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jcb JS 200 Series, Service Manual

The JCB JS 200 Series Service Manual is a comprehensive manual for maintaining and troubleshooting your equipment. Download this manual for free from manualshive.com to ensure your JCB JS 200 Series machine operates at its peak performance. Stay prepared and keep your machinery running smoothly with this essential manual.

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3 - 2

Dismantling 

(continued)

5.

Remove floating seal 

J

from each hub

C

using a pry bar.

6.

Remove floating seal 

J

from each side of idler wheel 

G

using a pry bar.

7.

If badly worn or damaged, remove the bushes 

K

from

idler wheel 

G

using a press or puller.

Protect parts from moisture and dust if left dismantled for
some time.

Assembly

1. 

Clean all parts thoroughly in a suitable solvent.  Dry shaft
and bore of idler wheel using compressed air in a place
free of dust and moisture.

Check components for wear as detailed under 

Wear

Limits

.  Polish out scratches and roughness using an oil

stone.  Then apply a coat of engine oil to all parts.

Carefully drive the new bushes 

K

into the idler wheel 

G

,

using a suitable dolly 

L

.

Section J

Track and Running Gear

9803/6400

Section J

3 - 2

Issue 1

Idler Wheel 

(continued)

C

J

J

G

J

J

C

J

J

K

G

K

K

G

L

Summary of Contents for JS 200 Series

Page 1: ...ISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE WATERLOO PARK UTTOXETER STAFFORDSHIRE ST14 5PA ENGLAND Tel ROCESTER 01889 590312 PRINTED IN ENGLAND Publication No 9803 6400 R General Inf...

Page 2: ...tions are alphabetically coded and deal with Dismantling Overhaul etc of specific components for example A Optional Equipment B Body Framework etc The page numbering in each alphabetically coded secti...

Page 3: ...and Nut Torque Specifications 1 1 Service Tools Section C Electrics 4 1 Section E Hydraulics 5 1 Section F Transmission 6 1 Sealing and Retaining Compounds 7 1 i General Information 9803 6400 i Issue...

Page 4: ...r weight M27 M30 41 46mm 1058 1235 1335 1545 108 126 136 158 780 910 985 1140 9 Turntable Bearing Undercarriage M20 M24 30 36mm 475 550 780 910 48 4 55 3 80 93 350 400 575 670 10 Turntable Bearing Sle...

Page 5: ...LECTRICS Electrical Test Equipment 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 0028...

Page 6: ...x Test Point 892 00266 1 1 4 in M BSP x 1 1 4 in F BSP x Test Point 892 00267 1 1 2 in M BSP x 1 1 2 in F BSP x Test Point Pressure Test Adapters 892 00255 1 4 in BSP x Test Point 892 00256 3 8 in BSP...

Page 7: ...92 00278 Gauge 0 40 bar 0 600 lb in2 892 00279 Gauge 0 400 bar 0 6000 lb in2 892 00280 Gauge 0 600 bar 0 8500 lb in2 816 50005 1 2 in BSP A x 1 2 in BSP B 816 60096 3 4 in BSP A x 3 4 in BSP B 816 000...

Page 8: ...Service Tools continued SECTION E HYDRAULICS Slew Motor Jig SST0033 Oil Seal Jig SST0034 Taper Bearing Ring Jig SST0035 Inner Ring Jig SST0036 Seal Press Fit Jig All dimensions are in mm 4 2 31 40 50...

Page 9: ...loose unwelded 1 3 993 99523 Anchor cross member supplied loose unwelded 1 4 993 99524 Ram eye end modification 1 5 556 43400 Lift ram 1 6 545 18000 Lynch pin 1 7 811 50232 11 4 in Pivot pin 1 Spanner...

Page 10: ...ued SECTION F TRANSMISSION Track Motor Jig SST0028 Inner Rail Press Jig SST0029 Snap Ring Jig SST0030 Oil Seal Jig SST0031 Case Fixing Jig SST0032 Bearing Jig All dimensions are in mm 49 5 100 40 5 70...

Page 11: ...tinued SECTION F TRANSMISSION Track Gearbox Jig SST0037 Re sealing Tool SST0038 Main Bearing Tool SST0039 Main Bearing Tool All dimensions are in mm SST0037 SST0038 SST0039 24 21 315 270 304 306 14 M1...

Page 12: ...Service Tools continued SECTION F TRANSMISSION Track Gearbox Jig SST0040 Ring Nut Tool SST0041 Planet Gear Tool All dimensions are in mm SST0040 SST0041 233 5 248 265 30 8 90 30 38 1sq 9 7 11 1 5x45 9...

Page 13: ...or hydraulic fittings up to 25 mm diameter JCB Threadlocker and Sealer A high strength locking fluid for sealing and retaining 4101 0550 10 ml High Strength nuts bolts and screws up to 50 mm diameter...

Page 14: ...Contents Page No Safety Notices 1 1 General Safety 2 1 Operating Safety 3 1 Maintenance Safety 4 1 4 2 i Care Safety 9803 6400 i Issue 1 Section 2 Section 2...

Page 15: ...per precautions 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 o...

Page 16: ...1 3 7 WARNING Clothing You can be injured if you 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...

Page 17: ...aking sure there is good ventilation If possible fit an exhaust extension If you begin to feel drowsy stop the machine at once Get out of the cab into fresh air INT 2 1 10 WARNING Hazardous Atmosphere...

Page 18: ...m soapy water Do not use petrol diesel fuel or paraffin to clean your skin INT 3 2 3 WARNING Fires If your machine is equipped with a fire extinguisher make sure it is checked regularly Keep it in the...

Page 19: ...1 1 WARNING Hydraulic Fluid 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 to suspected leak...

Page 20: ...Element 5 6 Cleaning Changing the Suction Strainer 5 7 Changing the Air Breather Element 5 8 Draining Tank Impurities 5 9 Changing the Pilot Oil Filter 5 9 Changing the Breaker In line Filter 5 10 Cha...

Page 21: ...Fan Belt 8 5 Fitting a New Fan Belt 8 5 Cleaning the Radiator and Oil Cooler 8 6 Draining Fuel Tank Impurities 8 7 Draining the Water Separator 8 7 Changing the Fuel Filter Element 8 7 Bleeding the Fu...

Page 22: ...Grease Lithium complex NLGI 2 inc CYLINDER extreme pressure additives HYDRAULIC SYSTEM JCB Hydraulic 203 litres Fluid 46 ISO VG46 44 64 UK gal 53 6 US gal SLEW RING BEARING JCB HP Grease Lithium comp...

Page 23: ...open or unlabelled containers Handling New Oil There are no special precautions need for the handling or use of new oil beside normal care and hygiene practices Used Oil Used engine crankcase lubrica...

Page 24: ...ting hours involving use of the breaker crusher or pulveriser When a breaker crusher or pulveriser is fitted ensure that the oil and filters are changed at the intervals shown in the table below The h...

Page 25: ...er severe conditions from new will affect its performance and shorten its service life 1 Carry out the Daily inspection procedure 2 Always warm up the machine sufficiently 3 Hold the engine speed to 8...

Page 26: ...rain water and sediment from fuel tank b Drain fuel water separator 3 Grease a All pivot pins Every 100 Operating Hours or 2 Weekly Whichever occurs first 1 Do a 50 hour service plus 2 Clean a Battery...

Page 27: ...ters g Engine oil check the degredation and cleanliness by sampling 6 Check Engine Running a Operation of throttle system b Operation of overload warning c Operation of stop control Every 1000 Operati...

Page 28: ...000 hour service plus 2 Change Hydraulic oil Hydraulic tank air breather element Hydraulic suction filter If using a breaker crusher or pulveriser see page 2 1 for revised servicing schedules Section...

Page 29: ...on port cover A on the lower centre section b Remove the grease discharge port cover B on the lower inner side c Remove contaminated grease d Replace the discharge port cover e Apply grease to the sle...

Page 30: ...et linkage to Bucket pin 3 1 total of 5 points Dipper to Bucket Linkage pin 1 Dipper to Bucket pin 1 Bucket ram dump end pin 1 Dipper ram eye end pin 4 1 total of 3 points Boom to Dipper connecting pi...

Page 31: ...Excavator End 3 3 Section 3 Routine Maintenance 9803 6400 Section 3 3 3 Issue 2 Greasing continued JS03720 JS02970 5 JS240 JS260 JS200 JS220 JS03490 JS03750...

Page 32: ...Do not disconnect the alternator the battery or any part of the charging circuit with the engine running 8 3 4 1 Charge Rate Depending on the Battery specific Gravity If the battery is charged and the...

Page 33: ...pressure 8 3 4 4 1 WARNING The temperature of the hydraulic oil will be high soon after stopping the engine Wait until it cools down less than 40 C before beginning maintenance 8 3 4 10 1 Prepare the...

Page 34: ...stop the engine for 5 minutes or more and release the bubbles from the oil in the hydraulic oil tank Air Bleeding from Ram WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you...

Page 35: ...leeding plug A and check that oil comes out from the air bleeding port DO NOT SLEW THE MACHINE c If no oil comes out stop the engine remove the air bleeding plug A and fill the motor case with hydraul...

Page 36: ...two marks on the tube If the fluid is cloudy water or air has entered the system Water or air in the system could damage the hydraulic pump Topping up Fluid Level WARNING DO NOT remove the hydraulic t...

Page 37: ...e engine Remove the starter key 2 Locate the Hydraulic oil tank or Filler Plate See Component Location Diagrams at the end of the section 3 Release Tank Pressure See Releasing Tank Pressure a Remove t...

Page 38: ...the Return filter See Components Location Diagram at the end of this section 3 Release Tank Pressure See Releasing Tank Pressure 4 Removing the Element a Remove the retaining bolts A and washers B an...

Page 39: ...ing bolts A and washers D lift off cover plate B b Remove the suction strainer C and clean with a suitable solvent or if renewing discard 5 Fit the Suction Strainer Fitting is a reversal of removal 6...

Page 40: ...one of two positions because of the slot G in the cover which locates over a similar shaped protrusion on the mounting stud b Remove the old filter element D together with the sponge packing E c Repl...

Page 41: ...raulic fluid flows out 4 Seal the System Refit the drain plug A Changing the Pilot Oil Filter 1 Prepare the Machine Position the machine on level ground Stop the engine Remove the starter key 2 Releas...

Page 42: ...the new filter with clean hydraulic fluid Screw the new filter into head B and tighten Check and top up the hydraulic fluid level Changing the Drain Line Filter 1 Prepare the Machine Position the mach...

Page 43: ...d remove Note Be careful not to drop any dirt from the nephron filter A 4 Replace the Nephron filter A a Peel off the 4 foil seals of the new nephron filter one on the upper and lower side and the oth...

Page 44: ...ainer must be large enough to hold the maximum gearbox capacity see Lubricants and Capacities CAUTION Oil will gush from the hole when the drain plug is removed Keep to one side when you remove the dr...

Page 45: ...ts and Capacities for oil type and volume Fill with new oil through filler port C until it reaches the full mark on the dipstick when settled refit the dipstick 4 Check for Leaks Run the machine opera...

Page 46: ...cket to the ground 2 Raise the Track Operate the boom and dipper controls so that the track on the side nearest the bucket is lifted up clear of the ground 3 Rotate the Track WARNING Rotating the trac...

Page 47: ...duce the gap increase the tension or open to release grease and increase the gap WARNING When opening the check valve always stand to one side and loosen a little at a time until grease starts to come...

Page 48: ...rs and Idler Wheels for Oil Leaks 1 Prepare the Machine See Checking Adjusting the Track Tension step 1 2 Look for Oil Leaks Check the top and bottom rollers and the idler wheels for oil leaks CAUTION...

Page 49: ...e the Air Filter See Identification of Machine Components 4 Open the Hydraulic Compartment 5 Remove the Elements Remove end cover A Remove the outer element B Remove the inner element C 6 Clean the Fi...

Page 50: ...on each new filter with oil Tighten the filter until the seal bites onto the filter housing Tighten the filter a minimum of one more turn 4 Fill the System Securely tighten the drain plug D and refil...

Page 51: ...ture every year before the cold weather starts Change it every two years Coolant Mixtures To prevent the coolant freezing in cold conditions antifreeze must be added JCB Four Seasons Antifreeze and Su...

Page 52: ...aking sure it is tight Close the radiator drain tap A 5 Fill the System Using the necessary mix of clean soft water and antifreeze see Coolant Mixtures fill via the expansion bottle cap until the leve...

Page 53: ...ee below 4 Secure the Alternator Re tighten bolts B Then re tighten bolt A Fitting a New Fan Belt 1 Loosen the Alternator Slacken bolts A and B and adjust tensioner C so that the fan belt can be remov...

Page 54: ...ne in dusty conditions inspect the net for clogging every day then replace 2 Swing Out type Oil Cooler if fitted a Remove the Oil Cooler mounting bolts A washers B Housing Cover C and stays D then swi...

Page 55: ...owed to rise above the red line D or water could get taken further into the system with serious consequences Changing the Fuel Filter Element 1 Stop the Engine Stop the engine and remove the key 2 Dis...

Page 56: ...ocate the priming pump and bleed point see Illustrations 4 Prepare for Bleeding Loosen the knob A on the priming pump B by turning it anti clockwise The knob will be lifted by spring pressure 5 Bleed...

Page 57: ...9 1 Section 3 Routine Maintenance 9803 6400 Section 3 9 1 Issue 2 Component Location Diagram...

Page 58: ...5 C 55 C c The engine speed should be within 50 rpm of the Reference Value d The hydraulic equipment should be operated several times before testing e The operation to be measured should be operated t...

Page 59: ...rm when it is lowered d Slew Speed The conditions for checking are that the attachment is facing forwards and that a vertical line is chalked on the turntable bearing and lowering then place the attac...

Page 60: ...The conditions for checking is to position the bucket in the open position slightly above ground and the engine stopped 2 Gently push the bucket from the side and put a mark on the ground this becomes...

Page 61: ...ower the body to the ground and confirm the needle reads zero 5 Next place the dial gauge on the rear of the vehicle and repeat the two above procedures to obtain L2 and L4 2 Install a dial gauge and...

Page 62: ...f 20 then set the attachment to a 90 position relative to the direction of travel 2 Confirm with an angle gauge that the machine is at 20 and mark the turntable bearing and lower ring 3 Stop the engin...

Page 63: ...0 metres wipe all the rods and confirm there are no scratches Refer to the service text for the No of reciprocations to accomplish the distance 2 Measure the width of the oil ring on each ram rod to s...

Page 64: ...application with a damaged or missing FOPS Structure If the FOPS has been in an accident do not use the machine until the structure has been renewed Modifications that are not approved by the manufac...

Page 65: ...Maintenance Specifications JS240 JS240LC Boom and Slew Frame Installation 5 1 Boom Ram Installation 5 1 Dipper Ram Installation 5 2 Dipper Pivot Installation 5 3 Dipper and Dipper Ram Installation 5 3...

Page 66: ...rntable Bearing Lower Frame 521 0 608 784 914 53 1 62 79 9 93 2 383 91 448 26 577 67 673 83 Apply 262 Turntable Bearing Slew Frame 521 0 608 784 914 53 1 62 79 9 93 2 383 91 448 26 577 67 673 83 Apply...

Page 67: ...2 1 Section B Body Framework 9803 6400 Section B 2 1 Issue 2 Undercarriage Dimensions JS200 JS220...

Page 68: ...2 2 Section B Body Framework 9803 6400 Section B 2 2 Issue 2 Undercarriage Dimensions JS200LC JS220LC...

Page 69: ...2 3 Section B Body Framework 9803 6400 Section B 2 3 Issue 2 Undercarriage Dimensions JS240 JS260...

Page 70: ...2 4 Section B Body Framework 9803 6400 Section B 2 4 Issue 2 Undercarriage Dimensions JS240LC JS260LC...

Page 71: ...3 1 Section B Body Framework 9803 6400 Section B 3 1 Issue 2 Main Body Weights JS200 JS200LC JS220 JS220LC JS240 JS240LC JS260 JS260LC A G I H J B C D E F...

Page 72: ...ights JS200 JS200LC JS220 JS220LC Machine fitted with 3 m boom 600 mm grouser shoes 0 7 m3 bucket JS200 220 0 8 m3 bucket JS200LC 220LC Position Weight kg Symbol Name JS240 JS240LC JS260 JS260LC A Ove...

Page 73: ...er assembly 37 6 500 mm grouser shoe assembly 1266 1348 1386 1485 7 600 mm grouser shoe assembly 1473 1569 1505 1633 8 700 mm grouser shoe assembly 1601 1706 1636 1775 9 10 Slew mechanism 194 335 11 S...

Page 74: ...n Boom b 681 679 Clearance c 1 0 3 5 Pin d 90 89 Bushing boom e 90 91 5 2 Boom ram Slew frame a 106 112 and slew frame installation Boom ram b 105 103 dump end Clearance c 1 0 2 5 Pin d 80 79 Bushing...

Page 75: ...rk 9803 6400 Section B 4 2 Issue 2 Maintenance Specifications Equipment Part Code Standard Service Name Name Value mm Limit mm 4 Dipper ram Boom a 121 127 installation Dipper ram b 120 118 dump end Cl...

Page 76: ...me Value mm Limit mm 6 Dipper and Boom a 121 127 Dipper ram installation Dipper ram b 120 118 eye end Clearance c 0 5 3 0 Pin d 80 79 Bushing e 80 81 5 Dipper ram Shim for adjustment KRP1349 Equipment...

Page 77: ...ard Service Name Name Value mm Limit mm 7 Bucket Ram Dipper a 101 107 installation Bucket ram b 100 98 eye end Clearance c 0 5 3 0 Pin d 75 74 Bushing e 75 76 5 bucket ram Shim for adjustment KRV1176...

Page 78: ...313 bucket link installation Bucket link b 306 304 Clearance c 1 0 3 5 Pin d 80 79 Bushing e 80 81 5 bucket link Shim for adjustment KRV1197 Equipment Part Code Standard Service Name Name Value mm Lim...

Page 79: ...ion B 4 6 Issue 2 Maintenance Specifications Equipment Part Code Standard Service Name Name Value mm Limit mm 11 Bucket and Bucket a 307 313 dipper installation Dipper b 306 304 Clearance c 1 0 3 5 Bu...

Page 80: ...Table Pin Shim Shim Outer Diameter Diameter Thickness 90 100 110 120 130 135 140 145 150 160 60 1 2 65 1 2 KNV0538 BHV1034 70 1 2 KNV0696 KNV0539 75 1 2 KRV1176 KHV0169 KNV0534 80 1 2 KRV1197 KRP1349...

Page 81: ...2 Maintenance Specifications Attachments continued Shim Adjustment Table continued Pin Shim Outer Diameter Diameter 165 170 180 185 190 200 210 220 230 240 250 60 65 70 75 80 85 90 KBV0764 KRV1180 95...

Page 82: ...stallation Boom b Clearance c 1 0 3 5 Pin d 100 99 Bushing boom e 100 101 5 2 Boom and Slew frame a 109 115 slew frame installation Boom ram b 108 106 dump end Clearance c 1 0 2 5 Pin d 90 89 Bushing...

Page 83: ...rk 9803 6400 Section B 5 2 Issue 2 Maintenance Specifications Equipment Part Code Standard Service Name Name Value mm Limit mm 4 Dipper Ram Boom a 121 127 installation Dipper ram b 120 118 dump end Cl...

Page 84: ...Value mm Limit mm 6 Dipper and Boom a 121 127 Dipper ram installation Dipper ram b 120 118 eye end Clearance c 0 5 3 0 Pin d 90 99 Bushing e 90 91 5 Dipper ram Shim for adjustment KRV1180 Equipment P...

Page 85: ...rd Service Name Name Value mm Limit mm 7 Bucket ram Dipper a 116 122 installation Bucket ram b 115 113 eye end Clearance c 0 5 3 0 Pin d 80 79 Bushing e 80 81 5 bucket ram Shim for adjustment KRV1197...

Page 86: ...3 bucket link installation Bucket link b 325 323 Clearance c 1 0 3 5 Pin d 90 89 Bushing e 90 91 5 bucket link Shim for adjustment KRV1180 Equipment Part Code Standard Service Name Name Value mm Limit...

Page 87: ...ion B 5 6 Issue 2 Maintenance Specifications Equipment Part Code Standard Service Name Name Value mm Limit mm 11 Bucket and Bucket a 326 323 Dipper installation Dipper b 325 323 Clearance c 1 0 3 5 Bu...

Page 88: ...Table Pin Shim Shim Outer Diameter Diameter Thickness 90 100 110 120 130 135 140 145 150 160 60 1 2 65 1 2 KNV0538 BHV1034 70 1 2 KNV0696 KNV0539 75 1 2 KRV1176 KHV0169 KNV0534 80 1 2 KRV1197 KRP1349...

Page 89: ...2 Maintenance Specifications Attachments continued Shim Adjustment Table continued Pin Shim Outer Diameter Diameter 165 170 180 185 190 200 210 220 230 240 250 60 65 70 75 80 85 90 KBV0764 KRV1180 95...

Page 90: ...ent procedures Reference is made to the tools in the text The majority of these tools can be obtained locally and the remainder from JCB Service see Service Tools Section 1 The work must only be carri...

Page 91: ...wire starter tube and two handles see Service Tools Section 1 i Insert the steel tube C into the old sealant on the inside of the glass ii Insert the braided cutting wire D down the centre of the ste...

Page 92: ...hened glass remove the cut off sealant and all remaining particles of shattered glass 5 If necessary trim off the remaining old sealant to leave approximately 1 to 2 mm on the upright face of the cab...

Page 93: ...glass stand N It is recommended that an access hole is cut in the board to accommodate the glass lifter making it easier and safer to handle small panes of glass The board should be covered with felt...

Page 94: ...glass and make sure that the adhesive forms a continuous pyramid shape Note 3 Once the pre heated adhesive has been applied to the glass install the glass in the aperture as soon as possible After ap...

Page 95: ...sealant can be cleaned from the glass using the Active Wipe 205 b Large amounts of excess sealant should be left to cure see Note 4 and then cut off with a sharp knife Note 4 On completion of the gla...

Page 96: ...k 9803 6400 Section B 12 1 Issue 1 Air Conditioning A306820 4 5 6 7 1 3 2 1 Compressor 2 Condenser 3 Receiver Drier 4 Expansion Valve 5 Evaporator Coil 6 Air Filter 7 Air Filter Direction of flow thro...

Page 97: ...rols Located on the Left side of the Rear Panel the heater air conditioning controls are used in conjunction with the heater fan controls Heater Controls A Ventilation control with the control turned...

Page 98: ...Switch Settings High Pressure Switch 28 bar 406 lbf in2 Low Pressure Switch 2 1 bar 30 4 lbf in2 Safety Procedures The air conditioning system includes a pressurised closed circuit containing a non CF...

Page 99: ...re located in the cab rear panel and two air vents N and P are located on the right hand console One air vent Q is located under the drivers seat The vents can be turned to direct the air flow where r...

Page 100: ...or low pressure water Air filters blocked Clean with detergent and water Compressor drive belt too slack Adjust to correct tension b Warm or slightly cool air Expansion valve stuck open or closed Ren...

Page 101: ...CON FUSE PRESSURE SWITCH AIR CON SWITCH LIGHT SWITCH RELAY BLOWER 3 RELAY BLOWER 2 RELAY BLOWER 1 COMPRESSOR CLUTCH B B B L B CNC CNA L O L L W L B W L THERMOSTAT W L L B L Y L Y L Y R R G G O G O L...

Page 102: ...Does the compressor clutch engage with YES Replace pressure switch assembly pressure switch assembly bypassed NO Renew the compressor clutch and retest 7 Does the clutch engage with thermostat switch...

Page 103: ...ant circuit To test for leaks in the high pressure side of the system i e from the compressor output to the expansion valve run the air conditioning for a few minutes then switch off the engine and te...

Page 104: ...depend on system components and ambient conditions make sure that the valves are closed and the readings are stable and that the system has a full charge The pressures on the manifold at 25 C with the...

Page 105: ...rator unit Diagnosis Refrigerant flow obstructed by dirt receiver drier clogged Correction 1 Evacuate A C system 2 Replace receiver drier 3 Charge system with R 134a 4 Operate system and check perform...

Page 106: ...Side Gauge High High Side Gauge High Other symptoms Sight Glass No bubbles visible even at lower engine RPM Diagnosis Refrigerant overcharge condenser cooling fins clogged with dirt or cooling fans ma...

Page 107: ...r symptoms Pipes Large amount of frost or moisture on low side pipes Diagnosis Excessive refrigerant in low side pipes possibly from expansion valve being opened too wide Correction 1 Leak test system...

Page 108: ...Chart 5 3 Boom Lowering Speed Regulation 5 4 Cushioned Boom Starting 5 5 Pressure Increasing System 5 7 3 Speed Travel and Max Flow Cut 5 10 Soft Hard Switch 5 14 Power Supply Cut Delay 5 15 Swing Br...

Page 109: ...anual supplement 9803 6450 is an addition to the following JS XO Machine Service Manuals Manual No Machine No Serial No 9803 6410 JS 130 759561 JS 160 180 703075 9803 6310 JS 130W 717027 JS 145W 81000...

Page 110: ...ATER SHUT DOWN 20A 15A LAMP LEVER LOCK 15A 10A LAMP SPARE LUBRICATOR 15A 10A LAMP SPARE WARNING BEACON 15A 10A LAMP SPARE OIL PUMP 15A 20A WIPER WASHER CONDENSER MOTOR 15A 15A HORN ROOM LAMP SPARE 10A...

Page 111: ...than 0 04 A greater variation indicates an internal fault on that particular cell If the electrolyte temperature is other than 15 C 60 F a correction factor must be applied to the reading obtained Add...

Page 112: ...Duty Optional 30A Fusible Link Starter Switch Back up Fuses 30B Fusible Link Engine Shut down Fuse 31 Fusible Link Fuse Box 32 Relay Battery 33 Solenoid Valve Free Swing Optional 34 Solenoid Valve Bl...

Page 113: ......

Page 114: ...ol 8 Control Lock Lever 9 Left Console 10 Door Lock Release Lever 11 Optional Circuit Pedal if fitted 12 Operators seat 1 Right Console 2 Right Excavator Joystick Control 3 Display Monitor 4 Right Han...

Page 115: ...escription see Operator s Handbook Note Your machine will be equipped with hand controller type A or B JS02980 A B RIGHT CONSOLE Idle Switch Washer Switch Wiper Switch Work lamp Switch One Touch Auto...

Page 116: ...Console side panel 3 3 Section C Electrics 9803 6400 Section C 3 3 Issue 2 Layout Buzzer Stop Switch Time Adjust H E A T O F F O N START CLOCK H M ADJUST CLOCK Starter Switch Horn Volume Soft Hard Po...

Page 117: ...see Operator s Manual Note Your machine will be equipped with hand controller type A or B Left Console Tilt Handle STOP SWING BRAKE P CONTROLS OFF LEFT CONSOLE Lever lock Switch Horn Switch Hour Mete...

Page 118: ...age HYD OIL TEMP WATER TEMP FUEL WORK MODE MODE CLOCK Machine Condition Indicators P WORK MODE MODE CLOCK HYD OIL TEMP Red Green White WATER TEMP Red Green White FUEL Red Green Lock Indicator Water Te...

Page 119: ...he engine has been operating for 12 seconds the engine oil pressure switch is monitored If an ON status is detected for more than 3 seconds engine stops One touch auto idle RPM is reduced to the machi...

Page 120: ...lay before the battery relay is cut OFF A power supply is maintained to allow electrical devices to be operated after key switch is tuned to OFF Power cut delay Modulates movement of control valve boo...

Page 121: ...hat determines the degree of rotation and rotational speed of the stepping motor The stepping motor rotates when it is synchronised with the pulse signal from the pulse oscillator The degree of rotati...

Page 122: ...lies the signal to the motor Stepping motor principle if 1st phase is on drive The wound phases of A B and C are rolled on the stator When a pulse enters A phase rotor is in 1 condition and A a A c ar...

Page 123: ...N8 2 to the driver and the driver sends a pulse clockwise rotation ABA1B1 to the throttle motor When the throttle motor rotates clockwise the limit switch is depressed and a signal is then sent to the...

Page 124: ...ottle input increases because of this the controller sends a counter clockwise revolution signal to the driver and the driver sends a counter clockwise pulse to the throttle motor again the controller...

Page 125: ...controller turns OFF the transistor on the CW side and turns ON the CCW side on the driver CW line is 5V and CCW side is 0V 3 The stop status in volume position CCW and CW of a transistor are turned O...

Page 126: ...stop motor and the switch within the motor are interlocked When the motor moves to the operating position the switch switches to the lower position and the power supply of the motor turns OFF and sto...

Page 127: ...ates turns to the stop position and the engine stops The motor switch is switched to upper position and it stops 4 7 Emergency stop button ON Component Key Pages 4 6 and 4 7 C Key switch D Emergency s...

Page 128: ...ply to the controller is turned OFF and the manual throttle circuit is activated There is a signal of 5V on the motor driver side When pressing manual throttle instruction of a rotational direction is...

Page 129: ...t must be done Note If a new throttle motor is fitted or the cable linkage adjusted the controller must have its memory wiped before programming can commence Automatic adjustment explanation 1 Engine...

Page 130: ...ome on A One touch idle operation is possible when in one touch idling mode regardless of whether the pilot pressure switches of IN2 IN3 IN4 are ON or OFF B When pressing the change switch lamp goes o...

Page 131: ...s decreased by 200 rpm from FULL rotation in L and F modes Relation of throttle volume and pulse are shown in diagram below Even though the position of throttle volume is the same engine RPM varies wi...

Page 132: ...ration condition A The following brief explanation assumes that this criteria has been met If the throttle control lever setting gives an engine speed lower condition C than condition A the breaker ci...

Page 133: ...attachment is not operating 3 Lower Pilot pressure switch is OFF travel is not operating 4 One touch idle is turned OFF 5 12 seconds after engine start 6 Throttle dial not moved Note The automatic wa...

Page 134: ...after 2 seconds 2 After the key switch is ON the clockwise limit switch is turned on and afterwards even though the key switch is not turned OFF or the emergency stop switch is not pressed the clockwi...

Page 135: ...mode to control pump flow rate In the H mode engine RPM is raised and current value is variable between Imax and Imin This utilises maximum output of the engine The S L and F modes have fixed current...

Page 136: ...quals 70 of engine target torque T IL is the constant current value Same as F mode If engine RPM is less than 1200 rpm the current is the same as L MODE irrespective of mode selection When L or F MODE...

Page 137: ...5 3 Section C Electrics 9803 6400 Section C 5 3 Issue 2 Pump Control FLOW CHART...

Page 138: ...t Boom Lowering Speed Regulation Regulating the speed of the boom lowering procedure is activated only in L F mode When changing to L F mode a transistor in the controller turns ON and switches a sole...

Page 139: ...al port of the pump This pilot pressure adjusts the pump swashplate angle to temporarily reduce the output flow and thereby initially slow down cushion start the boom lowering facility If travel and b...

Page 140: ...5 6 Section C Electrics 9803 6400 Section C 5 6 Issue 1 Pump Control Cushioned Boom Starting continued Flow Chart...

Page 141: ...ouch digging force UP is displayed on the monitor at the same time If the one touch digging force UP switch is pressed for a long period the pressure setting increases only for 8 seconds B Always in t...

Page 142: ...t voltage is output to the solenoid valve regardless of one touch digging force UP and results in pressure raising condition Result 1 A pressure increase is obtained when the travel lever is moved not...

Page 143: ...5 9 Section C Electrics 9803 6400 Section C 5 9 Issue 1 Pump Control Pressure Increasing System continued Flow Chart...

Page 144: ...gh speed position 3 Travelling at low speed pressing IN5 switch once when travelling at high speed shifts to low speed When a travel pressure switch is switched the max flow cut solenoid valve turns O...

Page 145: ...or swash plate Low side Pump Standard Upper only operation Pump Q cut Travel upper combined Travel motor swash plate Low side Pump Q cut 2 At high speed travel Travel only operation Travel motor swash...

Page 146: ...ash Plate Pump flow Q Cut Work mode is independent However since MAX rotation changes by the working mode the travel speed changes by travel mode and working mode Section C Electrics 9803 6400 Section...

Page 147: ...5 13 Section C Electrics 9803 6400 Section C 5 13 Issue 1 Pump Control 3 Speed Travel and Max Flow Cut continued Flow Chart...

Page 148: ...n Soft Hard Switch Output to the soft hard solenoid valve is OFF when key switch is ON This is its SOFT status After the engine is started the signal received from the panel switch is altered The sign...

Page 149: ...gram Time Chart When the signal IN1 from the key switch is turned OFF 24V from OUT 3 is output from the controller for 3 seconds After 3 seconds the output of OUT 3 stops and power to the coil from th...

Page 150: ...5 16 Section C Electrics 9803 6400 Section C 5 16 Issue 1 Pump Control Power Supply Cut Delay Flow Chart...

Page 151: ...ing and swing lever is in neutral 50 brake 24V is output to the swing brake solenoid valve SOL 2 the pilot pressure which ran through the pressure reducing valve enters the swing motor and operates wi...

Page 152: ...ke solenoid valve SOL 2 is turned OFF Pilot pressure enters directly and the brake is fully released b In returning the swing lever to neutral the signal of the pressure switch goes OFF The computer t...

Page 153: ...tion of the control valve and the pilot pressure is then shut off instantly spool of control V does not move b After 5 seconds 24V is output to the swing lock solenoid valve SOL 1 and the solenoid val...

Page 154: ...5 20 Section C Electrics 9803 6400 Section C 5 20 Issue 1 Pump Control Swing brake Swing lock continued Flow Chart...

Page 155: ...5 21 Section C Electrics 9803 6400 Section C 5 21 Issue 1 Pump Control Lever Lock Circuit Diagram Time Chart...

Page 156: ...ion C Electrics 9803 6400 Section C 5 23 Issue 1 Pump Control Travel Warning Circuit Diagram A travel pilot pressure switch is turned ON by travel lever operation and 24V is output for 10 seconds to t...

Page 157: ...5 22 Section C Electrics 9803 6400 Section C 5 22 Issue 1 Pump Control Lever Lock continued Flow Chart...

Page 158: ...he abnormality is indicated Check wiring and components of the relevant circuit Position 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 20 19 18 17 Spare Spare Spare Swing shut off solenoid V Lever lock solen...

Page 159: ...ostat sensor are AND processed and number 8 turns off 3 Number 8 is lit on the condition that numbers 1 7 are lit 4 When numbers 1 7 are off and the signal for number 8 is transmitted they light up in...

Page 160: ...thermostat sensor are AND processed and number 8 turns off 3 Number 8 is lit on the condition that numbers 1 7 are lit 4 When numbers 1 7 are off and the signal for number 8 is transmitted they light...

Page 161: ...e 1 Pump Control Display Monitor continued Fuel Remaining Circuit Diagram FUEL REMAINING RESISTANCE litres OHM MONITOR 284 13 10 8 243 284 21 13 7 200 243 27 21 6 158 200 34 27 5 115 158 44 34 4 72 11...

Page 162: ...emergency stop switch ON is displayed Refuel Fuel amount indicated if low Check and supply fuel Refill coolant Coolant level is low Check and supply cooling water Replenish battery fluid Battery liqui...

Page 163: ...site end of the throttle link at the throttle lever end B Then remove the link without disassembly 5 Checking operation of Throttle Link a Confirm whether the Spring chamber C of the link operates nor...

Page 164: ...the screw rotate the spring chamber out 3 Complete rotations counter clockwise from that position d Adjust the length of the link so that the stroke of the spring chamber is 1 5 5mm 10 Confirmation o...

Page 165: ...CHANGE button once 4 Press PATTERN button once 5 Press SELECT button until RESET is displayed in the message display 6 Press RESET button for 20 sec until buzzer sounds 7 Switch ignition off Controlle...

Page 166: ...gging mode is displayed in the message screen 15 Switch the ignition off Initial Set up of the Controller for Machine Identification continued 9 Repeatedly press S Mode switch until the monitor s desi...

Page 167: ...and remove the starter key 2 Locate the Flywheel housing a The flywheel housing is machined to accommodate the sensor b Remove the sensor by unscrewing it Note Check the O ring for damage or wear repl...

Page 168: ...Name Language 2 Engine R P M 3 Pump Input Amperage 4 No of Throttle Pulses 5 Hydraulic Oil Temperature 6 Water Temperature 7 Fuel Sensor Resistance Value 8 Throttle Volume Voltage Input 9 Transistor...

Page 169: ...hem Checking Methods When the engine key is inserted and turned to the ON position the STANDARD MODE is displayed in the Message display section and S is displayed in the WORK mode section and theTIME...

Page 170: ...minimum position it will output approximately 620 pulses to a maximum of 1023 as displayed in the clock display Pressing SELECT changes the display as shown Pressing SELECT changes the display as sho...

Page 171: ...open circuit 8 4 Section C Electrics 9803 6400 Section C 8 4 Issue 2 Self Test Select Self check Message FUEL SENSOR RESISTANCE VALUE WORK MODE MODE CLOCK CH FS Select Self check Message THROTTLE VOL...

Page 172: ...eturn to the STANDARD MODE for normal operation Note Engine has to be started to perform the above procedure Select boom down display should be Select slew left or right display should be Select any o...

Page 173: ...wn Start the engine Press the CHANGE switch to produce the display shown right Press the PATTERN switch to produce the display shown right Engine RPM is displayed in the CLOCK window Section C Electri...

Page 174: ...itch the ignition on and press the CHANGE button Press the PATTERN button once then press the SELECT button repeatedly until the monitor displays EA A1 The S and H MODE select switches are used to res...

Page 175: ...CH 1 Min engine RPM for scrap magnet use CH 7 Changing Proportional Solenoid mA Value If kerosene fuel is to be used it is necessary to reduce the current at the proportional solenoid on the hydraulic...

Page 176: ...nding on the result of the inspection or measurement inside the box continue on to either the YES or NO branch and onto the next box Inside each box the inspection or measurement method or values are...

Page 177: ...lenish battery fluid Battery fluid sensor not fitted fault should not be displayed 4 Air cleaner clogged Even though filter is cleaned the message does not go out 5 Engine oil pressure Drop Even thoug...

Page 178: ...and wiring Tighten or replace 12 Abnormal sound smell check Repair 13 Oil leakage check Repair 14 Air bleeding Air bleeding 15 Battery voltage engine stopped check 25 26V Replacement 16 Battery fluid...

Page 179: ...2 Bad connection of connector CN2 connector or terminal or controller defect replace controller Breakage of LW wiring between shut Repair LW off relay 1 and wiring controller Defective shut off Replac...

Page 180: ...oes out completely Measure resistance value of sensor at self check Is it within the range of values in chart below Refer to resistance values in chart below YES YES YES YES NO NO NO NO Key switch ON...

Page 181: ...is not flashing Troubleshoot Cause Remedy Replace Reserve tank level reserve switch defect tank Defective YW wiring between Repair YW reserve tank level wiring switch and CNB Defective YW wiring betwe...

Page 182: ...emedy Replace Air filter switch air filter defect switch Breakage or bad connection of BW Repair BW wiring between CNB wiring and air filter switch Breakage or bad connection of BW Repair BW wiring be...

Page 183: ...t Cause Remedy Oil pressure switch Replace defect ment Defective YG wiring between CNB Repair YG and oil pressure wiring switch Defective YG wiring between CNB Repair YG and oil pressure switch Replac...

Page 184: ...e MODE of the mode display is not flashing Troubleshoot Cause Remedy Oil filter switch Replace defect switch Defective LB Repair LB wiring between CNB wiring and oil filter switch Defective LB Repair...

Page 185: ...d connection or clean CN10 CN10 connector terminal Note When there is breakage in the wiring the bar graph goes out completely Is thermo sensor water temperature abnormal at self check comparison of a...

Page 186: ...terminal Note When there is breakage in the wiring the bar graph goes out completely Is thermo sensor oil temperature abnormal at self check comparison of actual and indicated temperature YES YES YES...

Page 187: ...lace controller Replace Alternator defect alternator Repair WR Breakage of WR wiring wiring between CNC between and alternator or CNC and bad connection of alternator alternator spade or clean termina...

Page 188: ...9 13 Section C Electrics 9803 6400 Section C 9 13 Issue 2 Fault Finding Fault Diagnosis continued Electrical Systems Message Fault Problem No 10 Note Message does not go out...

Page 189: ...YES NO Key switch ON When display solenoid valve connector is removed does message go out When CNB connector is removed does message go out NO NO NO NO NO YES For example when swing lock no 11 is dis...

Page 190: ...tor CN15 and measure resistances between female side terminals R and B R AND G R and W R and Y Are they within the range of 3 0 3 6 YES YES YES NO NO NO NO Remove driver connector CN15 Is it continuou...

Page 191: ...roblem No 11 Note Engine does not start even though the message electrical system abnormal is not displayed Prior Confirmation Items No abnormalities in engine or fuel system Fuse is not blown The mes...

Page 192: ...cut lever on stop side YES YES YES NO NO NO NO Remove the stop motor connector and connect female side cab side to service connector 6 pin Measure voltage between LR and ground connecting LR to and gr...

Page 193: ...roller Breakage of GL Repair wiring GL wiring Replace Driver defect driver Change voltage moving throttle volume with self check Is it within the range of 0 4 5V YES YES YES NO NO NO Without removing...

Page 194: ...0 Section C 9 19 Issue 1 Fault Finding Sensor Resistance Valve Water temperature Oil temperature Minimum Maximum 20 C 8 00k 10 20k 30 C 5 35k 6 50k 40 C 3 60k 4 55k 50 C 2 50k 3 10k 60 C 1 70k 2 20k 7...

Page 195: ...as limited by the fact that all checks are instantaneous and no facility existed for storing information on intermittent faults If the ignition was switched off the controller would reset itself and t...

Page 196: ...r The controller will store a back up reading of engine hours in case of failure or unauthorised tampering with the hour meter in the cab Machine actual working hours The controller will store the act...

Page 197: ...numerical codes in the mode screen clock screen and message window refer this to data sheet for channel 3 Press the select button again if a second fault has been stored the monitor will display the...

Page 198: ...Make a note of the numerical codes in the mode screen clock screen and message window refer to the attached performance logging pages 10 8 and 10 9 Press the select button again to read the second co...

Page 199: ...at the channel has been reset 6 Switch off the ignition IMPORTANT REPROGRAMMING THE CONTROLLER WILL NOT RESET THE INFORMATION STORED ON CHANNEL 3 AND CHANNEL 4 Section C Electrics 9803 6400 Section C...

Page 200: ...s resistance value will then relate to a temperature on the temperature graph on the following page FOR EXAMPLE The value given for the max engine water temperature reached is 95 Using the formula Res...

Page 201: ...10 7 Section C Electrics 9803 6400 Section C 10 7 Issue 1 CAPs II Diagnostic system K C...

Page 202: ...ock sol V 11 CN6 15 Max flow cut sol V 12 CN6 6 Soft hard change sol V 13 CN6 14 Spare 14 CN6 5 Spare 15 CN6 13 Negative control sol V 16 CN7 2 Battery relay 17 CN7 6 Heating relay 18 CN7 3 Swing brak...

Page 203: ...itch 13 CN2 11 Select switch 14 CN2 4 Reset switch 15 CN3 3 Hard soft change switch 16 CN3 7 Spare 17 CN3 6 Warning switch 18 CN3 2 Auto idle switch 19 CN3 5 Over heat switch oil 20 CN3 1 Over heat sw...

Page 204: ...hours 19 8 9 Water max temperature reached 20 9 1 Oil temperature 1st bar hours 21 9 2 Oil temperature 2nd bar hours 22 9 3 Oil temperature 3rd bar hours 23 9 4 Oil temperature 4th bar hours 24 9 5 Oi...

Page 205: ...Dismantling and Assembly 23 1 Control Valve JS200 JS240 Specification Technical Data 30 1 Precautions During Use 31 1 Operation 31 2 Trouble Shooting 32 1 Dismantling and Assembly 33 1 Relief Valve JS...

Page 206: ...tioning 76 1 Trouble Shooting 78 1 Maintenance Specifications 79 1 Rotary Coupling Schematic Technical Data 80 1 Operation 81 1 Dismantling and Assembly 82 1 Slew Motor Schematic Technical Data 83 1 O...

Page 207: ...at 20 litre min 4 4 UK gal Bucket JS220LC Long Reach only 240 kgf cm2 235 bar 3407 lb in2 at 20 litre min 4 4 UK gal Boom Raising 370 kgf cm2 363 bar 5263 lb in2 at 20 litre min 4 4 UK gal Boom Loweri...

Page 208: ...sure Relief 360 kgf cm2 353 bar 5119 lb in2 at 40 litre min 8 8 UK gal Dry Weight 270 kg 595 lb Boom Ram Cylinder Inside Diameter 125 mm Rod Diameter 85 mm Max Contracted Length 1790 mm Stroke 1295 mm...

Page 209: ...370 kgf cm2 363 bar 5263 lb in2 at 20 litre min 4 4 UK gal Boom Lowering Pressure 250 kgf cm2 245 bar 3555 lb in2 at 20 litre min 4 4 UK gal Function Travel priority Slew priority Boom and Dipper Loa...

Page 210: ...lve pressure relief 360 kgf cm2 353 bar 5119 lb in2 at 40 litre min 8 8 UK gal Dry Weight 270 kg 595 lb Boom Rams Cylinder Inside Diameter 130 mm Rod Diameter 90 mm Max Contracted Length 1843 mm Strok...

Page 211: ...4 17 1 75 13 6 Allen wrench PT 3 8 34 3 50 25 8 PT 1 2 49 5 00 36 10 PO PLUG PF 1 4 29 3 00 22 6 Material quality S35C PF PLUG PF 1 2 98 10 00 72 10 Material quality S45C PF 3 4 147 15 00 109 14 Allen...

Page 212: ...92 230 Rotary coupling bottom cover 31 37 3 2 3 8 23 27 Rotary coupling mounting bolts 103 10 5 76 Apply Loctite 242 Rotary coupling filter bolts 39 4 29 Rotary coupling motor cover 157 16 116 Rotary...

Page 213: ...5 1 Nut 5790 590 4265 21 M70 x 2 1 Boom Ram JS240 see Note on Contents Page This table refers to the JS240 Boom Ram sectional drawing Nm kgf m lbf ft Part No Remarks Qty Hexagonal socket 520 53 380 12...

Page 214: ...ILTER LINE 14 VALVE CHECK 15 VALVE CHECK 16 RADIATOR 17 RADIATOR 18 BREATHER AIR 19 TANK SUMP 20 FILTER LINE 21 STRAINER 22 VALVE RELIEF 23 FILTER RETURN 24 VALVE STOP 25 FILTER NEPHRON 26 VALVE STOP...

Page 215: ...Section E Section E Hydraulics 9803 6400 Issue 2 3 2 3 2 Schematics...

Page 216: ...IFICE 13 FILTER LINE 14 VALVE CHECK 15 VALVE CHECK 16 RADIATOR 17 RADIATOR 18 BREATHER AIR 19 TANK SUMP 20 FILTER LINE 21 STRAINER 22 VALVE RELIEF 23 FILTER RETURN 24 VALVE STOP 25 FILTER NEPHRON 26 V...

Page 217: ...Section E Section E 9803 6400 Issue 2 3 3 3 3 Hydraulics Schematics...

Page 218: ...3 5 Section E Hydraulics 9803 6400 Section E 3 5 Issue 1 Schematics Shuttle Block JS200 JS240...

Page 219: ...3999J A T P B A VALVE SPL KHJ0790U A HOSE NYLON KNJ1699 HOSE NYLON KTJ1133 SWING MOTOR KNJ1968L A HOSE ASSY COLOUR KNJ2004 Blue KNJ2005 Red KNJ2004 Green KNJ2005 Yellow KNJ1997 White KNJ1997 Clear KNJ...

Page 220: ...r setting the pressure 338 bar 19 bar 4977 lb in2 284 4 lb in2 lock with nut G 3 Low pressure setting Standard a Adjust the pressure as in the high pressure setting above by loosening plug D If the pl...

Page 221: ...ator housing 3 Start the engine and let it idle for a few minutes before switching the engine OFF and then setting the Key Switch to ON with engine OFF 4 Move the slew lever slowly either to the left...

Page 222: ...n the pump 4 Start the engine and confirm that the engine is at its maximum no load speed and it is in the S mode 5 Loosen the lock nut B of the Pilot Relief Valve 6 Adjust the adjusting screw C to th...

Page 223: ...at maximum no load speed and in the S mode e Operate the slew lever 5 Confirm the pressure of 299 8 14 4 bar 4408 213 lb in2 at the gauge Notes 1 If the water proof slew lock solenoid valve is not rem...

Page 224: ...uired by the above calculation between the spring D and spacer c After shim adjustment install the poppet E spring D shim s F piston B and liner C onto the sleeve d Fix the sleeve into a vice and inst...

Page 225: ...evel ground lower and open the dipper and set the bucket on the ground b Run the engine at maximum no load speed and in the S mode 2 Loosen the lock nut A and tighten the pressure raising adjusting sc...

Page 226: ...re of 377 bar 14 4 bar 5546 213 lb in2 If it is outside the limits adjust the port relief valve A by loosening the lock nut B and always coming up to the correct set pressure by first unscrewing and t...

Page 227: ...peed in the S mode b Position the arm operating lever in the opening position and maintain c Check the gauge for the set pressure of 377 bar 14 4 bar 5546 213 lb in2 If it is outside the limits adjust...

Page 228: ...o load speed in the S m o d e b Position the bucket lever in the opening position and maintain c Check the gauge for the set pressure of 377 bar 14 4 bar 5546 213 lb in2 If it is outside the limits ad...

Page 229: ...2 Refer to the section Temporary Setting of main relief pressure and complete step 2 3 Insert lock pin A into the drive sprocket on the appropriate side being measured 4 Pressure Adjustment a Start th...

Page 230: ...essure See previous section Temporary setting of main relief pressure item 3 6 Stop the engine and release the hydraulic pressure See Releasing Tank Pressure remove the pressure gauge and adaptor Sect...

Page 231: ...ge and adaptor to port a3 2 Pressure a Start the engine and lower the gate lock lever run the engine at maximum no load speed with the operator lever in neutral b Refer to the chart below for the pres...

Page 232: ...10 1 Section E Hydraulics 9803 6400 Section E 10 1 Issue 1 Hydraulic Pump JS200 JS240...

Page 233: ...10 2 Section E Hydraulics 9803 6400 Section E 10 2 Issue 1 Hydraulic Pump JS200 JS240...

Page 234: ...10 3 Section E Hydraulics 9803 6400 Section E 10 3 Issue 1 Hydraulic Pump JS200 JS240...

Page 235: ...rent JS200 305mA JS240 330mA Engine revolutions JS200 1 920r p m JS240 2 050r p m Section E Hydraulics 9803 6400 Section E 10 4 Issue 1 Hydraulic Pump JS200 JS240 JS240 Measured Pressure Flow l min ba...

Page 236: ...sirable to leave the pump motor unused for a long Both models period of time more than one year At intervals start the engine even if for short periods of time When left unused by itself rotating the...

Page 237: ...bration or sound it is possible that there is damage or cavitation inside the pump 3 Measure Pressure of Each Part When it is a control problem do not unnecessarily open ports for inspection purposes...

Page 238: ...on 1 1 Boost pressure is low Check to see if hydraulic oil is 1 2 Pump is broken white and cloudy 1 3 Air is sucked by suction pipe 1 4 Suction resistance is high 2 Damage of shoe caulking part 2 Repl...

Page 239: ...sliding surface The oil pressure controlled by the regulator is guided to the hydraulic cavities on both sides of the servo piston which moves the servo piston to the left and right causing the swash...

Page 240: ...sassembly procedures 3 Loosen the hexagonal socket head bolt 401 which connects the swash plate support 251 pump casing 217 and valve block 312 If the gear pump etc are attached to the back of the pum...

Page 241: ...6 Remove the hexagonal socket head bolt 406 and remove the seal cover 261 This is an oil seal on the seal cover 261 be careful not to damage it when removing the cover 261 7 Remove the hexagonal socke...

Page 242: ...piston 532 tilting pin 531 from the pump casing 271 and also the needle bearing 124 and spline coupling 114 from the valve block 312 Use a jig to remove tilting pin 531 take care not to damage the fi...

Page 243: ...on the screw threads when assembling 2 Place the pump casing with the regulator installation surface facing down Fit the swash plate tilting bush to the tilting pin 531 and then mate the swash plate...

Page 244: ...use a steel bar to fit it securely 4 Install the seal cover F 261 to the pump casing 271 and fix with hexagonal socket head bolt 406 Coat the oil seal inside the seal cover F with a thin coat of grea...

Page 245: ...the rear of the pump is assembled first b Take care not to mistake the direction of the valve block When looking from the front side the regulator is on the top and the delivery flange is on the left...

Page 246: ...16 Clearance between 0 028 0 039 0 043 0 0375 Replace piston or piston and cylinder cylinder bore D d 0 0 0 0 078 Backlash of piston 0 0 1 0 0 1 0 0 1 0 0 1 Replace piston and shoe caulking shoe assem...

Page 247: ...rds Section E Hydraulics 9803 6400 Section E 14 8 Issue 2 Hydraulic Pump JS200 JS240 Valve Plate sliding part Surface roughness 3 Z requiring modification Swash Plate shoe plate part Cylinder sliding...

Page 248: ...min Flow rate Q 5 1 L min Flow Rate 1 05 imp gal 1 12 imp gal Adjust screw 923 at 1 4 revolution Adjust screw 928 at 1 4 revolution Flow rate Q 18 L min 3 9 imp gal Flow rate Q 20 L min 4 3 imp gal O...

Page 249: ...Specifications continued Key 531 Tilting pin 532 Servo piston 548 Feedback pin 611 Feedback lever 621 Compensator piston 623 Compensator rod 625 Outer spring 626 Inner spring 643 Pilot piston 646 Pil...

Page 250: ...Blind cover 1 655 Set spring 1 854 Return spring 1 853 Spring base 1 852 Spool 1 851 Sleeve 1 848 Piston QMC 1 647 Stopper 1 646 Pilot spring 1 645 Adjust ring Q 1 644 Spring base Q 1 643 Pilot piston...

Page 251: ...tional solenoid current 70 75 Hz 400 600 mApp 2 Hydraulic symbol Checking the Proportional Solenoid Current Service Procedure Method 1 Refer to Self Test Self Test Function Pump Input Amperage Method...

Page 252: ...ABLE RANGE OF CURRENT PRESSURE PROFILE Primary press 40 kgf cm2 38 6 bar 568 8 lb in2 Flow in port A 0 l min Fluctuation of proportional solenoid current 70 75 Hz 400 600 mApp JS03740 0 100 200 300 40...

Page 253: ...w rate can be reduced by 35 Either of the two steps only can be selected not intermediate sections The regulator possesses the above four control mechanisms but when each control works in combination...

Page 254: ...t command current value I is normal or not Check fluctuation of solenoid current 2 Power shift pressure is low Renew the proportional pressure reducing valve 3 Disassemble and clean the compensatory p...

Page 255: ...tings If the adjusting screws must be moved measure and record the dimensions and positions 1 Remove the hexagonal socket head bolts 412 413 and remove the pump main body from the regulator 2 Remove t...

Page 256: ...l out adjusting ring Q 645 4 Remove the hexagonal socket head bolt 436 438 and remove the pilot cover 641 After removing the pilot cover remove the set spring 655 from the pilot part 5 Remove the stop...

Page 257: ...remove the fulcrum plug 614 and adjusting plug 615 Note For easy removal use M6 bolt to pull out the fulcrum plug 614 and adjusting plug 615 7 Remove the lever 2 613 Do not pull out the pin 875 Secti...

Page 258: ...Remove lever 1 612 Do not remove pin 875 10 Take out the pilot piston 643 and the spool 652 11 Take out the piston case 622 compensatory piston 621 and compensatory rod 623 and the regulator disassemb...

Page 259: ...that the spool and sleeve slide smoothly inside the casing 2 Be careful of the spool direction 4 Assemble the feedback lever 611 and insert the pin 874 aligning with the feedback pin hole Note 1 To f...

Page 260: ...the lever 2 pin hole Install the locking ring 858 8 Insert the adjusting plug 615 and assemble the locking ring Note 1 Ensure that the fulcrum plug and adjusting plug are inserted into the correct ho...

Page 261: ...djusting ring Q 645 into the pilot hole and assemble the spring base 624 inner spring 626 and outer spring 625 into the compensatory hole Note Make sure the spring base is fitted in the correct direct...

Page 262: ...Pressure 370 kgf cm2 363 bar 5263 lb in2 except JS220LC Long Reach at 20 l min 4 3 imp gal BL4 Dipper In Port Overload Relief Set Pressure 220 kgf cm2 216 bar 3132 lb in2 JS220LC Long Reach only at 20...

Page 263: ...30 2 Section E Hydraulics 9803 6400 Section E 30 2 Issue 1 Control Valve JS200 JS240...

Page 264: ...30 3 Section E Hydraulics 9803 6400 Section E 30 3 Issue 1 Control Valve JS200 JS240...

Page 265: ...30 4 Section E Hydraulics 9803 6400 Section E 30 4 Issue 1 Control Valve JS200 JS240...

Page 266: ...30 5 Section E Hydraulics 9803 6400 Section E 30 5 Issue 1 Control Valve JS200 JS240...

Page 267: ...30 6 Section E Hydraulics 9803 6400 Section E 30 6 Issue 1 Control Valve JS200 JS240...

Page 268: ...30 7 Section E Hydraulics 9803 6400 Section E 30 7 Issue 1 Control Valve JS200 JS240...

Page 269: ...al Do not raise the pressure of the main relief valve or port relief valve set pressure The difference between the main relief valve and port relief valve set pressure should be more than 2 0 MPa 20 k...

Page 270: ...f valve works to prevent the pressure of PSR port from becoming abnormally high The oil delivered by PL port passes through the neutral passage A of the 5 spool control valve via passage Y into the 4...

Page 271: ...ge of the signal passage b is cut off so the Pt port pressure rises Boom Spool Selection 2 Up II speed confluence Refer to Fig 1 3 5 8 When pilot port PaR2 is pressurised and the boom I spool is selec...

Page 272: ...e S load check valve T and from passage U flows through spool neck and passage X and flows from the cylinder port BL4 Also part of the oil delivered from PL flows through the restriction from the 5 sp...

Page 273: ...the load check valve s and flows through the spool neck from passage P and flows from passage R Q to cylinder port BL3 AL3 The return oil from cylinder port AL3 BL3 flows through the spool neck and is...

Page 274: ...aight travel can be maintained while simultaneous actions with other services are carried out Also the oil delivered to the PL port is delivered to the 5 spool side from the 5 spool side parallel pass...

Page 275: ...g the poppet Fig 10 During dipper dumping the spool moves to the left as shown Fig 9 and when oil flows to passage V Fig 15 2 it resists the force of the spring D of the load holding valve poppet U pu...

Page 276: ...31 8 Section E Hydraulics 9803 6400 Section E 31 8 Issue 1 Control Valve JS200 JS240 Operation continued...

Page 277: ...31 9 Section E Hydraulics 9803 6400 Section E 31 9 Issue 1 Control Valve JS200 JS240 Operation continued...

Page 278: ...31 10 Section E Hydraulics 9803 6400 Section E 31 10 Issue 1 Control Valve JS200 JS240 Operation continued Travel Fig 4...

Page 279: ...31 11 Section E Hydraulics 9803 6400 Section E 31 11 Issue 1 Control Valve JS200 JS240 Operation continued...

Page 280: ...31 12 Section E Hydraulics 9803 6400 Section E 31 12 Issue 1 Control Valve JS200 JS240 Operation continued...

Page 281: ...31 13 Section E Hydraulics 9803 6400 Section E 31 13 Issue 1 Control Valve JS200 JS240 Operation continued...

Page 282: ...31 14 Section E Hydraulics 9803 6400 Section E 31 14 Issue 1 Control Valve JS200 JS240 Operation continued...

Page 283: ...31 15 Section E Hydraulics 9803 6400 Section E 31 15 Issue 1 Control Valve JS200 JS240 Operation continued...

Page 284: ...lics 9803 6400 Section E 31 16 Issue 2 Control Valve JS200 JS240 Operation continued P C F A B D Dr E JS03700 P Poppet E Throttle A Filter F Spring B Poppet C Spring Cavity D Piston Load Holding Valve...

Page 285: ...9803 6400 Section E 31 17 Issue 2 Control Valve JS200 JS240 Operation continued V JS03710 B A D W C U U Poppet D Spring A Spring Cavity E Passage B Ram port passage F Passage C Throttle Load Holding V...

Page 286: ...31 18 Section E Hydraulics 9803 6400 Section E 31 18 Issue 1 Control Valve JS200 JS240 Operation continued...

Page 287: ...or cap is not on straight Loosen the cap and after aligning tighten 9 Temperature inside valve is not even Warm up the circuit Spool does not stroke 1 Valve is clogged inside with dirt Remove the dir...

Page 288: ...Reset the pressure and tighten the lock nut to the rated torque Oil leakage 1 Damaged seat or worn O ring Replace damaged or worn parts Check whether each part is sliding smoothly 2 Parts are sticking...

Page 289: ...Pull out spools 2 3 4 5 6 from the valve housing 1 in the sub assembly state 3 Because each spool end has adhesive coating on the thread portion heat the spool outer periphery at the threaded section...

Page 290: ...27 A F and disassemble the O ring 22 spring 23 and poppet 24 30 Loosen plug 26 Hexagonal 27 A F and disassemble the O ring 25 spring 27 and poppet 28 31 Remove the plug assembly 36 Hexagonal 27 A F 3...

Page 291: ...he spool with a torque of 9 8 12Nm 7 23 8 67lb ft 2 Assemble the spring seat 8 and spring 9 68 in the spool end 10 Hexagonal 22 A F apply adhesive to the thread and screw into the spool 3 4 5 6 with a...

Page 292: ...a torque of 83 93 Nm 61 45 68 68 lb ft 22 If the plug 52 Hexagonal socket 5 A F is disassembled wrap seal tape around the plug periphery leave one thread open from the end and wrap to the right 1 5 2...

Page 293: ...ith a torque of 78 88 Nm 57 84 65 07 lb ft 9 Install the port relief valve 31 Hexagonal 31 5 A F to the valve housing with a torque of 78 88 Nm 57 84 65 07 lb ft 10 Install the negative control relief...

Page 294: ...Check that there is no foreign matter clogging the main poppet pilot seat orifice 5 Check that the O ring and backup ring are not worn or deformed If a slight defect is found during the above inspect...

Page 295: ...hat there is no foreign matter clogging the piston 5 hole The end seat contact surface should be even 5 Check that the O ring and backup rings are not worn or deformed If a small defect is found in th...

Page 296: ...ped spool at full stroke 2 Spool is neutral Negative control signal The oil from neutral passage HP flows through signal orifice a to the low pressure passage LP Pressure develops from signal orifice...

Page 297: ...poppet seat surface has no defects and that the contact surface is even 2 Check that the poppet slides smoothly 3 Check that the springs are not broken deformed or worn 4 Check that the O rings are n...

Page 298: ...ort plate 1 212 1 Push rod 2 221 3 Spring 1 121 Seal washer 2 212 2 Push rod 2 241 1 Spring 1 122 O ring 1 213 Seal 4 241 2 Spring 1 125 Hexagonal socket bolt 2 214 O ring 4 301 Joint 1 126 Spring pin...

Page 299: ...Max 100 kgf cm2 96 7 bar 1422 lb in2 Secondary pressure 0 45 maximum control pressure kgf cm2 0 43 bar 639 2 lb in2 differs for each machine type Allowable back pressure Max 3 kgf cm2 2 89 bar 42 6 lb...

Page 300: ...method where the pilot valve output pressure is used on both ends of the control valve In order to provide this function the pilot valve consists of the following 1 Inlet port P which is supplied with...

Page 301: ...se rusting of parts due to moisture or dirt If the dismantling procedure must be interrupted be sure to provide anti rust treatment and keep the parts free from dirt and corrosion 5 During assembly en...

Page 302: ...e 6 Put spanners on the adjusting nut 312 and the flats of the disk 302 and remove them 7 Turn the joint to the left using a jig and loosen it The jig is shown in position in the photograph If the ret...

Page 303: ...as the plugs may fly out due to the force in the return springs 221 10 Remove the pressure reduction assembly return springs 221 from the casing Note Make a note of the relationship of positions of th...

Page 304: ...ll the spring seat 216 down and remove the two semicircular washers 1 215 with a small screwdriver Note Take care not to scratch the surface of the spool Do not pull down the spring seat by more than...

Page 305: ...st prevention Apply rust inhibiting agent to all parts Leave the parts to soak until oil and dirt become free The parts may be scratched if they are washed when dirty Washing the parts in dirty kerose...

Page 306: ...01 2 Attach the port plate with hexagonal socket head bolts 125 and seal washer 121 to the casing 101 Note Align the plate so that the spring pins 126 enter the holes in the casing Section E Hydraulic...

Page 307: ...level work bench push the spring seat up and insert the two semicircular washers 1 215 into the top of the spring seat such that they do not overlap Note Install the washer 1 215 so that its sharp ed...

Page 308: ...213 into the plug 211 Note Mount the seals so that the lips are as shown in the illustration 9 Mount the push rods 212 into the plug 211 Note Apply hydraulic oil to the surfaces of the push rods Sect...

Page 309: ...he casing 11 Mount the plate 151 12 Tighten the joint 301 into the casing to the specified torque with the jig Tightening torque 47 2 9 Nm 34 2 1 lb ft 13 Mount the disk 302 to the joint Note Screw in...

Page 310: ...justing nut 312 and tighten it to the specified torque using a spanner on the flats of the disk Adjusting nut tightening torque 68 6 4 9 Nm 50 3 6 lb ft Section E Hydraulics 9803 6400 Section E 41 10...

Page 311: ...ote control valve casing is too large assembly d The handle unit is loose Disassemble reassemble or replace the handle unit 2 Unstable secondary pressure a Sliding parts are sticking Repair the sticki...

Page 312: ...n or Primary pressure 30 kgf cm2 2000cc min during operation 29 bar 426 6 lb in2 Oil viscosity 23 cst Spool Replace when the sliding contact faces are The conditions are worn more than 10 micron or mo...

Page 313: ...10mm S1 S7 10B Spool outer diameter 10mm 18 Rod total length 8 6mm 24A Body inner diameter 12mm S8 24B Spool outer diameter 12mm 26 Rod total length 9 0mm No Qty Parts Name 1 1 Housing 2 1 Housing 3 1...

Page 314: ...50 2 Section E Hydraulics 9803 6400 Section E 50 2 Issue 1 Solenoid Valve 8 spool JS200 JS240 Schmatics Technical Data...

Page 315: ...70 cc min at 3 8 bar 3 99 kgf cm2 56 73 lb in2 31 cSt 3 1 x 10 5 M2 s B T 490 cc min at 3 8 bar 3 99 kgf cm2 56 73 lb in2 31 cSt 3 1 x 10 5 M2 s Hydraulic Oil Hydraulic Oil Temperature 20 95 C Ambient...

Page 316: ...antling to ensure correct assembly 4 Storing of the solenoid valve in a dismantled or partly dismantled state could cause rusting of parts due to moisture or dirt If the dismantling procedure must be...

Page 317: ...ssembly 21 from the cap 22 3 Remove the spacer 20 from the coil assembly 4 Remove the inner housing 19 Remove slowly so that the parts inside the housing do not fly out Section E Hydraulics 9803 6400...

Page 318: ...nd spring seat 14 If the spring seat is stuck to the inside of the inner housing use tweezers to remove it 6 Pull out the pipe 13 from the inner housing using a nylon brush 7 Slowly remove the spool 2...

Page 319: ...e body 24A with the special tool A 9 Remove the spring 6 using tweezers 10 Line up the disassembled parts on a clean place in such a way to facilitate reassembly Section E Hydraulics 9803 6400 Section...

Page 320: ...ling continued 11 Use a socket or torque wrench to remove the plug 31 12 Use a socket or torque wrench to remove the socket head bolt 5 Section E Hydraulics 9803 6400 Section E 51 5 Issue 1 Solenoid V...

Page 321: ...bolt for housing 1 and 2 and tighten to 24 5 4 9 Nm 18 08 0 5 kgf m 0 Nm 0 kgf m 3 Install the O ring 7 on the plug 31 and assemble to the housing tighten to 19 6 4 9 Nm 14 47 0 5 kgf m 0 Nm 0 kgf m S...

Page 322: ...pply grease to the O ring 5 Drop in the spring 6 from the middle of the body 24A At this time make sure it stays in line with the inner hole of the housing 6 Gently insert the spool 24B into the body...

Page 323: ...l should slide smoothly and if there is any resistance do not use it 8 Fit the O ring to the inner housing 19 and install pipe 13 spring seat 14 spring 15 plunger 16 stopper 17 and rod 26 into the hou...

Page 324: ...ng 19 Take care that parts which are assembled to the inner housing do not drop off Apply grease to the O ring 10 Install the spacer 20 to the coil assembly 21 11 Install the housing 22 to the coil as...

Page 325: ...S1 S3 S7 The assembly procedure for the solenoids at housing positions C1 and C3 to C7 is identical to that described in steps 11 to 12 but note that O ring 7 body 10A spool 10B 10 mm diameter and ro...

Page 326: ...51 11 Section E Hydraulics 9803 6400 Section E 51 11 Issue 2 Solenoid Valve 8 spool 22 21 19 12 20 13 14 15 16 17 18 10B 10A 10 9 8 7 6 22 21 19 12 20 13 14 15 16 17 26 24B 24A 24 9 8 23 6 JS02620...

Page 327: ...51 12 Section E Hydraulics 9803 6400 Section E 51 12 Issue 1 Solenoid Valve 8 spool...

Page 328: ...55 1 Schematic Section E Hydraulics 9803 6400 Section E 55 1 Issue 1 Shuttle Valve...

Page 329: ...m A2 port Key for illustrations opposite and on previous page A1 Right slew A2 Left slew A3 Boom up A4 Boom down A5 Bucket open A6 Bucket close A7 Dipper open A8 Dipper close B1 Right slew B2 Left sle...

Page 330: ...55 3 Schematic Section E Hydraulics 9803 6400 Section E 55 3 Issue 1 Cushion Valves...

Page 331: ...Section E 55 4 Issue 1 Cushion Valves Key 1 Dipper Control Valve 2 Boom Control Valve 3 Hydraulic Oil Tank 4 Filter 5 Cushion Valve 6 Solenoid Valve 7 Cushion Switch 8 Dipper Remote Control 9 Boom Rem...

Page 332: ...to the right b The pilot pressure inside the cushion spool enters the g cavity through the spool hole It then passes the reverse notch spool outer periphery and enters the control valve from C port c...

Page 333: ...tling effect the spool of the main control valve slowly returns to neutral Normal State When the cushion switch is switched to the normal position the solenoid valve is selected and the pilot pressure...

Page 334: ...E 60 1 Issue 3 Stacked Slew Brake Valve Solenoid Part Valve Part 1 Voltage DC24V 1 Working Pressure 3 9 MPa 40 kgf cm2 2 Consumed Power 12W 2 Working Flow 16 l min 3 Other Surge Suppressor 3 Decompres...

Page 335: ...he reducing spool and enters gallery b Gallery b is connected to the C passageway of the B section The pressurised oil which entered C passageway pushes up the steel ball and passes through the outer...

Page 336: ...C is stopped by the spool Also the pressurised oil from port B of the slew motor flows through the spool passage and to the tank port Because the pressurised oil for brake release runs off to the tan...

Page 337: ...ted to the tank passageway The pressurised oil which enters through P port flows to gallery a b and tries to push up the reducing spool The pressurised oil is throttled from gallery b and flows to e a...

Page 338: ...1295mm Stroke 1278mm Dry Weight 176kg Dry Weight 214kg Dipper Cylinder Inside Diameter 135mm Cylinder Inside Diameter 150mm Ram Rod Diameter 100mm Rod Diameter 105mm Max Contraction 2150mm Max Contra...

Page 339: ...ge amount of air in a new ram or one which has been left for a long time so the ram will not operate smoothly Also if pressure is applied suddenly without bleeding the air high temperature will be gen...

Page 340: ...ed 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 and is suitable for the job Make sure tha...

Page 341: ...bar and hammer 6 Restrain the eye end of the bucket ram rod to the ram cylinder to prevent the ram rod from extending 7 Remove the bucket ram hoses and install plugs or caps to prevent contamination 7...

Page 342: ...a sling to the bucket ram and lift it into the dipper 2 Install the pin bolt and nuts When checking or refitting JS machine pivot pins the retaining nuts and bolts should not be fastened up tight but...

Page 343: ...ing or refitting JS machine pivot pins the retaining nuts and bolts should not be fastened up tight but must have approximately 3mm of play so that the pin is free from tension Note Stroke the ram to...

Page 344: ...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 and is suitable for the job Make su...

Page 345: ...g a bar and hammer 6 Restrain the eye end of the Dipper ram rod to the ram cylinder to prevent the rod from extending 7 Remove the Dipper ram hoses and install plugs or caps to prevent contamination 7...

Page 346: ...ch a sling and lift the Dipper ram 10 Remove the nuts and bolts push out the pin using a bar and hammer Lift the ram from the boom Installation 1 Attach a sling and lift the Dipper ram onto the boom 7...

Page 347: ...not be fastened up tight but must have approximately 3mm of play so that the pin is free from tension 3 Install the grease tube to the Dipper ram 4 Connect the hoses to the Dipper ram 5 Hoist the Dipp...

Page 348: ...e retaining nuts and bolts should not be fastened up tight but must have approximately 3mm of play so that the pin is free from tension Note Stroke the ram to release entrapped air After releasing the...

Page 349: ...pment 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 and is suitable for...

Page 350: ...and hammer 5 Lower the Boom ram and place it on a stand 6 Restrain the eye end of the Boom ram rod to the ram cylinder to prevent movement of the rod 7 Release the Tank Pressure See Releasing the Tan...

Page 351: ...nation 9 Remove the nut and bolt and push out the pin with a hammer and bar 10 Lift the boom ram away from the unit Installation 1 Attach a sling to lift the boom ram Align the main frame to the insta...

Page 352: ...olts should not be fastened up tight but must have approximately 3mm of play so that the pin is free from tension 3 Install the hoses to the boom ram 4 Lift the boom ram and align the rod eye end with...

Page 353: ...ing nuts and bolts should not be fastened up tight but must have approximately 3mm of play so that the pin is free from tension 7 Connect the greasing tube Note Stroke the ram and release entrapped ai...

Page 354: ...y are to be left for a period of time 1 Drain the oil 2 Disconnect the external piping 3 Secure the ram Note Fix the ram in a vertical or horizontal position The vertical position is more favourable f...

Page 355: ...rk under raised equipment unless safely supported 13 1 1 6 When pulling out the piston rod from a horizontally positioned ram be careful to prevent the rod from falling just after it leaves the cylind...

Page 356: ...groove to allow insertion of a pry bar under the ring and pry the ring out with a pry bar Note Discard the removed seals 9 Remove the U ring back up ring and wiper ring Remove the U ring and back up...

Page 357: ...ving the nut A disassemble as indicated below a Tap the snap ring B on the piston rod end C with a plastic hammer and remove b Push the cushion bearing D back so that the stopper E can be removed c Pu...

Page 358: ...parts before installation 1 Cylinder head assembly a Assemble the Du bushing A using a jig B and press C b Assemble the wiper ring D using a jig E and press C c Assemble the back up ring F and U ring...

Page 359: ...Q with the corrective jig U so that it does not remain extended 4 Piston Rod Assembly a Secure the piston rod b Fit the cylinder head onto the piston rod using assembly jig V Note Do not get the wiper...

Page 360: ...ble the cushion bearing as follows a Expand the slit of the cushion seal HH and place the seal on the end of the piston rod JJ b Insert the cushion ring KK on the P surface and install the stopper LL...

Page 361: ...rings B during insertion e Phase the gaps of slide rings B at 180 7 Position the cylinder head as shown Install the mounting bolts temporarily tighten them in the order shown and re tighten the bolts...

Page 362: ...the maximum extension and stroke Inspection There is no looseness permanent deformation or outer leakage after applying the test pressure shown in the diagram for three times to each stroke end Outer...

Page 363: ...75 10 Section E Hydraulics 9803 6400 Section E 75 10 Issue 1 Hydraulic Rams Ram Piston Head Nut JS00980...

Page 364: ...1 Install the piston rod assembly in the dismantling assembly rig with the piston rod supported by block J 2 Secure the eye end of the piston rod to the rig at position G using a suitable pivot pin 3...

Page 365: ...Requirements Section E Hydraulics 9803 6400 Section E 75 12 Issue 1 Hydraulic Rams JS200 Ram Location Piston Nut Piston Nut Torque Gauge Pressure AF mm Nm lbf ft bar lb in2 Boom 95 5000 3700 35 500 Di...

Page 366: ...onents Note For the above Part No the tube diameter is 120 mm b Special characteristics Because the bushing is press fitted by the hydraulic press at the central part of the cylinder head it requires...

Page 367: ...ickly and accurately into the specified groove of the cylinder head evenly without deforming or damaging it Cylinder head insertion guide jig a Jig components Note The above Part No indicates those fo...

Page 368: ...meter Unit mm 80 90 95 100 105 110 115 120 125 130 135 140 150 160 Boom O Dipper O Bucket O Boom O Dipper O Bucket O Boom Dipper Bucket Jig No WSB 2162 WDB 2163 WDB 2049 WDB 2120 WDB 2050 WDB 2051 WDB...

Page 369: ...r head Note The mark O in the table below indicates KCH type Note The jig is set for the KCH type only Piston rod diameter Unit mm 50 55 60 65 70 75 80 85 90 95 100 105 110 Boom O Dipper O Bucket O Bo...

Page 370: ...ing by hand and fit it into the piston groove Be sure not to twist the O ring A twisted O ring may cause oil leakage Fit the inner guide jig on the upper section of the piston Carefully fit the thinne...

Page 371: ...l the seal ring fits into the groove Be sure to press the plate carefully so that the seal ring will fit straight on the inner guide jig and into the groove Finish this work quickly After confirming t...

Page 372: ...nt adheres to the jig Slowly insert the piston with the seal ring fitted into the correction jig Insert the piston evenly inside the correction jig Press the piston slowly with a press rod that has sm...

Page 373: ...Reconditioning continued Jig Usage continued After completion of the correction of the seal ring remove the jig in the following order 1 Remove the press rod 2 Remove the correction jig This completes...

Page 374: ...is a very important part so handle and store with utmost care Place the cylinder head on the work bench with the cylinder tube connecting surface facing up The work bench should be clean so that no d...

Page 375: ...face 2 Be careful that the blade does not jump out from the bushing end surface 1 Fit the Allen wrench into the chuck assembly adjuster head and at the same time insert the lever into the chuck assemb...

Page 376: ...ollar is facing up as shown in the figure 2 Keep the press work bench clean so that dust chipped metal and other foreign material do not cause damage to the bottom of the chuck assembly Press the uppe...

Page 377: ...rom the cylinder head the sound of the bottom surface of the chuck assembly jig hitting the work bench will be heard Note Normally it falls out with a load of less than 3 tons The press ram stroke var...

Page 378: ...rench into the chuck assembly adjuster head section At the same time insert a lever into the round hole of the chuck assembly rear section 2 Use the lever and Allen wrench so they are pushed down fron...

Page 379: ...ng continued Bush removal continued With the chuck assembly jig and bushing removed turn the adjuster with your fingers until there is no gap between the adjuster and the wedge upper surface Note Do n...

Page 380: ...e work bench clean so that dust or other foreign matter does not damage the bottom surface of the cylinder head Also make sure that it is level 2 Use compressed air to remove the foreign matter Tempor...

Page 381: ...e wedge stepped section of the chuck assembly jig Place the retainer so that the larger diameter part is facing up as shown Place the cylinder with the retainer jig and chuck assembly jig attached und...

Page 382: ...on in the cylinder head The press load should be less than 5 tons Verify that the bushing end surface is below the snap ring groove After the press fitting of the bushing is completed remove the retai...

Page 383: ...e of the cylinder head Face the lip side of the wiper ring to the groove of the retainer jig and insert Verify that there is no foreign matter in the groove where the wiper ring or the retainer is to...

Page 384: ...n line Pressing on the head section of the retainer jig press fit the wiper ring into the specified position in the cylinder head The press load should be less than 1 ton Press fit until the retainer...

Page 385: ...e to its outer peripheral surface Insert the guide with the larger diameter first until it reaches the stepped part of the piston rod 1 When inserting the guide onto the piston rod be careful not to d...

Page 386: ...assembly with both hands and be careful not to drop it 2 If oil is thinly coated on the peripheral surface of the guide and piston rod the cylinder assembly can be inserted smoothly After verifying t...

Page 387: ...re 1 Use an oil stone and remove the scratch scratches and rust that can be and make the sliding surface smooth felt by the fingernail Less than 1 5 S If oil leakage continues even though the rod surf...

Page 388: ...er ring The protrusion of the heel of the As a rule replace the rod packing at the Piston rod packing is excessive same time It is desirable to replace parts 1 sliding part which are attached to the b...

Page 389: ...mble cylinder head and inspect 2 from cylinder O ring and back up ring head joint Cylinder head Check tube and cylinder head thread for damage If any damage replace After inspection tighten to specifi...

Page 390: ...ove foreign material and cylinder head sliding area As above inspect the seal and sliding part material 4 Scratches wear are present Replace with new part Piston seal Inspect the cylinder tube inner s...

Page 391: ...y expand if it is stopped suddenly This is due to the compression of the hydraulic oil This occurs especially with long stroke rams 4 4 4 Pin bushing Pin Gap between installation part and Measure the...

Page 392: ...verload relief valve normal O Is the hydraulic oil dirty or deteriorated O Hydraulic Oil Is the hydraulic oil replaced periodically O Are the filters inspected periodically O Is the pin greasing suffi...

Page 393: ...n Nominal diameter mm Standard inner diameter mm Maximum inner diameter mm Treatment 55 75 0 06 0 19 0 30 Bushing replacement 80 120 0 06 0 195 0 30 Bushing replacement Nominal diameter mm Standard th...

Page 394: ...s 9803 6400 Section E 80 1 Issue 1 Rotary Coupling Schematic Technical Data Item Part Name 11 Axle 12 V ring 13 Rotor 14 O ring 15 Packing ring 16 Thrust plate 17 Hexagonal socket head bolt 18 O ring...

Page 395: ...0 2 Issue 1 Rotary Coupling Schematic Technical Data continued Item Part Name 1 High strength bolt 2 High strength washer 3 Loctite 262 4 Lock bar 5 Seal washer 6 Seal cap 7 Rubber packing 8 Seal ring...

Page 396: ...from the others by packing rings and O rings Both the axle and rotor can rotate and the oil can flow freely through the oil grooves The coupling is located in the centre of the machine between the lo...

Page 397: ...release the hydraulic pressure See Releasing Tank Pressure b Jack up the machine and insert wooden blocks under the tracks 2 Remove the access panel 3 Attach identification tags to the rotary couplin...

Page 398: ...with the bolt 17 6 Remove the O ring 18 Do not reuse the O ring 18 7 Remove the thrust plate 16 with the bolt 17 8 Using a jig push off the axle 11 from the rotor 13 Do not hit with a hammer Section E...

Page 399: ...9 Remove the V ring 12 from the axle 11 Note Do not reuse the V ring 12 10 Remove the O ring 14 and packing ring from the rotor 13 Note Do not reuse the packing ring 15 Section E Hydraulics 9803 6400...

Page 400: ...gs backup rings and seals with clean hydraulic fluid before fitting 1 a Clean the rotor 13 with cleaning fluid or compressed air b After cleaning check to see if there are any scratches or roughness o...

Page 401: ...en check once more for any protrusion twisting etc 4 Install the V ring 12 on the axle 11 and grease adequately Take care to prevent contamination of the grease by water or dirt 5 Install the axle 11...

Page 402: ...Tighten the lock bar installation bolt 1 and washer 2 to the specified torque 109 127 Nm 11 1 12 9 Kgf m 80 28 93 28 lb ft and install the lock bar 10 Reconnect the hoses and install the access cover...

Page 403: ...C Anti cavitation check valve D Mechanical brake J Cross line relief valve K A side cavity L B side cavity M Intermediate cavity N A side seat P B side seat R Anti pendulum valve S Anti pendulum valve...

Page 404: ...3 2 Section E Hydraulics 9803 6400 Section E 83 2 Issue 2 Slew Motor JS00970 Note Item numbers are referred to on the following pages Reduction Gear Components Key A A chamber B B chamber C Torque pat...

Page 405: ...E 83 3 Issue 2 Slew Motor JS02680 E A B D D C C F G Hydraulic Circuit Key A Hydraulic motor 151 cm3 rev B Bypass Anti pendulum valve C Anti cavitation check valve D Relief valve 285 kgf cm2 155 l min...

Page 406: ...n The above diagram indicates the relationships between the main components of the slew motor whose working principles are described on the following pages Slew Unit Planetary 2 stage Reduction Gear S...

Page 407: ...connected to housing 25 When the servo pressure at the brake release port X is zero the spring 14 force acts through brake piston 12 to press the friction and mating plates together locking cylinder 2...

Page 408: ...shocks arising due to sudden braking 3 Anti Pendulum Feature While the superstructure is coming to a halt as described in 2 it drives the motor as a pump The initial result is a braking effect on the...

Page 409: ...MOTOR The bearings should be renewed if any slight damage is noticed on the contact Taper roller bearing 3 surfaces of the rollers or needles Needle bearing 22 It is recommended that all bearings be r...

Page 410: ...o dismantle the slew motor assembly the inlet and outlet ports should be blanked and the outer surfaces washed down with a suitable solvent to remove all dirt and dust Dry using compressed air 2 Remov...

Page 411: ...of the parts to ensure correct reassembly Section E Hydraulics 9803 6400 Section E 92 2 Issue 2 Slew Motor 4 Remove the caps 37 with 14 mm A F hexagonal sockets and remove relief valves 34 from the m...

Page 412: ...lew Motor Motor Assembly Cylinder Assembly Dismantling cont d 10 Remove O ring 13 11 Remove balance plate 21 Remove the pins 15 from the balance plate Note The balance plate 21 must be reinstalled cor...

Page 413: ...ote Keep the springs in the order in which they are to be reinserted Motor Assembly Cylinder Assembly Dismantling cont d 14 It may be difficult to remove brake piston 12 from housing 25 due to resista...

Page 414: ...ve swash plate 6 piston assemblies 8 and retainer plate 7 together from cylinder 24 Section E Hydraulics 9803 6400 Section E 92 5 Issue 2 Slew Motor Motor Assembly Cylinder Assembly Dismantling cont d...

Page 415: ...ent marks or write numbers on the piston bores and the piston assemblies so that the piston assemblies can be replaced in the same bores during reassembly 21 Remove the outer ring of taper roller bear...

Page 416: ...g contact faces of piston assemblies 8 balance plate 21 and swash plate 6 with very fine paste on a flat surface Section E Hydraulics 9803 6400 Section E 92 7 Issue 2 Slew Motor CAUTION Cleaning Clean...

Page 417: ...E 92 8 Issue 2 Slew Motor Motor Assembly Cylinder Assembly Assembly cont d 4 Mount the piston assemblies 8 together with retainer plate 7 into cylinder 24 Note Insert the piston assemblies into the s...

Page 418: ...24 7 Apply a thin coat of JCB Retainer where the inner ring is mounted on motor output shaft 24 Motor Assembly Cylinder Assembly Assembly cont d 8 Using a jig see Special Tools Section 1 mount inner...

Page 419: ...so use a guide of 30 50 mm 1 2 1 9 in on the lower part of the housing Verify that spring 5 is inserted correctly into the back face of retainer plate 7 Section E Hydraulics 9803 6400 Section E 92 10...

Page 420: ...springs 14 back into brake piston 12 Note Insert the springs 14 the same order as they were found during dismantling Motor Assembly Cylinder Assembly Assembly cont d 16 Mount the bushings 20 with Tefl...

Page 421: ...17 and attach snap ring 23 Section E Hydraulics 9803 6400 Section E 92 12 Issue 2 Slew Motor Motor Assembly Cylinder Assembly Assembly cont d 20 Apply grease to the O ring and install O ring 13 to cov...

Page 422: ...00 Section E 92 13 Issue 2 Slew Motor Motor Assembly Cylinder Assembly Assembly cont d 24 Assembling the Make up and by pass valves Assemble the check valves 29 and springs 31 in cover 17 and tighten...

Page 423: ...t one full revolution by applying a torque of approx 39 32 Nm 29 lbf ft Note If the shaft does not turn the unit has not been assembled correctly so dismantle again and inspect 27 Degrease the mating...

Page 424: ...type and capacity is given in Fluids and Lubricants Note Bleed air in the chamber from the air bleed port before filling with grease as a build up of internal pressure can damage the oil seal After t...

Page 425: ...n the parts with a suitable solvent and blow them dry Replace all used O rings 1 If not already done remove cap 37 with a 14 mm A F hexagonal socket from the relief assemblies 34 and remove piston 38...

Page 426: ...and back up 35 mounted on to sleeve 39 and tighten to a torque of 157 Nm 116 lbf ft Check the relief set pressure The correlation between the set pressure of the relief valve and the adjusting shims...

Page 427: ...ys wear safety glasses INT 3 1 3 2 Remove the spur gear and 2nd stage holder assembly 76 Section E Hydraulics 9803 6400 Section E 94 1 Issue 2 Slew Motor Reduction Gear Dismantling Refer to the sectio...

Page 428: ...pport planetary gears 72 by hand and withdraw shaft 70 from holder 76 Section E Hydraulics 9803 6400 Section E 94 2 Issue 2 Slew Motor Reduction Gear Dismantling cont d 7 Ring gear removal Remove ring...

Page 429: ...collar 59 from the assembly 10 Remove the roller bearing 62 from gear case 58 Section E Hydraulics 9803 6400 Section E 94 3 Issue 2 Slew Motor Reduction Gear Dismantling cont d 11 Remove and discard...

Page 430: ...out the following procedure only when bearing 57 is damaged or badly worn and dismantling is necessary Support the self aligning roller bearing 57 then press the motor end of shaft 53 to remove bearin...

Page 431: ...ress fit it on the pinion shaft Note Do not heat to a temperature greater than 100 C Section E Hydraulics 9803 6400 Section E 94 5 Issue 2 Slew Motor Reduction Gear Assembly Refer to the sectional dra...

Page 432: ...ervice Tools section for the seal protector a Turn gear case 58 so that the output shaft is upwards and mount the pinion shaft assembly 53 onto the gear case using an M16 eye bolt screwed into the tap...

Page 433: ...on E Hydraulics 9803 6400 Section E 94 7 Issue 2 Slew Motor Reduction Gear Assembly cont d 10 Holder assembly mounting a Insert the planetary gear 72 bushing 71 and thrust plate 73 into holder 76 and...

Page 434: ...ing metal splinters when driving metal pins in or out Use a soft faced hammer or drift to remove and fit metal pins Always wear safety glasses INT 3 1 3 12 Holder assembly 76 and spur gear mounting Se...

Page 435: ...Turn the holder assembly slightly to mesh the teeth of the spur gear with the teeth of holder 65 b Carefully insert sun gear 66 and mesh the teeth of planetary gear 69 Section E Hydraulics 9803 6400 S...

Page 436: ...olume exceeds to the high pressure seal 5 l min 1 1 gal min Dismantle and inspect Oil hot and excessive Measure the oil Reduce the oil Refer to table 2 leakage in the motor temperature temperature Sei...

Page 437: ...w pressure to the brake does not rotate smoothly any defective parts release port Try to rotate when this torque is the shaft with a torque of applied Dismantle and approx 39 32 Nm inspect 29 lbf ft R...

Page 438: ...3 1 Precautions during Installation 4 1 Fault Finding 5 1 Removal and Replacement 6 1 Track Motor Dismantling and Assembly 7 1 Maintenance Specification 8 1 Track Gearbox Dismantling and Assembly 9 1...

Page 439: ...7 23 2 6 5 4 Plug 137 10 14 1 101 2 7 23 2 2 4 2 Plug 9 8 1 0 1 0 0 1 7 23 0 72 2 8 NPTF1 16 10 Plug 29 4 2 9 3 0 3 21 6 2 16 2 19 PT1 4 5 Plug 39 2 4 9 4 0 5 28 9 3 61 2 24 PT3 8 1 Orifice 2 45 0 49...

Page 440: ...n F 1 2 Issue 1 Torque Specifications Gearbox This table refers to the Gearbox sectional drawing Item Component Nm kgfm lb ft Remarks Qty 13 Ring Nut M320 x 2 1 1 Socket head bolt M10 x 25 10 2 Plug M...

Page 441: ...on gear Speed 1 44 384 Motionless more than 20 94 2135 Moving more than 16 67 1700 Release pressure MPa kgf cm2 less than 1 4 14 Pressure MPa kgf cm2 34 3 350 1st speed 198 7 212 2 2nd speed 198 7 212...

Page 442: ...2 2 Schematics specifications Section F Transmission 9803 6400 Section F 2 2 Issue 1 Motor Gearbox...

Page 443: ...ransmits it to the crawler Its characteristics are a The parking brake is self contained and when the motor stops the mechanical brake works b The motor is designed to be small light weight and compac...

Page 444: ...ressure oil pressure P is guided to port C the force presses against the swash plate at the rate of force F P X A A cross sectional area of piston per piston sub assembly The corresponding reaction fo...

Page 445: ...g 2 Counterbalance Valve The counterbalance valve serves to prevent the sudden stoppage of the axial piston motor and control its overrun When in neutral the control valve s pressure is generated at p...

Page 446: ...boosted hydraulic oil at P1 port side goes past the orifice and works on the flange face and resisting the spring on the opposite side with a force proportional to the pressure it tries to move the pl...

Page 447: ...er tries to return to neutral position by the spring When the plunger moves the plunger opening becomes smaller and because the piston motor continues to rotate due to inertia motor pumping function t...

Page 448: ...the brake is exhausted into the motor case to activate the brake Fig 5 1 Shuttle Function Fig 5 2 Shuttle Function Relief Valve The relief valve determines the drive force and brake force which contro...

Page 449: ...set Since the relief operating pressure in this state is low it is kept at low pressure about on third of the normally set pressure The low pressure holding time depends on the poppet orifice diameter...

Page 450: ...e is slanted to the position where the resultant thrust force of the piston sub assembly and the spring force are balanced with the thrust force of the 2 speed control piston The swash plate settles w...

Page 451: ...he state shown and the motor speed changes to first or low When the motor drive pressure drops lower than the set pressure P the pressure inside cavity B of the 2 speed valve also drops F2 F1 the 2 sp...

Page 452: ...3 10 Section F Transmission 9803 6400 Section F 3 10 Issue 1 Motor Gearbox Fig 8 1 1st Speed Fixed Mode...

Page 453: ...3 11 Section F Transmission 9803 6400 Section F 3 11 Issue 1 Motor Gearbox Fig 8 2 Automatic 2 Speed Mode in 2nd Speed State...

Page 454: ...3 12 Section F Transmission 9803 6400 Section F 3 12 Issue 1 Motor Gearbox Fig 8 3 Automatic 2 Speed Mode in 1st Speed State...

Page 455: ...ports and pilot ports completely sealed so that contaminants cannot enter the axial piston Rotation Direction The relationship between the flow direction of the hydraulic oil and the rotation directio...

Page 456: ...Note When using a hand pump or small capacity electric pump for filling with hydraulic oil be careful that the inner case pressure does not exceed 0 3 MPa 3 kgf cm2 Oil Capacity is 400 cm3 b Initial O...

Page 457: ...ck whether the specified pressurised speed is rate due to problems in hydraulic pump oil is delivered to the motor input side insufficient pressure control valve etc and then inspect each device and r...

Page 458: ...used when the boost repair or replace the double variation and pressure is low standard 0 4 0 5 MPa counterbalance valve pressure variation 4 5 kgf cm2 or when the double Disassemble the motor and re...

Page 459: ...move foreign matter repair stop or stops 1 Foreign matter is clogging damaged part and reassemble after slowly components cleaning Replace if damage or leakage is excessive 2 Spring is broken Replace...

Page 460: ...assemble after slowly cleaning Replace if damage or leakage is excessive 2 Spring is broken Replace spring Completely remove foreign matter repair the damaged part and reassemble after cleaning Replac...

Page 461: ...ameter drain is incorrect 7 The orifice of the 2 speed piston cavity Reassemble after cleaning drain is clogged 8 Number of washers is different and set Reassemble using correct number of washers pres...

Page 462: ...locking pin and knocking out the master pin a Remove bolts and lift off the track shoes adjacent to the master pin b Position a suitable hydraulic press so that its ram aligns with the master pin c I...

Page 463: ...Stop the engine and operate the control lever to relieve pressure in the hydraulic system Release pressure in the hydraulic tank See Releasing Tank Pressure in Routine Maintenance 7 Remove the motor c...

Page 464: ...pwards Remove plugs from ports A and B Fill the motor through port A with the specified hydraulic oil Fit plugs to ports A and B 2 Lift the gearbox and position it on the undercarriage Install the bol...

Page 465: ...g housings in the chain link Insert the seal rings and clamp into position j Using a plastic hammer tap the upper link down to align holes Note As the links overlap the seal rings will be held in posi...

Page 466: ...pipework remove plug from upper drain port A but make sure that a plug is fitted to lower drain port B Fill the motor with specified hydraulic oil through port A Connect the pipes Method 2 Fit the mot...

Page 467: ...ring from its groove in the motor 3 Fix the motor into a suitable vice or jig with the shaft facing upwards 4 Base plate disassembly a Relief valve disassembly Loosen the plug 2 7 6 and remove the re...

Page 468: ...5 spring seat 2 4 spring and 2 3 spring seat 5 Pull out the 2 2 plunger assembly While turning the plunger pull it out slowly being careful not to damage the outer circumference 6 2 speed control valv...

Page 469: ...g a screwdriver etc remove the 2 1 base plate Note Do not pry off the base forcibly as the 28 pin may stick 9 Remove the 5 valve plate 28 pin 22 O ring 33 O ring and 29 41 springs Note When pulling ou...

Page 470: ...nt care to do the work safely Be careful not to damage the sliding surface of the disk 11 Cylinder rod disassembly a Place the 1 case horizontally on the working bench and remove the 4 Cylinder block...

Page 471: ...ston 7 retainer plate 8 retainer holder and 19 pin from the 4 cylinder block 13 Remove the 14 snap ring using a jig or press and remove the 15 spring seat 16 spring and 17 spring seat Section F Transm...

Page 472: ...ce then loosen the 2 2 4 plug Note Unless absolutely necessary do not disassemble When fixing with a vice use a copper plate so as not to damage the plunger sliding area 16 Remove the 2 2 3 spring and...

Page 473: ...aulic fluid to all sliding parts bearings and other contact surfaces before assembly Replace all O rings and seals where appropriate cover with petroleum jelly before fitting 1 Cylinder block assembly...

Page 474: ...semble them so that the small diameter of the inner taper of the retainer plate comes into contact with the flange of the piston shoe Coat hydraulic oil on the piston bores of the cylinder block and t...

Page 475: ...7 9 Assembly continued 5 Assemble the 21 oil seal to the 1 case 6 Assemble the 12 ball bearings into the 1 case Section F Transmission 9803 6400 Section F 7 9 Issue 1 Motor...

Page 476: ...ued 7 Assemble the 10 steel balls 40 spring and 11 piston into the 1 case 8 Install the 3 shaft into the 1 case Note Be careful not to damage the oil seal lip Section F Transmission 9803 6400 Section...

Page 477: ...4 cylinder block into the 1 case Next assemble the 26 disk and 27 friction plate in order Apply hydraulic oil to the 9 swash plate before assembling the 4 cylinder block Check to see that the 4 cylind...

Page 478: ...tap the head of the jig with plastic hammer evenly and insert the 25 brake piston 13 Assemble the 22 33 O rings in the 1 case 14 Fix the 2 1 base plate on the work bench and assemble the 13 ball bear...

Page 479: ...e 11 mm hole of the 2 2 1 plunger and fix with a vice Assemble the 2 2 2 check valve and 2 2 3 spring in order b Assemble 2 2 4 plug which has 2 2 5 O ring attached to it into the 2 2 1 plunger and ti...

Page 480: ...2 kgf m 274 85 14 47 lb ft 22 Assemble the 2 9 valve assembly to the 2 1 base plate Note Take care to assemble the valve in the correct order If assembled in reverse the motor may become damaged 23 Af...

Page 481: ...7 15 Section F Transmission 9803 6400 Section F 7 15 Issue 2 Motor...

Page 482: ...7 16 Section F Transmission 9803 6400 Section F 7 16 Issue 1 Motor...

Page 483: ...worn cannot be completely removed replace 3 The engaged tooth is abnormally worn or broken 5 1 Deeply scarred thermally Roughness 0 2a 0 8a No seizure Cylinder block kit Valve Plate seized unevenly w...

Page 484: ...and Cylinder block kit Disk plate material is deeply scar deeper scarred or has peeling than 0 02mm 12 1 Flaking peeling is observed See note 1 When scar Ball bearing on the TENSOMEN cannot be complet...

Page 485: ...Breather Plug 3 Washer 4 Cover 5 O ring 6 Pad 7 Sun Gear 8 1st Reduction Assembly 9 2nd Reduction Assembly 10 Circlip 11 Planetary Set 12 Spacer 13 Nut 14 Gearbox Housing 15 Longlife Gasket 16 Center...

Page 486: ...nce Clean all surfaces with a suitable solvent and dry with compressed air Discard all O rings and seals which are disturbed during dismantling 1 Remove the 22 three socket head screws and remove the...

Page 487: ...gearbox around unscrew and remove the 2 two plugs from the end of the 4 cover 6 Remove the 1 socket head screw 7 Remove the 4 end cover Note Screws M22 x 1 5 can be inserted in the two open oil plug...

Page 488: ...ve the 5 O ring from its groove in the 4 end cover 9 Remove the 7 first stage sun gear 10 Remove the 8 first reduction assembly 11 Remove the 9 second reduction assembly Section F Transmission 9803 64...

Page 489: ...ve the 11 five planet gears off the third reduction assembly 14 Remove the 12 spacers positioned on the back of the planet gears of the third reduction assembly 15 Using a punch remove the deformed se...

Page 490: ...langed hub from the 14 gearbox housing Note To prevent oil leaks it is advisable to replace the lifetime seals both the metal ring and O rings at this time Seal replacement can only be done with the g...

Page 491: ...ver the O rings and seals with petroleum jelly Half Seal Installation The half seals used in re assembly require a specific technique to install Follow the instructions detailed below A Carefully clea...

Page 492: ...de the 14 gearbox housing 3 Assemble by using the same tool the 15 half seal on the 17 flanged hub Carefully clean the metal faces of the half seals 4 Lubricate the metallic face of the half seal with...

Page 493: ...he upper ball bearing sets into position Then fit the inner race 7 Place the 17 flanged hub inside the 14 gearbox housing Using a press and a metal drift push the 17 flanged hub against the shoulder o...

Page 494: ...lace the 12 spacers on the back of the planet gears of the third reduction assembly 12 Place the 11 five planet gears of the third reduction assembly onto the 17 flanged hub Using a press push on the...

Page 495: ...s place the 10 circlip into its groove 14 Insert the 9 second reduction assembly 15 Insert the 8 first reduction assembly 16 Position the 5 O ring into its groove in the 4 end cover Section F Transmis...

Page 496: ...housing 18 Fix the 4 end cover with the 1 socket screws 19 Tighten the two plugs Item 2 20 Rotate the gearbox and by means of circlip pliers place the 20 circlip into its groove inside the 19 coupling...

Page 497: ...on of the gearbox determined by the input side shoulder of the 17 hub with the 20 circlip inside the 19 coupling 24 Position the 21 hydraulic motor into the gearbox and secure the 22 socket screws The...

Page 498: ...inder Removal 5 1 Replacement 5 2 Dismantling 6 1 Assembly 6 2 Drive Sprocket Removal 7 1 Replacement 7 2 Wear Limits 8 1 Top Roller Removal 9 1 Replacement 9 2 Dismantling 10 1 Assembly 10 3 Wear Lim...

Page 499: ...ply 262 Idler wheel installation bolts 267 312 27 2 31 8 196 65 229 91 Apply 262 Top roller installation bolts 521 608 53 1 62 383 91 448 26 Apply 262 Bottom roller installation bolts 371 432 37 8 44...

Page 500: ...master pin is removed the track could fall forward and injure you TRACK 1 1 3 Fasten a sling around the idler wheel and recoil assembly and remove it from the undercarriage 4 Remove the bolts and rem...

Page 501: ...d fit the mounting bolts 2 Fasten a sling around the idler wheel and recoil assembly and enter it into the undercarriage 3 Position the idler wheel in the undercarriage using a bar 4 Connect the track...

Page 502: ...shaft D Pull out the shaft D from the idler wheel G 4 Remove the wire clip E or roll pin F and separate hub C from shaft D Remove O ring I from shaft D 3 Remove O ring I from shaft D Pull out the shaf...

Page 503: ...time Assembly 1 Clean all parts thoroughly in a suitable solvent Dry shaft and bore of idler wheel using compressed air in a place free of dust and moisture Check components for wear as detailed unde...

Page 504: ...C 4 Grease a new O ring I and install on one end only of shaft D Install shaft D into hub C Fit new wire clip E or roll pin F 5 Coat shaft D with grease Clean the metallic face of the seal coat the me...

Page 505: ...vered Insert this plug but leave the other one out until after testing 7 Using extreme care to prevent water entering the assembly lower it into a tank of water Connect compressed air at M and apply p...

Page 506: ...or renew JS240 b JS200 21 0 8 Build up or renew JS240 Wheel Width c JS200 84 3 3 80 3 14 Build up or renew JS240 Shaft Diameter d JS200 65 2 55 64 5 2 53 d JS200 70 2 75 69 5 2 73 Bush Bore d JS200 6...

Page 507: ...tion Gearbox Removal and Replacement Section F Move the idler wheel and recoil assembly to the end of the undercarriage using a bar WARNING Stand clear and to one side of the track while you remove th...

Page 508: ...c jack A and compress the Recoil Spring B 6 Remove the Recoil Spring Pull out the Spring Pin C and remove the castellated nut D Let the jack A down to relieve the pressure on the recoil spring B Remov...

Page 509: ...E together with the grease nipple F from the cylinder A 2 Pull out the Piston Rod G from the grease cylinder A 3 Remove the Dust Seal H from the grease cylinder A 4 Remove the Back up ring I and O ri...

Page 510: ...Coat the piston rod G with grease Insert the piston rod G into the grease cylinder A 4 Install the check valve E with the grease nipple F to the grease cylinder A torque to 58 84 Nm 43 4 lb ft Fasten...

Page 511: ...ury 8 3 4 5 2 Disconnect the track link WARNING Stand clear and to one side of the track while you remove the master pin When the master pin is removed the track could fall forward and injure you TRAC...

Page 512: ...ighten the bolts in a diagonal sequence Torque Settings Machine Nm lbf ft JS200 267 312 196 230 JS240 267 312 196 230 2 Remove the wooden blocks Connect the track link 3 Apply grease through the check...

Page 513: ...ts Item Dimension Machine Standard Size Service Limit Action mm in mm in Width a JS200 66 2 59 60 2 59 Renew JS240 Diameter b JS200 582 5 22 93 576 5 22 69 Renew JS240 Diameter c JS200 659 25 9 65 3 2...

Page 514: ...out If you over loosen too much grease could spurt out or the valve cover fly out and cause serious injury 8 3 4 5 2 Jack up the track high enough to permit roller removal Put wooden blocks between t...

Page 515: ...rack supported as shown under Removal install the roller Apply Loctite 262 to the threads and fit the mounting bolts 3 Remove the wooden blocks and jack 4 Apply grease through the check valve to adjus...

Page 516: ...ear 9803 6400 Section J 10 1 Issue 1 Top Roller continued Item Part Name 1 Roller 2 Shaft 3 Bushing 4 Floating seal 5 Bracket 6 Thrust plate 7 Hexagonal bolt 8 O ring 9 Cover 10 Snap ring 11 Plug 12 B...

Page 517: ...over and drain the oil 2 Remove the retaining ring C and remove cover D From cover D remove O ring E and discard 3 Remove bolt F and the thrust plate G from the end of the shaft 4 Pull the upper rolle...

Page 518: ...le solvent Dry shaft and bore of roller using compressed air in a place free of dust and moisture Check components for wear as detailed under Wear Limits Polish out scratches and roughness using an oi...

Page 519: ...o the roller A coat oil onto the floating seal surface 4 Install the new seal I into the bracket L Coat the metallic face of the seal with engine oil 5 Coat the shaft H with grease Install the roller...

Page 520: ...Using extreme care to prevent water entering the assembly lower it into a tank of water Connect a compressed air pipe V to the port N check for air bubbles Apply a pressure of 1 9 bar 28 lb in 2 9 Rem...

Page 521: ...mm in Carrier Roller a JS200 120 4 72 112 4 40 Renew JS240 b JS240 0 39 Renew JS240 c JS200 85 3 34 79 3 11 Renew JS240 Inner Flange width d JS200 46 1 81 45 5 1 79 Renew JS240 Outer Flange width d J...

Page 522: ...little at a time until grease starts to come out If you over loosen too much grease could spurt out or the valve cover fly out and cause serious injury 8 3 4 5 2 Lift the side of the undercarriage hig...

Page 523: ...r on the track link as shown Align the holes in the brackets with the tapped holes in the undercarriage 2 Lower the undercarriage sufficient to allow the mounting bolts to be installed 3 Apply Loctite...

Page 524: ...Issue 1 Bottom Roller continued Item Part Name Roller assembly outer flange 1 Roller outer flange Roller assembly inner flange 2 Roller inner flange 3 Shaft 4 Collar 5 Bushing 6 Floating seal 7 O rin...

Page 525: ...suitable solvent Remove the plug A and drain the oil 2 Remove locking wire B from each end of the shaft C Remove brackets D and E from shaft C 3 Remove seal F from brackets D and E using a pry bar 4...

Page 526: ...suitable solvent Dry shaft and bore of roller using compressed air in a place free of dust and moisture Check components for wear as detailed under Wear Limits Polish out scratches and roughness using...

Page 527: ...ft C and insert new locking wires B Wrap sealing tape around one plug A with one thread remaining uncovered Insert this plug but leave the other one out until after testing 6 Using extreme care to pre...

Page 528: ...ed 7 Hammer in locking wires B 8 Add the specified oil see Section 3 Install plug A using an appropriate pipe thread sealant Section J Track and Running Gear 9803 6400 Section J 13 5 Issue 1 Bottom Ro...

Page 529: ...S240 160 6 3 152 5 98 Renew b JS200 150 5 9 Renew JS240 Inner Flange width c JS200 86 3 38 80 3 14 Renew JS240 Outer Flange width d JS200 173 6 8 170 6 7 Renew JS240 Shaft Diameter e JS200 65 2 5 64 5...

Page 530: ...Contents Page No Routine Maintenance See Section 3 Technical Data 1 1 i Engine 9803 6400 i Issue 1 Section K Section K...

Page 531: ...10 Less than 2100 rev min JS220 Less than 2100 rev min JS240 Less than 2300 rev min JS260 Less than 2300 rev min Injection Timing static 12 BTDC Injector Opening Pressure 185 bar 2630 lbf in2 Inductio...

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