jcb Dumpster HTD5 Service Manual
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jcb Dumpster HTD5 Service Manual

jcb Dumpster HTD5 Service Manual

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Service Manual
Dumpster HTD5
Section 1 - General Information
Section 2 - Care & Safety
Section 3 - Maintenance
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section J - Tracks
Section K - Engine
Publication No.
9803/9570-4
World Class
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.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

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  • 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 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 1 - General Information Notes: 9803/9570-4...

  • Page 4: Table Of Contents

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section 1 - General Information Contents Page No. Introduction About this Publication ................1 - 1 Machine Identification Identifying Your Machine ................1 - 3 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ........1 - 5 Hydraulic Connections ................1 - 9 Service Tools Numerical List ..................1 - 13 Consumables...
  • Page 5 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 1 - General Information Contents Contents Page No. 1 - ii 1 - ii...

  • Page 6: Introduction

    About this Publication Introduction About this Publication This publication is designed for the benefit of JCB Where a torque setting is given as a single figure it may be Distributor Service Engineers who are receiving, or have varied by plus or minus 3%. Torque figures indicated are received, training by JCB Technical Training Department.
  • Page 7 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 1 - General Information Introduction About this Publication Page left intentionally blank 9803/9570-4...

  • Page 8: Machine Identification Identifying Your Machine

    The serial (VIN) number of the machine is stamped on the plate together with the machine weight, engine power and year of manufacture. JCB COMPACT PRODUCTS LIMITED HAREWOOD ESTATE, LEEK ROAD, CHEADLE, STOKE ON TRENT, UNITED KINGDOM, ST10 2JU.
  • Page 9 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 1 - General Information Machine Identification Identifying Your Machine Page left intentionally blank 9803/9570-4...

  • Page 10: Torque Settings

    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 11 manualequipospesados@gmail.com manualequipospesados@gmail.com 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...
  • Page 12 manualequipospesados@gmail.com manualequipospesados@gmail.com 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...
  • Page 13 manualequipospesados@gmail.com manualequipospesados@gmail.com 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 14: Hydraulic Connections

    manualequipospesados@gmail.com manualequipospesados@gmail.com 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 15 manualequipospesados@gmail.com manualequipospesados@gmail.com 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 16 manualequipospesados@gmail.com manualequipospesados@gmail.com 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...
  • Page 17 manualequipospesados@gmail.com manualequipospesados@gmail.com 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 18: Service Tools Numerical List

    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 19 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 1 - General Information Service Tools Numerical List Page left intentionally blank 1-14 9803/9570-4 1-14...

  • Page 20: Consumables

    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 21 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 1 - General Information Consumables Sealing and Retaining Compounds Page left intentionally blank 1-16 9803/9570-4 1-16...
  • Page 22 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 23 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 2 - Care and Safety Notes: 9803/9570-4...
  • Page 24 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 2 - Care and Safety Contents Page No. Safety Notices Important Information ................2-1 Safety Checklist ..................2-2 Safety Decals .................... 2-9...
  • Page 25 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 2 - Care and Safety Contents Contents Page No. 2-ii 2-ii...
  • Page 26 If you are other operators. unsure about anything, ask your JCB dealer or employer. Do not guess, you or others could be killed In this publication and on the machine, there are safety or seriously injured.
  • Page 27 If you do not understand messages. Read and understand them. They tell you of anything, ask your employer or JCB dealer to explain potential hazards and how to avoid them. If you do not fully it. Keep the Operator Manual clean and in good understand the warning messages, ask your employer or condition.
  • Page 28 Sparks in altered in any way which could affect or invalidate any such an area could cause an explosion or fire of these requirements. For advice consult your JCB resulting in death or serious injury. Distributor.
  • Page 29 Work sites can be noisy, do not rely on atmosphere, i.e. combustible vapours, gas or dust, spoken commands. without first consulting your JCB Distributor. INT-2-2-3 INT-2-1-14 WARNING CAUTION Banks and Trenches Regulations Banked material and trenches can collapse.
  • Page 30 Section 2 - Care and Safety Safety Notices Safety Checklist Maintenance Safety WARNING Use only the JCB approved attachments that are WARNING specified for your machine. Operating with non- specified attachments can overload the machine, Communications causing possible damage and machine instability Bad communications can cause accidents.
  • Page 31 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 2 - Care and Safety Safety Notices Safety Checklist WARNING WARNING If you try to charge a frozen battery, or jump start and Hydraulic Pressure run the engine, the battery could explode. Do not use Hydraulic fluid at system pressure can injure you. a battery if its electrolyte is frozen.
  • Page 32 5-3-1-9 Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning WARNING agents and solvents. INT-3-2-11 Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials WARNING such Viton, Fluorel Technoflon. Fluoroelastomeric materials...
  • Page 33 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 2 - Care and Safety Safety Notices Safety Checklist Thoroughly wash contaminated area with WARNING detergent and water. Arc Welding Contain all removed material, gloves etc. used in To prevent the possibility of damage to electronic this operation in sealed plastic bags and dispose components, disconnect the battery and the alternator accordance with...
  • Page 34 Keep all decals clean and readable. Replace lost or damaged decals. Each decal has a part number printed on it, use this number to order a new decal from your JCB distributor. INT-3-3-3_1 WARNING If you need eye-glasses for reading, make sure you wear them when reading the safety decals.
  • Page 35 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 2 - Care and Safety Safety Notices Safety Decals Page left intentionally blank 2-10 9803/9570-4 2-10...
  • Page 36 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 37 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Notes: 9803/9570-4...
  • Page 38 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Contents Page No. Routine Maintenance Health and Safety ..................3-1 Service Schedules ..................3-5 Lubricants and Capacities ................. 3-8 Check for Damage and Cleaning .............. 3-9 Safety Strut ....................3-10 Greasing ....................3-11 Engine Air Filter ..................3-13 Engine Oil ....................
  • Page 39 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Contents Page No. 3-ii 3-ii...

  • Page 40: Routine Maintenance

    New Oil Hygiene There are no special precautions needed for the handling JCB lubricants are not a health risk when used properly for or use of new oil, beside the normal care and hygiene their intended purposes. practices. However, excessive or prolonged skin contact can remove...
  • Page 41 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Routine Maintenance Health and Safety Throw away oil-soaked shoes. First Aid - Oil Eyes In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention. Swallowing If oil is swallowed do not induce vomiting. Get medical advice.
  • Page 42 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Routine Maintenance Health and Safety Battery Warning Symbols The following warning symbols may be found on the WARNING battery. Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the Symbol Meaning battery away from sparks and flames.
  • Page 43 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Routine Maintenance Health and Safety WARNING Electrical Circuits Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage. INT-3-1-4 DANGER Electrolyte Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery.

  • Page 44: Service Schedules

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Routine Maintenance Service Schedules Service Schedules A badly maintained machine is a danger to the operator Apart from the daily jobs, the schedules are based on and the people working around him. Make sure that the machine running hours.
  • Page 45 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Routine Maintenance Service Schedules Service Points and Fluid Level Checks - Engine Stopped Operation 1 Day Week Month Months Months 1 Year Fuel Tube Check/replace Fuel Injector (Yanmar) Clean & Reset Throttle Cable Lubricate HYDRAULICS Filter Element Change...
  • Page 46 (1) 1 month service is for 1st service only (2) Clean more frequently when operating in a dusty environment. (3) Clean more frequently when operating in a dusty environment. (4) Items should be completed by a Honda Dealer. (5) Items should be completed by a JCB Dealer 9803-9570-4...

  • Page 47: Lubricants And Capacities

    JCB 10/30 Multigrade MIL-L-46152, API CC/SF Engine Oil (Yanmar) 1.1 (0.24) JCB 10/30 Multigrade MIL-L-46152, API CC/SF Track Idler Wheels JCB HD90 Gear Oil API-GL-5, MIL-L-2105D Track Rollers JCB HD90 Gear Oil API-GL-5, MIL-L-2105D Hydraulic System up to M1360211 18.5 (4.07)

  • Page 48: Check For Damage And Cleaning

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Routine Maintenance Check for Damage and Cleaning Check for Damage and Cleaning WARNING The exhaust pipe becomes extremely hot when the engine is running and will remain so for some time after the engine is stopped. If you touch the hot pipe you could be severely burned.

  • Page 49: Safety Strut

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Routine Maintenance Safety Strut Safety Strut Fitting the Safety Strut Fully raise the skip and stop the engine. Remove the safety strut A from its storage position and fit around the ram shaft. Fit the securing bolt. Operate the control lever to gently lower the ram onto the strut.

  • Page 50: Greasing

    Greasing should be done with a grease gun. Normally, two strokes of the gun should be enough. Stop greasing when fresh grease appears at the joint. Use only JCB HP Grease. Before greasing, do the following: Park the machine on firm, level ground, raise the skip Fig 3.
  • Page 51 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Routine Maintenance Greasing Page left intentionally blank 3-12 9803-9570-4 3-12...

  • Page 52: Engine Air Filter

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Routine Maintenance Engine Air Filter Engine Air Filter Changing the Element - Honda Petrol Engine Stop the engine. Open the engine cover (if fitted). Remove the wing nut A and the air filter cover B. Remove the elements C and D and separate them.
  • Page 53 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Routine Maintenance Engine Air Filter Changing the Element - Yanmar Engine Stop the engine. Open the engine cover (if fitted). Unscrew the wing nut A and remove the air filter cover B. Remove and discard the element. Fit a new element and refit the air filter cover B.
  • Page 54 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Routine Maintenance Engine Air Filter Cleaning/changing the Element - Lombardini Engine Stop the engine. Open the engine cover (if fitted). Unscrew wing nut A and remove filter cover B. Unscrew wing nut C and remove filter element D. Remove pre-filter E from the main element and wash in soapy water.

  • Page 55: Engine Oil

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Routine Maintenance Engine Oil Engine Oil Checking the Oil Level - Honda Petrol Open the engine cover (if fitted). Engine Unscrew and withdraw the filler cap A and wipe clean the dipstick. Re-insert the dipstick into the oil filler Park the machine on level ground.
  • Page 56 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Routine Maintenance Engine Oil Changing the Oil - Honda Petrol Engine WARNING Hot oil and engine components can burn you. Make sure the engine is cool before doing this job. Used engine crankcase lubricants contain harmful contaminants.
  • Page 57 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Routine Maintenance Engine Oil Checking the Oil Level - Yanmar Engine Wipe off any spilt oil. Check for leaks. Make sure that the filler cap A is correctly refitted. Park the machine on level ground. Stop the engine.
  • Page 58 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Routine Maintenance Engine Oil Checking the Oil Level - Lombardini Engine Park the machine on level ground. Stop the engine. Allow time for the oil to drain back into the engine sump before taking a reading. If insufficient time is given a false low reading may be recorded which will result in overfilling the engine.
  • Page 59 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Routine Maintenance Engine Oil Changing the Oil - Lombardini Engine WARNING Hot oil and engine components can burn you. Make sure the engine is cool before doing this job. Used engine crankcase lubricants contain harmful contaminants.

  • Page 60: Spark Plug

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Routine Maintenance Spark Plug Spark Plug Honda Petrol Engine 0.70 - 0.80 mm To maintain an efficient engine, the spark plug should be 0.028 - 0.031 in. visually checked at regular intervals. It should be discarded and replaced if there is any sign of apparent wear or if the insulator is cracked or chipped.

  • Page 61: Fuel System

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Routine Maintenance Fuel System Fuel System Honda Petrol Engine Start the engine outdoors and allow it to warm up to normal operating temperature. WARNING Move the throttle lever to the idle position. Petrol Turn the throttle stop screw B to obtain the standard Petrol is extremely flammable and is explosive under idling speed (1400 rpm +/-150).
  • Page 62 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Routine Maintenance Fuel System Cleaning the Sedimenter Draining the Fuel System (for machine storage or removing contaminated fuel) Turn the fuel valve OFF. With the fuel valve at OFF, remove and empty the Remove the sedimenter cup A and O-ring B and sediment cup A.
  • Page 63 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Routine Maintenance Fuel System Changing the Fuel Filter - Lombardini Engine Remove the air filter cover and element. Drain the fuel tank into a clean receptacle. Mark the fuel hoses to ensure correct re-connection then disconnect the hoses from the filter A.

  • Page 64: Hydraulic System

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Routine Maintenance Hydraulic System Hydraulic System Checking the Oil Level Replacing the Hydraulic Filter Position the machine on firm level ground, fully raise the Remove the filler/filter cap B and lift out the cartridge D. Fit skip and fit the safety strut.
  • Page 65 manualequipospesados@gmail.com manualequipospesados@gmail.com Section 3 - Maintenance Routine Maintenance Hydraulic System Page left intentionally blank 3-26 9803-9570-4 3-26...
  • Page 66 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 67 manualequipospesados@gmail.com manualequipospesados@gmail.com Section B - Body and Framework Notes: 9803/9570-4...
  • Page 68 manualequipospesados@gmail.com manualequipospesados@gmail.com Section B - 1 Contents Page No. Engine Cover Removal and Replacement ..............B-1 Skip Removal and Replacement ..............B-3 Skip Mechanism Removal and Replacement ..............B-5 Hydraulic Tank Removal and Replacement - up to machine no. 1360211 ......B-9 Removal and Replacement - from machine no.
  • Page 69 manualequipospesados@gmail.com manualequipospesados@gmail.com Section B - 1 Contents Page No. B-ii B-ii...

  • Page 70: Engine Cover Removal And Replacement

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section B - Body and Framework Engine Cover Removal and Replacement Engine Cover Removal and Replacement Removal Open the cover and release the cover check wire. On machines with Yanmar engines, disconnect the wiring harness at the ignition switch. On early machines, pull the cover backwards at the base to release it from the machine by separating the hinge.
  • Page 71 manualequipospesados@gmail.com manualequipospesados@gmail.com Section B - Body and Framework Engine Cover Removal and Replacement Page left intentionally blank 9803/9570-4...
  • Page 72 manualequipospesados@gmail.com manualequipospesados@gmail.com Section B - Body and Framework Skip Removal and Replacement Skip Removal and Replacement Removal Position the machine on firm level ground and fully raise the skip. Place a sling securely around the skip A and attach to a suitable hoist.
  • Page 73 manualequipospesados@gmail.com manualequipospesados@gmail.com Section B - Body and Framework Skip Removal and Replacement Page left intentionally blank 9803/9570-4...
  • Page 74 manualequipospesados@gmail.com manualequipospesados@gmail.com Section B - Body and Framework Skip Mechanism Removal and Replacement General Notes When removing all the components of the lift mechanism from the machine it is recommended that the procedure should be done in the sequence given, i.e. remove the link first followed by the outer arms and then the inner arms.

  • Page 75: Skip Mechanism Removal And Replacement

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section B - Body and Framework Skip Mechanism Removal and Replacement Fig 3. 9803/9570-4...
  • Page 76 manualequipospesados@gmail.com manualequipospesados@gmail.com Section B - Body and Framework Skip Mechanism Removal and Replacement Link Removal taking care to locate the locking tab. Fit and tighten nut 7. K Skip ( T Remove the skip B-3). Refit the link (see above). Position the mechanism to allow access to Refit the skip.
  • Page 77 manualequipospesados@gmail.com manualequipospesados@gmail.com Section B - Body and Framework Skip Mechanism Removal and Replacement Page left intentionally blank 9803/9570-4...

  • Page 78: Hydraulic Tank

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section B - Body and Framework Hydraulic Tank Removal and Replacement - up to machine no. 1360211 Hydraulic Tank Removal and Replacement - up to machine no. 1360211 Removal Remove the safety strut. Start the engine and operate all hydraulic services to Position the machine on firm level ground and fully fill the system with oil.

  • Page 79: Removal And Replacement - From Machine No. 1360212

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section B - Body and Framework Hydraulic Tank Removal and Replacement - from machine no. 1360212 Removal and Replacement - from machine no. 1360212 Removal regularly during this operation and top up as necessary. Position the machine on firm level ground and fully Check for oil leaks.
  • Page 80 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 81 manualequipospesados@gmail.com manualequipospesados@gmail.com Section C - Electrics Notes: 9803/9570-4...
  • Page 82 manualequipospesados@gmail.com manualequipospesados@gmail.com Section C - Electrics Contents Page No. Circuit Diagrams Engine Electrical Circuits ................C-2 Switches Ignition Switch ..................C-4 Battery Battery Checks ..................C-6 Battery Removal and Replacement ............C-8...
  • Page 83 manualequipospesados@gmail.com manualequipospesados@gmail.com Section C - Electrics Contents Page No. C-ii C-ii...

  • Page 84: Circuit Diagrams Engine Electrical Circuits

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section C - Electrics Circuit Diagrams Engine Electrical Circuits Circuit Diagrams Engine Electrical Circuits Yanmar Engine Fig 1. Alternator Voltage Regulator Starter Motor Fuse Connector Starter Switch Battery Charge Warning Light Battery Wire Colours Yellow Green White G/W Green/White 9803/9570-4...
  • Page 85 manualequipospesados@gmail.com manualequipospesados@gmail.com Section C - Electrics Circuit Diagrams Engine Electrical Circuits Lombardini Engine OIL PRESSURE SWITCH REGULATOR ALTERNATOR OK CIRCUIT OIL PRESSURE CONNECTOR OK WARNING WARNING ALTERNATOR WARNING IG. SWITCH FUSE MALE CONNECTOR TERMINALS STARTER MOTOR BATTERY Fig 2. Yellow/Green Black Oil Pressure Switch Alternator...

  • Page 86: Switches Ignition Switch

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section C - Electrics Switches Ignition Switch Switches Ignition Switch Yanmar Engine Lombardini Engine Removal Removal Open the engine cover. Open the engine cover. Disconnect the wiring at the connector. Disconnect the wiring at the connector. Remove the switch mounting screws and withdraw Unscrew the two mounting bolts securing the ignition the switch A from the engine cover.
  • Page 87 manualequipospesados@gmail.com manualequipospesados@gmail.com Section C - Electrics Switches Ignition Switch Page left intentionally blank 9803/9570-4...
  • Page 88 manualequipospesados@gmail.com manualequipospesados@gmail.com Section C - Electrics Battery Battery Checks Checking the Battery Terminals - up to Checking the Battery Terminals - from machine no. 1360211 machine no. 1360212 Park the vehicle on firm level ground. Stop the engine Park the vehicle on firm level ground. Raise the skip and remove the ignition key.

  • Page 89: Battery Battery Checks

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section C - Electrics Battery Battery Checks Checking the Electrolyte Level - up to Checking the Electrolyte Level - from machine no. 1360211 machine no. 1360212 Maintenance free batteries used in normal temperate Maintenance free batteries used in normal temperate climate applications should not need topping up.

  • Page 90: Battery Removal And Replacement

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section C - Electrics Battery Battery Removal and Replacement Battery Removal and Replacement Fig 3. 9803/9570-4...
  • Page 91 manualequipospesados@gmail.com manualequipospesados@gmail.com Section C - Electrics Battery Battery Removal and Replacement Removal - up to machine no. 1360211 Park the machine on a firm level surface and stop the engine. Remove the engine cover A (if fitted) K Engine Cover ( T B-1) and move the engine back on its mounting to gain access K Engine Mounting ( T K-3) Note: The removal sequence requires two engineers, one to hold the battery assembly and the other to remove the...
  • Page 92 manualequipospesados@gmail.com manualequipospesados@gmail.com Section C - Electrics Battery Battery Removal and Replacement Removal - from machine no. 1360212 Park the vehicle on firm level ground. Raise the skip and fit the safety strut to the lift ram K Safety Strut ( T 3-10). Stop the engine and remove the ignition key.
  • Page 93 manualequipospesados@gmail.com manualequipospesados@gmail.com Section C - Electrics Battery Battery Removal and Replacement Page left intentionally blank C-10 9803/9570-4 C-10...
  • Page 94 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 95 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Notes: 9803/9570-4...
  • Page 96 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - 1 Contents Page No. Technical Data General Data .................... E-1 Operation Description Introduction to Hydraulic Schematic Symbols .......... E-3 Machine Schematic Circuit ..............E-10 Service Procedures Hydraulic Contamination ................ E-13 Cleaning Operation ................. E-15 Pressure Testing Main Relief Valve (M.R.V.) ..............
  • Page 97 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - 1 Contents Page No. E-ii E-ii...
  • Page 98 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Technical Data General Data Note: System Cleanliness is to be to ISO 16/13 - K Service Procedures ( T E-13) Loader Pump up to machine no. 1360178 Type DTL Triple Gear Displacement 8.8 cc/rev (0.537 in /rev) Maximum flow at 3000 rev/min and 150 bar (2175 lbf/in - Combined (all three elements)

  • Page 99: Technical Data General Data

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Technical Data General Data Relief Valve Operating Pressures Pressures are given at normal working temperature of 50 deg C. lbf/in Main Relief Valve: at max. rev/min 2175 Track Motor Relief Valve Setting 2175 Filter Type Cartridge Rams...

  • Page 100: Operation Description

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Operation Description Introduction to Hydraulic Schematic Symbols TE-001 General (Basic and Functional Symbols) Table 2. Rams Complex hydraulic components and circuits can be Single acting described to the engineer by using graphical symbols. The following pages illustrate and give a brief description for some of the more common symbols used.
  • Page 101 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Operation Description Introduction to Hydraulic Schematic Symbols Table 4. Control Valves Throttling orifice - normally Used to enclose several closed valves indicating they are supplied as one unit 3-Position, 4-port spring Throttling orifice - normally centered pilot operated valve open 3-position, 6-port spring...
  • Page 102 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Operation Description Introduction to Hydraulic Schematic Symbols Table 5. Energy Transmissions and Conditioning Working line, return or feed Reservoir - return line below fluid level Pilot control Drain lines Header tank Flexible pipe Pressure sealed tank Line junction Accumulator Crossing lines...
  • Page 103 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Operation Description Introduction to Hydraulic Schematic Symbols Table 6. Control Mechanisms Solenoid one winding Rotating shaft - one direction Solenoid two windings Rotating shaft - two directions Detent Electric motor operated Locking device Internal pressure pilot operated Over centre device External pressure pilot...
  • Page 104 K Fig 2. ( T E-7) - In circuit diagrams the pipework is usually shown connected to the box which represents the Three typical JCB style spools are known as 'D' spools, 'F' unoperated condition. (Hydraulic circuit diagrams are spools and 'N' spools.
  • Page 105 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Operation Description Introduction to Hydraulic Schematic Symbols Example of Schematic Circuit Fig 7. Simple Schematic Circuit Some of the symbols described on the preceding pages Example Circuit Key have been arranged into a simple schematic circuit. K Fig 7.
  • Page 106 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Operation Description Introduction to Hydraulic Schematic Symbols Page left intentionally blank 9803-9570-4...

  • Page 107: Machine Schematic Circuit

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Operation Description Machine Schematic Circuit Machine Schematic Circuit Component Key K Fig 8. ( T E-11) Cooler Filter Loader Gear Pump Loader Gear Pump Loader Gear Pump Right Hand Drive Motor Left Hand Drive Motor Tank Main Relief Valve Pressure Test Point RH Track Motor Pressure Test Point...
  • Page 108 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Operation Description Machine Schematic Circuit Lift Tip Ram RH Track LH Track Motor Motor Cooler Engine Filter Tank Fig 8. E-11 9803-9570-4 E-11...
  • Page 109 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Operation Description Machine Schematic Circuit Page left intentionally blank E-12 9803-9570-4 E-12...
  • Page 110 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Service Procedures Hydraulic Contamination TE-002_2 K Fig 1. ( T Hydraulic Fluid Quality cleaning unit. E-13). General Bulletin 011 also refers. Construction machinery uses a large volume of fluid in the Procedure hydraulic system for power transmission, equipment lubrication, rust prevention and sealing.

  • Page 111: Service Procedures Hydraulic Contamination

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Service Procedures 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 112: Cleaning Operation

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Service Procedures Cleaning Operation Cleaning Operation The purpose of cleaning the hydraulic oil is to remove rod side of the rams and new oil will be put into the contaminants of all types and sludge. head side.
  • Page 113 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Service Procedures Cleaning Operation Page left intentionally blank E-16 9803-9570-4 E-16...

  • Page 114: Pressure Testing

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Pressure Testing Main Relief Valve (M.R.V.) Make sure that the hydraulic oil is at correct working temperature (50 °C, 122 °F). K Engine Remove engine cover fitted) Cover ( T B-1) and move the engine back on its mounting K Engine Mounting ( T to gain access K-3).

  • Page 115: Track Motor Relief Valve

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Pressure Testing Track Motor Relief Valve Track Motor Relief Valve Make sure that the hydraulic oil is at correct working temperature (50 °C, 122 °F). K Engine Remove engine cover fitted) Cover ( T B-1) and move the engine back on its mounting K Engine Mounting ( T to gain access...

  • Page 116: Loader Pump Pump

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Loader Pump Pump Loader Pump Pump Removal If necessary, remove the coupling components E, F and G. K Engine Remove engine cover fitted) Cover ( T B-1) and move the engine back on its mounting (K Engine Mounting ( T to gain access to the pump K-3).
  • Page 117 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Loader Pump Pump Replacement Assemble the pump to the mounting plate and secure with nuts and bolts D. Position the pump assembly onto the engine, taking care to engage the splines of the drive coupling. Fit and tighten bolts C.
  • Page 118 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Loader Pump Pump Page left intentionally blank E-21 9803-9570-4 E-21...

  • Page 119: Dismantling, Inspection And Assembly

    Ensure that the end cover, spacer plates and flange are free from damage which could result in oil leakage in the region of the seal contact faces. If the shaft seal bore is worn, JCB Threadlocker and Sealer should be applied to the outside diameter of the seal.
  • Page 120 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Loader Pump Dismantling, Inspection and Assembly Fig 3. E-23 9803-9570-4 E-23...
  • Page 121 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Loader Pump Dismantling, Inspection and Assembly Page left intentionally blank E-24 9803-9570-4 E-24...
  • Page 122 Sprocket Replacement to ensure correct alignment of the K Drive Sprocket ( T sprocket bearing housing J-14). Raise the machine on the side to be worked on. Before fitting capscrew A apply JCB Retainer (High K Consumables ( T 1-15) Remove the track. Strength) to the threads.

  • Page 123: Drive Motors Track Drive Motor

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Drive Motors Track Drive Motor Dismantling Fig 2. Drain the oil from the motor and clean the outside Remove gear wheel set 5. Do not dismantle it. surfaces thoroughly before starting. Remove carden shaft 6 and channel plate 7. Remove the drive shaft key 1.
  • Page 124 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Drive Motors Track Drive Motor Remove ‘O’ ring 11 and bearing race 12. opposite rotor tooth profiles is at an angle of 15deg to K Fig 3. ( T E-27). the axis of the key slot, Drive out oil seal 13, using a plastic hammer, and remove dust seal 14.
  • Page 125 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Drive Motors Track Drive Motor Page left intentionally blank E-28 9803-9570-4 E-28...

  • Page 126: Control Valve

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Valves Control Valve Removal Mark all hoses to ensure correct replacement. Remove the hoses from the work ports. Cover With the engine stopped, operate the controls a few times exposed connections to prevent ingress of dirt. to allow hydraulic pressure to dissipate.
  • Page 127 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Valves Control Valve Fig 2. E-30 9803-9570-4 E-30...
  • Page 128 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Valves Control Valve Place assembly on a suitable bench. Pull off control rod knobs B. Unscrew nuts C and lift cover assembly over the control rods and away from the valve block. Collect bolts D. Replacement Replacement is a reversal of the removal procedure.
  • Page 129 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Valves Control Valve Control Valve Block P1 P1 T2 T2 Fig 4. Inlet Section Tip Section 2nd Speed Section Right Track Section Lift Section Left Track Section Torque Settings Lbf ft Section Tie Rod Nuts (C) 18.4 E-32 9803-9570-4...
  • Page 130 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Valves Control Valve Inlet Section Fig 5. Torque Settings Lbf ft MRV Body (A) 59.0 MRV Lock Nut (B) 14.8 Plug (C) 59.0 Tip Section Fig 6. Torque Settings Lbf ft Cap Screws (A) 4 - 6 3.0 - 4.4 Load Hold Valve Plug (B)
  • Page 131 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Valves Control Valve 2nd Speed Section Fig 7. Torque Settings Lbf ft Cap Screws (A) 4 - 6 3.0 - 4.4 Load Hold Valve Plug (B) 14.8 Port Plug (C) E-34 9803-9570-4 E-34...
  • Page 132 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Valves Control Valve Track Section Fig 8. Torque Settings Lbf ft Cap Screws (A) 4 - 6 3.0 - 4.4 Check Valve Plug (B) 14.8 Relief Valve Body (C) Plug (D) E-35 9803-9570-4 E-35...
  • Page 133 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Valves Control Valve Lift Section Fig 9. Torque Settings Lbf ft Cap Screws (A) 4 - 6 3.0 - 4.4 Load Hold Valve Plug (B) 14.8 Plug (C) E-36 9803-9570-4 E-36...

  • Page 134: Lift Ram

    Support the weight of the ram and drive out the dump end pivot pin. Lift the ram clear of the machine. Replacement Replacement is a reversal of the removal procedure. Grease all pins with JCB Special HP Grease. Fig 1. E-37 9803-9560-4 E-37...

  • Page 135: Tilt Ram

    Remove the trunnion block securing bolts C on both sides of the ram and withdraw both trunnion blocks. Lift the ram clear of the machine. Replacement Replacement is a reversal of the removal procedure. Grease all pins with JCB Special HP Grease. E-38 9803-9560-4 E-38...
  • Page 136 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Rams Tilt Ram Page left intentionally blank E-39 9803-9560-4 E-39...

  • Page 137: Lift And Tilt Ram

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Rams Lift and Tilt Ram Lift and Tilt Ram Fig 3. E-40 9803-9560-4 E-40...
  • Page 138 Ensure that lubricants used during assembly do not come into contact with the locking fluids. Apply JCB Activator to the threads of the piston head 6. Allow to dry for 15 minutes before bringing into contact with JCB Threadlocker and Sealer.
  • Page 139 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Rams Lift and Tilt Ram Page left intentionally blank E-42 9803-9560-4 E-42...

  • Page 140: Oil Cooler

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Oil Cooler Cooler Removal and Replacement Oil Cooler Cooler Removal and Replacement Removal It is not possible to repair the oil cooler, if it is damaged it must be renewed. K Engine Remove the engine cover (if fitted) Replacement Cover ( T B-1) and move the engine back on its...
  • Page 141 manualequipospesados@gmail.com manualequipospesados@gmail.com Section E - Hydraulics Oil Cooler Cooler Removal and Replacement Page left intentionally blank E-44 9803-9570-4 E-44...
  • Page 142 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 143 manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Notes: 9803/9570-4...
  • Page 144 manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Contents Page No. Technical Data General Data ..................... J-1 Track Maintenance Track Cleaning ..................J-3 Track Adjustment ..................J-4 Track Removal and Replacement ............. J-6 Track Rollers ..................... J-8 Idler Wheel and Recoil Unit ..............J-10 Drive Sprocket ..................
  • Page 145 manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Contents Page No. J-ii J-ii...
  • Page 146 manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Technical Data General Data Technical Data General Data Tracks Type Rubber Width 180 mm (7.09 in) Number of links Link Pitch 72 mm (2.8 in) Bottom Rollers Type Sealed for life Quantity 2 per side Idler Wheels Type Sealed for life...

  • Page 147: Technical Data General Data

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Technical Data General Data Page left intentionally blank 9803-9570-4...

  • Page 148: Track Maintenance

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Track Maintenance Track Cleaning Raising the Machine Cleaning the Tracks WARNING WARNING If two people are doing this job make sure that the Rotating the tracks off the ground may cause stones person operating the controls is a competent and other debris to be thrown with considerable force.

  • Page 149: Track Adjustment

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Track Maintenance Track Adjustment Track Adjustment Checking the Track Tension Adjusting the Track Tension - Manual Tensioner K Track Cleaning ( T Clean the tracks J-3). Dirt on the inside of the rubber track and on rollers and idler wheels Remove cover B.
  • Page 150 manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Track Maintenance Track Adjustment Adjusting the Track Tension - Hydraulic Tensioner Note: The tensioner valve contains grease under high pressure. Never unscrew the fitting C more than one complete turn. Never unscrew the grease nipple D. Remove cover B.

  • Page 151: Track Removal And Replacement

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Track Maintenance Track Removal and Replacement Track Removal and Replacement Removing a Track Installing a Track Park the machine on firm and level ground. Make sure that the machine is safely supported off the ground before proceeding. Using suitable lifting equipment, raise the machine off the ground.
  • Page 152 manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Track Maintenance Track Removal and Replacement Page left intentionally blank 9803-9570-4...

  • Page 153: Track Rollers

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Track Maintenance Track Rollers Track Rollers Fig 6. 9803-9570-4...
  • Page 154 manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Track Maintenance Track Rollers Roller - Removal and Replacement Roller - Dismantling and Assembly Removing Dismantling Raise the machine and fit suitable supports under the Remove bolts A and washers B from each side of the machine lower structure.

  • Page 155: Idler Wheel And Recoil Unit

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Track Maintenance Idler Wheel and Recoil Unit Idler Wheel and Recoil Unit Fig 7. J-10 9803-9570-4 J-10...
  • Page 156 manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Track Maintenance Idler Wheel and Recoil Unit Recoil Unit - Removal and Replacement Idler Wheel - Removal and Replacement Removal Removal K Track K Track Remove track Removal Remove track Removal Replacement ( T Replacement ( T J-6).
  • Page 157 manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Track Maintenance Idler Wheel and Recoil Unit Fig 8. Idler Wheel - Dismantling and Assembly Assembly Assemble new bearings E and H onto shaft C. Dismantling Fit circlip G into groove in idler wheel bore. Prise out seals A and F from the idler wheel.
  • Page 158 manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Track Maintenance Idler Wheel and Recoil Unit Page left intentionally blank J-13 9803-9570-4 J-13...

  • Page 159: Drive Sprocket

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Track Maintenance Drive Sprocket Drive Sprocket Removal and Replacement Note: From machine no. 1360035 a sprocket support bearing is fitted. The motor securing bolts also secure the bearing housing. Removal Support the weight of the track motor C and unscrew K Engine Remove the engine cover (if fitted) securing bolts D and E.
  • Page 160 4 and 5. If there is, repeat the procedure. Once correct assembly is achieved finally remove each nut or bolt in turn and apply JCB Retainer (High Strength) to the threads then re-tighten to 74Nm K Consumables ( T (54.6 lbf ft;...
  • Page 161 manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Track Maintenance Drive Sprocket Page left intentionally blank J-16 9803-9570-4 J-16...

  • Page 162: Track Damage

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Track Damage Types of Rubber Track Damage Track Damage Types of Rubber Track Damage Rubber tracks used numerous operating Refer to the quick reference table below, then to the environments/ applications, it is therefore possible that corresponding paragraph for illustrated examples of the damage may occur to the track.
  • Page 163 manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Track Damage Types of Rubber Track Damage Core Bars - Separation Core Bars - Breaking Cause: Breaking in the middle Low track tension - the core bars are likely to hit the Cause: running gear components and lead to separation from the track Excessive track tension together with a shock load, for example, climbing pavement edges.
  • Page 164 The teeth of the sprocket are worn (hook shaped). Operating environment is extremely abrasive Prevention: Make sure that the sprocket is genuine JCB, ensure sprocket is in good condition. Replace sprocket. When new tracks are fitted, the sprockets should always be checked (and renewed if Fig 2.
  • Page 165 The steel cord has been exposed and rusted. Prevention: Prevention: Clean the tracks with fresh water after operation. Make sure that the sprocket is genuine JCB, ensure Make sure that the visible metallic components of the sprocket is in good condition. track are greased.
  • Page 166 Prevention: Check the tension regularly. Make sure that the sprocket is genuine JCB, ensure sprocket is in good condition. Fig 7. Additional Notes: Individual strands of steel cord sticking out of the track Fig 6.
  • Page 167 manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Track Damage Types of Rubber Track Damage Steel Cord - Sticking Out Additional Notes: Individual strands of steel cord sticking out of the track Cause: does not necessarily mean the track needs to be replaced. Individual strands can be cut off (the number of steel cord Strands of the steel cord may sometimes stick out of strands is always over specified), however exposed...
  • Page 168 manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Track Damage Types of Rubber Track Damage Outer Track Rubber - Tearing/Cuts Outer Track Rubber - Fast Abrasion Cause: Cause: Cuts on the lug are often due to particularly sharp Sharp driving on hard and abrasive surfaces, for materials such as stones, the problem is particularly example concrete, asphalt etc.
  • Page 169 manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Track Damage Types of Rubber Track Damage Outer Track Rubber - Cracks Outer Track Rubber - Longitudinal Cracks Cause: Cause: Bending fatigue of the rubber after excessive use. The edges of the rubber track are often deformed Long storage (a few months) outside in the sunlight.
  • Page 170 manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Track Damage Types of Rubber Track Damage Inner Track Rubber - Tearing/Cuts Fig 14. Cause: Stones and sharp material can tear the rubber at the edges of the track. Driving close to pavement edges and ridges - causing the edges to be forcefully bent against the track frame.
  • Page 171 Prevention: Prevention: Make sure that the sprocket is genuine JCB, ensure Check the tension regularly. sprocket is in good condition. Do not let the machine sit too long in the same Check the track tension regularly (as recommended position when operating in these conditions.

  • Page 172: Track Repair

    manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Track Repair Recommended Repair Procedures Track Repair Recommended Repair Procedures Minor cuts which occur between the lugs can be repaired with a suitable repair kit. Cuts no longer than 30mm and no deeper than 10mm do not need to be repaired. Cuts beyond these dimensions should be repaired as detailed.
  • Page 173 manualequipospesados@gmail.com manualequipospesados@gmail.com Section J - Tracks Track Repair Recommended Repair Procedures Fig 4. Ensure that the adhesive applied in step 3 has completely dried and then apply another adhesive layer. When the second adhesive layer is almost dry (sticky to the touch) the rubber compound should be firmly applied to the cut.
  • Page 174 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 175 manualequipospesados@gmail.com manualequipospesados@gmail.com Section K - Engine Notes: 9803/9570-4...
  • Page 176 manualequipospesados@gmail.com manualequipospesados@gmail.com Section K - Engine Contents Page No. Technical Data All Engines ....................K-1 Engine Mounting Moving the Engine ..................K-3...
  • Page 177 manualequipospesados@gmail.com manualequipospesados@gmail.com Section K - Engine Contents Page No. K-ii K-ii...
  • Page 178 manualequipospesados@gmail.com manualequipospesados@gmail.com Section K - Engine Technical Data All Engines Technical Data All Engines Specifications Engine - Honda Petrol Max. engine speed with no load 3400 r/min Fuel tank 5.5 litres (1.2 gal) Engine - Yanmar Diesel Max. engine speed with no load 3200 r/min Fuel tank 3.5 litres (0.77 gal)
  • Page 179 manualequipospesados@gmail.com manualequipospesados@gmail.com Section K - Engine Technical Data All Engines Page left intentionally blank 9803/9570-4...
  • Page 180 manualequipospesados@gmail.com manualequipospesados@gmail.com Section K - Engine Engine Mounting Moving the Engine Engine Mounting Moving the Engine Sliding the Engine Backwards The engine can be moved back on its mounting to enable access to the loader pump, track motors and valve block also the battery up to machine no.
  • Page 181 manualequipospesados@gmail.com manualequipospesados@gmail.com Section K - Engine Engine Mounting Moving the Engine Page left intentionally blank 9803/9570-4...

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