures the exhaust gas pressure differential between the inlet and outlet of the particle filter. The signal from the sensor is seen by the engine ECU.
Page 522 Section C - Electrics Engine and Power Control Engine Exhaust After Treatment – After replacing the engine. – After replacing an engine ECU. – After replacing the DPD pressure differential sensor. – After replacing the DPD. To calibrate the sensor, proceed as follows: If the engine has been running, let it cool for a period of three hours.
Page 523 Section C - Electrics Engine and Power Control Engine Exhaust After Treatment DPD Exhaust Gas Temperature Sensors C258 The DPD is fitted with two exhaust gas temperature sensors, sensor 1 (C258) at the exhaust inlet and sensor 2 (C259) after the oxidation catalyst. The signals from the sensors are seen by the engine ECU.
Page 524 Section C - Electrics Engine and Power Control Engine Exhaust After Treatment Load Assist Valve C351 C146740 Fig 39. K Load assist valve - hydraulic schematic ( T C-100) control line connected to port Pi2 at pump 2. The pump control pressure decays and brings the pump onto full flow.
Page 525 Section C - Electrics Engine and Power Control Engine Exhaust After Treatment 3 Bar 1 Bar Key to Oil Flow & Pressure 5Bar 5Bar Full Pressure Pressure Servo 5Bar Neutral Exhaust 5Bar Cavitation Lock Up 5Bar 5Bar 5Bar 5Bar 5Bar @ 114 l/min 3Bar @ 138 l/min ON 20 Bar OFF 15 Bar...
Page 526 Section C - Electrics Engine and Power Control Engine Exhaust After Treatment PCB (C100) C015 MECU +ve 24V IGN ON C351 C148730 Fig 41. Load assist valve - electrical schematic C-101 9813/5100-1 C-101...
Page 527 Section C - Electrics Engine and Power Control Engine Exhaust After Treatment DPD Fault Finding Check the operation of the regeneration switch in the cab. Use the Servicemaster T4i DPD diagnostics tool.K Servicemaster Diagnostics The engine ECU monitors the status of the DPD sensors Tool ( T C-91) and particle filter regeneration events.
Page 528 Section C - Electrics Engine and Power Control Engine Exhaust After Treatment Fault Codes Code Causes Result P042B, DPD exhaust gas temperature sensor 2 fault P042C, P042B P0426, DPD exhaust gas temperature sensor 1 fault P0427, P0428 P1455 Time period between DPD regeneration is exceeded Engine torque reduction, DPD regeneration suspended, EGR control suspended P1471 DPD regeneration insufficient...
Page 529: Engine Automatic Warm Up
Section C - Electrics Engine and Power Control Engine Automatic Warm Up Engine Automatic Warm Up Overview MECU CANbus Engine ECU C128680 Fig 42. This feature allows the engine to quickly warm up to The upper pilot pressure switch 8 is open (excavator normal operating temperature if the vehicle is not being services not selected).
Page 530 Section C - Electrics Engine and Power Control Engine Automatic Warm Up increases the engine speed in 300 rpm steps at three minute intervals up to the maximum of 1800 rpm. After three minutes of running at 1800 rpm the engine revs will return to the hand throttle setting.
Page 531: Engine Automatic Idle
Section C - Electrics Engine and Power Control Engine Automatic Idle Engine Automatic Idle The engine automatic idle function is set to ON or OFF by pressing button 1. For a full description of how the system K Engine works refer to the applicable data in this section. Idle Control ( T C-77) C128380 Fig 44.
Page 532: Electro Viscous Fan
Section C - Electrics Engine and Power Control Electro Viscous Fan Electro Viscous Fan Location The fan target speed is determined by the MECU and based hydraulic engine coolant temperatures. The electro viscous fan 1 is located at the front of the engine.
Page 533 Section C - Electrics Engine and Power Control Electro Viscous Fan Wires and Connectors C128700-C1 Fig 46. Electro viscous fan harness connector C038 Harness Connector C038 Pins Details Speed sensor supply (+ 5V ) PWM signal - solenoid (24V) Return - solenoid Return - speed sensor (0V) Speed sensor signal K Fig 47.
Page 534 Section C - Electrics Engine and Power Control Electro Viscous Fan C-109 9813/5100-1 C-109...
Page 535 Section C - Electrics Engine and Power Control Electro Viscous Fan Testing is 100 C and the hydraulic oil is 70 C the fan will run at 925 rpm not 740 rpm. The expected fan speed for different engine coolant and Use the fan test mode to test the fan and its solenoid hydraulic coolant temperatures are given in the tables.
Page 536: Engine Coolant Level Switch
Section C - Electrics Engine and Power Control Engine Coolant Level Switch Engine Coolant Level Switch Location outside of the bottle. Float 2 is located over the switch cavity inside the bottle. The float is retained by a float stop The coolant level switch 1 is located in the coolant expansion bottle 4.
Page 537 Section C - Electrics Engine and Power Control Engine Coolant Level Switch Wires and Connectors C132030-C3.eps Fig 49. Harness connector C028 C016 MECU J2 C028 C130290 Fig 50. Circuit C-112 9813/5100-1 C-112...
Page 538 Section C - Electrics Engine and Power Control Engine Coolant Level Switch Removal and Replacement Guide To remove the coolant level switch, proceed as follows: Note: There is no need to drain the coolant. Coolant will not be lost when the coolant level switch is removed. Disconnect the electrical harness connector at the coolant level switch.
Page 539: Vacuum Switch
Section C - Electrics Engine and Power Control Vacuum Switch Vacuum Switch Location The vacuum switch 1 is located in the induction hose between the air filter and turbocharger. C132250.jpg Fig 51. Overview If the air flow to the engine induction system is restricted, by a blocked air filter element for example, the air pressure inside the air filter housing is reduced.
Page 540 Section C - Electrics Engine and Power Control Vacuum Switch Wires and Connectors C132250-C1.eps Fig 52. Vacuum switch harness connector C027 C015 MECU J1 C027 C129200 Fig 53. Circuit C-115 9813/5100-1 C-115...
Page 541: Fuel Level Sensor
Section C - Electrics Engine and Power Control Fuel Level Sensor Fuel Level Sensor Location Wires and Connectors The fuel level sensor 1 is located in the fuel tank. C129640 Fig 54. Overview A level sensor is fitted in the fuel tank to measure the level of fuel in the tank.
Page 542 Section C - Electrics Engine and Power Control Fuel Level Sensor C-117 9813/5100-1 C-117...
Page 543 Section C - Electrics Engine and Power Control Fuel Level Sensor Testing The tables list the expected fuel level sensor outputs for different fuel tank contents. Fuel Fuel Remaining (%) Sensor Resistance (Ohms) 107.5 0 (‘no fuel’ alarm active) gauge needle points to red segment 102.5 5 (‘no fuel’...
Page 544: Refuelling Pump
Section C - Electrics Engine and Power Control Refuelling Pump Refuelling Pump Location The refuelling pump 1 is mounted inside the machine toolbox compartment. C128830 Fig 57. Overview The refuelling pump is operated by a momentary switch located in the machine toolbox. The refuelling pump can be used in two different modes: automatic or manual refill.
Page 545 Section C - Electrics Engine and Power Control Refuelling Pump Wires and Connectors signal is sent via the diode to an input on the MECU at connector J1 pin 22. The DECU turns ON. K Fig 60. Circuit ( T C-121) A signal is also sent to an input on the MECU at connector J2 pin 19.
Page 546 Section C - Electrics Engine and Power Control Refuelling Pump C-121 9813/5100-1 C-121...
Page 547 Section C - Electrics Engine and Power Control Refuelling Pump Page left intentionally blank C-122 9813/5100-1 C-122...
Page 548: Cab Systems And Lighting
Section C - Electrics Cab Systems and Lighting Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.
Page 549: Related Topics
Section C - Electrics Cab Systems and Lighting Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures.
Page 550: Camera System
Section C - Electrics Cab Systems and Lighting Camera System Camera System Component Location The Camera - is fitted to the counterweight to view from the rear of the machine Wires and Connectors K Fig 2. Circuit ( T C-126) Table 2.
Page 551 Section C - Electrics Cab Systems and Lighting Camera System C-126 9813/5100-1 C-126...
Page 552: Standard Work Lights
Section C - Electrics Cab Systems and Lighting Standard Work Lights Standard Work Lights Component Location Work lights are mounted on the boom, toolbox and counterweight to provide additional light when required. Overview The work lights are operated from a three position rocker switch in the right hand console.
Page 553 Section C - Electrics Cab Systems and Lighting Standard Work Lights C-128 9813/5100-1 C-128...
Page 554: Cab Work Lights
Section C - Electrics Cab Systems and Lighting Cab Work Lights Cab Work Lights Component Location Additional work lights (optional) are mounted on the roof of the cab pointing forward for increased lighting. Overview The work lights are operated from a 2 position rocker switch in the right hand console.
Page 555 Section C - Electrics Cab Systems and Lighting Cab Work Lights C-130 9813/5100-1 C-130...
Page 556: Beacon
Section C - Electrics Cab Systems and Lighting Beacon Beacon Component Location C115 The machine is fitted with three separate beacon sockets. – Socket 1 - is situated in the centre section of the machine on the front edge of the top plate for powering a cab mounted beacon which can be selected to operate alone.
Page 557 Section C - Electrics Cab Systems and Lighting Beacon CAB BASE EARTH POINT C115 (INT) (EP07) SWITCH: BEACON BACKLIGHTING 1009D C025 1 SOCKET: BEACON - MAIN C025 2 C139 1 SOCKET: RH REAR BEACON C139 2 REVOLVER C138 1 EARTH SOCKET: LH REAR BEACON STUD (EP03) C138 2...
Page 558: Horn
Section C - Electrics Cab Systems and Lighting Horn Horn Overview The horn is operated from a switch located on the LH joystick handle. Wires and Connectors K Fig 10. ( T C-134) The LH joystick horn button (C060) is supplied with 24V from the ignition splice S032 via pin 3 (C060 X4).
Page 559 Section C - Electrics Cab Systems and Lighting Horn C-134 9813/5100-1 C-134...
Page 560: Wipers And Washers
Section C - Electrics Cab Systems and Lighting Wipers and Washers Wipers and Washers Overview The wiper and washer circuits are operated from three rocker switches in the right hand console. – Lower Wiper Switch (if fitted) – Upper Wiper Switch –...
Page 561 Section C - Electrics Cab Systems and Lighting Wipers and Washers Wires and Connectors C116 C058 C142-1, K Fig 15. ( T C-138) C142-2 Upper/Main Wiper Switch and Motor 24V connects to the upper wiper switch (C116) via fuses 26 and 3 in the main fuse board (C100 X4). The upper wiper switch has three positions: –...
Page 562 Section C - Electrics Cab Systems and Lighting Wipers and Washers C118 C126 C129480-C7.eps Fig 13. Harness connectors C126 and C118 Washer Switch When the momentary washer switch (C117) is pressed 24V connects from pin 1 to wire 8008 which sends a signal to the park/intermittent controller on both wiper motors (C125, C058) to start three wipes.
Page 563 Section C - Electrics Cab Systems and Lighting Wipers and Washers C-138 9813/5100-1 C-138...
Page 564: Cab Interior Lamp
Section C - Electrics Cab Systems and Lighting Cab Interior Lamp Cab Interior Lamp Overview interior light operated manually or automatically to illuminate the cab. There are three settings for the interior light: – Off – Automatic - light illuminates when the cab door is opened –...
Page 565 Section C - Electrics Cab Systems and Lighting Cab Interior Lamp C-140 9813/5100-1 C-140...
Page 566: 24 To 12 Volt Converter
Section C - Electrics Cab Systems and Lighting 24 to 12 Volt Converter 24 to 12 Volt Converter Component Location C067 The 24 to 12V converter module is located in the back of C111 the cab next to the main fuse and relay board. Overview The 24 to 12V voltage converter module provides 12V power for operation of the radio, auxiliary power sockets...
Page 567 Section C - Electrics Cab Systems and Lighting 24 to 12 Volt Converter C-142 9813/5100-1 C-142...
Page 568 Section C - Electrics Cab Systems and Lighting 24 to 12 Volt Converter C-143 9813/5100-1 C-143...
Page 569 Section C - Electrics Cab Systems and Lighting 24 to 12 Volt Converter Page left intentionally blank C-144 9813/5100-1 C-144...
Page 570: Charging System
Section C - Electrics Charging System Introduction Charging System Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications K Related Topics ( T table.
Page 571: Related Topics
Section C - Electrics Charging System Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 572: Description
Section C - Electrics Charging System Description Description Overview Power from the alternator is fed into the machine circuits and to charge the batteries via primary fuse B. The L terminal is connected to the MECU (C025) which monitors the voltage output from the alternator (C042). The MECU broadcasts the value of the voltage output on the CANbus.
Page 573 Section C - Electrics Charging System Description 2000 C-148 9813/5100-1 C-148...
Page 574: Alternator
Section C - Electrics Charging System Alternator Alternator Location The alternator 1 is located on the engine driven by the engine Front End Accessory Drive belt (FEAD). C128800 Fig 3. Overview The 24V 55 A alternator is a three phase generator having a rotating field winding and static power windings.
Page 575: Test Procedures
Section C - Electrics Charging System Test Procedures Test Procedures High Rate Discharge Test Note: Do not hold the switch in the LOAD position for more than 10 seconds. This test is to determine the electrical condition of the Check the results against the table: battery and to give an indication of the remaining useful `life'.
Page 576 Section C - Electrics Charging System Test Procedures Specific Gravity Testing Readings should be as tabulated and should not vary between cells by more than 0.04. A greater variation indicates an internal fault on that particular cell. The specific gravity of the electrolyte gives an idea of the state of charge of the battery.
Page 577 Section C - Electrics Charging System Test Procedures Page left intentionally blank C-152 9813/5100-1 C-152...
Page 578: Harness Systems
Section C - Electrics Harness Systems Installation and Interconnections C-153 9813/5100-1 C-153...
Page 579 Section C - Electrics Harness Systems Installation and Interconnections C-154 9813/5100-1 C-154...
Page 580 Section C - Electrics Harness Systems Installation and Interconnections C-155 9813/5100-1 C-155...
Page 581 Section C - Electrics Harness Systems Installation and Interconnections C-156 9813/5100-1 C-156...
Page 582 Section C - Electrics Harness Systems Installation and Interconnections C-157 9813/5100-1 C-157...
Page 583: Earth Points
Section C - Electrics Harness Systems Earth Points C-158 9813/5100-1 C-158...
Page 584 Section C - Electrics Harness Systems Earth Points C-159 9813/5100-1 C-159...
Page 585: Harness Drawing List
Multi function display CANbus termination resistor Livelink ECU (if fitted) Revolving Chassis K Fig 18. ( T C-174) 334/J9834 T2 Engines (JCB 672) Main components connected to this harness: Gearbox control solenoids Hydraulic control valve solenoids Alternator TMAF sensor Engine cooling fan...
Page 586 Section C - Electrics Harness Systems Harness Drawing List K ( T C-181) 334/J9567 Main components connected to this harness: Boom work lights Ambient temperature sensor Cab Roof Main components connected to this harness: Radio speakers Interior lights Door and window switches Cab work lights Heater Harness 332/K2461...
Page 587: Drawings
Section C - Electrics Harness Systems Drawings Drawings Drawings are reproduced from production electrical harness drawings. Each harness drawing includes tables showing wire connections and destinations for all the connectors on the harness. To identify the correct harness drawing for a particular machine refer to the relevant Harness Drawings table.
Page 588 Section C - Electrics Harness Systems Drawings C-163 9813/5100-1 C-163...
Page 589 Section C - Electrics Harness Systems Drawings C-164 9813/5100-1 C-164...
Page 590 Section C - Electrics Harness Systems Drawings C-165 9813/5100-1 C-165...
Page 591 Section C - Electrics Harness Systems Drawings C-166 9813/5100-1 C-166...
Page 592 Section C - Electrics Harness Systems Drawings C-167 9813/5100-1 C-167...
Page 593 Section C - Electrics Harness Systems Drawings C-168 9813/5100-1 C-168...
Page 594 Section C - Electrics Harness Systems Drawings C-169 9813/5100-1 C-169...
Page 595 Section C - Electrics Harness Systems Drawings C-170 9813/5100-1 C-170...
Page 596 Section C - Electrics Harness Systems Drawings C-171 9813/5100-1 C-171...
Page 597 Section C - Electrics Harness Systems Drawings C-172 9813/5100-1 C-172...
Page 598 Section C - Electrics Harness Systems Drawings C-173 9813/5100-1 C-173...
Page 599 Section C - Electrics Harness Systems Drawings C-174 9813/5100-1 C-174...
Page 600 Section C - Electrics Harness Systems Drawings C-175 9813/5100-1 C-175...
Page 601 Section C - Electrics Harness Systems Drawings C-176 9813/5100-1 C-176...
Page 602 Section C - Electrics Harness Systems Drawings C-177 9813/5100-1 C-177...
Page 603 Section C - Electrics Harness Systems Drawings C-178 9813/5100-1 C-178...
Page 604 Section C - Electrics Harness Systems Drawings C-179 9813/5100-1 C-179...
Page 605 Section C - Electrics Harness Systems Drawings C-180 9813/5100-1 C-180...
Page 606 Section C - Electrics Harness Systems Drawings C-181 9813/5100-1 C-181...
Page 607 Section C - Electrics Harness Systems Drawings C-182 9813/5100-1 C-182...
Page 608 Section C - Electrics Harness Systems Drawings C-183 9813/5100-1 C-183...
Page 609 Section C - Electrics Harness Systems Drawings C-184 9813/5100-1 C-184...
Page 610 Section C - Electrics Harness Systems Drawings C-185 9813/5100-1 C-185...
Page 611: Connector Codes
Section C - Electrics Harness Systems Connector Codes Connector Codes Table 17. Connector Codes Connector Device Harness Connector Device Harness Code Location Code Location C039 Sensor - Pressure - AC Revolver Harness C002 CANbus Terminating Revolver Harness C040 Solenoid - AC Revolver Harness Resistor Compressor Clutch...
Page 612 Section C - Electrics Harness Systems Connector Codes Connector Device Harness Connector Device Harness Code Location Code Location C068 Camera - Camera Harness C100 X3 Module - Cab Fuse and Cab Harness Counterweight (If Relay PCB X3 fitted) C100 X4 Module - Cab Fuse and Cab Harness C070...
Page 613 Section C - Electrics Harness Systems Connector Codes Connector Device Harness Connector Device Harness Code Location Code Location C147 Light - Console Fascia Harness C258 Sensor - Temperature Illumination Exhaust Inlet C149 Sensor - TMAF Sensor C259 Sensor - Temperature Exhaust Outlet C150 Motor Seat...
Page 614: Wire Numbers And Functions
The # indicates the start of the identification number. It is always printed to the left of the identification number. 8191 The wire's unique identification number. The wire functions and numbers allocated to them are consistent K Wire Numbers and Functions ( T through out the JCB range of products. C-189). C-189 9813/5100-1 C-189...
Page 615 The descriptions are applicable to JCB specification wiring harnesses. The machine may be fitted with some wiring that does not conform to the JCB specifications, typically when it is part of equipment supplied by other manufacturers. Fig 31.
Page 616: Wiring Harness Repair
Repair Procedure acceptable standard it is strongly recommended that the following tools, equipment and procedures are always used. Note that JCB harnesses have an International Table 19. Tools Required Protection rating of 67 (I.P.67). Part No.
Page 617 Section C - Electrics Harness Systems Wiring Harness Repair readily visible. They secured using corresponding size and matching colour-coded jaws of the crimp tool to ensure joint security. This tool also incorporates a ratchet closing mechanism which will not release until the splice is fully closed to the correct compression size.
Page 618 Section C - Electrics Harness Systems Wiring Harness Repair Side wings 40-G down, reflector head completely open. In this mode the infra-red heat waves are dominant (recommended for the light coloured plastic splices). Fig 38. Hold the heater vertically and, using a match or cigarette lighter, light the gas as shown.
Page 619 Section C - Electrics Harness Systems Wiring Harness Repair Page left intentionally blank C-194 9813/5100-1 C-194...
Page 620: Battery
Section C - Electrics Battery Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.
Page 621: Related Topics
Section C - Electrics Battery Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 622: Maintenance
Section C - Electrics Battery Maintenance Maintenance To ensure that the battery provides optimum performance – Never boost-charge a maintenance free battery. the following steps should be observed: – Never charge a maintenance free battery at a voltage in excess of 15.8 Volts. Make sure that the electrical connections are clean –...
Page 623: Test Procedures
Section C - Electrics Battery Test Procedures Test Procedures Refer to Section C - Battery Charging System. K Related Topics ( T C-196) C-198 9813/5100-1 C-198...
Page 624: Disconnection And Connection
Section C - Electrics Battery Disconnection and Connection Disconnection and Connection Battery Disconnection/Connection T3-019_2 WARNING Keep metal watch straps and any metal fasteners on your clothes, clear of the positive (+) battery terminal. Such items can short between the terminal and nearby metal work.
Page 625: Removal And Replacement
Section C - Electrics Battery Removal and Replacement Removal and Replacement C131930.eps Fig 2. Removal Replacement Open the battery cover. Refer to Section 2. Replacement is the opposite of the removal procedure. K Related Topics ( T C-196) K Disconnection and Disconnect the battery leads.
Page 626: Machine Diagnostic Modes
Section C - Electrics Machine Diagnostic Modes Introduction Machine Diagnostic Modes Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications K Related Topics ( T table.
Page 627: Related Topics
Section C - Electrics Machine Diagnostic Modes Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 628: Selecting The Diagnostic Modes
Section C - Electrics Machine Diagnostic Modes Selecting the Diagnostic Modes Selecting the Diagnostic Modes Start the engine and enable the hydraulic controls. If Turn the select rotary control 3 until the display necessary operate the machine until the hydraulic oil highlights the required mode symbol.
Page 629 Section C - Electrics Machine Diagnostic Modes Selecting the Diagnostic Modes Test Run Mode Pressure Switch Status Mode To select the test run mode, proceed as follows: To select the pressure switch status mode, proceed as follows: Start the engine and enable the hydraulic controls. If necessary operate the machine until the hydraulic oil Start the engine and enable the hydraulic controls.
Page 630 Section C - Electrics Machine Diagnostic Modes Selecting the Diagnostic Modes Fan Test Mode The expected fan speed in the fan test mode = 1947 x 0.7 (1360 rpm). To select the fan test mode, proceed as follows: Interpreting the test results: When interpreting the fan speed result use a tolerance of plus or minus 5%.
Page 631 Section C - Electrics Machine Diagnostic Modes Selecting the Diagnostic Modes Page left intentionally blank C-206 9813/5100-1 C-206...
Page 632: Fault Code System
Section C - Electrics Fault Code System Introduction Fault Code System Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications K Related Topics ( T table.
Page 633: Related Topics
Section C - Electrics Fault Code System Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 634: Operation Overview
Section C - Electrics Fault Code System Operation Overview Operation Overview Fault Code Display A fault codes will be displayed on the display monitor LCD. For details about navigating the display screens refer to Section 2. The colour of the display will change according to the severity of the fault displayed.
Page 635 Section C - Electrics Fault Code System Operation Overview Critical Fault The display is Red, the buzzer will sound, an Icon representing area of machine affected and a fault code will display to indicate faults that may result in serious damage to the machine or make the machine dangerous to operate.
Page 636 The log enters the fault code together with the current time and date. The fault code log can be read on the DECU LCD. Alternatively use the JCB diagnostics tool. Reading the Fault Code Log with Servicemaster Error codes logged can be accessed via a suitable laptop computer running the applicable diagnostics software.
Page 637: Engine 'P' Codes
Transmission For details of ‘P’ fault codes refer to the applicable service manual: – 9806/4400 Isuzu 6HK1 T4i Engine Service Manual. A full list of fault codes is also given in JCB Servicemaster. Refer also to Section K. C-212 9813/5100-1...
Page 638: Cab Area 'B' Codes
Section C - Electrics Fault Code System Cab Area ‘B’ Codes Cab Area ‘B’ Codes Refer to JCB Servicemaster for a full list of fault codes. C-213 9813/5100-1 C-213...
Page 639: Chassis 'C' Codes
Section C - Electrics Fault Code System Chassis ‘C’ Codes Chassis ‘C’ Codes Refer to JCB Servicemaster for a full list of fault codes. C-214 9813/5100-1 C-214...
Page 640: Canbus 'U' Codes
Section C - Electrics Fault Code System CANbus ‘U’ Codes CANbus ‘U’ Codes Refer to JCB Servicemaster for a full list of fault codes. C-215 9813/5100-1 C-215...
Page 641 Section C - Electrics Fault Code System CANbus ‘U’ Codes Page left intentionally blank C-216 9813/5100-1 C-216...
Page 642: Servicemaster Tools Set
Section C - Electrics Servicemaster Tools Set Introduction Servicemaster Tools Set Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications K Related Topics ( T table.
Page 643: Related Topics
Section C - Electrics Servicemaster Tools Set Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 644: Tools Suites
Enable diagnostics of machine switches, sensors and actuators for systems such as power, hydraulic and travel controls. View or save the machine ECU fault code logs. (Tools related to JCB engines are not applicable). T063930 T4i Diagnostics (This tool is located in the AMS machine section of the JS tools, use the tools under the Tier 4i tab only) - T4i Data Display, T4i 6 Cylinder Injector Checker, T4i DPD.
Page 645 Section C - Electrics Servicemaster Tools Set Tools Suites Tool Icon Description Flashloader Enables upload and download of machine ECU program files stored on the ECU flash memory, to and from a suitable laptop PC. T063940 7 DECU Current DECU flash file for loading via the DECU USB port. C142190 Fault Codes Reference file listing all possible fault codes.
Page 646: Diagnostics Connectors
Section C - Electrics Servicemaster Tools Set Diagnostics Connectors Diagnostics Connectors Connect the diagnostics plug from the DLA to the diagnostics socket on the machine. For details about the DLA refer to Servicemaster SYSTEM. Diagnostics Socket Location The diagnostics socket 2 is located on the cab fuse and relay board. To get access, open cover 1. C129890 Fig 1.
Page 647: Servicemaster Machine Selection
Section C - Electrics Servicemaster Tools Set Servicemaster Machine Selection Servicemaster Machine Selection Open Servicemaster, refer Servicemaster SYSTEM. Click on the construction tab. Click on the tracked excavators icon. C131180 Fig 2. Click on the DECU machines icon, Icons for the diagnostic tool suite for all DECU control system machines are displayed.
Page 648: Routine Maintenance Procedures
Section C - Electrics Routine Maintenance Procedures Scheduled Tasks The table below lists the Electrical related Scheduled Note: Maintenance schedules can vary according to tasks. The procedures are in addition to the scheduled machine operating conditions and environments. Refer to tasks detailed in Section 2.
Page 649: Starter Motor
Section C - Electrics Routine Maintenance Procedures Starter Motor Starter Motor Check (Condition) Inspect the starter motor installation as follows: – Check the security of the starter motor to engine fixing bolts. Make sure that they are tightened to the correct torque.
Page 650: Alternator
Section C - Electrics Routine Maintenance Procedures Alternator Alternator Check (Condition) Inspect the alternator installation as follows: – Check the security of the alternator to engine fixing. – Check that the electrical connections at the alternator are clean and secure. –...
Page 651: Battery Maintenance
Section C - Electrics Routine Maintenance Procedures Battery Maintenance Battery Maintenance To ensure that the battery provides optimum performance the following steps should be observed: Make sure that the electrical connections are clean and tight. Smear petroleum jelly on connectors to prevent corrosion.
Page 652 Section C - Electrics Routine Maintenance Procedures Battery Maintenance Battery CAUTION T3-061 Damaged or spent batteries and any residue from fires WARNING or spillage should be put in a closed acid proof receptacle and must be disposed of in accordance Batteries give off an explosive gas.
Page 653 Section C - Electrics Routine Maintenance Procedures Battery Maintenance Warning Symbols First Aid - Electrolyte The following warning symbols may be found on the Do the following if electrolyte: battery. Gets into your eyes Symbol Meaning Immediately flush with water for 15 minutes, always get Keep away from children.
Page 654: Overload Warning System
Section C - Electrics Routine Maintenance Procedures Overload Warning System Overload Warning System Check (Operation) Test the overload warning system as follows: – Switch on the overload warning system. Refer to Section 2, Operation, Working With the Excavator Arm. – Make sure that the machine instrumentation activates the applicable overload warning system active indicators.
Page 655 Section C - Electrics Routine Maintenance Procedures Overload Warning System Page left intentionally blank C-230 9813/5100-1 C-230...
Page 656 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 657 Section E - Hydraulics Notes: 9813/5100-1...
Page 658 Section E - Hydraulics Contents Page No. Systems and Schematics Introduction ....................E-1 Schematics ....................E-2 Servo Line (Machine) ................E-11 Servo Line (Cab) ..................E-13 Servo/Pilot Pressure and Return Line ............ E-14 Hydraulic System Introduction ..................... E-17 Related Topics ..................E-18 Specifications ..................
Page 659 Section E - Hydraulics Contents Page No. Swing Gearbox Introduction ................... E-150 Related Topics ..................E-151 Reduction Gear Structure and Working Principles ....... E-152 Dismantling and Assembly ..............E-153 Rotary Coupling Introduction ................... E-170 Operation ....................E-171 Removal and Replacement ..............E-172 Dismantling ...................
Page 660 Section E - Hydraulics Contents Page No. Test 013: Testing Track Motor Drain Line Flow Rate ......E-266 Test 014: Testing the High Speed Tracking Setting ......E-267 Test 015: Testing the Low Speed Tracking Setting ....... E-268 Test 016 - Flow Testing Hydraulic Pumps - Record Sheet ....E-269 Test 017: Testing Swing Bearing ............
Page 661 Section E - Hydraulics Contents Page No. E-iv E-iv...
Page 662: Systems And Schematics
This topic contains hydraulic schematics for the complete system. Detailed schematics for individual systems are given throughout the manual. K Introduction ( T E-1) K Schematics ( T E-2) K JS300 ( T E-2) K JS330 ( T E-5) K JS370 ( T E-8) 9813/5100-1...
Page 663 Section E - Hydraulics Systems and Schematics Schematics Schematics JS300 Item Description Variant Swing Motor Rotary Coupling 6 Port Arm Cylinder Arm HBCV HBCV Travel Motor/Gearbox Coupling Male 1/2 Low Flow Coupling Female 1/2 Low Flow TAB Cylinder Boom HBCV LH...
Page 664 Section E - Hydraulics Systems and Schematics Schematics Item Description Variant Valve Dual Controls Dual Controls Pressure Switch Hammer/Aux Shuttle Valve Merged Valve Merged Valve RH Joystick Cushion Valve Valve LH Joystick Solenoid valve - load assist Pilot Valve Solenoid Valve Merged, Hammer/Aux Travel Pilot Valve Cab Manifold...
Page 665 Section E - Hydraulics Systems and Schematics Schematics 9813/5100-1...
Page 666 Section E - Hydraulics Systems and Schematics Schematics JS330 Item Description Variant Swing Motor Rotary Coupling 6 Port Arm Cylinder Arm HBCV HBCV Travel Motor/Gearbox Coupling Male 1/2 Low Flow Coupling Female 1/2 Low Flow Tab Cylinder Boom HBCV LH HBCV Boom HBCY RH HBCV...
Page 667 Section E - Hydraulics Systems and Schematics Schematics Item Description Variant Shuttle Valve Merged Valve Merged Valve RH Joystick Cushion Valve Valve LH Joystick Pressure Switch HBCV Pilot Valve Solenoid Valve Merged, Hammer/Aux Travel Pilot Valve Cab Manifold Pressure Switch Auto Boost 8 Station Valve Accumulator...
Page 668 Section E - Hydraulics Systems and Schematics Schematics 9813/5100-1...
Page 669 Section E - Hydraulics Systems and Schematics Schematics JS370 Item Description Variant Swing Motor Rotary Coupling 6 Port Arm Cylinder Arm HBCV HBCV Travel Motor/Gearbox Coupling Male 1/2 Low Flow Coupling Female 1/2 Low Flow TAB Cylinder Boom HBCV LH HBCV Boom HBCV RH HBCV...
Page 670 Section E - Hydraulics Systems and Schematics Schematics Item Description Variant Shuttle Valve Merged Valve Merged Valve RH Joystick Cushion Valve Valve LH Joystick Pressure Switch TAB HBCV Pilot Valve Solenoid Valve Merged, Hammer/Aux Travel Pilot Valve Cab Manifold 8 Station Valve Accumulator Servo Filter Main Pump...
Page 671 Section E - Hydraulics Systems and Schematics Schematics E-10 9813/5100-1 E-10...
Page 672: Servo Line (Machine
Section E - Hydraulics Systems and Schematics Servo Line (Machine) Servo Line (Machine) JS300 Cab manifold Travel pedal 8 Station Solenoid valve a Accumulator Shuttle valve Swing Lock Solenoid Valve Cushion valve Main control valve a Dipper 2 b Boom...
Page 673 Section E - Hydraulics Systems and Schematics Servo Line (Machine) E-12 9813/5100-1 E-12...
Page 674: Servo Line (Cab
Section E - Hydraulics Systems and Schematics Servo Line (Cab) E-13 9813/5100-1 E-13...
Page 675: Servo/Pilot Pressure And Return Line
Section E - Hydraulics Systems and Schematics Servo/Pilot Pressure and Return Line Servo/Pilot Pressure and Return Line JS300 Slew Motor Rotary coupling 8 Station Cushion Valve Tank Manifold Main Pump Main Control valve Cab Manifold Re-Gen Load Assist Valve Hose Colour...
Page 676 Section E - Hydraulics Systems and Schematics Servo/Pilot Pressure and Return Line E-15 9813/5100-1 E-15...
Page 677 Section E - Hydraulics Systems and Schematics Servo/Pilot Pressure and Return Line Page left intentionally blank E-16 9813/5100-1 E-16...
Page 678: Hydraulic System
Section E - Hydraulics Hydraulic System Introduction Hydraulic System Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications K Related Topics ( T table.
Page 679: Related Topics
Section E - Hydraulics Hydraulic System Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 680: Specifications
Section E - Hydraulics Hydraulic System Specifications Specifications Main Hydraulic Pump Table 2. JS300 Type Twin variable displacement piston pump Displacement Volume 139 cm /rev (8.48 in /rev ) x 2 Operating Pressure RATED 343 bar (4975 lb/in Maximum Output...
Page 681 Section E - Hydraulics Hydraulic System Specifications Swing Motor Table 7. JS300 Type Fixed displacement piston motor Displacement 180 cm /rev (11.0 in /rev) Rated Pressure 255 bar Max Pressure 331 bar Max Flow 291 l/min (64 UK gal) Relief Setting...
Page 682 Section E - Hydraulics Hydraulic System Specifications Main Control Valve Table 11. JS300 Type Hydraulic Pilot System Operating System Set pressure relief Main Relief Pressure: Standard 343 bar (5685 lb/in ) at 138 litre/min (30.3 UK gal) Pressure Raising 373 bar (5410 lb/in...
Page 683 Boom 2 Other Priority and Merge Spool 8 9 10 SPOOL STROKE (mm) Fig 1. Boom Ram Table 13. JS300 JS330 JS370 Cylinder Inside Diameter 140mm (5.5 in) 140mm (5.5 in) 150mm (5.9 in) Rod Diameter 100mm (3.9 in) 100mm (3.9 in) 100mm (3.9 in)
Page 684 Section E - Hydraulics Hydraulic System Specifications Bucket Ram Table 15. JS300 JS330 JS370 Cylinder Inside Diameter 140mm (5.51 in) 140mm (5.51 in) 150mm (5.9 in) Rod Diameter 95mm (3.7 in) 100mm (3.9 in) 100mm (3.9 in) Max Contracted Length 1890+/-3mm (74.4 in)
Page 685: Hydraulic Operation And Schematics
Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics Hydraulic Operation and Schematics Introduction The schematic diagrams show overview of the system. For machine specific schematics refer to Systems and K Related Topics ( T E-18) Schematics. This section identifies the main system components and their locations.
Page 686 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics Hydraulic Pump Regulation higher pump pressure at pistons E and F before the sumater spool starts to select, hence more hydraulic horsepower. The regulator on pump A1 works the same as Note: The pressures quoted are for illustration purposes above.
Page 687 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics E-26 9813/5100-1 E-26...
Page 688 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics Neutral Circuit K Fig 3. ( T For Schematic, E-28). With all the controls in the neutral position, flow from pump 1 enters the main control valve 14 at port P2 and flow from pump 2 enters the main control valve 14 at port P1.
Page 689 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics 1 Bar 3 Bar Key to Oil Flow & Pressure 5Bar 5Bar Full Pressure Pressure Servo 5Bar Neutral Exhaust 5Bar Cavitation Lock Up 5Bar 5Bar 5Bar 5Bar 5Bar @ 114 l/min 3Bar @ 138 l/min ON 20 Bar OFF 15 Bar...
Page 690 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics Linear Travel Valve Spools Operation If another service (boom up for example) is selected at the same time as straight line travel, there would be a flow difference at the LH and RH track motors. This would cause the machine to track to one side even though both travel spools are fully selected.
Page 691 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics E-30 9813/5100-1 E-30...
Page 692 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics Travel - Middle Speed K Fig 5. ( T For schematic, E-32). When both tracks are selected forward, servo pressure from port 2 (LH travel lever), and port 4 (RH travel lever) 35 enters the main control valve 14 at Pa6 and Pa1 respectively, selecting the left and right hand travel spools.
Page 693 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics E-32 9813/5100-1 E-32...
Page 694 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics Boom Up K Fig 6. ( T For schematic, E-34). Servo pressure from the hand controller 48 enters the servo shuttle valve 46 at port A3 and is distributed to: Boom up pressure switch 45 at port S2 Port B3 to the cushion control valve 49 at port F and exits at port H, to the main control valve 14 at port Pa8...
Page 695 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics E-34 9813/5100-1 E-34...
Page 696 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics Boom Down K Fig 7. ( T For schematic, E-36). Servo pressure from the RH hand controller 51 at port 4 enters the servo shuttle valve 46 at port and is distributed to port B4 to port E of the cushion control valve 49.
Page 697 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics E-36 9813/5100-1 E-36...
Page 698 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics Dipper Out K Fig 8. ( T E-38) For schematic, Servo pressure from the hand controller 50 is sent to port A5 of the shuttle valve 46 and is distributed to: Port B5 to port B of the cushion valve 49, through the valve leaving at port D.
Page 699 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics E-38 9813/5100-1 E-38...
Page 700 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics Dipper In K Fig 9. ( T E-40) For schematic, Servo pressure from the hand controller 50 is sent to port A6 of the servo shuttle valve 46 and is distributed to: Port B6 to port A on the cushion valve 49, through the valve leaving at port C (if machine is fitted with HBCV, pressure is also sent via port A1 to port P on the HBCV to...
Page 701 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics E-40 9813/5100-1 E-40...
Page 702 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics Bucket Opening K Fig 10. ( T For schematic, E-42). Servo pressure from port 1 of the hand controller 48 selects the bucket open spool position via the pilot shuttle block 46, port A8 and B8.
Page 703 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics E-42 9813/5100-1 E-42...
Page 704 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics Bucket Close K Fig 11. ( T For schematic, E-44). Servo pressure from the RH hand controller 48 is sent from port 3 via ports A7 and B7 of the shuttle valve 46 to port Pb7 of the main control valve 14 and moves the bucket spool into the bucket close position and selects the upper pressure switch.
Page 705 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics E-44 9813/5100-1 E-44...
Page 706 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics Priority Valves K Fig 12. ( T For schematic, E-46). Boom over Swing Priority (A) This is selected by the operator via switch in the right hand console. When there is a boom up & swing pressure switch signal the boom priority solenoid on the 8 spool block 60 is energised sending a signal via port C6 to the main control valve 14 at port Pi1.
Page 707 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics E-46 9813/5100-1 E-46...
Page 708 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics Swing Circuit When Swing is selected a signal is sent from the servo shuttle valve 46 via port C8 to the main control valve 14 at port Pc3. This selects Swing over dipper priority valve B K Fig 13.
Page 709 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics E-48 9813/5100-1 E-48...
Page 710 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics 100% Swing Lock K Fig 14. ( T For schematic, E-50). When the Swing lock button is operated in the cab, the MECU gives two outputs: To the 2 swing shut off solenoids 44. This blocks both swing pilot signals preventing the signal from reaching the swing spool;...
Page 711 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics E-50 9813/5100-1 E-50...
Page 712 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics Auxiliary Circuit K Fig 15. ( T E-52) For Schematic, An auxiliary circuit gives a bi-directional flow to the equipment being used: The Option pedal 53 can be selected back or forward depending on the direction the operator wants the equipment to move.
Page 713 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics Key to Oil Flow & Pressu re VENTS TO ATMOSPHERE Full Pressu re Pressu re Servo Neutral Exhaust Cavitation Lock Up 3.5 Bar 5Bar 5Bar OPTION HAM/AUX 5Bar 5Bar 5Bar 5Bar 5Bar 5Bar...
Page 714 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics Merged Flow K Fig 16. ( T For schematic, E-54). This option allows the flow of both pumps to come together where the attachment requires high oil flow. When the merged option is selected, using the rocker switch in the cab and the auxiliary pedal 53 is operated, the hammer/auxiliary switch 45 is closed.
Page 715 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics Key to Oil Flow & Pressu re VENTS TO ATMOSPHERE Full Pressu re Pressu re Servo Neutral Exhaust Cavitation Lock Up 3.5 Bar 5Bar 5Bar OPTION HAM/AUX 5Bar 5Bar 5Bar 5Bar 5Bar 5Bar...
Page 716 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics Hammer Circuit K Fig 17. ( T E-56) For Schematic, The hammer function only works when the hammer pedal 53 is pressed in a forward direction. In this position pilot pressure from the foot pedal closes the hammer pressure switch 45.
Page 717 Section E - Hydraulics Hydraulic System Hydraulic Operation and Schematics Key to Oil Flow & Pressu re VENTS TO ATMOSPHERE Full Pressu re Pressu re Servo Neutral Exhaust Cavitation Lock Up 3.5 Bar 5Bar 5Bar OPTION HAM/AUX 5Bar 5Bar 5Bar 5Bar 5Bar 5Bar...
Page 718: Hydraulic Pump/Regulator
Section E - Hydraulics Hydraulic Pump/Regulator Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.
Page 719: Hydraulic Pump Operation
Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Operation Hydraulic Pump Operation TE-029_2 Main Pumps (P1 and P2) The rotary group consists of the drive shaft 7, cylinder rod 19, piston shoe 4, 5, press plate 11, spherical bush 12, spacer 13 and cylinder spring 14.
Page 720 Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Operation Pump Hydraulic Circuit Diagram C077790 Fig 2. Table 1. Key A1,2 Delivery port Suction port Drain port Pi1,2 Pilot port Proportional pressure reducing valve Pm1,2 Q max cut port a1-3 Gauge port Gauge port Gear pump delivery port Gear pump suction port...
Page 721 Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Operation Hydraulic Pump/Regulator Exploded View 803230 Fig 3. E-60 9813/5100-1 E-60...
Page 722 Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Operation E-61 9813/5100-1 E-61...
Page 723: Hydraulic Pump Removal And Replacement
Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Removal and Replacement Hydraulic Pump Removal and Replacement Removal WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented.
Page 724 – Before fastening pump flange 2 to engine, make sure the mating surfaces are fully together. – Apply JCB Threadlocker to bolts 3 and 6. – Fill the pump casing inside fully with oil and operate at low engine revs with no services selected for 3 minutes.
Page 725: Hydraulic Pump Dismantling And Assembly
Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Dismantling and Assembly Hydraulic Pump Dismantling and Assembly The working environment must be clean and the workbench covered with a cloth or rubber sheet to prevent damage to the components. The illustration opposite shows both halves of the tandem double axial piston pump, but the procedures refer mostly to Pump 1.
Page 726 Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Dismantling and Assembly Place the pump on the workbench with its regulator mounting face downwards. Match mark the mating flanges of pump casing 5 and valve block 8. Separate the pump casing from the valve block. Remove the piston/cylinder assembly Z comprising cylinder 9, piston assemblies 10, set plate 11, spherical bush 12 and cylinder springs 13 from pump...
Page 727 Note: When removing the tilting pin use a protector to plate support bearing 32A. prevent damage to the pin head. Also take care not to damage the servo piston as a result of the JCB Threadlocker used to secure it. Remove needle bearings 28 and splined coupling 29 K Fig 3.
Page 728 Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Dismantling and Assembly Assembly Before assembling: a Thoroughly clean all components with clean hydraulic oil and dry with compressed air. b Apply clean hydraulic oil to all sliding surfaces, bearings, etc. If previously removed from pump casing 5, install tilting pin 27 and servo piston 26.
Page 729 Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Dismantling and Assembly sure the internal splines of the cylinder and the spherical bearing are aligned. Insert the piston/cylinder sub-assembly into pump casing 5. 379630-C1 Fig 16. Grease oil seal 16 and fit seal cover 15 to swash plate support 17.
Page 730 Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Dismantling and Assembly 379680-C1 Fig 19. Refit servo pump assembly X, tighten the securing screws to a torque of 6.9 Nm (5 lbf ft). K Fig 13. ( T E-66). K Fig 13. ( T Refit drain plug 1.
Page 731: Regulator Dismantling And Assembly
Section E - Hydraulics Hydraulic Pump/Regulator Regulator Dismantling and Assembly Regulator Dismantling and Assembly The working environment must be clean and the ring 12. Do not interfere with the settings of any of workbench covered with a cloth or rubber sheet to prevent these components as this could alter the pre-set flow damage to the components.
Page 732 Section E - Hydraulics Hydraulic Pump/Regulator Regulator Dismantling and Assembly Remove socket head screws 19 and 20 and lift off pilot cover 21. Take out set spring 22. 379430-C1 Fig 25. Remove lever 32 leaving pin 33A in position on the lever.
Page 733 Section E - Hydraulics Hydraulic Pump/Regulator Regulator Dismantling and Assembly Note: 3 Piston case 40 can be removed by pressing compensating rod 42 from the opposite side of regulator body 1. 379450-C1 Fig 27. Withdraw feedback lever 35. 379460-C1 Fig 28. Remove lever 36 from pin 37 (in the regulator body) leaving pin 37A in position on the lever.
Page 734 Section E - Hydraulics Hydraulic Pump/Regulator Regulator Dismantling and Assembly E-73 9813/5100-1 E-73...
Page 735 Section E - Hydraulics Hydraulic Pump/Regulator Regulator Dismantling and Assembly Assembly Before assembling: – Thoroughly clean all components with clean hydraulic oil and dry with compressed air. – Apply clean hydraulic oil to all sliding surfaces, bearings, etc. – Renew any damaged components. –...
Page 736 Section E - Hydraulics Hydraulic Pump/Regulator Regulator Dismantling and Assembly Insert adjusting plug 31. Fit a new seal 30A and install snap ring 30. Check that feedback lever 35 moves freely but does not have excessive play. Insert return spring 25 and spring seat 24 into hole A of regulator body 1.
Page 737 Section E - Hydraulics Hydraulic Pump/Regulator Regulator Dismantling and Assembly 379530-C1 Fig 36. E-76 9813/5100-1 E-76...
Page 738: Coupling
Section E - Hydraulics Hydraulic Pump/Regulator Coupling Coupling TE-032 Assembly Install the cylindrical hub E onto the splined pump shaft and secure with the bolts F. Secure the coupling plate/flywheel A to the engine Note: The hub must be installed with the recess closest to with bolts B.
Page 739: Hydraulic Control Valve
Section E - Hydraulics Hydraulic Control Valve Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.
Page 740: Related Topics
Section E - Hydraulics Hydraulic Control Valve Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 741: Layout
Section E - Hydraulics Hydraulic Control Valve Layout Layout Table 2. Torque Settings Torque Item Bolts - Main Control Valve to Frame 275 Nm SAE split flange bolts - Main control valve to bucket/arm line M10, 42 +/-5 Nm SAE split flange bolts - Main control valve to rotary joint M12, 62 +/-6 Nm SAE split flange bolts - Main control valve to Swing motor M14, 93 +/-8 Nm...
Page 742 Section E - Hydraulics Hydraulic Control Valve Layout Negative Control Valve Ps1 Restrictor Orifice Negative Control Valve Ps2 Shuttle Valve Load Hold Check Valves (x6) E1 Dipper 2, E2 Boom 1, E3 travel Restrictor, E4 Dipper 1, E5 Boom 2, E6 Option Priority Valve F1 Boom over Bucket, F2 Boom over Swing, F3 Option/Tab Option Blank...
Page 743 Section E - Hydraulics Hydraulic Control Valve Layout C046810-C2.eps Fig 1. E-82 9813/5100-1 E-82...
Page 744 Section E - Hydraulics Hydraulic Control Valve Layout C046820-C2.eps Fig 2. E-83 9813/5100-1 E-83...
Page 745 Section E - Hydraulics Hydraulic Control Valve Layout Fig 3. E-84 9813/5100-1 E-84...
Page 746 Section E - Hydraulics Hydraulic Control Valve Layout Fig 4. Main Control Valve viewed in Direction of Arrow A K Table 3. ( T For port location, E-86). E-85 9813/5100-1 E-85...
Page 747 Section E - Hydraulics Hydraulic Control Valve Layout Table 3. Port Identification Item Port Function 2 Stage MRV Linear Travel Spool DR2 Drain Travel (L) Backwards Bucket Close Spool Bucket Close ARV Boom 1 Down Spool Arm 2 In Spool Boom Up ARV Swing/Priority Valve Dipper Option Tab/Option ARV...
Page 748 Section E - Hydraulics Hydraulic Control Valve Layout Fig 5. Main Control Valve Viewed in Direction of Arrow B K Table 4. ( T E-88) E-87 9813/5100-1 E-87...
Page 749 Section E - Hydraulics Hydraulic Control Valve Layout Table 4. Port Identification Item Port Function Pump 2 Input Travel (L) Backwards Hammer/Auxiliary Option Merge In (if fitted) Swing Left Boom Priority Arm 1 Out Negative control (Pump 2) Tank Swing Over Dipper Priority Arm 1 In Swing Right Hammer/Auxiliary Option...
Page 750 Section E - Hydraulics Hydraulic Control Valve Layout Fig 6. Main Control Valve viewed in Direction of Arrow C K Table 5. ( T E-90) E-89 9813/5100-1 E-89...
Page 751 Section E - Hydraulics Hydraulic Control Valve Layout Table 5. Port Identification Item Port Function Tank (Option) Travel (R) Forwards Option ARV / Blank Hammer.Auxiliary Option Swing Left Boom 2 Up (Boost) Arm In ARV Arm 1 Out Tank (Option) par1 Tab/Option ARV TAB/Option Drain...
Page 752 Section E - Hydraulics Hydraulic Control Valve Layout Fig 7. Main Control Valve viewed in Direction of Arrow D K Table 6. Port Identification For port identification, E-92). E-91 9813/5100-1 E-91...
Page 753 Section E - Hydraulics Hydraulic Control Valve Layout Table 6. Port Identification Item Port Function Pump 1 Feed Travel (R) Forward Boom 1/Arm 2 priority Bucket Bucket Close Boom 1 Down prs1 Not Used prs2 Not Used Tank BR1 Tab/Option Tank Option AR1 Tab/Option Negative control (Pump 1)
Page 754 Section E - Hydraulics Hydraulic Control Valve Layout Fig 8. Main Control Valve viewed from above Table 7. Port Identification Item Port Function Tank Option Merged Switching Valve Swing/Boom 2 priority over Arm DR6 Drain DR5 Drain E-93 9813/5100-1 E-93...
Page 755 Section E - Hydraulics Hydraulic Control Valve Layout Fig 9. Main Control Valve viewed from below Table 8. Item Function U/B Mounting Points - bolt torque 275 Nm E-94 9813/5100-1 E-94...
Page 756 Section E - Hydraulics Hydraulic Control Valve Layout E-95 9813/5100-1 E-95...
Page 757: Hydraulic Control Levers
Section E - Hydraulics Hydraulic Control Levers Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.
Page 758: Related Topics
Section E - Hydraulics Hydraulic Control Levers Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 759: Operation
Section E - Hydraulics Hydraulic Control Levers Operation Operation TE-008 The remote control valve is a pressure reduction valve The control handles contain electrical push button and used to control the servo pressure operated system. Four rocker switches which are used to operate auxiliary pressure reduction valves used to control the servo services.
Page 760 Section E - Hydraulics Hydraulic Control Levers Operation A409170-C1 Fig 1. JS03240-C1 Fig 2. E-99 9813/5100-1 E-99...
Page 761: Removal And Replacement
Replacement is the reversal of the removal sequence. the hoses are open. Note: All hydraulic adapters that are installed together with INT-3-1-11_2 a bonded sealing washer must also have JCB Threadseal applied to the threads of the adapter. WARNING Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin.
Page 762 Section E - Hydraulics Hydraulic Control Levers Removal and Replacement A407780-C1 Fig 3. Table 2. Left hand Control Valve Right hand Control Valve Port Hose Colour Port Hose Colour Orange Green Green Blue Violet Yellow Pink White White E-101 9813/5100-1 E-101...
Page 763: Dismantling And Assembly
Section E - Hydraulics Hydraulic Control Levers Dismantling and Assembly Dismantling and Assembly Dismantling Note: Ensure retaining plate moves freely to prevent sudden release due to spring pressure beneath. Note: All parts are precision made and require the utmost Clean the valve exterior using approved solvent and care when being handled.
Page 764 Section E - Hydraulics Hydraulic Control Levers Dismantling and Assembly Remove seals 9 and 10 from guide 8 and discard. Note: Leave all parts to soak in suitable solvent until dirt is loosened. Using clean solvent wash all parts and allow to air dry.
Page 765 Section E - Hydraulics Hydraulic Control Levers Dismantling and Assembly A408130-C1 Fig 4. E-104 9813/5100-1 E-104...
Page 766 Section E - Hydraulics Hydraulic Control Levers Dismantling and Assembly Table 3. Item Description Qty. Item Description Qty. Item Description Qty. Lower body Plunger Control handle Upper body Split Washer Locknut `O'-ring Spring seat Mounting knuckle `O'-ring Compression spring Joint nut Dowel pin Return spring Rocker plate...
Page 767 Section E - Hydraulics Hydraulic Control Levers Dismantling and Assembly Inspection Note: Before assembling the remote control valve make sure that a thorough inspection of all the components is carried out. Remember that although a failed component may be easy to identify, the cause may be less easy to trace.
Page 768 Section E - Hydraulics Hydraulic Control Levers Dismantling and Assembly Fault Finding Symptom Possible cause Remedy Low secondary pressure. Primary pressure is low. Apply the correct primary pressure. Spring 4 is damaged. Renew the spring. Clearance between the spool and Renew the remote control valve seating is too large.
Page 769: Travel Pedal Valve
Section E - Hydraulics Travel Pedal Valve Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.
Page 770: Related Topics
Section E - Hydraulics Travel Pedal Valve Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 771: Removal And Replacement
Section E - Hydraulics Travel Pedal Valve Removal and Replacement Removal and Replacement C132370.jpg Fig 1. E-110 9813/5100-1 E-110...
Page 772 Section E - Hydraulics Travel Pedal Valve Removal and Replacement Hose Identification Replacement K Fig 1. ( T E-110) K Fig 1. ( T E-110) Replacement is the opposite of the removal procedure. Colour Band To Pedal Valve Port During the replacement procedure do this work also: White –...
Page 773: Dismantling And Assembly
Section E - Hydraulics Travel Pedal Valve Dismantling and Assembly Dismantling and Assembly TE-007 Note: Parts can be damaged by use of excessive force. Remove spring washer 16 from the casing 10 using Parts can be damaged by corrosion caused by humidity tweezers etc.
Page 774 Section E - Hydraulics Travel Pedal Valve Dismantling and Assembly a Place all parts in container with clean de-greasing Note: Adhered dirt and grease may cause damage during agent (first washing). the first washing; soak well to loosen and float these off. Dirty de-greasing agent may cause damage to the parts.
Page 775 Section E - Hydraulics Travel Pedal Valve Dismantling and Assembly Inspection Fix casing 20 in a vice. Fit return spring 21 into casing. Before assembling the Directional control valve make sure Fit the pressure reduction valve sub-assembly, that a thorough inspection of all the components is carried assembled in 1 and 2 above, into casing 20.
Page 776 Fit cam and steel balls 6 to cover 2. Press down cam 6 and insert cam shaft 5 from the outside. Packing Apply JCB Threadlock or equivalent to the surfaces of hexagonal socket screws 3. Fit grease cap 12 to plug 7.
Page 777: Solenoid Valve Block
Section E - Hydraulics Solenoid Valve Block Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.
Page 778: Related Topics
Section E - Hydraulics Solenoid Valve Block Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 779: Operation
Section E - Hydraulics Solenoid Valve Block Operation Operation CT10 CT8 CT7 CT6 CT5 CT11 CT3 CT4 T023420-C1.eps Fig 1. E-118 9813/5100-1 E-118...
Page 780 Section E - Hydraulics Solenoid Valve Block Operation Table 2. Solenoid Function Electrical Harness connector Hydraulic hose tape colour internal Colour Swing Park Brake Black No hose Controls Enable White No hose Swing Lock Orange Orange Max Flow Control Green Light Green Travel Speed Grey...
Page 781 Section E - Hydraulics Solenoid Valve Block Operation Swing Park Brake (CT1) Travel Speed (CT5) When the Swing pressure switch is closed on the servo When FAST speed travel is selected in the cab (hare) the shuttle valve, the MECU sends a signal to the CT1 CT5 solenoid energises, which directs servo pressure to solenoid, which allows servo pressure across the solenoid, the track drive motors via port C5 to select high speed...
Page 782 Section E - Hydraulics Solenoid Valve Block Operation C034920-1 Fig 2. E-121 9813/5100-1 E-121...
Page 783: Removal And Replacement
Note: All hydraulic adapters that are installed together with residual hydraulic pressure trapped in the service a bonded sealing washer must also have JCB Threadseal hose line must be vented. Make sure the hose service applied to the threads of the adapter.
Page 784: Dismantling And Assembly
Section E - Hydraulics Solenoid Valve Block Dismantling and Assembly Dismantling and Assembly T023430 Fig 3. Dismantling Using a 5mm Allen key remove valve J, ball K and seat L. Unscrew cap A from solenoid valve. Inspection Slide solenoid B, away from the main control valve. Before assembling the solenoid valve make sure that a Loosen spool C and extract spool from the main thorough inspection of all the components is carried out.
Page 785 Lubricate spool C, spring E and balls F and K with clean hydraulic oil. K Table 3. Tighten components to specified torque Torque Settings ( T E-124). Apply JCB Threadseal to accumulator thread G. Table 3. Torque Settings Item Kgf m lbf ft 18.4 40.6...
Page 786 Section E - Hydraulics Solenoid Valve Block Dismantling and Assembly Page left intentionally blank E-125 9813/5100-1 E-125...
Page 787: Swing Motor
Section E - Hydraulics Swing Motor Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.
Page 788: Related Topics
Section E - Hydraulics Swing Motor Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 789: Motor Operating Principles
Section E - Hydraulics Swing Motor Motor Operating Principles Motor Operating Principles The following detailed description explains the operating expels low pressure hydraulic fluid T via the output side cycle of an individual piston. A(b) of the control plate, port b and back to tank. Driving force F2 varies according to the flow rate of the high High pressure hydraulic fluid P from the pump flows via pressure hydraulic fluid input.
Page 790: Swing Brake Operation
Section E - Hydraulics Swing Motor Swing Brake Operation Swing Brake Operation Cylinder block F is splined to output shaft G. Two friction locking cylinder block F and casing E and preventing plates A are splined to the outer edge of the cylinder block rotation.
Page 791: Swing Motor Configuration
Section E - Hydraulics Swing Motor Swing Motor Configuration Swing 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 Fig 3. E-130 9813/5100-1 E-130...
Page 792 Section E - Hydraulics Swing Motor Fault Finding Fault Finding Motor Does Not Rotate Symptom Cause Remedy The pressure is low. The relief valve is not set correctly. Set to the correct value. The relief valve does not work properly. Plunger sticking.
Page 793 Section E - Hydraulics Swing Motor Fault Finding Motor Brake Working Poorly Symptom Cause Remedy Low brake torque. The friction plate is worn out. Dismantle and renew worn parts. The brake piston is sticking. Dismantle and clean. The brake releasing pressure is low. Check and repair the supply circuit.
Page 794 Section E - Hydraulics Swing Motor Removal and Replacement Removal and Replacement TE-027 C078320 Fig 4. Removal Make an alignment line across the gearbox and motor mounting flanges, to provide a reference during assembly. WARNING Remove bolts X. Hydraulic Pressure Hydraulic fluid at system pressure can injure you.
Page 795 Section E - Hydraulics Swing Motor Removal and Replacement Replacement Replacement is a reversal of the removal sequence. WARNING Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear protective glasses and gloves.
Page 796 Section E - Hydraulics Swing Motor Dismantling and Assembly Dismantling and Assembly Hydraulic Motor Components 122 121 111 982 706 707 051-1 Fig 5. E-135 9813/5100-1 E-135...
Page 797 Section E - Hydraulics Swing Motor Dismantling and Assembly Relief valve Socket head screw Reverse protection valve sub-assembly Stop ring Drive shaft Stop ring Spacer Snap ring Cylinder block Locking ring Spherical bush Cylindrical roller bearing race Cylinder spring Cylindrical roller bearing race Push rod Spacer F Plug...
Page 798 Section E - Hydraulics Swing Motor Dismantling and Assembly Dismantling Note: The part numbers quoted in the following Dismantling and Assembly procedures relate to the K Fig 5. ( T E-135) illustration Plug or tape over the hydraulic ports and thoroughly clean and dry the motor housing 301/ valve housing 303 assembly.
Page 799 Section E - Hydraulics Swing Motor Dismantling and Assembly Fig 9. Fig 11. Remove brake piston 702 using the special extraction Remove the pistons 121, piston shoes 122, retaining plate 123, spherical bush 113, spacer F 117 and shoe jig - refer to Section 1 - Service Tools. plate 124.
Page 800 Section E - Hydraulics Swing Motor Dismantling and Assembly Fig 14. Fig 13. To remove oil seal 491, position front cover 304 on the bed of a press (as shown). Using a suitable diameter disc, i.e. one which will penetrate the front cover bore and contact the oil seal, apply pressure to remove the oil seal.
Page 801 Section E - Hydraulics Swing Motor Dismantling and Assembly Fig 16. E-140 9813/5100-1 E-140...
Page 802 Section E - Hydraulics Swing Motor Dismantling and Assembly Inspection below, and dress any sliding surfaces with excessive roughness. Check all parts for wear and/or damage. Renew any components which do not fall within the wear parameters Wear Limits Check Standard Recommended Action Required...
Page 803 Section E - Hydraulics Swing Motor Dismantling and Assembly Assembly Using a suitable jig, install a new oil seal 491 into front cover 304. Make sure the oil seal is installed the right way round (see Dismantling, step 17). Position main housing 301 on a bench with the flange for valve housing 303 uppermost.
Page 804 Section E - Hydraulics Swing Motor Dismantling and Assembly Fig 22. Fig 24. Position main housing 301 with the front cover end downwards. Install the three separator plates 743 and the two friction plates 742 alternately with the separator locating lugs A positioned as shown below and locating the friction plates with cylinder block 111.
Page 805 Section E - Hydraulics Swing Motor Dismantling and Assembly Fig 26. Fig 28. Install brake piston 702 just in main housing 301 with slits B positioned as shown below. Screw in two M8 bolts and gently tap these evenly to fully install the brake piston.
Page 806 Section E - Hydraulics Swing Motor Dismantling and Assembly Fig 30. Insert brake springs 712, making sure they locate properly in their seating groove in brake piston 702. Fig 32. Apply a film of grease to the mating face of valve plate 131.
Page 807 Section E - Hydraulics Swing Motor Dismantling and Assembly Fig 34. Fit a new O-ring 472, lightly greased, to valve housing 303. Fig 36. Into valve housing 303 fit plunger 351 followed by spring 355. Check that the plunger moves freely in its guide.
Page 808 Section E - Hydraulics Swing Motor Dismantling and Assembly JS06230-C1 Fig 39. Fig 38. The seat 44 is press-fitted into sleeve 39. Remove it Install reverse protection valve sub-assembly 52 onto using a soft object, taking care not to scratch the seat valve housing 303 and secure with socket head face.
Page 809 Section E - Hydraulics Swing Motor Dismantling and Assembly Assembly Press fit seat 44 into sleeve 39 which has an 'O'-ring Mount poppet 43, spring 42, shim 40, piston 38, liner 51 onto sleeve 39. 3Screw cap 37 (with a 14 mm A/F hexagonal socket) with 'O'-ring 36 and back-up 35 mounted, on to sleeve 39 and tighten to a torque of 157 Nm (116 lbf ft).
Page 810 Section E - Hydraulics Swing Motor Dismantling and Assembly Page left intentionally blank E-149 9813/5100-1 E-149...
Page 811: Swing Gearbox
Section E - Hydraulics Swing Gearbox Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.
Page 812: Related Topics
Section E - Hydraulics Swing Gearbox Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 813: Reduction Gear Structure And Working Principles
Section E - Hydraulics Swing Gearbox Reduction Gear Structure and Working Principles Reduction Gear Structure and Working Principles Fig 1. Table 2. Key from the gears. The bearing in chamber A is lubricated with gear oil and the bearing in chamber B with grease. A Chamber B Chamber Torque path...
Page 814: Dismantling And Assembly
Section E - Hydraulics Swing Gearbox Dismantling and Assembly Dismantling and Assembly C068760 Fig 2. Component Identification Circlip O-ring Seal ring 1st Reduction Sun Gear Ring gear Gearbox housing Bolt O-ring Drain plug Oil breather and level plug 2nd Reduction planet gear Bearing 1st Reduction planet gear Ring nut...
Page 815 Section E - Hydraulics Swing Gearbox Dismantling and Assembly Dismantling Lift out 1st Reduction Planet gear assembly. Cleanliness is the utmost importance when servicing the gearbox. All precautions to prevent any ingress of dirt, grit etc. must be taken Note: For details of service tools referred to, see Service Tools, Section 1.
Page 816 Section E - Hydraulics Swing Gearbox Dismantling and Assembly C068830 C068860 Fig 7. Fig 9. Lift out 2nd Reduction Planet gear assembly. Lift out 2nd Reduction Sun Gear. C068840 C068870 Fig 8. Fig 10. K Fig 11. ( T Remove O-ring from ring...
Page 817 Section E - Hydraulics Swing Gearbox Dismantling and Assembly C068890 Fig 11. C068910 Fig 13. Remove O-ring from the ring gear. Assemble the Socket Box Wrench and Nut Adapter on the ring nut, see Service Tools, Section 1. C068900 Fig 12. C068920 Fig 14.
Page 818 Section E - Hydraulics Swing Gearbox Dismantling and Assembly C068950 C068930 Fig 17. Fig 15. Using suitable lifting equipment, raise the gearbox housing. C068940 Fig 16. Use a 3 leg puller to release gear box housing from C069690 Pinion shaft and bearing. Using suitable lifting Fig 18.
Page 819 Section E - Hydraulics Swing Gearbox Dismantling and Assembly C069700 C069720 Fig 19. Fig 21. by using a puller and stopper, remove the bearing using a rubber hammer and stopper, remove the seal outer ring. ring from the gearbox housing. C069710 C069730 Fig 20.
Page 820 Section E - Hydraulics Swing Gearbox Dismantling and Assembly C069740 Fig 23. C069760 Fig 25. Lift the pinion shaft and place onto spacer tube. C069750 Fig 24. By using a press, push on the pinion shaft to separate it from the bearing. Remove bearing and nylon ring K Fig 25.
Page 821 Section E - Hydraulics Swing Gearbox Dismantling and Assembly Inspection Before assembling the gear box make sure that a thorough inspection of all the components is carried out. Remember that although a failed component may be easy to identify, the cause may be less easy to trace. It is also possible that a failed component may have caused damage to other areas of the gearbox.
Page 822 Section E - Hydraulics Swing Gearbox Dismantling and Assembly Assembly Note: Apply clean hydraulic fluid to all sliding contact faces during assembly. New seals must be used on assembly. Place seal on to it's seat in the gearbox housing. C069270 Fig 28.
Page 823 Section E - Hydraulics Swing Gearbox Dismantling and Assembly C069450 Fig 30. C069470 Fig 32. Push the bearing outer ring against the gearbox housing shoulder using a press. Place the spacer onto the pinion shaft C069490 Fig 33. C069460 Fig 31. Note: Only required if pinion replacement part Apply grease...
Page 824 Section E - Hydraulics Swing Gearbox Dismantling and Assembly C069520 Fig 36. C069500 Fig 34. Using the Stopper Tool and a press, see Service Tools, Section 1. Push the bearing against the pinion Apply a coat of grease to the nylon ring. shaft shoulder.
Page 825 Fig 41. Using the Stopper Tool (see Service Tools, Section 1) and a press, assemble the output unit. Apply JCB Threadlocker to the thread of a NEW ring K Fig 40. ( T E-164) K Fig 42. ( T E-165) nut.
Page 826 Section E - Hydraulics Swing Gearbox Dismantling and Assembly C068930 C069590 Fig 44. Fig 42. Stake the ring nut near seat no. 6 Assemble the Socket Box Wrench and Nut Adapter (see Service Tools, Section 1) on the ring nut. Tighten the ring nut (see Torque Settings at end of this section) C069630...
Page 827 Section E - Hydraulics Swing Gearbox Dismantling and Assembly C068870 Fig 48. C069640 Fig 46. Insert 2nd Reduction Sun Gear in the 2nd Reduction planetary gear assembly. Place the ring gear onto the gearbox housing ensuring the previously marked lines align. C068840 Fig 49.
Page 828 Section E - Hydraulics Swing Gearbox Dismantling and Assembly C069680 Fig 52. C069660 Fig 50. Insert 1st Reduction planet gear assembly. Assemble the cover onto the gear ring. C068810 Fig 53. C069670 Fig 51. K Fig 54. ( T E-168) Insert 1st Reduction Sun Gear.
Page 829 Section E - Hydraulics Swing Gearbox Dismantling and Assembly C068800 Fig 54. Item Kgf m lbf ft 1400 1032 E-168 9813/5100-1 E-168...
Page 830 Section E - Hydraulics Swing Gearbox Dismantling and Assembly Page left intentionally blank E-169 9813/5100-1 E-169...
Page 831: Rotary Coupling
Section E - Hydraulics Rotary Coupling Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.
Page 832: Operation
Section E - Hydraulics Rotary Coupling Operation Operation The coupling is located in the centre of the machine between the lower and upper sections and rotates around the slew centre line. 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 833: Removal And Replacement
Section E - Hydraulics Rotary Coupling Removal and Replacement Removal and Replacement Removal WARNING Hydraulic Pressure Jack up the machine by pressing the boom/dipper on Hydraulic fluid at system pressure can injure you. the ground. Install wooden blocks under the tracks. Before connecting or removing any hydraulic hose, K Fig 2.
Page 834 Bolt - Lock bar to rotary joint 259Nm Bolts - Rotary Joint to Frame 116Nm Replacement Installation is the reverse of removal. Apply JCB Threadlocker and Sealer to screws A. WARNING Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin.
Page 835: Dismantling
Section E - Hydraulics Rotary Coupling Dismantling Dismantling as a guide to the dismantling and assembly procedures K Fig 1. ( T refer to the sectional illustration, E-171). Remove the bolt B and cover A. Remove the 'O'-ring C. Do not reuse the 'O'-ring C. Remove bolts D and the thrust plate E.
Page 836 Section E - Hydraulics Rotary Coupling Dismantling C068260 Fig 8. Remove the 'O'-rings, and packing rings from the rotor G. C031310-C1 Note: Do not reuse 'O'-rings and the packing rings. Fig 7. Remove dust seal X from the axle H. E-175 9803/5100-1 E-175...
Page 837 Section E - Hydraulics Rotary Coupling Dismantling 716710-C1 Fig 9. E-176 9803/5100-1 E-176...
Page 838: Assembly
Section E - Hydraulics Rotary Coupling Assembly 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, backup rings and seals.
Page 839 Section E - Hydraulics Rotary Coupling Assembly After installing the 'O'-ring, packing rings and packing, 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. Install the new dust seal X on the axle H.
Page 840 Section E - Hydraulics Rotary Coupling Assembly C031340-C1 Fig 15. On completion of assembly ensure the dust seal is fitted correctly as shown. C031330-C1 Fig 14. Install a new seal F. Install the thrust plate E and bolts D. Install a new 'O'-ring C. Install the cover A and bolts B.
Page 841 Section E - Hydraulics Rotary Coupling Assembly Page left intentionally blank E-180 9803/5100-1 E-180...
Page 842: Hydraulic Rams
Section E - Hydraulics Hydraulic Rams Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.
Page 843: Related Topics
Section E - Hydraulics Hydraulic Rams Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 844: Precautions During Use
Special seal materials are necessary so check to piston rod. see if the ram that you are using is suitable or not. Use genuine JCB parts when replacing parts. E-183 9813/5100-1 E-183...
Page 845 Section E - Hydraulics Hydraulic Rams Precautions During Use a If parts other than genuine JCB parts are used, the desired results may not be obtained. Use only genuine JCB parts. Caution during dismantling and reassembly. a Dismantling the ram while it is still installed on the machine can be dangerous as unexpected movements of the machine can occur.
Page 846: Removal And Replacement
Section E - Hydraulics Hydraulic Rams Removal and Replacement Removal and Replacement Typical Bucket Ram P11-E001_2 Removal WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented.
Page 847 Section E - Hydraulics Hydraulic Rams Removal and Replacement 803091 Fig 6. 803140 Fig 4. Remove the ram hoses and install plugs or caps to prevent contamination. Push the pin out using a bar and hammer. Attach slings to support the ram. WARNING Metal Splinters You can be injured by flying metal splinters when...
Page 848 Section E - Hydraulics Hydraulic Rams Removal and Replacement Install the pin, bolt and nuts to the cylinder end of the ram. 803093 Fig 10. 803092 Fig 8. Replacement Attach slings to the ram and lift it into position on the dipper.
Page 849 Section E - Hydraulics Hydraulic Rams Removal and Replacement A409820-C2 Fig 14. 803094 Note: When checking or refitting JS machine pivot pins, Fig 12. the retaining nuts and bolts should not be fastened up tight to the pivot boss but must have approximately 3mm of play so that the pin is free from tension.
Page 850 Section E - Hydraulics Hydraulic Rams Removal and Replacement Typical Boom Ram P11-E002_2 Removal WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses.
Page 851 Section E - Hydraulics Hydraulic Rams Removal and Replacement Release the tank pressure, see Releasing the Tank Pressure. 709600 Fig 20. Remove the hoses, and install plugs or caps to prevent contamination. 803222-1 Fig 18. Restrain the eye end of the piston rod to the ram cylinder, to prevent movement of the rod.
Page 852 Section E - Hydraulics Hydraulic Rams Removal and Replacement Replacement Attach slings to the ram. Align the ram to its installation position. 803223-1 Fig 22. Lift the ram away from the unit. 803224-1 Fig 23. Install the pin and then the bolt and nuts. WARNING Metal Splinters You can be injured by flying metal splinters when...
Page 853 Section E - Hydraulics Hydraulic Rams Removal and Replacement 803226-1 Fig 26. Lift the ram and align the rod eye end with the pin 803225-1 Fig 24. position. A409820-C2 Fig 25. 803213-1 Fig 27. Note: When checking or refitting JS machine pivot pins, the retaining nuts and bolts should not be fastened up tight Install the pin with a bar and hammer.
Page 854 Section E - Hydraulics Hydraulic Rams Removal and Replacement Note: When checking or refitting JS machine pivot pins, the retaining nuts and bolts should not be fastened up tight to the pivot boss but must have approximately 3mm of play so that the pin is free from tension.
Page 855 Section E - Hydraulics Hydraulic Rams Removal and Replacement Typical Dipper Ram P11-E003_1 Removal WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses.
Page 856 Section E - Hydraulics Hydraulic Rams Removal and Replacement 803151 Fig 34. 803150 Fig 35. WARNING Restrain the eye end of the ram piston rod to the ram Metal Splinters cylinder to prevent the piston rod from extending. You can be injured by flying metal splinters when driving metal pins in or out.
Page 857 Section E - Hydraulics Hydraulic Rams Removal and Replacement WARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or copper pin to remove and fit metal pins. Always wear safety glasses.
Page 858 Section E - Hydraulics Hydraulic Rams Removal and Replacement 803201 Fig 41. 803181-1 Fig 40. 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 copper pin to remove and fit metal pins.
Page 859 Section E - Hydraulics Hydraulic Rams Removal and Replacement A409820-C2 803171 Fig 45. Fig 43. Note: When checking or refitting JS machine pivot pins, Hoist the ram to align the piston rod eye end with the the retaining nuts and bolts should not be fastened up tight dipper pin position.
Page 860 Section E - Hydraulics Hydraulic Rams Removal and Replacement Typical Triple Articulated Boom (TAB) P11-E004 Removal WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented.
Page 861 Section E - Hydraulics Hydraulic Rams Removal and Replacement Knock out the pivot pin using a bar and hammer. WARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or copper pin to remove and fit metal pins.
Page 862 Section E - Hydraulics Hydraulic Rams Removal and Replacement Replacement Attach suitable lifting gear and manoeuvre the TAB ram to locate the cylinder end eye with its mounting. Fig 56. Note: When checking or refitting JS machine pivot pins, the retaining nuts and bolts should not be fastened up tight to the pivot boss but must have approximately 3mm of play so that the pin is free from tension.
Page 863 Section E - Hydraulics Hydraulic Rams Removal and Replacement Fig 60. Note: When checking or refitting JS machine pivot pins, JS07310-C1 the retaining nuts and bolts should not be fastened up tight Fig 58. to the pivot boss but must have approximately 3mm of play so that the pin is free from tension.
Page 864: Dismantling And Assembly
Section E - Hydraulics Hydraulic Rams Dismantling and Assembly Dismantling and Assembly TE-023_2 Dismantling the Piston Rod from the Cylinder Tube Refer to Section 1, Service Tools. Before starting work, clean all surfaces with a suitable solvent and dry with compressed air. Each part is precision made, so handle with care.
Page 865 Section E - Hydraulics Hydraulic Rams Dismantling and Assembly Dismantling the Piston Rod Note: protect all the parts from dirt. Secure the piston rod pack on the bench, brace the K Fig 63. ( T piston rod head E-204). 373460a-V1 Fig 63.
Page 866 Section E - Hydraulics Hydraulic Rams Dismantling and Assembly Removing the Piston Seals Note: Never reuse seals. While dismantling, handle the piston very carefully. Remove the two slide ring A, two wear rings B, two backup rings C, slipper seal D and slipper seal back up ring E from the piston.
Page 867 Section E - Hydraulics Hydraulic Rams Dismantling and Assembly Removing the Cylinder Head Seals remove the o-ring A and back up ring from the cylinder head. C030810 Fig 72. Using a special pull out tool, remove the U-packing ring. Using the pull out tool then remove the backup K Fig 73.
Page 868 Section E - Hydraulics Hydraulic Rams Dismantling and Assembly K Fig 76. ( T Remove the du-bush E-207). C030900 Fig 76. C030880 Fig 74. Using suitable tool, split du-bush K Fig 75. ( T E-207). C030890 Fig 75. E-207 9813/5100-1 E-207...
Page 869 Section E - Hydraulics Hydraulic Rams Dismantling and Assembly Assembly of Piston Seals Before Assembly Ensure that piton surface is clean and free from damage. Ensure that slipper seal insertion tool is free from defects. Burrs or marks may damage the seals and cause leakage.
Page 870 Section E - Hydraulics Hydraulic Rams Dismantling and Assembly Fit the heated slipper seal A (approximately 200°C) into its installation grove B using the insertion jig. Damage to the surface of the slipper seal cap will affect its sealing performance. Be careful not to scratch the surfaces of the seal when installing.
Page 871 Section E - Hydraulics Hydraulic Rams Dismantling and Assembly Assembling the Cylinder Head Seals Before Assembly Check that the assembly tools are free from defect. Clean tools before starting. Clean cylinder head before assembly. Check that grooves are clean and not damaged. locate du-bush to cylinder and push into place using K Fig 85.
Page 872 Section E - Hydraulics Hydraulic Rams Dismantling and Assembly C031040-C1 Fig 89. C031060 Fig 91. Deform the u-packing ring into a loose curve with the Install retaining ring into groove u-packing holder and insert it into its fitting groove K Fig 92. ( T E-211).
Page 873 Section E - Hydraulics Hydraulic Rams Dismantling and Assembly Assembly of the Piston Rod The cylinder components must be cleaned before assembly. The piston and cylinder head must be cleaned before seal assembly and be kept clean up until this stage. Do not clean piston or cylinder head with seals fitted.
Page 874 Section E - Hydraulics Hydraulic Rams Dismantling and Assembly Assembly of Piston Rod in Cylinder Tube Make sure that assembly tools and cylinder tube are clean before assembly. The piston rod pack must be protected from dirt up until this stage. Assembly should be made vertically.
Page 875 Section E - Hydraulics Hydraulic Rams Dismantling and Assembly 373740b-V1 Fig 98. Put the piston rod pack into the cylinder tube. Make sure that the piston guiding ring does not get jammed during assembly. Clean hydraulic oil will help, but do not use a brush as hairs may come off.
Page 876: Maintenance Specifications
Section E - Hydraulics Hydraulic Rams Maintenance Specifications Maintenance Specifications In order to ensure long life of the hydraulic ram, carry out is found, repair as soon as possible referring to the inspection and maintenance regularly. If an abnormal point troubleshooting chart.
Page 877 Section E - Hydraulics Hydraulic Rams Maintenance Specifications Inspection, Inspection, Maintenance Contents Daily Monthly Annually Note Maintenance Point Are the bolts, nuts loose? Are the bolts, nuts tightened? Ram Cylinder Are there cracks in the welding or other damage? (Including Piping) Are there big depressions or dents in the cylinder? Use Limit Table 3.
Page 878: Shuttle Valve
Section E - Hydraulics Shuttle Valve Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.
Page 879: Related Topics
Section E - Hydraulics Shuttle Valve Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 880: Removal And Replacement
Replacement Replacement is a reversal of the removal sequence. Note: All hydraulic adapters that are installed together with a bonded sealing washer must also have JCB Threadseal applied to the threads of the adapter. E-219 9813/5100-1...
Page 881: Dismantling And Assembly
Boom Load Hold Red/Green Lubricate valve 3, ball 4 and seat 5 with clean hydraulic oil. Dipper Out Light Green/ Violet Apply JCB Threadseal to plugs 2. Dipper Pink/Violet Arm Load Hold Pink/Green K Table 3. Tighten components to specified torque.
Page 882 Section E - Hydraulics Shuttle Valve Dismantling and Assembly A407821-C2 Fig 1. E-221 9813/5100-1 E-221...
Page 883 Section E - Hydraulics Shuttle Valve Dismantling and Assembly Page left intentionally blank E-222 9813/5100-1 E-222...
Page 884: Cushion Valve
Section E - Hydraulics Cushion Valve Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.
Page 885: Related Topics
Section E - Hydraulics Cushion Valve Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 886: Operation
Section E - Hydraulics Cushion Valve Operation Operation The machine defaults to cushioned mode on start up. The following descriptions describe only the `dipper in' function but, `dipper out', `boom in' and `boom out' circuits all operate in the same way. T023050-1 Fig 1.
Page 887 Section E - Hydraulics Cushion Valve Operation Cushioned Mode - Hand Controller In Neutral A409220-C1 Fig 3. Cushioned Mode - Hand Controller in Neutral When the hand control is in neutral, hot oil is taken from the pressurised oil cooler line, entering port R of the cushion valve, through the outer spool and around the inner spool, via the galleries E and F, around the middle of the outer, via galleries G and H, returning to the tank via port T.
Page 888 Section E - Hydraulics Cushion Valve Operation Cushioned Mode - Hand Controller at Dipper In A409230-C1 Fig 4. Cushioned Mode - Hand Controller at Dipper In Pilot pressure enters port A of cushion valve from the left hand controller. The left-hand inner and outer spools move over to the right.
Page 889 Section E - Hydraulics Cushion Valve Operation Cushioned Mode - Hand Controller Moved from Dipper In to Neutral A409240-C1 Fig 5. Cushioned Mode - Hand Controller Moved from Dipper In to Neutral When the hand controller is released, the left hand inner and the outer spools move over to the left, back into the neutral position.
Page 890 Section E - Hydraulics Cushion Valve Operation Cushion Control Off A409250-C1 Fig 6. Cushion Control Off When the cushion switch is illuminated, the cushion solenoid is energised and pilot pressure is fed to port S on the cushion valve. The two inner left and right cushion spools are both pushed into the centre of the outer spool, so that the unrestricted galleries X and the cushion valve spools are open to allow the pilot outputs from the hand...
Page 891: Removal And Replacement
Replacement Replacement is a reversal of the removal sequence. Note: All hydraulic adapters that are installed together with a bonded sealing washer must also have JCB Threadseal applied to the threads of the adapter. E-230 9813/5100-1...
Page 892: Dismantling And Assembly
Section E - Hydraulics Cushion Valve Dismantling and Assembly Dismantling and Assembly Dismantling Port Hose Colour Green K Fig 7. ( T E-232). Clear Remove adapter A and `O'-ring B from valve. Extract spring C, spool D and spring E. Remove adapter F from valve and repeat step 2.
Page 893 Section E - Hydraulics Cushion Valve Dismantling and Assembly A407750-C1- A407750-C1 Fig 7. E-232 9813/5100-1 E-232...
Page 894: Hydraulic System Fault Finding
Section E - Hydraulics Hydraulic System Fault Finding Introduction Hydraulic System Fault Finding Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications K Related Topics ( T table.
Page 895: Related Topics
Section E - Hydraulics Hydraulic System Fault Finding Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures.
Page 896: Hydraulic Contamination
Section E - Hydraulics Hydraulic System Fault Finding Hydraulic Contamination Hydraulic Contamination TE-002_3 Hydraulic Fluid Quality Procedure Connect the cleaning unit in place of the hydraulic filter. This machine uses a large volume of fluid in the hydraulic K Fig 1. ( T E-235).
Page 897 Section E - Hydraulics Hydraulic System Fault Finding Hydraulic Contamination Contaminant Standards Dirt that damages your system is in many cases too small to be seen with the eye. The particle size is measured in microns. 1 micron = 0.001 mm (0.0000394 in). Listed below are a few typical comparisons: –...
Page 898: Main Control Valve
Section E - Hydraulics Hydraulic System Fault Finding Main Control Valve Main Control Valve Table 2. 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 899: Relief Valve
Section E - Hydraulics Hydraulic System Fault Finding Relief Valve Relief Valve Table 3. Symptoms Possible Causes Countermeasures Pressure does not rise at all 1. The main poppet, sleeve or pilot poppets Check whether foreign matter is in are sticking open or foreign matter is in the each poppet.
Page 900: Hydraulic System
Section E - Hydraulics Hydraulic System Fault Finding Hydraulic System Hydraulic System Table 4. Symptoms Possible Causes Countermeasures The hydraulic system is not 1. Pump problem. Check the pressure or replace the pump. working well or not at all 2.Foreign matter clogging inside the relief Disassemble the relief valve and clean.
Page 901: Slew Motor
Section E - Hydraulics Hydraulic System Fault Finding Slew Motor Slew Motor Table 5. Symptom Cause External Inspection Countermeasure Repair K Table 6. ( T Motor does Internal damage to the Measure the oil drain High possibility of E-241). not run motor.
Page 902 Section E - Hydraulics Hydraulic System Fault Finding Slew Motor Symptom Cause External Inspection Countermeasure Repair Insufficient Wear or seizure of the Open motor inlet and High possibility of internal Inspect the parts and torque motor sliding surfaces. outlet ports and apply 20 damage to the motor if bearing according to a-e kgf/cm...
Page 903: Hydraulic Pump
Section E - Hydraulics Hydraulic System Fault Finding Hydraulic Pump Hydraulic Pump Often the regulator and attendant valves or pump are Abnormal Vibration and Sound. Check to see if combined which makes it very difficult to discover the there is any abnormal vibration or sound in the pump reason for the trouble.
Page 904: Hydraulic Rams
Section E - Hydraulics Hydraulic System Fault Finding Hydraulic Rams Hydraulic Rams K Table 11. Hydraulic Ram Faults and Remedies E-244). However, machine trouble is most often caused, not by just one faulty part, but its relationship with other parts. Not all of the possible causes It is often not easy to find the part causing the fault.
Page 905 Section E - Hydraulics Hydraulic System Fault Finding Hydraulic Rams Table 11. Item Symptoms Related Parts Trouble Treatment On the sliding surface, there are Use an oil stone and remove the scratch scratches and rust that can be and make the sliding surface smooth. felt by the fingernail.
Page 906 Section E - Hydraulics Hydraulic System Fault Finding Hydraulic Rams Item Symptoms Related Parts Trouble Treatment Back up ring The protrusion of the heel of the As a rule, replace the rod packing at the same packing is excessive. time. (It is desirable to replace parts which are attached to the buffer ring at the same time).
Page 907 Section E - Hydraulics Hydraulic System Fault Finding Hydraulic Rams Item Symptoms Related Parts Trouble Treatment Oil leakage Crack in welding Replace with new parts. from pipe and cylinder tube Cracks will develop into fractures. Cylinder tube welded seam Fractures are very dangerous, so if any pipe (hollow cracks are found, stop work immediately piston rod)
Page 908 Section E - Hydraulics Hydraulic System Fault Finding Hydraulic Rams Item Symptoms Related Parts Trouble Treatment 4-2 Inner oil Piston seal Scratches, wear are present Replace with new part. Inspect the cylinder leakage. tube inner surface. Piston rod Cylinder tube Scratches, rust on the inside Remove the scratches/rust by honing or extends...
Page 909: Fault Finding Tests
Section E - Hydraulics Hydraulic System Fault Finding Fault Finding Tests Fault Finding Tests Slow or Underpowered: Additional information Measure the amount of deviation over a 20 m (165.6 ft) – boom up operation distance and record ground conditions. – bucket service operation –...
Page 910 Section E - Hydraulics Hydraulic System Fault Finding Fault Finding Tests Loss of Fast Speed Carry out the following tests: Test 006 Testing operation of main hydraulic spool Test 008 Testing engine speed settings Test 012 Testing track motor relief valve settings Test 014 Testing track motor speeds and pressure switches.
Page 911: Test 001: Testing Negative Control Signal
Section E - Hydraulics Hydraulic System Fault Finding Test 001: Testing Negative Control Signal Test 001: Testing Negative Control Signal Port Pi1 Port Pi2 C068630-C3.eps Fig 2. Fit test gauges (0 - 60 bar, 10 - 1000lb in ) into hose connections to ports Pi1 and Pi2 with tee-piece adapter.
Page 912 Section E - Hydraulics Hydraulic System Fault Finding Test 001: Testing Negative Control Signal Table 12. Expected Pressures (H power band) Port Pi1 Port Pi2 (30 - 35 bar*) (30 - 35 bar*) With max engine rpm's and no services selected record negative control pressure 435 - 507 lb/in 435 - 507 lb/in...
Page 913: Test 002: Test Max Flow Signal
Section E - Hydraulics Hydraulic System Fault Finding Test 002: Test Max Flow Signal Test 002: Test Max Flow Signal Port Pm1 Port Pm2 C068630-C2 Fig 3. Warm up machine hydraulic temperature to 50 °c Fit test gauges (0 - 60 bar, 10 - 1000lb in ) into hose connections to ports Pm1 and Pm2 with tee-piece (122°...
Page 914: Test 003: Testing Main Pump Pressure
Section E - Hydraulics Hydraulic System Fault Finding Test 003: Testing Main Pump Pressure Test 003: Testing Main Pump Pressure Port G1 (nearest engine) Port G2 Fig 4. Fit test gauges 0 - 600 bar (8700 lb/in ) into ports G1 and G2.
Page 915 Section E - Hydraulics Hydraulic System Fault Finding Test 003: Testing Main Pump Pressure E-254 9813/5100-1 E-254...
Page 916: Test 004: Testing Horsepower Control
Section C - Engine Throttle and Power Mode Check the horsepower control by measuring the Control. Proportional Solenoid Valve (PSV) output pressure at Table 15. JS300, JS330 Function Expected PSV Pressure Expected Current (mA) No service selected in H power band 9.32 bar...
Page 917: Test 005: Checking The Operation Of The Main Hydraulic Spool
Section E - Hydraulics Hydraulic System Fault Finding Test 005: Checking the Operation of the Main Hydraulic Spool Test 005: Checking the Operation of the Main Hydraulic Spool Fig 6. Sectional view of valve block showing spool and pilot ports lInsert a piece of stiff clean wire (Approximately 2 mm (0.08 Cylinder port B in) diameter)) through the adapter in the port not being...
Page 918 Section E - Hydraulics Hydraulic System Fault Finding Test 005: Checking the Operation of the Main Hydraulic Spool A409210-C4.eps Fig 7. K Fig 7. ( T E-257) K Fig 7. ( T E-257) Key: Key: All Other Spools Boom 2 Spool Stroke (mm) Pressure (bar) Table 17.
Page 919: Test 006: Test The Pressure Switches
Section E - Hydraulics Hydraulic System Fault Finding Test 006: Test the Pressure Switches Test 006: Test the Pressure Switches Select the pressure switch status mode on the DECU LCD monitor to display the actual pressure switch states. Refer to Section C, Machine Diagnostic Modes. The expected pressure switch states are shown in the table.
Page 920: Test 007: Testing Engine Speed Settings
Section E - Hydraulics Hydraulic System Fault Finding Test 007: Testing Engine Speed Settings Test 007: Testing Engine Speed Settings When the engine is operating normally the engine speed will be with in the values given for different machine operating modes. Warm Engine water temperature above 50 °C (122 °F).
Page 921: Test 008: Testing Machine Cycle Times
Section E - Hydraulics Hydraulic System Fault Finding Test 008: Testing Machine Cycle Times Test 008: Testing Machine Cycle Times Table 19. Service Operated Time (seconds) Machine JS300 JS330 JS370 Bucket in Bucket out Arm in Arm out Boom up...
Page 922 Section E - Hydraulics Hydraulic System Fault Finding Test 008: Testing Machine Cycle Times Bucket Ram Speed Dipper Ram Speed Position the dig end as shown. Position the dig end as shown. A357571 A357571 A357570-C2 A357570-C2 Fig 8. Fig 9. Measure the time it takes the bucket ram to open from Measure the time it takes the dipper ram to open from the closed position.
Page 923 Section E - Hydraulics Hydraulic System Fault Finding Test 008: Testing Machine Cycle Times Boom Ram Speed Swing Speed Position the dig end as shown. Position the dig end in the minimum Swing position facing forwards. Rotate the upper framework and after one complete rotation measure the time it takes for the next rotations.
Page 924 Section E - Hydraulics Hydraulic System Fault Finding Test 008: Testing Machine Cycle Times Travel Linearity The machine should have an approach A of 5 metres (16.5 ft) and a travel distance B of 20 metres (65.62 ft). Approach the reference line C and adjust the position of the track shoe/travel direction against the reference line in the first 5 metres (16.5 ft).
Page 925: Test 011: Testing Swing Brake Pressure
Section E - Hydraulics Hydraulic System Fault Finding Test 011: Testing Swing Brake Pressure Test 011: Testing Swing Brake Pressure A405810-C1 Fig 13. Fit pressure test gauge 0 - 60 bar (1000 lb in ) into hose connection on hose A on the Swing motor. Warm up hydraulic system to 50 °C.
Page 926: Test 012: Testing Track Motor Relief Valve Settings
Disconnect the travel pressure switch on the main K Table 21. ( T E-265) control valve. Table 21. Expected relief valve setting JS300 Select and stall left hand track motor forward 319 bar (4626.7 lb/in Select and stall left hand track motor reverse 319 bar (4626.7 lb/in Select and stall right hand track motor forward 319 bar (4626.7 lb/in...
Page 927: Test 013: Testing Track Motor Drain Line Flow Rate
Section E - Hydraulics Hydraulic System Fault Finding Test 013: Testing Track Motor Drain Line Flow Rate Test 013: Testing Track Motor Drain Line Flow Rate Fig 15. View of track motor (Cover removed) K Table 22. ( T E-266) Warm up hydraulic system to 50 °C (122 °F).
Page 928: Test 014: Testing The High Speed Tracking Setting
Section E - Hydraulics Hydraulic System Fault Finding Test 014: Testing the High Speed Tracking Setting Test 014: Testing the High Speed Tracking Setting If experiencing high speed tracking faults, carry out following checks: Test 008 Testing track motor speeds Test 006 Testing pressure switches The tracking motors change to high speed when the FAST...
Page 929: Test 015: Testing The Low Speed Tracking Setting
Section E - Hydraulics Hydraulic System Fault Finding Test 015: Testing the Low Speed Tracking Setting Test 015: Testing the Low Speed Tracking Setting If experiencing low speed tracking faults, carry out following checks: Test 008 Testing track motor speeds Test 006 Testing pressure switches The tracking motors change to low speed when the SLOW...
Page 930: Test 016 - Flow Testing Hydraulic Pumps - Record Sheet
Section E - Hydraulics Hydraulic System Fault Finding Test 016 - Flow Testing Hydraulic Pumps - Record Sheet Test 016 - Flow Testing Hydraulic Pumps - Record Sheet Minimum Flow Pump 1 Minimum Flow Pump 2 Power Pressure in Pressure in Flow Power Pressure in...
Page 931: Test 017: Testing Swing Bearing
Section E - Hydraulics Hydraulic System Fault Finding Test 017: Testing Swing Bearing Test 017: Testing Swing Bearing Checking Swing Bearing Backlash Fig 20. Set bucket 1mtr (40 in) above ground with dipper fully record measurement and check against limits below. extended.
Page 932 Section E - Hydraulics Hydraulic System Fault Finding Test 017: Testing Swing Bearing Checking Swing Bearing Vertical Lift Fig 21. Fig 23. First set the Dipper in a perpendicular position and Start the engine and lift the main body with the bucket, position the bucket 200 mm (9 in) above the ground, when the bottom of the shoe is 100 mm (4 in) above stop the engine.
Page 933 Section E - Hydraulics Hydraulic System Fault Finding Test 017: Testing Swing Bearing Note: Always stop the engine when installing or removing the dial gauge or reading the dial gauge. Fig 25. Next, place the dial gauge on the rear of the vehicle and repeat the two above procedures to obtain L2 and L4.
Page 934: Ram Creep Tests - All Services
Section E - Hydraulics Hydraulic System Fault Finding Ram Creep Tests - All Services Ram Creep Tests - All Services TE-030 If ram creep is suspected the following procedures must be can be measured using a hydraulic oil temperature carried out to define if the leakage is within tolerance. Ram probe, refer to Section 1, Service Tools.
Page 935 Section E - Hydraulics Hydraulic System Fault Finding Ram Creep Tests - All Services Allowable ram creep rates Port relief valve (ARV) failure If the port relief valve itself had failed, if contamination was Boom 30mm stuck on the valve seat or if the valve seat itself was Dipper 60mm damaged then this would allow oil to constantly bypass to...
Page 936: Hydraulic System Test Procedures
Section E - Hydraulics Hydraulic System Test Procedures Introduction Hydraulic System Test Procedures Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications K Related Topics ( T table.
Page 937: Related Topics
Section E - Hydraulics Hydraulic System Test Procedures Related Topics Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information.
Page 938: Pressure Testing - General
Section E - Hydraulics Hydraulic System Test Procedures Pressure Testing - General Pressure Testing - General Confirmation of the Oil Temperature Confirm the oil temperature is between 45°C - 55°C using the self check function. If the temperature is low use the following warm-up procedure.
Page 939 Section E - Hydraulics Hydraulic System Test Procedures Pressure Testing - General Pressure Testing Points C068440-C1 Fig 1. Main Pump P1 Main Pump P2 Servo Pressure K Table 2. JS300 ( T E-279) E-278 9813/5100-1 E-278...
Page 940 Section E - Hydraulics Hydraulic System Test Procedures Pressure Testing - General Table 2. JS300 Part Name Measurement Method Measurement Pressure bar (lb/in K Fig 1. Port ( T E-278) K Main Main Relief Dipper Relief TP1 or TP2 Standard: 343 bar (4974 lb/in...
Page 941 Section E - Hydraulics Hydraulic System Test Procedures Pressure Testing - General Table 3. JS330, JS370 Part Name Pressure bar (lb/in Measurement Method Measurement K Fig 1. Port ( T E-278) K Main Main Relief Dipper Relief TP1 or TP2 Standard: 319 bar (4626 lb/in ) Power Relief Valve (MRV)
Page 942: Pressure Relief Valve Location
Section E - Hydraulics Hydraulic System Test Procedures Pressure Relief Valve Location Pressure Relief Valve Location C047240-C1> Fig 2. K Table 4. ( T E-282) E-281 9813/5100-1 E-281...
Page 943 Section E - Hydraulics Hydraulic System Test Procedures Pressure Relief Valve Location Table 4. Main Relief Valve (MRV) Tab/Dozer Relief Valve Arm Out Relief Valve Option Relief Valve Boom Up Relief Valve Bucket Close Relief Valve Option Relief Valve Arm In Relief Valve T.A.B./Dozer Relief Valve Boom Down Relief Valve Bucket Open Relief Valve...
Page 944: Main Relief Valve (Mrv) Pressure
Section E - Hydraulics Hydraulic System Test Procedures Main Relief Valve (MRV) Pressure Main Relief Valve (MRV) Pressure TE-012 Prepare the Machine a Operate the dipper out and lower the boom to set the bucket on the ground. C030150-1 Fig 3. b Make the machine safe, refer to Section E, Service Procedures.
Page 945 Section E - Hydraulics Hydraulic System Test Procedures Main Relief Valve (MRV) Pressure a confirm that the engine is at its maximum no-load speed and it is in the L mode. b Stall the dipper. c Hold nut C and slacken locknut B. Screw nut A out to reduce pressure or in to increase pressure.
Page 946: Servo Relief Pressure
Section E - Hydraulics Hydraulic System Test Procedures Servo Relief Pressure Servo Relief Pressure TE-013 Prepare the Machine Start the engine and confirm that the engine is at its minimum no-load speed and it is in the E mode. The a Operate the dipper out and lower the boom to set pressure gauge reading should be compared to the the bucket on the ground.
Page 947: Auxiliary Relief Valves
Section E - Hydraulics Hydraulic System Test Procedures Auxiliary Relief Valves Auxiliary Relief Valves TE-014_2 General Prepare the machine a Operate the dipper out and lower the boom to set the bucket on the ground. C030150-1 Fig 7. b Make the machine safe, refer to Section E, Service Procedures.
Page 948 Section E - Hydraulics Hydraulic System Test Procedures Auxiliary Relief Valves Boom Ram Boom Up Prepare the machine a Operate the dipper out and lower the boom to set the bucket on the ground. C030150-1 Fig 8. b Make the machine safe, refer to Section E, C002690-C1 Service Procedures.
Page 949 Section E - Hydraulics Hydraulic System Test Procedures Auxiliary Relief Valves Boom Down b The pressure gauge reading (Boom down) should be compared to the technical data at the start of the section. If it is outside the limits, adjust the Prepare the machine ARV.
Page 950 Section E - Hydraulics Hydraulic System Test Procedures Auxiliary Relief Valves Dipper Ram Prepare the Machine a Operate the dipper out and lower the boom to set the bucket on the ground. C030150-1 Fig 14. b Make the machine safe, refer to Section E, Service Procedures.
Page 951 Section E - Hydraulics Hydraulic System Test Procedures Auxiliary Relief Valves Bucket Ram Prepare the Machine a Operate the dipper out and lower the boom to set the bucket on the ground. C030150-1 Fig 17. b Make the machine safe, refer to Section E, Service Procedures.
Page 952 Section E - Hydraulics Hydraulic System Test Procedures Auxiliary Relief Valves Option ARV (Monoboom) Operate the option by pressing the foot pedal. Check the pressure on the gauge, adjust the ARV. Prepare the Machine. Note: For accurate setting, the pressure should be adjusted up to the required level.
Page 953: Slew Motor Pressure Relief
Section E - Hydraulics Hydraulic System Test Procedures Slew Motor Pressure Relief Slew Motor Pressure Relief TE-015 Prepare the machine Note: If the water-proof slew lock solenoid valve is not removed. Full slew pressure can not be read. a Operate the dipper out and lower the boom to set the bucket on the ground.
Page 954 Section E - Hydraulics Hydraulic System Test Procedures Slew Motor Pressure Relief c Re-assemble relief valve assembly d Fix the sleeve into a vice and install the cap A with a torque of 156.9 Nm (115.17 lb ft). e Install the relief assembly in the slew motor unit, and confirm the pressure.
Page 955: Travel Motor Relief Pressure
Section E - Hydraulics Hydraulic System Test Procedures Travel Motor Relief Pressure Travel Motor Relief Pressure TE-016 Prepare the Machine Start the engine, select MID speed travel, lower the gate lock lever and run the engine at minimum no- a Operate the dipper out and lower the boom to set load speed in the E mode.
Page 956: Routine Maintenance Procedures
Section E - Hydraulics Routine Maintenance Procedures Scheduled Tasks The table below lists the Hydraulic System related Note: Maintenance schedules can vary according to Scheduled tasks. The tasks are in addition to the tasks machine operating conditions and environments. Refer to detailed in Section 2.
Page 957: Service Points
Section E - Hydraulics Routine Maintenance Procedures Service Points Service Points Upper Structure C134660.eps Fig 1. Item Description Cover, suction strainer Breather, hydraulic tank Cover, return filter Filler port, Swing gearbox (if fitted) Drain plug, Swing gearbox Cushion valve filter Hydraulic Control Valve Dipstick, Swing gearbox E-296...
Page 958 Section E - Hydraulics Routine Maintenance Procedures Service Points Hydraulic Compartment C130170-C8.eps Fig 2. Item Description Servo filter element Drain filter E-297 9813/5100-1 E-297...
Page 959 Section E - Hydraulics Routine Maintenance Procedures Service Points Cooling Pack Compartment C132300.eps Fig 3. Item Description Hydraulic Oil Cooler Matrix Engine Coolant Matrix Intercooler Matrix Air Conditioning Condensor E-298 9813/5100-1 E-298...
Page 960: Hydraulic Oil
Section E - Hydraulics Routine Maintenance Procedures Hydraulic Oil Hydraulic Oil Replace Note: Have a drain pan ready. Renew the suction strainer D and return filter E. Prepare machine. Refer Section K Suction Strainer ( T E-303) K Return Maintenance, Maintenance Positions. Filter ( T E-301)).
Page 961: Hydraulic Tank Breather
Section E - Hydraulics Routine Maintenance Procedures Hydraulic Tank Breather Hydraulic Tank Breather Replace Refit the filter cover C Adjust the cover so that it fits over the stud, and Prepare machine. Refer Section Maintenance, Maintenance Positions. install hexagonal nut B and rubber boot A. Release tank pressure.
Page 962: Return Filter
Section E - Hydraulics Routine Maintenance Procedures Return Filter Return Filter Replace Install a new return filter E. Re-assemble in the reverse order using a new cover O-ring B. Prepare machine. Refer Section Maintenance, Maintenance Positions. Release Tank Pressure. Refer to Section 2, Maintenance, Hydraulic System.
Page 963: Drain Filter
Section E - Hydraulics Routine Maintenance Procedures Drain Filter Drain Filter Replace Prepare machine. Refer Section Maintenance, Maintenance Positions. Release tank pressure. Refer to Section 2, Maintenance, Hydraulic System. K Service access drain filter. Points ( T E-296) Unscrew and remove filter A from head B. Fit the new filter.
Page 964: Suction Strainer
Section E - Hydraulics Routine Maintenance Procedures Suction Strainer Suction Strainer Clean / Replace At the applicable service interval clean the suction strainer using a suitable cleaning fluid. Refer to Section 2, Maintenance, Maintenance Schedules. Prepare machine. Refer Section Maintenance, Maintenance Positions. Make sure that...
Page 965: Cushion Valve Filter
Section E - Hydraulics Routine Maintenance Procedures Cushion Valve Filter Cushion Valve Filter The cushion valve filter is located next to the control valve Release the tank pressure. Refer to Section 2, Maintenance, Hydraulic System. K Service Clean / Replace Get access to the cushion valve filter 6.
Page 966: Major Component Mounting Bolts
Section E - Hydraulics Routine Maintenance Procedures Major Component Mounting Bolts Major Component Mounting Bolts Check Check the security and torque of the major component mounting bolts as detailed in Section 2, Technical Data, Torque Values. E-305 9813/5100-1 E-305...
Page 967: Servo Filter Element
Section E - Hydraulics Routine Maintenance Procedures Servo Filter Element Servo Filter Element Replace c Screw the filter case A to the head B and torque tighten with the wrench. Prepare machine. Refer Section Table 2. Torque Settings Maintenance, Maintenance Positions. Item kgf m lbf ft...
Page 968: Relief Valves
Section E - Hydraulics Routine Maintenance Procedures Relief Valves Relief Valves For relief valve locations refer to Test Procedures in this section. Check (Condition) Check the condition of the relief valve installations as follows: – Check the adjustment lock nut security. –...
Page 969: Oil Cooler
Section E - Hydraulics Routine Maintenance Procedures Oil Cooler Oil Cooler Clean Release the fastener 3. Pivot the condenser away from the oil cooler matrix. Check the oil cooler matrix 2 for external contamination with dirt or debris. Use a soft brush and compressed air to On completion, return the condenser to its normal remove dirt and debris.
Page 970: Swing Gearbox
Section E - Hydraulics Routine Maintenance Procedures Swing Gearbox Swing Gearbox Check (Condition) Check the general condition and operation of the Swing gearbox as follows: Prepare machine. Refer Section Maintenance, Maintenance Positions. K Service Get access to the Swing gearbox. Points ( T E-296) Inspect the Swing gearbox casings for defects and oil leaks.
Page 971 Section E - Hydraulics Routine Maintenance Procedures Swing Gearbox K Check (Oil Level) ( T E-309) Check the oil level. Check for oil leaks. Run the machine, operate the Swing controls and make sure there are no oil leaks. E-310 9813/5100-1 E-310...
Page 972: Swing Brake
Section E - Hydraulics Routine Maintenance Procedures Swing Brake Swing Brake Check (Operation) Check that the Swing brake releases as follows: Start the engine and operate the Swing service. If the Swing operation is slow, or does not operate, the Swing brake or its control system may be defective.
Page 973 Section E - Hydraulics Routine Maintenance Procedures Swing Brake Page left intentionally blank E-312 9813/5100-1 E-312...
Page 974 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 975 Section F - Transmission Notes: 9813/5100-1...
Page 976 Section F - Transmission Contents Page No. Technical Data Travel Equipment ..................F-1 Traction Motor / Reduction Gear Introduction ....................F-3 Description ....................F-4 Operation ....................F-5 Removal and Replacement ..............F-15 Dismantling ....................F-20 Inspection ....................F-28 Assembly ....................F-30 Start Up and Running In ................
Page 977 Section F - Transmission Contents Page No. F-ii F-ii...
Page 978: Technical Data
Section F - Transmission Technical Data Travel Equipment Table 1. JS300 Motor Displacement 106.7/181.3 cc/rev Gearbox Ratio 1:56.4 Max Pressure 343 bar Max Flow 243 litres Max Drain Pressure 2/8 bar Parking Brake Torque 581 Nm Minimum Pressure for Park Brake Release...
Page 979 Section F - Transmission Technical Data Travel Equipment JS330 JS360/370 Checkvalve Cracking Pressure <0.3 bar <0.3 bar 2 Speed Control Pressure 44 bar 49 bar Oil Quantity approx 6 litres approx 5 litres Dry Weight approx 310 kg approx 360 kg Fig 1.
Page 980: Traction Motor / Reduction Gear
Section F - Transmission Traction Motor / Reduction Gear Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.
Page 981: Description
Section F - Transmission Traction Motor / Reduction Gear Description Description The motor is of the variable swash plate, axial piston type. connected to the return line. The next 180° of cylinder Pressurised oil is routed via rear flange A and timing plate block rotation causes the piston to complete its cycle by F into cylinder block D.
Page 982: Operation
Section F - Transmission Traction Motor / Reduction Gear Operation Operation Middle Speed check valve trapping the pressure at the spool end and only allows it to vent through the restrictor, allowing the counterbalance spool to return slowly. Returning oil from Note: Second stage MRV is not selected during travel on the motor is slowly blocked in its path to tank and as the this machine.
Page 983 Section F - Transmission Traction Motor / Reduction Gear Operation Key to Oil Flow & Pressu re Full Pressu re Pressu re Servo Neutral Exhaust Cavitation Lock Up Fig 2. Creep/Middle Speed 9813/5100-1...
Page 984 Section F - Transmission Traction Motor / Reduction Gear Operation High Speed When high-speed travel is selected, the electronic control unit (MECU) sends a signal to solenoid CT5 on the 8-spool solenoid block. The solenoid energises, allowing servo pressure to cross the solenoid and sends a signal to port Ps of the drive motor, which moves the two speed travel spool E to the high-speed position.
Page 985 Section F - Transmission Traction Motor / Reduction Gear Operation Key to Oil Flow & Pressu re Full Pressu re Pressu re Servo Neutral Exhaust Cavitation Lock Up Fig 3. High Speed 9813/5100-1...
Page 986 Section F - Transmission Traction Motor / Reduction Gear Operation Brake Valve the plunger diaphragm opening becomes smaller and because the piston motor continues to rotate due to inertia (motor pumping function), the pressure at M2 port side Brake Function rises and braking occurs.
Page 987 Section F - Transmission Traction Motor / Reduction Gear Operation Counterbalance Valve control valve A has no pressure at ports P1 or P2, so ports M1 and M2 are blocked by the flange and check valve and the motor does not rotate. The counterbalance valve serves to prevent the stoppage of the axial piston motor and its overrun.
Page 988 Section F - Transmission Traction Motor / Reduction Gear Operation C076890 Fig 6. Motor Rotating When hydraulic oil delivered from the hydraulic pump is proportional to the pressure, it tries to move the plunger to guided to P1 port of the counterbalance valve through the the right side.
Page 989 Section F - Transmission Traction Motor / Reduction Gear Operation passageway area so the piston motor will rotate at a speed suitable to P1 port side pressure, that is, the P1 port side flow rate. Shuttle Function The counterbalance valve has a shuttle function. When the plunger moves from the state in the top illustration to that in the lower illustration, the parking brake release port P3 is opened to guide the pressurised oil to the brake...
Page 990 Section F - Transmission Traction Motor / Reduction Gear Operation Parking Brake brake piston across, thereby un-clamping the friction and counter plates to release the parking brake. When parking or stopping the machine the shuttle function causes the The parking brake consists of alternate friction and counter pressurised oil in the parking brake cylinder to be released plates (A and B), a piston C and an activating spring D.
Page 991 Section F - Transmission Traction Motor / Reduction Gear Operation Rotation Direction The relationship between the flow direction of the hydraulic oil and the rotation direction is as shown below. Table 1. Oil Input Oil Output Rotation direction (viewed Port Port from output shaft end of motor)
Page 992: Removal And Replacement
Section F - Transmission Traction Motor / Reduction Gear Removal and Replacement 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. Fig 14.
Page 993 Section F - Transmission Traction Motor / Reduction Gear Removal and Replacement e Remove the seal rings from each side of the chain link. Operate the traction motor to remove the track. Fig 18. Support the motor so that the cables are in tension, Fig 16.
Page 994 Make sure that all ports are plugged to prevent the ingress of dirt. Lift the assembly and position it on the undercarriage. Fig 20. Install the bolts and washers, using JCB Threadseal A408272-C1 on the bolt threads. Tighten the bolts in a diagonal Fig 21.
Page 995 Section F - Transmission Traction Motor / Reduction Gear Removal and Replacement Check the amount of oil in the gearbox, refer to Insert the pointed guide pin from the inner face and Routine Maintenance. tap through its full length. Install the drive sprocket, refer to Section J, Track and Running Gear.
Page 996 Section F - Transmission Traction Motor / Reduction Gear Removal and Replacement Fig 27. F-19 9813/5100-1 F-19...
Page 997: Dismantling
Section F - Transmission Traction Motor / Reduction Gear Dismantling Dismantling In the following procedures, the part numbers in bold type (e.g. 2-7) correspond with the numbers on the illustrations. K Fig 17. ( T F-21) K Fig 18. ( T F-21).
Page 998 Section F - Transmission Traction Motor / Reduction Gear Dismantling Base plate disassembly a Loosen socket head bolt 20. Note: Since the base plate is forced upwards by springs, loosen the bolts evenly. Fig 31. Pull out plunger assembly 2-2. While turning the plunger, pull it out slowly, being careful not to damage the outer circumference.
Page 999 Section F - Transmission Traction Motor / Reduction Gear Dismantling Note: When pulling out pin 28, if using pincers, be careful Cylinder rod disassembly not to damage the outer circumference. Be careful not to damage the sliding surface of valve plate 5. a Place case 1 horizontally on the working bench and remove cylinder block 4, piston sub-assembly 6, retainer plate 7, retainer holder 8, pin 19, snap...
Page 1000 Section F - Transmission Traction Motor / Reduction Gear Dismantling Fig 40. Fig 38. Remove piston 6, retainer plate 7, retainer holder 8 and pin 19 from cylinder block 4. Fig 41. Plunger disassembly Push though a 10 mm bar in plunger 2-2, 11 mm hole JS10530 and fix with a vice then loosen plug 2-2-4.

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jcb JS300 Service Manual

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