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Section C

9803/8550

Section C

Test Methods

2 - 3

*2 - 3

Issue 2*

Testing a Diode or a Diode Wire

A diode wire is a diode with male connector fitted on one end and a female connector fitted on the other end. The diode is
sealed in heatshrink sleeving.

On the AV0 2003
Move the right hand slider to position A, and the left hand slider switch to position C.
Connect the black probe to the end of the diode marked with a band, or to the male connector of the diode wire, the red probe
should be connected to the other end of the diode or diode wire. If the Avometer does not buzz the diode is faulty.
Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe
should be connected to the other end of the diode or diode wire. If the Avometer does not read "1" the diode is faulty.

On an analogue meter
Select the Ohms 1000s (1k) range.
Connect the black probe to the end of the diode marked with a band, or to the male connector of the diode wire, the red probe
should be connected to the other end of the diode or diode wire. The meter should read 20-400 K , if it reads more than this
the diode is faulty.

Select the Ohms 100s range.
Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe
should be connected to the other end of the diode or diode wire. The meter should read 300-400 , if it reads less than this the
diode is faulty.

*

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Summary of Contents for 1CX

Page 1: ...STAFFORDSHIRE ST14 5PA ENGLAND Tel ROCESTER 01889 590312 PRINTED IN ENGLAND Publication No 9803 8550 General Information 1 Care Safety 2 Routine Maintenance 3 Attachments A Body Framework B Electrics...

Page 2: ...www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 3: ...nts 3 1 1 1 2 1 1 3 1 2 4 1 2 5 1 3 5 2 5 5 3 2 5 4 2 Section C Contents 6 1 1 5 1 2 3 1 3 2 1 4 1 1 5 1 2 1 2 2 2 2 2 3 2 2 4 Deleted 3 1 1 3 2 2 4 1 1 4 2 3 4 3 1 4 4 1 5 1 1 5 2 3 6 1 3 6 2 2 6 3 2...

Page 4: ...2 1 2 32 2 1 32 3 1 32 4 1 32 5 2 32 6 3 33 1 1 33 2 1 33 3 2 33 4 3 35 1 1 Section F Contents 3 1 1 4 1 2 1 1 3 2 1 4 1 1 5 2 Section G Contents 2 1 1 2 1 2 1 Section K Contents 4 1 1 4 1 2 4 1 3 2 2...

Page 5: ...and cautions pertinent to aspects of workshop procedures etc 3 Routine Maintenance includes service schedules and recommended lubricants for all the machine The remaining sections are alphabetically...

Page 6: ...www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 7: ...rque Settings 2 1 Service Tools 3 1 Numerical List 3 1 Electrics 4 1 Hydraulics 4 2 Sealing and Retaining Compounds 5 1 i General Information 9803 8550 i Issue 1 Section 1 Section 1 www WorkshopManual...

Page 8: ...ion plate The hydraulic motors have the date of manufacture stamped on a plate as shown at D The hydraulic pump unit serial number is stamped on a plate on the bottom of the pump as shown at E If any...

Page 9: ...2 0 87 9 16 14 3 13 16 170 17 3 125 5 8 15 9 15 16 238 24 3 175 3 4 19 0 11 8 407 41 5 300 7 8 22 2 15 16 650 66 3 480 1 25 4 11 2 970 99 0 715 11 4 31 7 17 8 1940 198 0 1430 11 2 38 1 21 4 3390 345 0...

Page 10: ...225 11 2 305 31 1 225 SAE Adapters with O rings Adapter Size Torque Settings in Nm kgf m lbf ft 7 16 20 2 0 15 9 16 35 3 6 26 3 4 81 8 3 60 7 8 108 11 0 80 11 16 183 18 7 135 15 16 298 30 4 220 15 8 3...

Page 11: ...00223 Hand Pump 4 3 892 00252 Test Block 4 3 892 00253 Pressure Test Kit 4 2 892 00255 Pressure Test Adapter 4 2 892 00256 Pressure Test Adapter 4 2 892 00257 Pressure Test Adapter 4 2 892 00258 Press...

Page 12: ...Tools AVO Test Kit 1 892 00283 Tool Kit Case 2 892 00281 AVO Meter 3 892 00286 Surface Temperature Probe 4 892 00284 Microtach Digital Tachometer 5 892 00282 Shunt open type 6 892 00285 Hydraulic Oil...

Page 13: ...oint Pressure Test Adapters 892 00255 1 4 in BSP x Test Point 892 00256 3 8 in BSP x Test Point 892 00257 1 2 in BSP x Test Point 892 00258 5 8 in BSP x Test Point 816 15118 3 4 in BSP x Test Point 89...

Page 14: ...e 1 4 in BSP x 5 metres 892 00274 Adapter 1 4 in M BSP x 3 8 in M BSP Taper 892 00262 1 4 in M BSP x 1 4 in F BSP x Test Point 892 00706 Test Probe 892 00278 Gauge 0 40 bar 0 60 lbf in2 892 00279 Gaug...

Page 15: ...892 00075 1 2 in BSP x 1 2 in BSP 892 00077 3 4 in BSP x 3 4 in BSP Male Cone Blanking Plug 816 00294 1 4 in BSP 816 00189 3 8 in BSP 816 00190 1 2 in BSP 816 00197 5 8 in BSP 816 00196 3 4 in BSP 81...

Page 16: ...ue 1 Service Tools 892 01027 Piston Seal Assembly Tool 110mm 175mm R 1 4mm 3o R 3mm 7mm 11o 10mm 20mm 5mm 338500 Ram Seal Protection Sleeves 892 01017 For 30 mm Rod Diameter 892 01018 For 40 mm Rod Di...

Page 17: ...B Cleaner Degreaser For degreasing components prior to use of anaerobic adhesives and sealants 4104 1557 Aerosol The part numbers and descriptions of sealing and retaining compounds available from JCB...

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Page 19: ...Safety 9803 8550 Section 2 i Issue 2 Contents Page No Safety Notices 1 1 General Safety 2 1 Operating Safety 2 2 Maintenance Safety 2 2 Safety Decals 2 4 www WorkshopManuals co uk Purchased from www W...

Page 20: ...are not taken it is highly probable that the operator or others could be killed or seriously injured INT 1 2 1 WARNING Denotes a hazard exists If proper precautions are not taken the operator or other...

Page 21: ...do not wear the proper clothing Loose clothing can get caught in the machinery Wear protective clothing to suit the job Examples of protective clothing are a hard hat safety shoes safety glasses a we...

Page 22: ...nance work you do not understand To avoid injury and or damage get the work done by a specialist engineer GEN 1 5 CAUTION Cleaning Cleaning metal parts with incorrect solvents can cause corrosion Use...

Page 23: ...re wheel specialist to do any repair work INT 3 2 6 WARNING Battery Gases Batteries give off explosive gases Keep flames and sparks away from the battery Do not smoke close to the battery Make sure th...

Page 24: ...worn 1 Ensure that components have cooled then remove and place material into plastic bags 2 Thoroughly wash contaminated area with 10 calcium hydroxide or other suitable alkali solution if necessary...

Page 25: ...2 5 Safety Decals cont d Section 2 Care and Safety 9803 8550 Section 2 2 5 Issue 1 203470 www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

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Page 27: ...ne 10 2 Changing the Oil and Filter XUD engine 10 2 Checking the Oil Level 100 series engine up to machine no 807552 10 4 Changing the Oil and Filter 100 series engine up to machine no 807552 10 4 Che...

Page 28: ...ries Total coolant cap 11 litres JCB Four seasons Antifreeze ASTM D3306 BS6580 Antifreeze 5 5 litres Summer Coolant water see Coolant Mixtures Fuel System 45 litres Diesel oil see Types of Fuel ASTM D...

Page 29: ...freeze Inhibited Ethanediol AL 39 11 Antifreeze 1 45 US gal see Coolant Mixtures 100 and 400 series Total coolant cap 2 9 US gal Permanent Antifreeze ASTM D3306 BS6580 Antifreeze 1 45 US gal Fuel Sys...

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Page 31: ...d skin contact with used engine oils 2 Apply a barrier cream to the skin before handling used engine oil 3 Note the following when removing engine oil from skin a Wash your skin thoroughly with soap a...

Page 32: ...ave a lower viscosity They also limit wax formation in the fuel at low temperatures Wax forming in the fuel can stop the fuel flowing through the filter Flow improvers may also be available These can...

Page 33: ...ning 1 Warning lights extinguished 2 Operation of all electrical equipment 3 Exhaust for excessive smoke 4 Operation of all hydraulic services Grease 1 Quickhitch pivot points 2 Loader arm pivot point...

Page 34: ...first Do the Daily to 250 hour jobs plus Clean 1 Cab heater filter if fitted Check Engine Stopped 1 Pivot pins and bushes 2 Battery charge and condition 3 Battery electrolyte level if applicable Chang...

Page 35: ...Slowly lower the loader arm onto the safety strut Stop the movement immediately the weight of the arm is supported by the strut Note Extreme care must be taken when lowering the loader arm onto the s...

Page 36: ...grease to each one Refit the dust caps after greasing Quickhitch Pivot Points for interval see Service Schedule Lower the loader arm as far as it will go Tilt the Quickhitch fully forward to facilitat...

Page 37: ...ther side of the machine Note Grease point 11 is at the lift ram chassis pivot 11 grease points each side Total 22 grease points WARNING Raised loader arms can drop suddenly and cause serious injury B...

Page 38: ...gine and ensure it cannot be started while you are doing this job Note Grease point 5 is at dipper ram dump end Grease point 14 is on end of dipper Total 14 grease points Note Lubricate the kingpost m...

Page 39: ...ch direction five times 6 Remove plug D and recheck the oil level If level is low repeat steps 3 to 5 until all air is expelled Oiling Door Hinges cabbed machines for interval see Service Schedule Oil...

Page 40: ...O YOUR EYES Flush with water for 15 minutes get medical help immediately IS SWALLOWED Do not induce vomiting Drink large quantities of water or milk Then drink milk of magnesia beaten egg or vegetable...

Page 41: ...nnect the bulb at K 4 Do not touch the bulb with bare fingers Fit the new bulb Make sure that the bulb is seated correctly and the spring clip H is secure 5 Reassemble the light unit in the reverse or...

Page 42: ...er ease the Switch A from its socket in the control panel 2 The bulb holder B can then be pulled from the back of the Switch and the bulb will come with it 3 The bulb C is a straight pull from the hol...

Page 43: ...slowly to prevent blow back CAUTION If the fluid is cloudy water or air has entered the system This could damage the hydraulic pump Contact your JCB distributor 7 3 6 1 Changing the Filter for interva...

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Page 45: ...ection plug A and check that the oil level is up to the bottom of the aperture 4 If necessary top up through the aperture using the recommended oil Wipe up any oil spillage 5 Check that the washer on...

Page 46: ...blocks Note Ensure that the jack is capable of lifting at least 3000 kg 3 tons 4 Remove the rear wheel 5 Adjust the tension as described below a Loosen the six bolts B securing the hub locking ring C...

Page 47: ...table Tyres Non inflatable tyres are available as an option These tyres consist of a number of individual segments bolted to the wheel rim Damaged segments can be renewed individually Loosen and remov...

Page 48: ...E 6 Clean inside the canister C and dust valve D 7 Test the seating of seals B and J a Smear the seals on the new elements with grease b Insert the new elements in canister C c Remove the elements and...

Page 49: ...for interval see Service Schedule WARNING Hot oil and engine components can burn you Make sure the engine is cool before doing this job 2 3 3 2 WARNING Oil is toxic If you swallow any oil do not indu...

Page 50: ...e filter canister F remember that it will be full of oil b Check that the filter head adapter is secure c Clean the filter head d Add clean engine lubricating oil to the new filter canister Allow enou...

Page 51: ...gine up to machine no 807552 for interval see Service Schedule WARNING Hot oil and engine components can burn you Make sure the engine is cool before doing this job 2 3 3 2 1 Do Steps 1 to 2 of Checki...

Page 52: ...er hand tight only 11 Fill the engine with the recommended oil to the MAX mark on the dipstick A through the filler point B Wipe off any spilt oil refit the filler cap and make sure it is secure 12 Ma...

Page 53: ...ngine from machine no 807553 for interval see Service Schedule WARNING Hot oil and engine components can burn you Make sure the engine is cool before doing this job 2 3 3 2 1 Do Steps 1 to 2 of Checki...

Page 54: ...will not start by removing the engine shut off solenoid ESOS fuse Turn the engine using the starter key until the oil pressure warning light is extinguished 13 Refit the engine shut off solenoid fuse...

Page 55: ...eals J 3 off discard O ring L 9 Lubricate all seals and O rings with clean fuel oil 10 Fit new seals J 3 off to base G bowl B and element F fit O ring H to the centre of the element F 11 Fit element F...

Page 56: ...tap A 4 Support the bowl B and unscrew bolt C Remove the bolt C remove and discard washer D and O ring E 5 Remove filter element F bowl B and base G as a unit 6 Discard O ring H 7 Separate element F...

Page 57: ...y have rested in the maximum lift position To move the diaphragm use the starter key to turn the engine then try the priming lever again Later Machines Slacken bleed screw M and operate the priming pu...

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Page 59: ...damage down to deg C deg F deg C deg F 50 33 27 45 49 Never use less than 45 antifreeze solution otherwise there will not be enough corrosion protection Never use more than 50 antifreeze solution oth...

Page 60: ...Service Schedule 1 Park the machine on level ground Stop the engine and let it cool down Open the bonnet 2 Carefully loosen filler cap A just enough to let any pressure escape Remove the cap when all...

Page 61: ...Stop the engine and check for leaks Changing the Coolant 100 400 series engines for interval see Service Schedule 1 Park the machine on level ground Stop the engine and let it cool down Open the bonne...

Page 62: ...re the engine cannot be started Disconnect the battery before doing this job 2 3 3 5 Adjusting the Alternator Belt 1 Loosen nut A and bolt B which secure the alternator 2 Adjust the fan belt by Peugeo...

Page 63: ...al Purpose and Light Duty Shovels 3 1 6 in 1 Shovels 3 1 Pallet Forks 4 1 Manure Silage Fork With Top Grab 5 1 Attachment Frame 6 1 Section A Optional Attachments 9803 8550 Section A i Issue 1 www Wor...

Page 64: ...e replacing both half couplings DON T leave the coupling where it may be run over by a machine or otherwise crushed this will distort the coupling sleeve and prevent correct connection and disconnecti...

Page 65: ...ace close to suspected leaks Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid If hydraulic fluid penetrates your skin get medical help imm...

Page 66: ...rs rams Should the rams require service see Section E Hydraulics WARNING Fine jets of hydraulic fluid at high pressure can penetrate the skin Do not use your fingers to check for hydraulic fluid leaks...

Page 67: ...ne to which the fork may be fitted Before lifting any load check the weight of the load against the Safe Working Load of the machine 2 4 5 3 Daily Maintenance 1 Clean with the rest of the machine 2 Oi...

Page 68: ...3 Check for signs of hydraulic leaks WARNING Fine jets of hydraulic fluid at high pressure can penetrate the skin Do not use your fingers to check for hydraulic fluid leaks Do not put your face close...

Page 69: ...e machine Daily Maintenance 1 Clean with the rest of the machine 2 Check for damage Repair or replace as necessary Section A Optional Attachments 9803 8550 Section A 6 1 Issue 2 Attachment Frame 20417...

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Page 71: ...val and Replacement 2 1 Dipper Removal and Replacement 3 1 Boom Removal and Replacement 4 1 Kingpost Assembly Removal and Replacement up to machine no 807225 Slew Cylinder 5 1 Kingpost 5 1 Removal and...

Page 72: ...move the two bolts A and the metal strip B which hold the floor mat in position 2 Carefully feed the mat out from the left hand side of the machine the mat is split at the right hand side to make this...

Page 73: ...both sides Mark the hoses to ensure correct reconnection Remove the bolts retaining the lift ram eye end pivot pin A from both sides Ensuring that the weight of the loader arm is supported at the fron...

Page 74: ...ion Remove the bolt retaining the dipper ram eye end pivot pin B Supporting the ram drift out the dipper ram eye end pivot pin Allow the ram to rest on the boom WARNING Lifting Equipment You can be in...

Page 75: ...t pin WARNING Lifting Equipment You can be injured if you use faulty lifting equipment Make sure that lifting equipment is in good condition Make sure that lifting tackle complies with all local regul...

Page 76: ...Section B Body and Framework 9803 8550 Section B 5 1 5 1 Issue 4 Kingpost Assembly S242442 X 347390 www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 77: ...he crane lift the excavator assembly up which will free the pinion from the carriage base then pull the assembly back away from the carriage taking care to collect shim 11 Note Shim 11 is not fitted t...

Page 78: ...Section B Body and Framework 9803 8550 Section B 5 3 5 3 Issue 2 Kingpost Assembly S242442A www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 79: ...bolt 9 and kingpost pivot pin 10 Using the crane lift the excavator assembly up which will free the pinion from the carriage base then pull the assembly back away from the carriage taking care to coll...

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Page 81: ...istance 2 3 Measuring Continuity 2 3 Testing a Diode or Diode Wire 2 4 Battery Safety 3 1 Maintenance 3 1 Testing Specific Gravity 3 2 Battery Testing 3 2 Alternator Service Precautions 4 1 Charging T...

Page 82: ...fitted Interior Light if fitted Side Lights if fitted Relays up to machine no 751599 Overheat Delay Relay A Alarm Buzzer B Indicator Flasher Relay C Neutral Start Relay D Loader Isolation Relay E Hor...

Page 83: ...p 6 Horn Low coolant warning Stabiliser warning 15 amp 7 Hazard warning Rear wiper Interior light 10 amp 8 Front wiper Washer bottle Direction indicators 10 amp 9 Heater Heated seat 10 amp 10 Reverse...

Page 84: ...L H Side Lights B3 R H Side Lights B4 Front Work Lights B5 Rear Work Lights B6 Reverse Alarm Brake Lights B7 Hand Held Attachments Float Hydraulics B8 Face Level Fan B9 Junction Box B10 Beacon Interio...

Page 85: ...ront Work Lights B5 Rear Work Lights B6 Junction Box B7 Heater Motor B8 Front Wash wipe B9 Reverse Alarm Brake Lights B10 Direction Indicators Fuse Colour Code Orange 5 amp Red 10 amp Blue 15 amp Rela...

Page 86: ...lbf in2 falling B Transmission Oil Temperature Switch Normally open closes at 107 113 C 225 235 F rising C Reverse Alarm Pressure Switches Normally open closes at 7 bar 100 lbf in2 rising D Brake Ligh...

Page 87: ...t lead should be plugged into the black socket sometimes this socket is also marked by a or E or marked as COMMON or COM The red test lead should be plugged into the red socket marked with V or 2 When...

Page 88: ...probes are placed On the AV0 2003 Move the right hand slider switch to position B and the left hand slider switch to the appropriate Ohms range On an analogue meter Move the dial to the appropriate O...

Page 89: ...and or to the male connector of the diode wire the black probe should be connected to the other end of the diode or diode wire If the Avometer does not read 1 the diode is faulty On an analogue meter...

Page 90: ...or 15 minutes Get medical help fast IF SWALLOWED Do not induce vomiting Drink large quantities of water or milk Then drink milk of magnesia beaten egg or vegetable oil SKIN Flush with water Remove aff...

Page 91: ...1 CHECK 0 12 6 Volts LOAD less than 6 Volts 2 CHECK 6 12 4 Volts LOAD less than 9 Volts and falls steadily but remains in yellow zone 3 CHECK less than 10 Volts LOAD less than 3 Volts 4 CHECK more th...

Page 92: ...ery is in a fully charged condition switch on the working lights for 3 minutes before commencing the test Alternatively operate the starter for a few moments with Fuse 5 ESOS removed Install a 100 amp...

Page 93: ...twards remove the pivot bolt A and lift it from the engine Examine the drive belt for wear Replacement Replacement is a reversal of the removal procedure Position the alternator until belt deflection...

Page 94: ...Section C Electrics 9803 8550 Section C Issue 1 Alternator 4 3 4 3 S213570 www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 95: ...ly remove rectifier 10 and stator 11 as an assembly Unsolder the interconnecting wires at X Y and Z only if renewing either of these components Remove nut and washer 12 using an 8mm Allen key in the s...

Page 96: ...ng from the start relay to the solenoid If the reading between terminal D and earth is below 8 0V connect the voltmeter between terminal E and earth An increase in the reading to 8 0V indicates either...

Page 97: ...gf m Service Procedures Servicing this equipment is not recommended Should faults occur then the starter motor should be changed for a Service Replacement Removal and Replacement 100 and 400 Series En...

Page 98: ...ght Timer 63 Hydraulic Float Switch 64 Hydraulic Float Pressure Switch 65 Hydraulic Float Relay 66 Hydraulic Float Solenoid 67 High flow Hydraulic Solenoid 68 High flow Hydraulic Switch Lamps 80 Pre h...

Page 99: ...35 33 31 25 202 803 841 840 804 644 643 627 605 403 600 614 402 404 400 7 408 409 401 415 411 426 416 419 420 406 407 424 412 413 414 813 427 405 651 649 650 648 425 842 11 6 660 601 649 855 850 805...

Page 100: ...5 6 9 10 12 13 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 106 36 37 38 39 40 41 42 43 44 46 47 48 49 50 51 52 53 54 55 55 56 56 57 58 59 60 61 62 63 64 65 100 101 102 103 104 105 107...

Page 101: ...Light 47 Washer Motor 48 Front Wiper Motor 49 Rear Wiper Motor 50 Rear Wiper Switch 51 Heater Blower Switch 52 Heater Blower Resistor 53 Heater Blower 54 Reverse Alarm 55 Reverse Alarm Switches 56 Bra...

Page 102: ...s Switch 41 Front Worklight Switch 42 Rear Worklight Switch 43 Indicator Switch Warning Light 44 Hazard Warning Switch 45 Flasher Unit 46 Horn Switch 47 Front Horn 48 Rear Horn when fitted 49 Beacon S...

Page 103: ...FUSE A1 FUSE A2 FUSE A3 FUSE A4 FUSE A5 FUSE A6 FUSE A7 HAZARD SWITCH FUSE B9 FUSE B8 FUSE B7 FUSE B8 FUSE A9 FUSE A8 FUSE A10 FUSE B10 FUSE B5 FUSE B4 IGN RELAY 1 2 3 4 5 6 ISOLATION RELAY 600V 600G...

Page 104: ...871 HORN SWITCH 312 FUSE A10 300 FUSE A8 FUSE A9 303 303A 303G 894 600AJ 600DY 600AP M INTERIOR LIGHT 205B 101 FUSE B6 600CC FUSE B7 102 M 800D 600EB 600BH 600GR 106R FUSE B8 FUSE B9 103 M M 106H 839...

Page 105: ...42 Rear Worklight Switch 43 Indicator Switch Warning Light 44 Flasher Unit 45 Hazard Warning Switch 46 Horn Switch 47 Front Horn 48 Rear Horn when fitted 49 Beacon Switch 50 Junction Box 51 Heater Bl...

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Page 107: ...No Throttle Controls Hand and Foot Throttles Description 1 1 Removal and Replacement 1 1 Adjustment 1 1 Throttle Cable Removal and Replacement 1 2 Adjusting the Idle and Non Stalling Settings 1 2 www...

Page 108: ...xpose the hand throttle cable connection Disconnect the cable by twisting and pulling The hand throttle may then be removed by undoing nut B and lifting the unit from the instrument panel Lift the flo...

Page 109: ...n Stalling Settings Note These adjustments should be carried out with the engine warm Loosen the nut 9 and deceleration screw 8 so that the latter protrudes 13 to 14 mm from the face of the regulator...

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Page 111: ...8 1 Operation 8 2 Bi Restrictor Operation 8 3 Slew Operation 8 4 Slew A R V and Anti Cavitation Operation 8 5 A R V Operation 8 6 Pilot Operated A R V Pressure Relief Operation 8 7 Pressure Reducing S...

Page 112: ...Circuit Problem Solving 14 0 Loader Valve Removal and Replacement 14 1 Dismantling and Assembly 14 2 Main Relief Valve and Auxiliary Relief Valves Removal and Replacement 14 4 Dismantling and Assembly...

Page 113: ...e Dual Lever Drive Control from machine number 751012 to 752462 31 1 from machine number 752463 31 3 High flow Machine Single Lever Drive Control up to machine number 751011 32 1 from machine number 7...

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Page 115: ...gal min 23 8 US gal min at 3600 rev min 57 l min 12 5 UK gal min 15 US gal min at 3600 rev min 185 192 bar 2683 2785 lbf in2 188 196 kgf cm2 3600 rpm 121 Nm 89 lbf ft 12 kgf m Tandem axial piston Ser...

Page 116: ...cm2 lbf in2 207 211 3006 235 240 3410 100 103 102 105 1450 1494 235 240 3410 241 246 3500 241 246 3500 241 246 3500 241 246 3500 241 246 3500 241 246 3500 241 246 3500 241 246 3500 138 141 2001 207 B...

Page 117: ...ar 48 l min 10 5 UK gal min 12 7 US gal min at 3000 rev min 185 192 bar 2683 2785 lbf in2 188 196 kgf cm2 3200 rpm 121 Nm 89 lbf ft 12 kgf m Tandem gear 90 l min 19 8 UK gal min 23 8 US gal min at 360...

Page 118: ...s Dipper Ram Bucket Ram bar kgf cm2 lbf in2 207 211 3006 235 240 3410 100 103 102 105 1450 1494 235 240 3410 241 246 3500 241 246 3500 241 246 3500 241 246 3500 241 246 3500 241 246 3500 241 246 3500...

Page 119: ...draulic fluid leaks Do not put your face close to suspected leaks Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid If hydraulic fluid pene...

Page 120: ...nt causing temporary malfunction scuffing sticking and leakage and can lead to major problems The main contaminants can be classified as follows 1 Solid Particles sand fibres metallic particles weldin...

Page 121: ...oil WARNING The oil will be under pressure Make sure the hose ends are secured and emptying into a suitable container 0079 Check oil level and top as required 9 Connect the hydraulic line to the head...

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Page 123: ...olenoid Valve together with its associated electrical circuitry is designed to both limit the pressure in the circuit and act as a safety device The safety function ensures that the machine controls c...

Page 124: ...l circuitry acts as a safety device The safety function ensures that the machine loader and transmission controls cannot be operated without the operator being seated correctly and the door properly c...

Page 125: ...r valve block in order to relieve excessive pressure in the services as shown on page E 8 6 When the service is in neutral and there are no excessive forces acting on the equipment service pressure at...

Page 126: ...ns 9 1 Issue 4 16 17 18 19 20 21 92 212 1 2 3 4 TANK JOYSTICK LOADER BRAKE PRESSURE IN SOL 18 SOL 19 Z X Y 9 10 12 8 7 14 FUSE A1 FUSE A2 11 A204763 EXTRACTS FROM WIRING DIAGRAM SCHEMATICS www Worksho...

Page 127: ...t Switch 21 Override Switch Pressure Reducing Solenoid Valve from machine no 751600 This valve supplies hydraulic oil at reduced pressure to operate the loader joystick and the automatic parking brake...

Page 128: ...the chambers formed between the internal gear teeth and the gear rim rollers Key A Output Shaft B Brake Pack C Cardan Shaft D Gearwheel Set E Valve Drive F Disc Valve Oil under pressure passes throug...

Page 129: ...forward direction for 90 of the time so the flushing is taken off the return line port B when in forward This is the normal flushing rate When the motors are in reverse mode there is higher pressure...

Page 130: ...hrough the loader valve 2 excavator valve 4 and filter F1 to main pumps P1 and P2 A small amount of oil flows through the charge valve Pa enters the pump casing and is returned via line z to tank T Oi...

Page 131: ...ervos on pumps P1 and P2 The swash plates are tilted causing flow to pass to the motors M1 and M2 and the machine moves forward Return oil from the motors flows back into the main pumps Any excess oil...

Page 132: ...l not travel in a straight line 2 7 8 10 11 12 13 14 Poor drive performance no tractive effort 3 5 6 Machine creeps in neutral 7 Machine will not move at idle but moves at max revs 3 Hydraulic fluid i...

Page 133: ...ing chain case oil level 12 Joystick inoperative Check joystick plunger movement leaking seals etc 13 Chain tension Check chain tension 3 9 2 F1 5 14 Motor failure Inspect motor for damage Repair as r...

Page 134: ...similar Remove and plug all connections to the main pump assembly and the servo units Detach the electrical wiring from the left hand side of the pump by cutting the cable ties Slacken the pump mount...

Page 135: ...B is bolted to the engine with four capscrews E The inner section A is tightened onto the pump shaft spline with cap screw D Coat threads of capscrew D with JCB Threadlocker and Sealer and torque tigh...

Page 136: ...Section E Hydraulics 9803 8550 Section E Pumps 11 3 11 3 Issue 3 A168042 A B S246240 C 348890 www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 137: ...inlet line from the hydraulic filter to the pump unit is filled with fluid by cracking the hose connection at the rear main pump Install a 0 35 bar 0 500 lb in2 0 35 kg cm2 pressure gauge in the char...

Page 138: ...12 1 Section E Hydraulics 9803 8550 Section E 12 1 Issue 1 Pumps 168150 www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 139: ...efully remove the seal cover 7 Take care not to damage the shaft or housing Remove the O ring 8 from the seal cover and discard Press out the seal 9 from the seal cover 7 using an arbor press and disc...

Page 140: ...Section E Hydraulics 9803 8550 Section E Issue 1 Pumps 12 3 12 3 168030 www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 141: ...olts 2 to 47 61 Nm 4 8 6 2 kgf m 35 45 lbf ft Torque tighten plug 14 to 54 135 Nm 40 100 lbf ft 5 5 14 kgf m Charge Pressure Checking and Adjustment 1 Stop engine Connect a 0 40 bar 0 600 lb in2 0 42...

Page 142: ...Section E Hydraulics 9803 8550 Section E Issue 1 Pumps 12 5 12 5 168160 www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 143: ...and foreign material Mark the position of control linkage 33 before removing it from the swash plate 38 Retain shims 36 as a set All gaskets and O rings should be be renewed on reassembly Lightly lub...

Page 144: ...ult 3 but adjust screw B 12 7 Issue 4 A C B D This condition may be corrected by adjusting the pump servo units but before attempting this carry out the following preliminary checks Check tyre pressur...

Page 145: ...nnected etc while the work is carried out HYD 8 1 1 Place the machine safely onto blocks so that all four wheels are clear of the ground Ensure that the machine is stable Position the operator s seat...

Page 146: ...total strip and rebuild Such a procedure is outside the scope of this Service Manual 3 Remove O ring 5 from seal carrier 3 Discard the O ring 4 Using a suitable press press out lip seal 6 from the sea...

Page 147: ...d cannot be repaired 3 Remove and discard O rings 3 and 4 and back up ring 5 from plug 1 4 Inspect relief valve 2 and mating seat in plug 1 for damage Replace if necessary 5 Install a new outer O ring...

Page 148: ...hten the locknut 8 Check the charge pressure and adjust as necessary Charge Pressure Checking and Adjustment 1 Stop engine Connect a 0 40 bar 0 600 lb in2 0 42 kg cm2 pressure gauge into the test poin...

Page 149: ...e stationary 6 Finally tighten locknut A to 23 Nm 17 lbf ft taking care to retain the set position of adjusting screw B 7 Re check for wheel movement Section E Hydraulics 9803 8550 Section E 12 12 Iss...

Page 150: ...speed of the wheels on the opposite side of the machine Note that excessive wheel speed may result in cooling problems due to overheating of the hydraulic oil If necessary the appropriate adjusting s...

Page 151: ...d D 5 Restart the engine and re check the operation of left and right motors Note that when the left motor is selected the right motor should now drive and the left motor should drive when the right m...

Page 152: ...hing line B This is important otherwise a true leakage rate cannot be obtained 5 Install a 0 400 bar 0 6000 lb in2 0 422 kg cm2 pressure gauge into the appropriate test point C on the pump to measure...

Page 153: ...uld indicate a fault in the charge pressure relief valve in the hydrostatic pump or the pressure reducing solenoid valve 6 If the supply pressure is correct check the feed hose to the joystick for blo...

Page 154: ...Section E Hydraulics 9803 8550 Section E Pumps 12 17 12 17 Issue 2 S167751 139690 www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 155: ...cut in track corresponds to the inlet side of the flange Assemble the gear bearing pack components 4 5 6 and 7 separately It is important to return the flange end bearing 6 to the flange end of the un...

Page 156: ...ction E Hydraulics 9803 8550 Section E Issue 1 Pumps 12 19 12 19 291090 2 7 A 6 4 5 8 9 10 3 X 11 12 17 16 14 15 18 19 20 13 22 21 1 B www WorkshopManuals co uk Purchased from www WorkshopManuals co u...

Page 157: ...gh so that the bronze base is visible the complete pump must be renewed Renew pump if faces of bearing blocks are scored or if side faces of gears are chipped or damaged DO NOT use any abrasives on th...

Page 158: ...13 1 Section E Hydraulics 9803 8550 Section E 13 1 Drive Motors Issue 2 205150 B A 204320 S246250 A B www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 159: ...oses A from the motor Plug exposed connections Withdraw capscrews B 4 off The motors can now be lifted clear Replacement Replacement is the reversal of the removal procedure Note The motors fitted fro...

Page 160: ...Section E Hydraulics 9803 8550 Section E Drive Motors 13 3 13 3 Issue 2 167730 S167730A S167730B B A A www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 161: ...mbly Note Soak new brake plates in oil for 1 hour before assembly Before assembling lubricate all parts with oil Grease all seals and O rings with Vaseline Ensure bearing 44 is pressed fully onto the...

Page 162: ...Section E Hydraulics 9803 8550 Section E Issue 1 Drive Motors 13 5 13 5 S243720 X S243870 www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 163: ...rom end cover 64 Remove and discard O ring 73 Unscrew capscrews 74 in a progressive manner then remove end cover 64 from brake housing 60 Remove and discard gasket 70 Withdraw spring disc 78 from brak...

Page 164: ...se lips of seal with JCB HP Grease Carefully press bearing cup 7 into the front casing Position drive shaft 1 vertically on a press Warm bearing cone 8 and press into position on the shaft Pack the fr...

Page 165: ...www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 166: ...Section E Hydraulics 9803 8550 Section E Issue 1 Drive Motors 13 8 13 8 387340 www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 167: ...and press shaft 35 out of bearings 36 and 38 Remove the cone from bearing 36 Using a soft steel drift remove bearing cups 36 and 38 from front casing 19 Remove bearing cone 38 from shaft 35 using a p...

Page 168: ...late pack is to be fitted the overall length of the pack when clamped must be between 28 1 and 28 3 mm The desired dimension should be achieved using shims 9 and 10 fitted between the end of the plate...

Page 169: ...all loader excavator functions 1 2 3 4 6 7 19 All hydraulic rams slow to operate 3 4 7 10 12 One hydraulic service fails to operate or operates slowly 13 14 15 16 18 Engine tends to stall when hydrau...

Page 170: ...ace piston rod E22 1 Check pressure setting of MRV E15 1 Check that associated pivot pins are adequately greased 19 Poor engine performance Check engine performance K1 1 20 Oil cooler obstructed Remov...

Page 171: ...valve at inlet A six work ports B four servo connections C two on the opposite side one high pressure carry over D and one outlet E Cover exposed connections to prevent ingress of dirt Mark the hoses...

Page 172: ...3 8550 Section E Issue 1 Valves 14 2 14 2 205140 1 2 3 4 5 6 7 9 8 10 9 12 11 12 11 12 11 12 11 13 13 14 15 16 17 18 18 19 21 20 18 23 22 B 8 25 24 C G F E D www WorkshopManuals co uk Purchased from w...

Page 173: ...pool 17 Only spool E is described but F and G are similar 8 Remove the auxiliary relief valves 18 2 from E 1 from F 9 Remove plugs 20 1 from F 2 from G remove and discard O rings 21 3 off 10 Remove th...

Page 174: ...and Assembly The manufacturers do not recommend renewing individual components of the M R V or A R V s Each valve should be renewed as a unit if a component is defective Renew all O rings Lubricate p...

Page 175: ...and noting the maximum gauge reading Keep clear of the loader arm The maximum pressure should be as stated in Technical Data If the pressure is incorrect remove dome nut B slacken locknut C and adjus...

Page 176: ...ock using blanking plugs 892 00059 and bonded washers 1406 0021 Pressurise until oil begins to escape from the drain hole D At this point the gauge will indicate the crack pressure of the A R V The pr...

Page 177: ...he hydraulic oil at correct working temperature the seat facing forward and the engine running at 1000 rev min The difference in the two pressures should equal the opening pressure of the check valve...

Page 178: ...Section E Hydraulics 9803 8550 Section E Issue 1 Valves 17 1 17 1 205170 www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 179: ...9 and 24 to 27 To prevent spool rotation when turning screw 13 hold a rod through the eye end of the spool Lubricate new seals with Hydraulic Fluid and take care to prevent them from being damaged by...

Page 180: ...Section E Hydraulics 9803 8550 Section E Issue 1 Valves 18 1 18 1 175600 www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 181: ...F position Ensure that orifice X is clear Lubricate new seals with Hydraulic Fluid Ensure that plug 7 locates in groove Y of rotary spool 9 Torque nut 5 finger tight before locking lever 4 Ensure that...

Page 182: ...Section E Hydraulics 9803 8550 Section E Valves Issue 3 19 1 19 1 204990 A B 2 X 1 4 5 3 E 204330 F 348890 www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 183: ...essary Assembly Assembly is a reversal of the dismantling procedure Fit new O ring seals Torque tighten to 23 28 Nm 17 21 lbf ft 2 3 2 9 kgf m Check and if necessary adjust the setting of cartridge va...

Page 184: ...in 9 spring 10 spring retainer 11 and spool 12 Inspect the spool and spool bore for signs of wear nicks scratches etc Assembling Assembly is the reversal of the dismantling procedure Renew all O rings...

Page 185: ...ngs vent the pressure trapped in the hoses in accordance with the instructions given in this publication HYD 1 5 Mark the joystick flange and supporting flange at 1 to ensure correct realignment on re...

Page 186: ...20 2 Section E Hydraulics 9803 8550 Section E 20 2 Issue 1 Servo Joysticks 167950 www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 187: ...nents from different valve units A Handle assembly used on the loader control joystick Assembly Lubricate all parts with hydraulic fluid before assembly O rings and seals should be lightly coated with...

Page 188: ...ection E Hydraulics 9803 8550 Section E Issue 1 Servo Joysticks 20 4 20 4 2 3 8 9 14 15 1 4 5 6 7 10 11 12 13 17 16 18 19 20 21 388480 www WorkshopManuals co uk Purchased from www WorkshopManuals co u...

Page 189: ...t joysticks Assembly Lubricate all parts with hydraulic fluid before assembly O rings and seals should be lightly coated with petroleum jelly prior to assembly Ensure that valve units are returned to...

Page 190: ...Section E Hydraulics 9803 8550 Section E Rams 22 1 22 1 Issue 2 140731 Z X Y 5 343030 www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 191: ...rod piston head end cap and cylinder using a wire brush Use JCB Cleaner Degreaser to ensure that all threads are free from grease hydraulic oil and locking fluids Allow 15 minutes for the solvent to d...

Page 192: ...rill through the piston head into the piston rod shown at Z Use an undersized diameter drill first as a guide and then drill using the correct size diameter drill to suit refer to the table for drill...

Page 193: ...of the end cap Wait 15 minutes before bringing the two together and then torque tighten the end cap into the cylinder Note If hydraulic oil contacts uncured Threadlocker a weakening of the bond will...

Page 194: ...www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 195: ...the force of spring 6 Lubricate new seals 4 with clean engine oil and fit to rack Renew O ring 7 Re assemble components in reverse order Tighten capscrews 2 to 300 Nm 221 lbf ft 31 kgf m Repeat for ot...

Page 196: ...www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 197: ...r key removed 1 Vent the hydraulic pressure see page E 2 1 2 Remove the battery compartment cover and the corresponding inside panel 3 Remove the hydraulic filler cap 4 Remove the hydraulic tank drain...

Page 198: ...in access to the hydraulic tank cover plate 4 Remove the hydraulic tank drain plug at the rear of the tank and drain the hydraulic oil to below the level of the tank cover plate Note Always drain into...

Page 199: ...www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 200: ...4E Dipper Spool 4F Bucket Spool 4G Auxiliary Spool 4H Hydraclamp Valve 4J Slew ARV 4K Slew ARV 4L Boom Ram Head Side ARV 4M Boom Ram Rod Side ARV 4N Dipper Ram Rod Side ARV 4P Dipper Ram Head Side ARV...

Page 201: ...2 2A 2B 2C 2X 2E 2F 2G 3 P3 4 4A 4B 4C 4D 4E 4F 4H 4J 4K 4L 4M 4N 4P 4R 5 7 30 12 6 32 36 38 37 34 35 33 50 51 S1 C 8 2Z M1 M2 P1 P2 4G 4Q 4S 4T T T 2D 2H 2J A204773A 8A 8B 8C 8D Schematic Diagram A20...

Page 202: ...A 2B 2C 2X 2E 2F 2G 3 P3 4 4A 4B 4C 4D 4E 4F 4H 4J 4K 4L 4M 4N 4P 4R 5 7 30 12 6 32 36 38 37 34 35 33 50 51 S1 C 8 2Z M1 M2 P1 P2 4G 4Q 4S 4T T T 2D 2H 2J A243002A 8A 8B 8C 8D 52 10 Schematic Diagram...

Page 203: ...lve 4J Slew ARV 4K Slew ARV 4L Boom Ram Head Side ARV 4M Boom Ram Rod Side ARV 4N Dipper Ram Rod Side ARV 4P Dipper Ram Head Side ARV 4Q Bucket Ram Rod Side ARV 4R Bucket Ram Head Side ARV 4S Auxiliar...

Page 204: ...oom Ram Rod Side ARV 4N Dipper Ram Rod Side ARV 4P Dipper Ram Head Side ARV 4Q Bucket Ram Rod Side ARV 4R Bucket Ram Head Side ARV 4S Auxiliary ARV 4T Auxiliary ARV 5 Crowd Rams 6 Manually Operated Du...

Page 205: ...2 2A 2B 2C 2X 2E 2F 2G 3 P3 4 4A 4B 4C 4D 4E 4F 4H 4J 4K 4L 4M 4N 4P 4R 5 7 30 12 6 32 36 38 37 34 35 33 50 51 S1 C 8 2Z M1 M2 P1 P2 4G 4Q 4S 4T T T 2D 2H 2J 316741 8A 8B 8C 8D 52 10 X T Schematic Dia...

Page 206: ...tic Diagram 1 F1 11 2Y 9 2 2A 2B 2C 2X 2E 2F 2G 3 P3 4 4A 4B 4C 4D 4E 4F 4H 4J 4K 4L 4M 4N 4P 4R 5 7 30 12 6 10 32 36 38 37 34 35 33 50 51 S1 C 8 2Z M1 M2 P1 P2 4G 4Q 4S 4T T T 2D 2H 2J A243003A 52 ww...

Page 207: ...pool 4G Auxiliary Spool 4H Hydraclamp Valve 4J Slew ARV 4K Slew ARV 4L Boom Ram Head Side ARV 4M Boom Ram Rod Side ARV 4N Dipper Ram Rod Side ARV 4P Dipper Ram Head Side ARV 4Q Bucket Ram Rod Side ARV...

Page 208: ...Ram Head Side ARV 4M Boom Ram Rod Side ARV 4N Dipper Ram Rod Side ARV 4P Dipper Ram Head Side ARV 4Q Bucket Ram Rod Side ARV 4R Bucket Ram Head Side ARV 4S Auxiliary ARV 4T Auxiliary ARV 5 Crowd Rams...

Page 209: ...ic Diagram 1 F1 11 2Y 9 2 2A 2B 2C 2X 2E 2F 2G 3 P3 4 4A 4B 4C 4D 4E 4F 4H 4J 4K 4L 4M 4N 4P 4R 5 7 30 12 6 10 32 36 38 37 34 35 33 50 51 S1 C 8 2Z M1 M2 P1 P2 4G 4Q 4S 4T T T 2D 2H 2J 316761 52 X T w...

Page 210: ...2E 2F 2G 3 P3 4 4A 4B 4C 4D 4E 4F 4H 4J 4K 4L 4M 4N 4P 4R 5 7 30 12 6 32 36 38 37 34 35 33 50 51 S1 C 8 2Z M1 M2 P1 P2 4G 4Q 4S 4T T T S2 13 15 2D 2H 2J 14 14A 14B 14C F2 A204773B 8A 8B 8C 8D Schemati...

Page 211: ...K Slew ARV 4L Boom Ram Head Side ARV 4M Boom Ram Rod Side ARV 4N Dipper Ram Rod Side ARV 4P Dipper Ram Head Side ARV 4Q Bucket Ram Rod Side ARV 4R Bucket Ram Head Side ARV 4S Auxiliary ARV 4T Auxiliar...

Page 212: ...mp Valve 4J Slew ARV 4K Slew ARV 4L Boom Ram Head Side ARV 4M Boom Ram Rod Side ARV 4N Dipper Ram Rod Side ARV 4P Dipper Ram Head Side ARV 4Q Bucket Ram Rod Side ARV 4R Bucket Ram Head Side ARV 4S Aux...

Page 213: ...F 2G 3 P3 4 4A 4B 4C 4D 4E 4F 4H 4J 4K 4L 4M 4N 4P 4R 5 7 30 12 6 10 32 36 38 37 34 35 33 50 51 S1 C 8 2Z M1 M2 P1 P2 4G 4Q 4S 4T T T S2 13 15 2D 2H 2J 14 14A 14B 14C F2 A243000B 2W 8A 8B 8C 8D 52 Sch...

Page 214: ...E 2F 2G 3 P3 4 4A 4B 4C 4D 4E 4F 4H 4J 4K 4L 4M 4N 4P 4R 5 7 30 12 6 10 32 36 38 37 34 35 33 50 51 S1 C 8 2Z M1 M2 P1 P2 4G 4Q 4S 4T T T S2 13 15 2D 2H 2J 14 14A 14B 14C F2 316751 2W 8A 8B 8C 8D 52 X...

Page 215: ...Dipper Ram Head Side ARV 4Q Bucket Ram Rod Side ARV 4R Bucket Ram Head Side ARV 4S Auxiliary ARV 4T Auxiliary ARV 5 Crowd Rams 6 Manually Operated Dump Valve 7 Lift Rams 8 Drive Control Joystick 8A Re...

Page 216: ...4G Auxiliary Spool 4H Hydraclamp Valve 4J Slew ARV 4K Slew ARV 4L Boom Ram Head Side ARV 4M Boom Ram Rod Side ARV 4N Dipper Ram Rod Side ARV 4P Dipper Ram Head Side ARV 4Q Bucket Ram Rod Side ARV 4R B...

Page 217: ...C 2X 2E 2F 2G 3 P3 4 4A 4B 4C 4D 4E 4F 4H 4J 4K 4L 4M 4N 4P 4R 5 7 30 12 6 10 32 36 38 37 34 35 33 50 51 S1 C 8 2Z M1 M2 P1 P2 4G 4Q 4S 4T T T S2 13 15 2D 2H 2J 14 14A 14B 14C F2 A243004 2W 52 14 Sche...

Page 218: ...2X 2E 2F 2G 3 P3 4 4A 4B 4C 4D 4E 4F 4H 4J 4K 4L 4M 4N 4P 4R 5 7 30 12 6 10 32 36 38 37 34 35 33 50 51 S1 C 8 2Z M1 M2 P1 P2 4G 4Q 4S 4T T T S2 13 15 2D 2H 2J 14 14A 14B 14C F2 316771 2W 52 14 X T Sc...

Page 219: ...d Side ARV 4N Dipper Ram Rod Side ARV 4P Dipper Ram Head Side ARV 4Q Bucket Ram Rod Side ARV 4R Bucket Ram Head Side ARV 4S Auxiliary ARV 4T Auxiliary ARV 5 Crowd Rams 6 Manually Operated Dump Valve 7...

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Page 221: ...urn oil from the hand tool is fed directly back to tank Relief Valve 3b prevents pressure in the hand tool circuit from rising too far Manual Valve 2 is turned off to isolate the hand tool circuit whe...

Page 222: ...www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 223: ...1 Tyre Pressures see Section 3 Wheel Hub Assembly Removal and Replacement up to machine no 751599 1 2 Dismantling and Assembly up to machine no 751599 1 3 Removal and Replacement from machine no 7516...

Page 224: ...ts to the correct torque see Section 3 Routine Maintenance WARNING A raised and badly supported machine can fall on you Position the machine on a firm level surface before raising one end Ensure the o...

Page 225: ...ion the drive chain is at its slackest Remove the nuts and washers B and the retaining ring C Pull the hub assembly out and remove the chain from the sprocket E Remove the hub assembly from the chassi...

Page 226: ...axle 4 and discarded Examine the stub axle and casing for wear or damage Assembly The numerical sequence shown in the dismantling procedure should be reversed Lubricate all bearings and seals with JC...

Page 227: ...www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 228: ...tion F Transmission 9803 8550 Section F Issue 1 Tyres and Wheels 1 4 1 4 S255770 A D B C B C 1 2 3 4 4A 5 6 7 8 9 S255780 X S255790 Y Z www WorkshopManuals co uk Purchased from www WorkshopManuals co...

Page 229: ...Position the hub to give 25 mm 1 in of slack on the opposite side of the chain at the midway point d When the correct tension is achieved fit and tighten bolts C and tighten nut B Finally torque tigh...

Page 230: ...www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 231: ...akes 9803 8550 Section G i Issue 2 Contents Page No Preparation for Towing Winching up to machine number 751011 1 1 from machine number 751012 1 2 www WorkshopManuals co uk Purchased from www Workshop...

Page 232: ...hydraulic pumps 3 2 1 2 1 Block the wheels to prevent accidental movement when the brakes are released 2 Remove the floor plates to gain access to the hydraulic pump assembly see Section 3 Routine Ma...

Page 233: ...raulic pump assembly see Section 3 Routine Maintenance 3 Press in the by pass plungers on the four Charge Check valves A underneath the pump This will open the valves and allow oil from the motors to...

Page 234: ...www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 235: ...No Specification Technical Data XUD Engine 1 1 Technical Data 100 Series Engine up to machine no 807552 1 2 Technical Data 400 Series Engine from machine no 807553 1 3 Removal and Replacement 2 1 www...

Page 236: ...23 5 1 25 30 bar 363 435 lbf in2 25 5 33 kgf cm2 Maximum variation between cylinders 5 bar 72 5 lbf in2 5 1 kgf cm2 1 3 4 2 0 15 0 20 mm 0 0059 0 0078 in 0 30 0 35 mm 0 0118 0 0138 in 20 mbar 0 29 lbf...

Page 237: ...Injector Setting Pressure 150 162 bar 2175 2350 lbf in2 153 165 kgf cm2 Cooling System Fan Type Mechanical Coolant Pressure 0 5 bar 7 25 lbf in2 0 5 kgf cm2 Thermostat operating temperature 82 94 C 18...

Page 238: ...BTDC Injector Codes 131 406 360 Injector Setting Pressure 147 bar 2133 lbf in2 Cooling System Fan Type Mechanical Coolant Pressure 1 bar 14 5 lbf in2 Thermostat operating temperature opens at 82 C 180...

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Page 240: ...Section K Engine 9803 8550 Section K Issue 1 2 1 2 1 Removal and Replacement 205180 204290 E E C B A D www WorkshopManuals co uk Purchased from www WorkshopManuals co uk...

Page 241: ...RNING Lifting Equipment You can be injured if you use faulty lifting equipment Make sure that lifting equipment is in good condition Make sure that lifting tackle complies with all local regulations a...

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