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jcb JS130, Service Manual

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Service
Manual

JS130

from machine no. 758000

JS160

from machine no. 702000

PUBLISHED BY THE

TECHNICAL PUBLICATIONS DEPARTMENT

OF JCB SERVICE: ©

WORLD PARTS CENTRE

UTTOXETER, STAFFORDSHIRE, ST14 7BS,

ENGLAND

Tel. ROCESTER (01889) 590312

PRINTED IN ENGLAND

Publication No. 9803/6410

R

General Information

Care & Safety

Routine Maintenance

Attachments

Body & Framework

Electrics

1

2

3

A

B

C

Hydraulics

E

F

Transmission

G

Brakes

J

Track & Running Gear

K

Engine

Issue 1

Summary of Contents for JS130

Page 1: ...OF JCB SERVICE WORLD PARTS CENTRE UTTOXETER STAFFORDSHIRE ST14 7BS ENGLAND Tel ROCESTER 01889 590312 PRINTED IN ENGLAND Publication No 9803 6410 R General Information Care Safety Routine Maintenance...

Page 2: ...nings and cautions pertinent to aspects of workshop procedures etc 3 Routine Maintenance includes service schedules and recommended lubricants for the whole machine The remaining sections are alphabet...

Page 3: ...ons 1 1 Torque Settings 1 2 Service Tools Section B Body and framework 3 1 Section C Electrics 4 1 Section E Hydraulics 5 1 Section F Transmission 6 1 Sealing and Retaining Compounds 7 1 i General Inf...

Page 4: ...230 7 Shoe Bolt M16 24 310 360 640 750 32 37 65 76 5 229 266 472 553 8 Counter weight M27 41 845 980 86 100 622 723 9 Turntable Bearing Undercarriage M16 M20 24 280 310 475 550 28 4 31 8 48 4 55 3 205...

Page 5: ...M3 0 39 0 04 0 28 M4 0 78 0 08 0 57 M5 1 67 0 17 1 2 M6 2 84 0 29 2 1 8 04 0 82 5 9 11 3 1 15 8 3 M8 7 06 0 72 5 2 19 6 2 00 14 5 27 7 2 82 20 4 M10 14 0 1 43 10 3 39 1 3 99 28 8 55 0 5 61 40 6 M12 24...

Page 6: ...e with 2 or 6 cartridge capacity required to pre heat adhesive prior to use No plug supplied Note 110V models available upon request contact JCB Technical Service 992 12400 2 cartridge x 240V 992 1260...

Page 7: ...0846 S186330 Braided Cutting Wire consumable heavy duty cut out wire used with the glass extraction tool above 892 00849 approx 25m length S186340 Cut out Knife used to remove broken glass 992 12800 S...

Page 8: ...nts also used to re install glass in rubber glazing because metal tools will chip the glass edge 892 00847 S186550 Rubber Spacer Blocks used to provide the correct set clearance between glass edge and...

Page 9: ...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 10: ...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 x Test Point 892 00257 1 2...

Page 11: ...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 12: ...lded 993 99524 Ram Eye End Modification Plate Assembly 556 43400 Lift Ram 545 18000 Lynch Pin 811 50232 1 1 4 Pivot Pin Ram Piston Nut Removal Fitting Spanner 993 99512 Spanner 55 mm A F 993 99513 Spa...

Page 13: ...0 079 14 0 55 4 0 16 38 0 2 1 50 0 008 61 0 2 2 40 0 008 70 2 76 Fitting Tool for Inner Ring of Taper Roller Bearing 3 42 1 65 JS07120 100 3 94 110 4 33 32 2 0 1 1 27 0 004 35 5 0 1 1 40 0 004 Seal Pr...

Page 14: ...Tools continued SECTION E HYDRAULICS Slew Motor Unit JS160 Puller for Brake Piston Stud is threaded M10 on both ends for 20 mm 0 8 in and fitted with two M10 nuts JS07100 40 1 57 40 1 57 2 x 9 0 35 1...

Page 15: ...7 in G 9 mm 0 35 in H 24 mm 0 94 in I Dia 81 mm 3 91 in J Dia 76 mm 2 99 in K 24 mm 0 94 in L 95 mm 3 74 in M Radius 0 7 mm 0 028 in N 120 mm 16 5 in O 4 0 mm 0 157 in P 3 0 mm 0 118 in Q 15 O ring G7...

Page 16: ...6410 Section 1 5 7 Issue 1 Service Tools continued SECTION E HYDRAULICS Remote Control Valve JS130 JS160 JS07160 30 25 21 28 19 42 25 17 19 50 13 65 26 5 23 5 15 1 2 Joint Removal Tool Items 1 and 2...

Page 17: ...9803 6410 Section 1 5 8 Issue 1 Service Tools continued SECTION E HYDRAULICS Hydraulic Pump Guide Rods Swash Plate Levelling Tool Front Shaft Protection Tool Rear Shaft Protection Tool Oil Seal Inser...

Page 18: ...Service Tools continued SECTION E HYDRAULICS Hydraulic Rams Reconditioning Bush Removal Assembly Jig Seal Ring Insertion Jig Inner Bush Removal Assembly Jig Seal Ring Bedding Jig Cylinder Head Insert...

Page 19: ...0 236 15 0 59 30 1 18 JS07170 94 5 0 2 3 72 0 008 120 4 72 130 5 43 3 0 118 15 o Seal Protector Heat polyvinyl tube in hot water and form to the required shape on the pinion shaft 65 2 56 60 2 36 100...

Page 20: ...ols continued SECTION F TRANSMISSION Slew Gearbox JS160 continued 6 2 6 2 Seal Fitting Jig 50 3 15 9 15 30 99 8 124 158 JS07210 Seal Fitting Jig SST0033 JS07220 30 o 155 2 16 4 49 5 80 75 Jig for Tape...

Page 21: ...rked below plus applicator nozzle etc Ultra Fast Adhesive For direct glazing 4103 2109 310 ml Active Wipe 205 For direct glazing 4104 1203 250 g Black Primer 206J For direct glazing 4201 4906 30 ml Cl...

Page 22: ...Contents Page No Safety Notices 1 1 General Safety 2 1 Operating Safety 3 1 Maintenance Safety 4 1 i Care Safety 9803 6410 i Issue 1 Section 2 Section 2...

Page 23: ...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 24: ...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 clothin...

Page 25: ...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 26: ...contaminated with oil thoroughly in warm 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 sur...

Page 27: ...hile the hoses are open INT 3 1 11 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...

Page 28: ...evel 5 4 Changing the hydraulic oil 5 5 Changing the Return Filter Element 5 6 Flushing Filters 5 6 Cleaning Changing the Suction Strainer 5 7 Changing the Air Breather Element 5 8 Draining Tank Impur...

Page 29: ...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 30: ...TEM JCB Hydraulic Fluid 46 ISO VG46 124 litres 124 litres 27 3 UK gal 27 3 UK gal 32 8 US gal 32 8 US gal SLEW RING BEARING JCB Special HP Grease Lithium based No 2 consistency GEAR TEETH JCB Special...

Page 31: ...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 32: ...ting hours involving use of the breaker or crusher When a breaker or crusher is fitted ensure that the oil and filters are changed at the intervals shown in the table below The hydraulic oil must be s...

Page 33: ...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 34: ...100 Operating Hours or 2 Weekly Whichever occurs first 1 Do a 50 hour service plus 2 Clean a Battery terminals b Fuel lift pump strainer 3 Change a Engine oil b Engine oil main filter element c Servo...

Page 35: ...k Engine Running a Operation of throttle system b Operation of overload warning c Operation of stop control Every 1000 Operating Hours or 6 Monthly Whichever occurs first 1 Do a 500 hour service plus...

Page 36: ...st 1 Do a 1000 hour service plus 2 Change Hydraulic oil Hydraulic tank air breather element Hydraulic suction filter If using a breaker or crusher see page 2 1 for revised servicing schedules Section...

Page 37: ...nspection 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...

Page 38: ...ll prevent the engine being started 8 3 1 3 No Greasing Points Reference Number of greasing points drawing Boom 3 Boom ram eye end pin 1 2 Centralised greasing total of 6 points Dipper ram dump end pi...

Page 39: ...3 3 Section 3 Routine Maintenance 9803 6410 Section 3 3 3 Issue 1 Greasing continued Excavator End...

Page 40: ...before connecting or disconnecting the battery When you have installed the battery in the machine wait five minutes before connecting it up 5 3 4 3 CAUTION Do not disconnect the alternator the battery...

Page 41: ...ressure 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 M...

Page 42: ...tighten the air bleeding plug A g Stop the engine and allow the bubbles to make their way through the hydraulic tank Air Bleeding from Ram WARNING Hydraulic Pressure Hydraulic fluid at system pressur...

Page 43: ...ne at low speed loosen the air bleeding 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...

Page 44: ...el should be between the 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 N...

Page 45: ...nd of the section 3 Release Tank Pressure See Releasing Tank Pressure a Remove the filler port cover B and O ring C b Use a pump and discharge the hydraulic oil into an empty waste container c Remove...

Page 46: ...s to be cleaned The slave filter should be fitted in place of the main return filter during flushing only 1 Vent hydraulic tank pressure see Releasing Tank Pressure and then remove tank cover C main h...

Page 47: ...t 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 Check the Hydraulic fluid Lev...

Page 48: ...ther Element B a Remove the hexagonal nut D and sealing washer E b Remove the cover A note slot c Replace the air breather element B when installing re fit the sponge packing F above element 5 Re fit...

Page 49: ...task is complete when clean hydraulic 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...

Page 50: ...t the seal of 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 Pos...

Page 51: ...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 52: ...box Oil Level 2 Drain the Oil on One Side a Place a container below the drain plug to catch the oil The container must be large enough to hold the maximum gearbox capacity see Fluids and Capacities CA...

Page 53: ...Remove any metallic particles c Refit the drain plug Make sure it is tight 3 Fill with New Oil See Lubricants and Capacities for oil type and volume Fill with new oil through filler port C until it r...

Page 54: ...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 55: ...grease to reduce 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 st...

Page 56: ...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 57: ...Locate the Air Filter See Component Location Diagram 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 Filter...

Page 58: ...filter heads c Smear the seal on each new filter with oil Screw in the new filter canisters hand tight only 4 Fill the System Securely tighten the drain plug D and refill the engine with new oil thro...

Page 59: ...the antifreeze mixture 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 Universal A...

Page 60: ...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 61: ...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 62: ...achine 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 washers A the housing cover and stays then s...

Page 63: ...nces should the float C be allowed 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 e...

Page 64: ...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 65: ...Section 3 Section 3 9803 6410 Issue 1 9 1 9 1 Routine Maintenance Component Location Diagram...

Page 66: ...mperature should be 45 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...

Page 67: ...loading of the arm 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 lower ring t...

Page 68: ...sh 1 The conditions for checking are to position the bucket in the open position slightly above ground and to stop the engine 2 Gently push the bucket from the side and put a mark on the ground this b...

Page 69: ...ntable Bearing 1 First set the Dipper in a perpendicular position and position the bucket 200 mm above the ground stop the engine 3 Start the engine and lift the main body with the bucket when the bot...

Page 70: ...lope of 20 then set the attachment to a 90 position relative to the direction of travel 2 Confirm with an angle gauge that the vehicle is at 20 and mark the turntable bearing and lower ring 3 Stop the...

Page 71: ...the ram specification in Technical Data Section E to determine the number of ram strokes needed to achieve the required total ram movement 3 Measure the width of the oil ring on each ram rod to see if...

Page 72: ...ication 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 manufacturer...

Page 73: ...lation 4 6 Shim Adjustment Table 4 7 Maintenance Specifications JS160 Boom and Slew Frame Installation 5 1 Boom Ram Installation 5 1 Dipper Ram Installation 5 2 Dipper Pivot Installation 5 3 Dipper an...

Page 74: ...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 75: ...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 76: ...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 77: ...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 78: ...he 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...

Page 79: ...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 80: ...2 1 Section B Body Framework 9803 6410 Section B 2 1 Issue 1 Undercarriage JS130 Dimensions JS03170 883 5mm 2 11 21mm 1 120mm 4 7 188mm 7 4 200mm 7 8 228 5mm 9 178mm 7 140mm 5 5...

Page 81: ...work 9803 6410 Section B 2 2 Issue 1 Undercarriage JS160 Dimensions JS03160 883 5mm 2 11 473 5mm 1 6 6 465 5mm 1 6 3 1061mm 3 5 7 25mm 1 120mm 4 7 215mm 8 4 189mm 7 4 279 5mm 11 200mm 7 8 177 5mm 7 99...

Page 82: ...12550 6850 15110 G Attachment 2200 4850 2400 5290 Includes counterweight and H Boom including rams 1210 2670 1600 3530 slew ring bearing C Counterweight 2540 5600 2930 6460 I Dipper 580 1280 600 1320...

Page 83: ...036 lb 8 Slew mechanism 101 kg 223 lb 197 kg 434 lb 9 Slew ring bearing 170 kg 375 lb 242 kg 534 lb 10 Counterweight 2540 kg 5601 lb 2930 kg 6461 lb 11 Engine 387 kg 853 lb 354 kg 781 lb 12 Radiator 6...

Page 84: ...allation Boom b 568 566 Clearance c 1 0 3 5 Pin d 75 74 Bushing boom e 75 76 5 2 Boom ram Slew frame a 86 92 and slew frame Boom ram b 85 83 installation dump end Clearance c 1 0 2 5 Pin d 65 64 Bushi...

Page 85: ...ork 9803 6410 Section B 4 2 Issue 1 Maintenance Specifications Equipment Part Code Standard Service Name Name Value mm Limit mm 4 Dipper ram Boom a 99 105 installation Dipper ram b 98 96 dump end Clea...

Page 86: ...Name Value mm Limit mm 6 Dipper and Boom a 99 105 Dipper ram installation Dipper ram b 98 96 eye end Clearance c 0 5 3 0 Pin d 70 69 Bushing e 70 71 5 Dipper ram Shim for adjustment Equipment Part Co...

Page 87: ...dard Service Name Name Value mm Limit mm 7 Bucket Ram Dipper a 88 94 installation Bucket ram b 87 85 eye end Clearance c 0 5 3 0 Pin d 65 64 Bushing e 65 66 5 bucket ram Shim for adjustment Equipment...

Page 88: ...255 261 bucket link installation Bucket link b 254 252 Clearance c 1 0 3 5 Pin d 65 64 Bushing e 65 66 5 bucket link Shim for adjustment Equipment Part Code Standard Service Name Name Value mm Limit m...

Page 89: ...ion B 4 6 Issue 1 Maintenance Specifications Equipment Part Code Standard Service Name Name Value mm Limit mm 11 Bucket and Bucket a 255 261 dipper installation Dipper b 254 252 Clearance c 1 0 3 5 Bu...

Page 90: ...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 91: ...1 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 92: ...stallation Boom b 635 633 Clearance c 1 0 3 5 Pin d 80 79 Bushing boom e 80 81 5 2 Boom ram Slew frame a 111 117 and slew frame Boom ram b 110 108 installation dump end Clearance c 1 0 2 5 Pin d 70 69...

Page 93: ...rk 9803 6410 Section B 5 2 Issue 1 Maintenance Specifications Equipment Part Code Standard Service Name Name Value mm Limit mm 4 Dipper Ram Boom a 111 117 installation Dipper ram b 110 108 dump end Cl...

Page 94: ...me Value mm Limit mm 6 Dipper and Boom a 111 117 Dipper ram installation Dipper ram b 110 108 eye end Clearance c 0 5 3 0 Pin d 70 69 Bushing e 70 71 5 Dipper ram Shim for adjustment Equipment Part Co...

Page 95: ...dard Service Name Name Value mm Limit mm 7 Bucket ram Dipper a 91 97 installation Bucket ram b 90 88 eye end Clearance c 0 5 3 0 Pin d 65 64 Bushing e 65 66 5 bucket ram Shim for adjustment Equipment...

Page 96: ...301 307 bucket link installation Bucket link b 300 298 Clearance c 1 0 3 5 Pin d 80 79 Bushing e 80 81 5 bucket link Shim for adjustment Equipment Part Code Standard Service Name Name Value mm Limit m...

Page 97: ...ion B 5 6 Issue 1 Maintenance Specifications Equipment Part Code Standard Service Name Name Value mm Limit mm 11 Bucket and Bucket a 301 307 Dipper installation Dipper b 300 298 Clearance c 1 0 3 5 Bu...

Page 98: ...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 99: ...1 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 100: ...k 9803 6410 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 101: ...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 full...

Page 102: ...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 103: ...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 104: ...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 105: ...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 106: ...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 107: ...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 test for leakage...

Page 108: ...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 109: ...it 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 performance LOW...

Page 110: ...ge 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 malfunctio...

Page 111: ...ms 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 2 Evacu...

Page 112: ...when ice melts Correction 1 Evacuate A C system 2 Replace receiver drier 3 Remove moisture by repeatedly evacuating system 4 Charge system with R 134a 5 Operate system and check performance LOW SIDE R...

Page 113: ...m 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 Brake Swing Lock...

Page 114: ...1 1 Section C Electrics 9803 6410 Section C 1 1 Issue 1 Torque Specifications Torque Specifications Component Nm kgfm lb ft Remarks Battery securing bolts 19 6 29 4 2 3 14 46 21 69...

Page 115: ...the blown fuse is unknown or the fuse fails repeatedly check the electrical circuit s concerned Lighting and Horn Voltage Wattage No off Working light Tank 24 V 70 W 1 Boom 24 V 70 W 1 Roof light Cab...

Page 116: ...should not vary between cells by more 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...

Page 117: ...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 118: ......

Page 119: ...3 1 Section C Electrics 9803 6410 Section C 3 1 Issue 1 Layout Operator s Cab...

Page 120: ...yout Right Console For correct operation and description see Operator s Manual JS03290 RIGHT CONSOLE Right Console tilt handle Idle Switch Washer Switch Wiper Switch Work lamp Switch One Touch Auto ch...

Page 121: ...Console side panel 3 3 Section C Electrics 9803 6410 Section C 3 3 Issue 1 Layout Buzzer Stop Switch Time Adjust JS03010 H E A T O F F O N START CLOCK H M ADJUST CLOCK Starter Switch Horn Volume Soft...

Page 122: ...sole For correct operation and description see Operator s Manual Left Console Tilt Handle JS03000 STOP SWING BRAKE P FAN JS003300 LEFT CONSOLE Lever lock Switch Horn Switch Hour Meter Emergency Stop S...

Page 123: ...L TEMP WATER TEMP FUEL WORK MODE MODE CLOCK Machine Condition Indicators LOCK SWING P CONTROLS WORK MODE MODE CLOCK HYD OIL TEMP Red Green White WATER TEMP Red Green White FUEL Red Green Lock Indicato...

Page 124: ...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 125: ...lay before the battery relay is cut OFF A power supply is maintained to allow electrical devices to be operated after key switch is turned to OFF Power cut delay Modulates movement of control valve bo...

Page 126: ...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 127: ...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 128: ...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 129: ...hrottle 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 controll...

Page 130: ...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 131: ...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 132: ...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 133: ...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 134: ...d or cable linkage adjusted the controller must have the memory wiped before programming can commence Automatic adjustment explanation 1 Engine RPM at the time of full throttle FULL is read H mode MAX...

Page 135: ...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 136: ...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 137: ...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 138: ...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 139: ...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 140: ...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 141: ...If engine RPM is less than 1200rpm the current is the same as L MODE irrespective of mode selection When L or F MODE are selected at the same time as travel upper side pressure SW OFF travel pressure...

Page 142: ...5 3 Section C Electrics 9803 6410 Section C 5 3 Issue 1 Pump Control FLOW CHART...

Page 143: ...ering procedure is activated only in L F mode When changing to L F mode a transistor in the controller turns ON and switches a solenoid valve Pilot pressure is sent on the raising side of the boom spo...

Page 144: ...ilot pressure is sent to the negative control signal port of the pump This pilot pressure adjusts the pump swashplate angle to temporarily reduce the output flow and thereby initially slow down cushio...

Page 145: ...5 6 Section C Electrics 9803 6410 Section C 5 6 Issue 1 Pump Control Cushioned Boom Starting continued Flow Chart...

Page 146: ...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 147: ...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 148: ...5 9 Section C Electrics 9803 6410 Section C 5 9 Issue 1 Pump Control Pressure Increasing System continued Flow Chart...

Page 149: ...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 150: ...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 151: ...sh 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 6410 Section...

Page 152: ...5 13 Section C Electrics 9803 6410 Section C 5 13 Issue 1 Pump Control 3 Speed Travel and Max Flow Cut continued Flow Chart...

Page 153: ...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 154: ...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 155: ...5 16 Section C Electrics 9803 6410 Section C 5 16 Issue 1 Pump Control Power Supply Cut Delay Flow Chart...

Page 156: ...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 157: ...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 158: ...ntly 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 valve shifts Oil within the brake piston of the motor flows to the tank Th...

Page 159: ...5 20 Section C Electrics 9803 6410 Section C 5 20 Issue 1 Pump Control Swing brake Swing lock continued Flow Chart...

Page 160: ...5 21 Section C Electrics 9803 6410 Section C 5 21 Issue 1 Pump Control Lever Lock Circuit Diagram Time Chart...

Page 161: ...5 22 Section C Electrics 9803 6410 Section C 5 22 Issue 1 Pump Control Lever Lock continued Flow Chart...

Page 162: ...ion C Electrics 9803 6410 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 163: ...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 164: ...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 numerical sequence after a 30 second delay 5 Number 7 is put out on th...

Page 165: ...s 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 numerical sequence after a 30 second delay 5 Number 7 is put out...

Page 166: ...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 167: ...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 168: ...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 169: ...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 170: ...Reset Pattern Self check 6 3 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 Controller s original progr...

Page 171: ...ECTRICAL FAULT or any other warning message is displayed on the message monitor If a warning is displayed the computer will not be able to complete its reset cycle 6 4 Initial Set up of the Controller...

Page 172: ...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 173: ...Name Languages 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 174: ...entally operate them 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 se...

Page 175: ...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 176: ...n circuit 8 4 Section C Electrics 9803 6410 Section C 8 4 Issue 1 Self Test Select Self check Message FUEL SENSOR RESISTANCE VALUE WORK MODE MODE CLOCK CH FS Select Self check Message THROTTLE VOLUME...

Page 177: ...turn 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 swing left or right display should be Select any o...

Page 178: ...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 179: ...ce the buzzer Setting Automatic Idle Time Switch 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...

Page 180: ...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 181: ...ue on to either the YES or NO branch and onto the next box Inside each box the inspection or measurement method or values are written The necessary preparatory work operations and values are listed Ma...

Page 182: ...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 183: ...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 184: ...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 185: ...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 186: ...ot flashing Troubleshoot Cause Remedy Replace Reserve tank level reserve switch defect tank switch Defective YW wiring between Repair YW reserve tank level wiring switch and CNB Defective YW wiring be...

Page 187: ...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 188: ...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 189: ...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 190: ...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 191: ...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 192: ...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 193: ...9 13 Section C Electrics 9803 6410 Section C 9 13 Issue 1 Fault Finding Fault Diagnosis continued Electrical Systems Message Fault Problem No 10 Note Message does not go out...

Page 194: ...ES 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 displ...

Page 195: ...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 196: ...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 197: ...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 198: ...reakage 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 CN10 con...

Page 199: ...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 200: ...3 Fault Finding 12 1 Dismantling and Assembly 14 1 Hydraulic Pump Regulator Introduction Specifications 18 1 Schematics 18 2 Operation 18 4 Dismantling and Assembly 18 6 Control Valve Introduction Tec...

Page 201: ...ion 74 1 Dismantling and Assembly 75 1 Re Conditioning 76 1 Fault Finding 78 1 Maintenance Specifications 79 1 Rotary Coupling Technical Data 80 1 Operation 81 1 Removal 82 1 Replacement 82 2 Dismantl...

Page 202: ...re Refer to Pressure Testing Section E 4 1 Overload Relief Pressure Boom Raising Dipper Bucket Refer to Pressure Testing Section E 4 1 Boom Lowering Pressure Function Travel priority Slew priority Boo...

Page 203: ...65 kg 364 lb Boom Ram Cylinder Inside Diameter 100 mm 3 94 in Rod Diameter 75 mm 2 95 in Max Contracted Length 1561 mm 61 46 in Stroke 1081 mm 42 56 in Dry Weight 116 kg 256 lb Dipper Ram Cylinder Ins...

Page 204: ...e Refer to Pressure Testing Section E 4 1 Overload Relief Pressure Boom Raising Arm Bucket Refer to Pressure Testing Section E 4 1 Boom Lowering Pressure Function Travel priority Slew priority Boom an...

Page 205: ...25 kg 496 lb Boom Rams Cylinder Inside Diameter 115 mm 4 53 in Rod Diameter 80 mm 3 15 in Max Contracted Length 1689 mm 66 65 in Stroke 1184 mm 46 61 in Dry Weight 157 kg 346 lb Dipper Ram Cylinder In...

Page 206: ...E 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 NEPHRON FILTER 26 VALVE STOP 27 VALVE...

Page 207: ......

Page 208: ...NE 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 NEPHRON FILTER 26 VALVE STOP 27 VALVE...

Page 209: ......

Page 210: ...3 4 Section E Hydraulics 9803 6410 Section E 3 4 Issue 2 Schematics Shuttle Block...

Page 211: ...Section E Section E Hydraulics 9803 6410 Issue 2 3 5 3 5 Schematics Pilot Control Line Hose Connection Diagram JS03540...

Page 212: ...Section E Section E Hydraulics 9803 6410 Issue 1 3 6 3 6 Schematics Pilot Control Line Hose Connection Diagram JS03540...

Page 213: ...se relief valve C Boom lower relief valve D Bucket open relief valve E Bucket close relief valve F Dipper out relief valve G Dipper in relief valve L Hammer relief valve Key G1 Main Pump P1 G2 Main Pu...

Page 214: ...ng Pressure Testing General Confirmation of the oil Temperature Confirm the oil temperature is between 45 55 C using the self check function If the temperature is low use the following warm up procedu...

Page 215: ...ut X Adjust setting screw Y to indicate a pressure below the required level and then bring the pressure back up for final setting Tighten lock nut X a The pressure gauges reading should be compared to...

Page 216: ...r lever lowered start the engine 4 Raise the boom to its full height and stop the engine switch the ignition ON 5 Move the boom operating lever fully from neutral to lower and back to neutral and chec...

Page 217: ...ine and confirm that the engine is at its maximum no load speed and it is in the S mode The pressure gauge reading should be compared to the technical data at the start of this section If it is outsid...

Page 218: ...at the machine does not slew Note If the water proof connector of the slew lock solenoid valve is not removed step 3a slew lock status can be obtained with the slew lock switch ON step 3b but the slew...

Page 219: ...ngine and park the machine on level ground Operate the dipper out and lower the boom to set the bucket on the ground b Run the engine at maximum no load speed in the S mode 2 Increase MRV Pressure Loo...

Page 220: ...liary Relief Valves General step 2 3 Start the engine lower the gate lock lever and run the engine at maximum no load speed in the S mode 4 Pressure Adjustment Boom up Note For accurate setting the pr...

Page 221: ...sure gauge reading Boom down should be compared to the technical data at the start of the section If it is outside the limits adjust ARV 7 Stop the engine and release the hydraulic pressure see Releas...

Page 222: ...level and then bring the pressure back up for final setting Tighten lock nut X a Raise the boom to its full height b Move the dipper fully out and then continue to operate the control lever as at A c...

Page 223: ...Release lock nut X Adjust setting screw Y to indicate a pressure below the required level and then bring the pressure back up for final setting Tighten lock nut X a Raise the boom b Open the bucket fu...

Page 224: ...ower the gate lock lever and run the engine at maximum no load speed in the S mode 3 Operate the hammer by pressing the button C on the front of the L H control lever Check the pressure on the gauge a...

Page 225: ...he locked travel motor and measure the pressure in forward and reverse 6 Pressure Adjustment Note For accurate setting the pressure should be adjusted up to the required level Release lock nut A Adjus...

Page 226: ...nt cc in3 rev 9 08 0 55 9 08 0 55 Working pressure maximum 42 bar 612 lbf in2 43 kgf cm2 42 bar 612 lbf in2 43 kgf cm2 Maximum flow l UK gal US gal min 20 2 5 34 US 5 3 21 2 5 60 US 5 6 10 1 Section E...

Page 227: ...egulator JS00040 JS00050 Key A Negative control signal B Maximum flow signal C Mode change electrical signal E Solenoid proportional pressure control SPPC valve F Total horsepower control electrical s...

Page 228: ...refore the pump displacement varies according to the swash plate angle which is controlled by machine demand The fixed valve plate 9 contains two crescent shaped ports X The valve plate is located so...

Page 229: ...nal B Maximum flow signal K Horsepower control signal from pump proportional solenoid control valve L Swash plate angle P1 Front pump P2 Rear pump Pp Pilot pump 10 4 Section E Hydraulics 9803 6410 Sec...

Page 230: ...ugh piston 38 When PC pressure and the pressure of springs 43 44 are equal the regulator piston stops moving Pressure PC decreases as pump pressure falls and springs 43 44 cause spool 40 to move to th...

Page 231: ...vel is dependent on the mode selected The solenoid converts the electrical signal into a thrust from plunger E When solenoid 58 is energised the thrust of plunger E moves spool 103 to the left to conn...

Page 232: ...draulic motors served by the pump causing low flow rate or loss of pressure b The sliding area of the pump is worn allowing a large amount of pressurised oil to escape from the drain port c Air is bei...

Page 233: ...d pump internal pressure b Oil seal failure originating from restricted drain line and raised pump internal pressure Remedy Top up the hydraulic oil and bleed air from the system Clean the strainer If...

Page 234: ...14 1 Section E Hydraulics 9803 6410 Section E 14 1 Issue 1 JS00010 Hydraulic Pump Regulator Dismantling and Assembly...

Page 235: ...14 2 Section E Hydraulics 9803 6410 Section E 14 2 Issue 1 Hydraulic Pump Regulator JS00030 Dismantling and Assembly cont d...

Page 236: ...14 3 Section E Hydraulics 9803 6410 Section E 14 3 Issue 1 Hydraulic Pump Regulator JS00020 Dismantling and Assembly cont d...

Page 237: ...Nut 2 49 Nut 2 50 Sub block 1 51 Disc filter 2 52 Cover LF 1 53 Cover LR 1 54 Piston 2 55 Steel ball 2 56 Relief valve assembly 1 57 Pilot gear pump 1 58 Solenoid valve 1 59 Hose 1 60 Adjustable elbow...

Page 238: ...ow a complete strip down but unless absolutely necessary avoid disturbing or dismantling the control elements of the pump i e those retained by covers 30 52 and 53 and by plugs 31 and 35 Any interfere...

Page 239: ...ock assembly 50 and put to one side Dismantling cont d 5 Unscrew the six socket head bolts 73 and remove rear cover 3 Then remove bearings 14 from the swash plate Note It may be necessary to lightly t...

Page 240: ...r socket head bolts 75 and take out oil seal case 16 Note Take care not to damage the oil seal lip with the shaft spline Dismantling cont d 9 Unscrew the six socket head bolts 73 and remove flange 2 T...

Page 241: ...e parts with those removed from the rear end at step 7 12 Unscrew the three socket head bolts 72 on the rear side and remove cover LR 53 At this point sleeve 37 may come out with the cover Take care n...

Page 242: ...spool 40 assembly Note Take care not to mix these parts with those removed at step 12 Dismantling cont d 17 Remove the stoppers 24 and 25 on the rear side using an M6 bolt screwed into the threaded h...

Page 243: ...ve 33 20 Return to sub block assembly 50 removed at step 4 Remove the O rings 89 1 off 91 1 off 93 2 off and 111 1 off plus disc filter 51 Dismantling cont d 21 Unscrew the four securing bolts and rem...

Page 244: ...14 11 Section E Hydraulics 9803 6410 Section E 14 11 Issue 1 Hydraulic Pump Regulator 23 Using a screwdriver remove oil seal 15 from oil seal case 16 and discard the seal Dismantling cont d...

Page 245: ...iding part is deeply scratched or has a rough surface b The spline is excessively worn or damaged a The cylinder block sliding contact surface is deeply scratched or has a rough surface a The piston s...

Page 246: ...ew Do not apply excessive amounts of adhesive Wipe off any surplus Leave the pump for at least twelve hours after assembly to allow the adhesive to dry fully Ensure that all components are re fitted t...

Page 247: ...r 12 b Install piston assembly 6 into retainer plate 11 and insert the pistons in cylinder block assembly 4 4 Pass shaft 5 through cylinder block assembly 4 from the rear double splined end first Asse...

Page 248: ...est from the pistons b Assemble swash plate 7 into the pump housing Note Position regulator piston 23 with the groove for slide metal 22 in the centre and locate the two during assembly Assembly cont...

Page 249: ...r race of bearing 13 into the flange b Fit O ring 78 into the flange c Insert pin 62 into pump housing 1 and then assemble flange 2 onto the housing along the guide rods fitted at step 12 d Install fo...

Page 250: ...cage standing upright see step 10 Repeat step 11 Repeat steps 12 and 13 referring to rear cover 3 instead of flange 2 Assembly cont d 16 Fit O rings 81 86 87 and 88 and back up rings 96 97 and 98 onto...

Page 251: ...cover R 30 Assembly cont d 20 Install assembled cover R 30 into the pump housing first aligning the slot in bridging piece 29 by means of a piece of wire from the opposite side to accommodate sleeve...

Page 252: ...t 13 1 kgf m Repeat steps 22 and 23 for rear cover 53 23 Using a suitable tool see Service Tools Section 1 and a press fit oil seal 15 squarely into oil seal case 16 with the open side of the seal fac...

Page 253: ...d orifice 110 Note Check that the orifice and its mounting position are not clogged 27 Fit sub block 50 assembly onto the pump housing and secure with the four socket head bolts 74 tightened to a torq...

Page 254: ...ction The pump regulator consists of two variable displacement type axial piston pumps P1 and P2 supplying pressurised oil to operate machine functions plus one gear type pilot pump Pp to provide pilo...

Page 255: ...Regulator JS130 JS160 REAR FRONT A1 A2 B1 B3 A3 P1 Dr1 a4 Pi2 Pm2 Pi1 Pm1 a3 a2 a1 Key A1 2 Delivery port B1 Suction port Dr1 Drain port Pi1 2 Pilot port P1 Proportional pressure reducing valve Pm1 2...

Page 256: ...3 6410 Section E 18 3 Issue 1 Hydraulic Pump Regulator JS130 JS160 Hydraulic Pump Regulator B 3 A 3 P i2 P i1 P m2 a 4 P 1 P m1 D r1 a 1 a 1 a 2 B 3 P 1 P i2 A 3 A 3 A 1 B 3 B 1 A 2 a 3 a 2 a 4 D r1 D...

Page 257: ...emand The fixed valve plate contains two crescent shaped ports The valve plate is located so that when a piston reaches its nearest point to the plate it comes into line with the pump inlet port Durin...

Page 258: ...18 5 Section E Hydraulics 9803 6410 Section E 18 5 Issue 1 Hydraulic Pump Regulator JS130 JS160 Proportional Reducing Valve...

Page 259: ...draulics 9803 6410 Section E 18 6 Issue 1 Hydraulic Pump Regulator JS130 JS160 Hydraulic Pump 28 30 25 416150 17 16 3 15 14 21 2 4 31 11 12 13 9 314 30 32 8 1 B 6A 6 22 23 24 23 21A 33 27 26 29 7 18A...

Page 260: ...which they came The item numbers called up in the following procedures correspond with those in the exploded view Dismantling Before dismantling the pump ports should be plugged and the external surfa...

Page 261: ...embly Z comprising cylinder 9 piston assemblies 10 set plate 11 spherical bush 12 and cylinder springs 13 from pump casing 5 Take care not to damage the sliding surfaces of the components 7 Pump 1 onl...

Page 262: ...pport around its flange using a plastic hammer 9 Remove shoe plate 19 and swash plate 20 from pump casing 5 10 Using a plastic hammer gently tap shaft 21 out of swash plate support 18 complete with it...

Page 263: ...head Also take care not to damage the servo piston as a result of the retaining compound used to secure it 13 Remove needle bearings 30 see Note 3 and splined coupling 31 from valve block 8 Note 3 Do...

Page 264: ...o align the flange match marks and then fit swash plate support 18 to pump casing 5 by gently tapping it with a plastic hammer 3 Place the pump casing on the workbench with its regulator mounting face...

Page 265: ...port 18 using new O ring 16 Secure it with socket head screws 14 tightened to a torque of 11 8 Nm 8 7 lbf ft 6 Assemble the piston cylinder sub assembly Z comprising cylinder 9 piston assemblies 10 se...

Page 266: ...e the spline on shaft 21 with the splined coupling Secure with the four socket head screws 7 tightened to a torque of 235 Nm 173 lbf ft 9 Refit regulator 4 to pump casing 5 using a new O ring Take car...

Page 267: ...803 6410 Section E 18 14 Issue 1 Hydraulic Pump Regulator JS130 JS160 F G C A B E D A C E G F B D 379671 40 23 25 22 26 39 24 41 42 15 13 14 36 35 34 32 18 17 16 37A 33A 38 3 2 8 1 37 33 29 28A 28 30...

Page 268: ...c oil Retain all washers snap rings etc for later re use O rings should be renewed 1 If not already done separate the regulator 1 from the pump casing by removing socket head screws 2 and 3 2 off each...

Page 269: ...end of adjusting ring 16 to facilitate its easy removal 4 Remove socket head screws 19 and 20 and lift off pilot cover 21 Take out set spring 22 5 Remove snap ring 23 taking care not to allow the com...

Page 270: ...ote 2 Use an M6 screw Y attached to the ends of fulcrum plug 29 and adjusting plug 31 to facilitate their easy removal 7 Remove lever 32 leaving pin 33A in position on the lever 8 Knock out pin 34 4 m...

Page 271: ...pin 37A in position on the lever 11 Draw out pilot piston 38 and spool 39 12 Withdraw piston case 40 compensating piston 41 and compensating rod 42 Note 3 Piston case 40 can be removed by pressing com...

Page 272: ...body 1 3 Fit spool 39 and sleeve 26 into hole A of regulator body 1 Check that the spool and the sleeve slide smoothly in the body without binding Check the orientation of the spool with respect to f...

Page 273: ...Fit a new seal 28A and install snap ring 28 8 Insert adjusting plug 31 Fit a new seal 30A and install snap ring 30 Check that feedback lever 35 moves freely but does not have excessive play 9 Insert...

Page 274: ...pilot spring 17 and adjusting ring 16 into hole E of regulator body 1 Insert spring seat 15 flat face first inner spring 14 and outer spring 13 into hole D of regulator body 1 12 Install the cover 6 a...

Page 275: ...upply BKT Bucket ram BM Boom rams Technical Data Rated flow 120 l min 26 4 gal min Maximum pressure for normal use 350 kgf cm2 4978 lbf in2 Oil temperature range 20 90 C 4 4 194 F Maximum oil temperat...

Page 276: ...ve or port relief valve set pressures The difference between the main relief valve and port relief valve set pressures should be more than 20 kgf cm2 285 lbf in2 Carry out warming up sufficiently befo...

Page 277: ...3 6410 Section E 32 1 Issue 1 Control Valve Key TL Left hand track motor TR Right hand track motor AM Dipper ram OPT Auxiliary supply to attachment if fitted SW Slew motor supply BKT Bucket ram BM Boo...

Page 278: ...32 2 Hydraulic Circuit Diagram Section E Hydraulics 9803 6410 Section E 32 2 Issue 1 Control Valve JS01700...

Page 279: ...33 1 Neutral Circuit Section E Hydraulics 9803 6410 Section E 33 1 Issue 1 Control Valve JS01610...

Page 280: ...passes through the neutral gallery A over each spool B and returns to tank via the foot release valve section C When no spools are operated a balance of forces acting on spool D causes it to move to...

Page 281: ...is directed to outlet port BL2 by lifting check valve G At the same time because neutral gallery F is closed the foot release valve H closes and stops signal pressure FL to the pump controller enabli...

Page 282: ...check valve G At the same time pressure is appiled to the centre bypass valve J This causes oil from pump P2 flowing through the neutral gallery F to be re directed into the dipper circuit Therefore t...

Page 283: ...tlet port BR2 by lifting the check valve G Oil from pump P1 flowing through the neutral gallery F is re directed by applying pilot pressure to the centre bypass valve J combining the high pressure flo...

Page 284: ...33 6 Boom Raise BM Operation Section E Hydraulics 9803 6410 Section E 33 6 Issue 1 Control Valve L...

Page 285: ...e K is closed ports G and L are shut off Oil bleeds from check valve M through pilot hole P to gallery J causing check valve M to open allowing oil to enter the outlet port BR1 Combined flow from both...

Page 286: ...w check valve M flows through ports G and H to open check valve K and pass through port L to the gallery J Pressure in gallery J depresses the check valve M allowing oil to flow from the ram to the ex...

Page 287: ...33 9 Slew Operation SW Priority Circuit Section E Hydraulics 9803 6410 Section E 33 9 Issue 1 Control Valve JS01770...

Page 288: ...taneously the main flow of oil from pump P1 opens check valve F and operates the slew motor Oil also passes through a restrictor G and is directed via the parallel gallery to the dipper ram thus ensur...

Page 289: ...33 11 Travel Operation TL TR Priority Circuit Section E Hydraulics 9803 6410 Section E 33 11 Issue 1 Control Valve JS01760...

Page 290: ...ht hand track drive Swing Operation with Linear Travel As the pilot signal operated by the left hand joystick controller starts to operate the slew spool the signal inside the control valve is initial...

Page 291: ...nect all hydraulic hoses from valve ports A Seal exposed connections to prevent the ingress of dirt Mark the hoses to ensure correct re connection Disconnect all pilot hoses from spool housing B Seal...

Page 292: ...1 7 Logic check valve 34 13 8 Linear travel switching valve 34 14 9 Main relief valve 34 15 10 Overload relief valve 34 17 11 Dipper load diverter valve 34 18 12 Boom lower stroke limit valve 34 19 13...

Page 293: ...Hydraulics 9803 6410 Issue 1 34 3 34 3 Section E Section E Control Valve JS01820 Dismantling and Assembly cont d...

Page 294: ...assemblies with care they are precision made and are easily damaged 6 Prior to assembly all components should be liberally coated with hydraulic oil to ensure full movement between moving parts 7 Ensu...

Page 295: ...alve assembly are retained in the 4 spool section of the body and the check valve and spring are retained in the 3 spool section 4 Remove O rings and discard Assembly 1 Clean surfaces of valve block s...

Page 296: ...crew 5 holding spring guides 6 7 Remove spring guides 6 and spring 7 Cleaning 1 Clean all parts with clean oil and dry with compressed air Inspect all parts 2 Ensure spool 3 moves smoothly 3 Check spr...

Page 297: ...aning Inspection 1 Clean all parts with clean oil and dry with compressed air Inspect all parts 2 Ensure check valve 11 moves smoothly 3 Check spring 10 has no defects deformation or wear 4 Remove sli...

Page 298: ...ers 7 and spring 8 Cleaning Inspection 1 Clean all parts with clean oil and dry with compressed air Inspect all parts 2 Ensure spool 5 and piston 3 move smoothly 3 Check spring 8 has no defects deform...

Page 299: ...spring 6 Cleaning Inspection 1 Clean all parts with clean oil and dry with compressed air Inspect all parts 2 Ensure spool 3 moves smoothly 3 Check the spring has no defects deformation or wear 4 Remo...

Page 300: ...9 spring 10 spool 11 outer sleeve 12 and spacer 13 Cleaning Inspection 1 Clean all parts with clean oil and dry with compressed air Inspect all parts 2 Ensure spool 11 moves smoothly 3 Check spring h...

Page 301: ...Load Holding Valve 34 11 Section E Hydraulics 9803 6410 Section E 34 11 Issue 1 Control Valve JS01140 JS01170 JS01150 JS01190 JS01160 JS01200...

Page 302: ...hdraw poppet valve 20 19 Tilt and tap cover to remove sleeve 21 Note Ensure the sliding surface of the sleeve is protected Cleaning and Inspection 1 Clean all parts with clean oil and dry with compres...

Page 303: ...nto sleeve 9 and withdraw 10 Remove spring 10 11 Remove check valve 11 Cleaning Inspection 1 Clean all parts with clean oil and dry with compressed air Inspect all parts 2 Ensure piston 3 sleeve 5 che...

Page 304: ...and spring 6 Cleaning Inspection 1 Clean all parts with clean oil and dry with compressed air Inspect all parts 2 Ensure spool 3 moves smoothly 3 Check spring 6 has no defects deformation or wear 4 Re...

Page 305: ...nt screw housing 10 with locknut 3 from relief valve body 4 13 Remove spring seat 12 spring 13 and poppet 14 from housing 10 Cleaning Inspection 1 Clean all components in clean oil and dry with compre...

Page 306: ...1 until piston 12 seats onto internal surface Z 3 Adjust housing 10 until high pressure setting is correct see Pressure Testing 4 Tighten locknut 3 Low Pressure Setting 1 Slacken adjusting screw 1 an...

Page 307: ...leeve 6 piston 7 poppet 8 and spring 9 6 Remove O rings and seals 10 and 11 and discard Cleaning Inspection 1 Clean all parts in clean oil and dry with compressed air Inspect all parts 2 Ensure piston...

Page 308: ...ng Inspection 1 Clean all parts in clean oil and dry with compressed air Inspect all parts 2 Ensure spool 7 piston 9 and check valve 11 move smoothly 3 Check that springs 4 and 10 have no defects defo...

Page 309: ...Clean all parts in clean oil and dry with compressed air Inspect all parts 2 Ensure piston 5 moves smoothly 3 Remove slight defects by lapping 4 Renew damaged or badly worn parts Assembly Assembly is...

Page 310: ...and dry with compressed air Inspect all parts 2 Ensure check valve 5 moves smoothly 3 Check that spring 4 has no defects deformation or wear 4 Remove slight defects by lapping 5 Renew damaged or badl...

Page 311: ...lean all parts in clean oil and dry with compressed air Inspect all parts 2 Ensure check valves 4 and 6 move smoothly 3 Check that spring 5 has no defects deformation or wear 4 Remove slight defects b...

Page 312: ...with compressed air Inspect all parts 2 Ensure pilot holes are clean and free from sediment and foreign matter 3 Remove slight defects by lapping 4 Renew damaged or badly worn parts Assembly Assembly...

Page 313: ...nd dry with compressed air Inspect all parts 2 Ensure check valve 3 moves smoothly 3 Check that spring 4 has no defects deformation or wear 4 Remove slight damage by lapping 5 Renew damaged or badly w...

Page 314: ...ure check valve 4 moves smoothly 3 Check that spring 3 has no defects deformation or wear 4 Remove slight defects by lapping 5 Ensure pilot holes in check valve 4 are clean and free from sediment and...

Page 315: ...ve O ring 4 and discard Cleaning Inspection 1 Clean all parts with clean oil and dry with compressed air Inspect all parts 2 Ensure sleeve 3 moves smoothly 3 Remove slight defects by lapping 4 Renew d...

Page 316: ...and dry with compressed air Inspect all parts 2 Ensure check valve 4 moves smoothly 3 Check that spring 3 has no defects deformation or wear 4 Repair slight damage by lapping 5 Renew damaged or badly...

Page 317: ...duction valves used to control the pilot pressure are located in the main housing Direction of the output pilot pressure is controlled by selective movement of the control lever The valves and control...

Page 318: ...l pin 1 3 O ring 1 12 Split washer 4 21 Control handle 1 4 O ring 1 13 Spring seat 4 22 Locknut 1 5 Dowel pin 2 14 Compression spring 4 23 Mounting knuckle 1 6 Body assembly screw 1 15 Return spring 4...

Page 319: ...e opposite end In some cases pilot pressure is applied to both ends of the control valve spool Function Oil supplied by the hydraulic pilot pump enters at port P and the function of the spools 17 is t...

Page 320: ...ly apply hydraulic oil to O rings and seals 8 Ensure all screws and bolts are tightened to the torque settings given Dismantling Details of the service tools used in the dismantling and assembly proce...

Page 321: ...e spring seats 13 split washers 12 return springs 15 pressure control springs 14 and spools 17 Note Identify each set of parts and their locations for assembly 11 Slacken and remove body assembly scre...

Page 322: ...ate retaining plate 18 onto plunger guides 8 and using the jig screw knuckle joint into position Torque tighten to 30 Nm 3 kgf m 22 lbf ft 2 Locate rocker plate 25 and torque tighten to 30 Nm 3 kgf m...

Page 323: ...andle unit is loose a Sliding parts are sticking b Fluctuations in the tank line pressure c Air is trapped in the piping a The tank line pressure is too high b Sliding parts are sticking Remedy Apply...

Page 324: ...r more than the non sliding contact faces Replace if the tip is worn more than 1 mm 0 039 in Replace the parts if the wear in the pin and joint lead to loose movement of more than 2 mm 0 079 in Invest...

Page 325: ...valves are mounted centrally below the cab floor and are operated by either the control levers or the foot pedals Specification Working pressure 40 kgf cm2 568 8 lbf in2 Oil temperature range 20 C to...

Page 326: ...2 Shim 0 008 in 3 Body 4 Spool 5 Sleeve 6 Cover 7 Plunger 8 Pin 9 Boot 10 Collar 11 Compression spring 12 Compression spring 13 Name plate 14 Cam 15 Shim 17 Socket head cap screw 18 Flange screw 19 Pl...

Page 327: ...4 Storing the valve when dismantled could cause rusting of parts Ensure they are suitably protected by anti rust treatment 5 During assembly ensure all parts are clean and free from burrs and scratche...

Page 328: ...8 4 Take off cam 14 Dismantling and Assembly cont d Dismantling 5 Using soft metal pads for protection clamp the valve body into a vice Remove socket head cap screw 17 Note Remove screw with care spr...

Page 329: ...l assembly from valve body 3 Note Record spool locations to ensure correct reassembly Dismantling and Assembly cont d Dismantling cont d 9 Note The spool assembly is pre adjusted with shim 15 and shou...

Page 330: ...mble washer 19 shim 15 spring 11 and sleeve 5 Fit screw 18 and tighten to a torque of 2 98 Nm 2 2 lbf ft Insert spring 12 with the spool assembly into the body 3 Ensure spools are in the correct locat...

Page 331: ...tion E 46 5 Issue 1 Remote Control Valve Travel 5 Locate washer 20 on pin 8 and insert split pin 23 into the hole in pin 8 Bend open split pin ends to retain pin 23 6 Refit boot 9 onto body 3 Dismantl...

Page 332: ...Pressurised hydraulic oil directed by the operator s controls from the remote control valves to the main control valve is redirected by the shuttle valve to perform additional pilot control functions...

Page 333: ...Dipper close B1 Right slew B2 Left slew B3 Boom up B4 Boom down B5 Bucket close B6 Bucket open B7 Dipper open B8 Dipper close C1 Slew pressure switch C2 Boom up C3 Boom up down S1 Slew brake valve S2...

Page 334: ...55 3 General Information cont d Section E Hydraulics 9803 6410 Section E 55 3 Issue 1 Shuttle Valve Key Y Steel ball Z Valve seats...

Page 335: ...rough port B1 to operate the right slew control valve spool Pressurised oil entering port A1 passes through hole d into chamber e and moves steel ball b to the left allowing oil to pass through port C...

Page 336: ...Cushion Valves Schematic Key 1 Dipper Control Valve 2 Boom Control Valve 3 Hydraulic Oil Tank 4 Line Filter 5 Cushion Valve 6 Cushion Valve Solenoid Valve 7 Cushion Switch 8 Dipper Remote Control Val...

Page 337: ...ircuits operate in exactly the same way 1 Cushioned Mode Remote Control Lever in Neutral When the remote control lever is in neutral the hot oil taken from the oil cooler line enters port R of cushion...

Page 338: ...d enters the dipper control valve via port C c The pilot return oil from the dipper control valve enters oilway f via port D and the outer surface of spool Y From oilway f it passes the cushion spool...

Page 339: ...s to neutral allowing pilot oil returning from the control valve via port C to pass through orifice b The cushion spool moves further to the left side due to the pressure differential across orifice b...

Page 340: ...pilot outputs from dipper remote control valve 8 The hot oil from port R returns to the hydraulic oil tank via port T when dipper remote control lever 8 is at neutral When the dipper remote control is...

Page 341: ...low 16 l min 3 52 gal min Pressure reducing valve setting 12 5 kgf cm2 177 7 lbf in2 Oil temperature range TBA Weight TBA Voltage 24 V DC Power rating 12 W JS160 Working pressure 40 kgf cm2 569 lbf in...

Page 342: ...lew lock 7 Solenoid control valve slew brake 8 Pressure reducing valve Key 1 Waterproof 2 pin electrical contact housing 2 Power source pink 3 Ground grey 4 Low voltage cable 0 85 mm 00132 in2 5 Mount...

Page 343: ...Brake Valve Technical Data JS160 Key 6 Solenoid control valve slew lock 7 Solenoid control valve slew brake 8 Pressure reducing valve Key 1 Waterproof 2 pin electrical contact housing 2 Power source 3...

Page 344: ...solenoid spool 1 and enters passageway a The oil then passes over the lower end of the pressure reducing valve spool 2 and enters chamber b which is connected to passageway C As oil enters passageway...

Page 345: ...connected to tank passageway T Pilot pressure entering port P flows to passageway a and chamber b and tries to lift the reducing valve spool 2 Oil in chamber b is throttled into passageway e and spri...

Page 346: ...When the solenoid valve 6 for slew lock is energised the spool 1 moves down stopping oil from passageway C Return oil from the slew motor enters port B and flows through spool passage 2 to tank port...

Page 347: ...47 44 in Stroke 1335 mm 52 56 in Dry Weight 160 kg 353 lb Dry Weight 210 kg 463 lb Bucket Cylinder Inside Diameter 95 mm 3 74 in Cylinder Inside Diameter 105 mm 4 13 in Ram Rod Diameter 70 mm 2 76 in...

Page 348: ...nd maximum speed the seals will be damaged There is a large 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 sudde...

Page 349: ...e 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 s...

Page 350: ...rs 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 6 Restrain the eye end of the ram piston rod to the ram cylinder...

Page 351: ...You can be injured by flying metal splinters when driving metal pins in or out Use a soft faced hammer or drift to remove and fit metal pins Always wear safety glasses INT 3 1 3 Bucket Ram Replacement...

Page 352: ...hoses 4 Hoist the ram to align with the link 5 Install the pin bolt and nuts Note Stroke the ram to release entrapped air After releasing the air check for oil leakage 72 4 Section E Hydraulics 9803...

Page 353: ...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 the...

Page 354: ...rs 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 6 Restrain the eye end of the ram piston rod to the ram cylinder...

Page 355: ...and hammer Lift the ram clear WARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out Use a soft faced hammer or drift to remove and fit metal pins Alwa...

Page 356: ...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 3 Install the grease tube 4 Connect the hoses 5 Hoist the ram to a...

Page 357: ...eleasing the air check for oil leakage WARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out Use a soft faced hammer or drift to remove and fit metal p...

Page 358: ...NING Lifting Equipment You can be injured if you use faulty lifting equipment Make sure that lifting equipment is in good condition Make sure that lifting tackle complies with all local regulations an...

Page 359: ...etal 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 5 Lower the ram and place it on a stand 6 Restrain the eye end of the piston rod...

Page 360: ...ers You can be injured by flying metal splinters when driving metal pins in or out Use a soft faced hammer or drift to remove and fit metal pins Always wear safety glasses INT 3 1 3 10 Lift the ram aw...

Page 361: ...Always wear safety glasses INT 3 1 3 3 Install the hoses 4 Lift the ram and align the rod eye end with the pin position 5 Install the pin with a bar and hammer WARNING Metal Splinters You can be inju...

Page 362: ...all the collar and then the bolt and nuts 7 Connect the grease tube Note Stroke the ram and release entrapped air After releasing the air check for oil leakage 74 5 Section E Hydraulics 9803 6410 Sect...

Page 363: ...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 for disma...

Page 364: ...walk or work 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...

Page 365: ...into the buffer ring pull out the ring from the groove to allow insertion of a pry bar under the ring then remove the ring Note Discard the removed seals 9 Remove the U ring back up ring and wiper rin...

Page 366: ...removing the nut A dismantle as indicated below a Tap the snap ring B on the piston rod C with a plastic hammer and remove b Push the cushion bearing D back and remove locating ring E c Remove cushion...

Page 367: ...ng a jig E and press C c Assemble the back up ring F and U ring G 2 Buffer ring assembly Note After installing the square ring K in the groove bend the buffer ring FF into a U shape J and set it in th...

Page 368: ...s unnecessary for the bucket cylinder Where there is a cushion at the retraction side end of piston rod assemble the cushion bearing as detailed in step 5 before fitting the piston Y d Insert a shim A...

Page 369: ...he P surface and install the collar LL Note While fitting the collar LL take care that it does not break c Move the cushion ring KK to the right until it is in contact with the collar LL d Tap the sna...

Page 370: ...180 7 Position the cylinder head as shown Install the mounting bolts temporarily tighten them in the order shown and re tighten the bolts to the specified torque in the sequence shown 8 Installing the...

Page 371: ...ent deformation or external leakage after applying the test pressure shown in the diagram for three times to each stroke end External Leakage Check the oil leakage amount at the rod Maximum allowable...

Page 372: ...75 10 Section E Hydraulics 9803 6410 Section E 75 10 Issue 1 Hydraulic Rams Ram Piston Head Nut Removal and Fitting JS00980...

Page 373: ...s to remove all air from the cylinder 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 po...

Page 374: ...is determined by reading the pressure on gauge F in the rig circuit with the spanner at 90 to the rig ram and converting it according to the table above Note The pressures in the above table assume th...

Page 375: ...upper section of the piston Carefully fit the thinner end of the inner guide jig on the upper section of the piston Apply a thin coat of lubricant to the inner guide jig periphery and then set the sea...

Page 376: ...the seal ring fits into the groove Be sure to press the plate carefully so that the seal ring will fit squarely on the inner guide jig and into the groove Carry out this operation smoothly After confi...

Page 377: ...ing jig and place the jig with the tapered section facing up Be careful that no dust chipped metal and lint adheres to the jig Slowly and evenly insert the piston with the seal ring fitted into the be...

Page 378: ...draulic Rams Reconditioning cont d After completion of the bedding of the seal ring remove the jig in the following order 1 Retract the press rod 2 Remove the bedding jig This completes the fitting an...

Page 379: ...1 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 dust or other foreign matter can cause damage to the pipe join...

Page 380: ...ircumferential surface 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 int...

Page 381: ...lar is uppermost as shown 2 Keep the press bench clean to prevent dust chipped metal and other foreign material causing damage to the bottom of the chuck assembly Press the upper part of the retainer...

Page 382: ...face until the bushing falls out from the cylinder head Note Normally it falls out with a load of less than 3 tonnes The press ram stroke varies with the cylinder head size and is about 32 52 mm 1 Use...

Page 383: ...or the outer periphery Also ensure that the work bench is level 1 Place the chuck assembly with bushing on the work bench horizontally and insert the Allen wrench into the chuck assembly adjuster head...

Page 384: ...ioning cont d Bushing Removal cont d With the chuck assembly and bushing removed turn the adjuster with your fingers until there is no gap between the adjuster and the wedge upper surface Note Do not...

Page 385: ...sure that it is level 2 Use compressed air to remove the foreign matter CAUTION When using compressed air wear safety glasses and gloves Do not direct compressed air at your skin 8 3 4 2 Temporarily p...

Page 386: ...dge stepped section of the chuck assembly Place the retainer so that the larger diameter part is facing up as shown Place the cylinder with the retainer and chuck assembly attached underneath the pres...

Page 387: ...n in the cylinder head The press load should be less than 5 tonnes Check that the bushing end surface is below the snap ring groove After the press fitting of the bushing is completed remove the retai...

Page 388: ...tom surface of the cylinder head Position the cylinder head on the work bench as shown Check that there is no foreign matter in the groove where the wiper ring or the retainer is to be inserted Insert...

Page 389: ...are in line as shown Press fit the wiper ring into the specified position in the cylinder head Press fit until the retainer s collar contacts the cylinder head The press load should be less than 1 ton...

Page 390: ...revent damage to its outer surface Position the piston rod so that the threaded part is facing you Ensure that the piston rod thread and shaft are free from damage by dust or other foreign matter Loca...

Page 391: ...with both hands taking care 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 checking that the cylin...

Page 392: ...damaged the U ring and other seals so dismantle and inspect Piston rod 2 If the scratches and rust cover such a wide area that they cannot be repaired by an oil stone renew the piston rod and U ring w...

Page 393: ...he protrusion of the heel of the As a rule renew the rod packing at the packing is excessive same time It is desirable to renew parts 1 Piston rod which are attached to the buffer ring at the oil leak...

Page 394: ...linder 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 renew After inspection tighten to specified torque...

Page 395: ...nd sliding part material 4 Scratches wear are present Replace with new part Piston seal Inspect the cylinder tube inner surface also Scratches rust on inside Remove the scratches rust by honing or wit...

Page 396: ...may 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 mounting and Measure the pin an...

Page 397: ...s 9803 6410 Section E 80 1 Issue 1 Rotary Coupling Item Part Name 11 Axle 12 V ring 13 Rotor 14 O ring 15 Packing ring 16 Thrust plate 17 Hexagonal socket head screw 18 O ring 19 Cover 20 Hexagonal so...

Page 398: ...ection E 80 2 Issue 1 Rotary Coupling Technical Data cont d 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 9...

Page 399: ...from the upper to the lower section is not affected by the rotational movement and allows the machine to slew 360 in both directions The rotary coupling consists of the inner axle and outer rotor wit...

Page 400: ...tion the machine on a firm level surface before raising one end Ensure the other end is securely chocked Do not rely solely on the machine hydraulics or jacks to support the machine when working under...

Page 401: ...lacement 1 Align the assembly 9 to the lower frame and tighten rotating joint installation bolts 1 and washers 2 Install lock bar Z and tighten mounting screws X and washers Y to specified torque of 1...

Page 402: ...discard O ring 18 3 Remove screws 17 and thrust plate 16 4 Using a jig see Special Tools Section 1 push off axle 11 from the rotor 13 Do not hit with a hammer Section E Hydraulics 9803 6410 Section E...

Page 403: ...ection E Hydraulics 9803 6410 Section E 82 4 Issue 1 Rotary Coupling Dismantling cont d 5 Remove and discard V ring 12 from axle 11 6 Remove and discard O ring 14 and packing rings 15 from rotor 13 JS...

Page 404: ...p 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 on the in...

Page 405: ...etc 4 Install V ring 12 on axle 11 and coat with grease Take care to prevent contamination of the grease by water or dirt 5 Install axle 11 to the rotor 13 Note Set V ring 12 so that it will not be c...

Page 406: ...Install O ring 18 into the rotor 13 8 Install cover 19 onto the rotor 13 using cap screws 20 Torque Settings 20 31 46 37 29 Nm 23 2 27 5 lbf ft Section E Hydraulics 9803 6410 Section E 82 7 Issue 1 R...

Page 407: ...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 408: ...3 2 Section E Hydraulics 9803 6410 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 409: ...E 83 3 Issue 1 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 410: ...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 411: ...nnected 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 24...

Page 412: ...hocks 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 s...

Page 413: ...brake torque excluding reduction gear More than 30 kgf m 217 lbf ft Brake release pressure Min 30 kgf cm2 426 6 lbf in2 Weight 99 kg 218 lb JS160 Motor type Fixed displacement piston motor Reduction...

Page 414: ...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 415: ...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 416: ...of the parts to ensure correct reassembly Section E Hydraulics 9803 6410 Section E 92 2 Issue 1 Slew Motor 4 Remove the caps 37 with 14 mm A F hexagonal sockets and remove relief valves 34 from the m...

Page 417: ...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 418: ...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 419: ...ve swash plate 6 piston assemblies 8 and retainer plate 7 together from cylinder 24 Section E Hydraulics 9803 6410 Section E 92 5 Issue 1 Slew Motor Motor Assembly Cylinder Assembly Dismantling cont d...

Page 420: ...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 421: ...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 6410 Section E 92 7 Issue 1 Slew Motor CAUTION Cleaning Clean...

Page 422: ...E 92 8 Issue 1 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 423: ...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 424: ...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 6410 Section E 92 10...

Page 425: ...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 426: ...17 and attach snap ring 23 Section E Hydraulics 9803 6410 Section E 92 12 Issue 1 Slew Motor Motor Assembly Cylinder Assembly Assembly cont d 20 Apply grease to the O ring and install O ring 13 to cov...

Page 427: ...10 Section E 92 13 Issue 1 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 428: ...103 Nm 76 lbf ft 29 Attach the level gauge A with a pipe wrench setting the height as shown A 26 Final checks after assembling Open the inlet and outlet ports and apply 30 kgf cm2 427 lbf in2 pilot p...

Page 429: ...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 430: ...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 431: ...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 432: ...ins Always wear safety glasses INT 3 1 3 2 Remove the spur gear and 2nd stage holder assembly 76 Section E Hydraulics 9803 6410 Section E 94 1 Issue 1 Slew Motor Reduction Gear Dismantling Refer to th...

Page 433: ...1 3 6 Support planetary gears 72 by hand and withdraw shaft 70 from holder 76 Section E Hydraulics 9803 6410 Section E 94 2 Issue 1 Slew Motor Reduction Gear Dismantling cont d 7 Ring gear removal Rem...

Page 434: ...collar 59 from the assembly 10 Remove the roller bearing 62 from gear case 58 Section E Hydraulics 9803 6410 Section E 94 3 Issue 1 Slew Motor Reduction Gear Dismantling cont d 11 Remove and discard...

Page 435: ...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 436: ...ress fit it on the pinion shaft Note Do not heat to a temperature greater than 100 C Section E Hydraulics 9803 6410 Section E 94 5 Issue 1 Slew Motor Reduction Gear Assembly Refer to the sectional dra...

Page 437: ...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 438: ...on E Hydraulics 9803 6410 Section E 94 7 Issue 1 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 439: ...d by flying 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 mou...

Page 440: ...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 6410 S...

Page 441: ...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 442: ...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 443: ...d View Gearbox JS130 7 3 Component List JS130 7 4 Cross Sectional View JS160 7 6 Exploded View Motor JS160 7 7 Exploded View Gearbox JS160 7 8 Component List JS160 7 9 Traction Motor Dismantling 8 1 I...

Page 444: ...imum pressure 343 bar 4978 lbf in2 350 kgf cm2 2 Speed switching pressure 19 6 68 6 bar 284 296 lbf in2 20 70 kgf cm2 Parking brake Braking torque 255 Nm 188 lbf ft 26 kgf m Release pressure 9 8 bar 1...

Page 445: ...When the piston reaches the end of its power stroke the cylinder is disconnected from the oil supply line and instead is connected to the return line The next 180 of cylinder block rotation causes the...

Page 446: ...ce of the two springs 128 This spool position completely shuts off ports A and B from the motor feed and return ports C and D The inertia of motor M immediately following de selection of travel causes...

Page 447: ...116 and friction plate 115 to separate This releases the braking force from cylinder block 104 which is free to rotate Travel Stopped When travel is de selected pressurised oil is no longer fed to ch...

Page 448: ...maximum angle O1 up against surface Y of spindle 2 In this swash plate position the piston stroke volume is maximised to produce low speed revolution High Speed Operation When high speed is selected p...

Page 449: ...rt A or B When the pressure reaches 235 bar 3414 lbf in2 240 kgf cm2 this overcomes the pilot pressure at port D forcing spool 186 upwards to produce the condition described under Low Speed Operation...

Page 450: ...remove the filler plug and level plug or fill level plug and add the correct grade of gear oil until it begins to overflow from the port Clean off surplus oil seal tape the plug threads and securely t...

Page 451: ...e b O ring is damaged c Seal surface is scratched a Poor motor efficiency b Excessive leakage inside brake valve c Parking brake spring broken d Parking brake friction plate worn Remedy Set correct pr...

Page 452: ...in right or left control valve a Pump regulator and or related parts faulty b Leakage outside pump is excessive a Internal leakage is excessive a Motor or reduction gear is broken b Vibration of pipe...

Page 453: ...Gear Fault finding cont d Symptom 15 Does not change from high speed to low speed Possible cause a Faulty operation of switching valve b Faulty operation of 2 speed switching piston Remedy Check for...

Page 454: ...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 455: ...en blocks 6 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 Section 3 7 Remove the motor co...

Page 456: ...facing upwards 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 assembly and position it on the undercarriage Instal...

Page 457: ...ing 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 po...

Page 458: ...emove 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 motor and con...

Page 459: ...e system residual pressure Disconnect the hose from motor casing drain port D1 left hand motor or D2 right hand motor In place of the hose removed connect an open ended hose long enough to reach the o...

Page 460: ...7 1 Section F Transmission 9803 6410 Section F 7 1 Issue 1 Traction Motor Reduction Gear Cross sectional View JS130 JS00250...

Page 461: ...7 2 Section F Transmission 9803 6410 Section F 7 2 Issue 1 JS00270 Traction Motor Reduction Gear Exploded View Traction Motor JS130...

Page 462: ...7 3 Exploded View Reduction Gear JS130 Section F Transmission 9803 6410 Section F 7 3 Issue 1 Traction Motor Reduction Gear JS00260...

Page 463: ...kit 105 Piston 9 106 Shoe 9 No Description Qty 107 Retainer plate 1 108 Thrust ball 1 109 Timing plate 1 110 Washer 2 112 Piston 1 113 Spring 10 114 Spring 1 115 Friction plate 2 116 Plate 2 118 Valv...

Page 464: ...ner 1 204 Plug 1 205 Shim 1 206 Spring 1 208 O ring 1 209 O ring 1 210 O ring 1 211 Back up ring 2 Body kit 209 O ring 2 212 Body 1 213 Piston 1 214 Plug 1 215 Plug 2 216 Steel ball 2 217 Back up ring...

Page 465: ...7 6 Cross sectional View JS160 Section F Transmission 9803 6410 Section F 7 6 Issue 1 Traction Motor Reduction Gear JS00280...

Page 466: ...7 7 Section F Transmission 9803 6410 Section F 7 7 Issue 1 Traction Motor Reduction Gear Exploded View Traction Motor JS160 JS00300...

Page 467: ...7 8 Exploded View Reduction Gear JS160 Section F Transmission 9803 6410 Section F 7 8 Issue 1 Traction Motor Reduction Gear JS00290...

Page 468: ...h plate 1 104 Cylinder block 1 Piston kit 105 Piston 9 106 Shoe 9 No Description Qty 107 Retainer plate 1 108 Thrust ball 1 109 Timing plate 1 110 Washer 2 111 Washer 1 112 Piston 1 113 Spring 10 114...

Page 469: ...204 Plug 2 205 Shim 2 206 Spring 2 208 O ring 2 209 O ring 2 210 O ring 2 211 Back up ring 4 Body kit 212 Body 1 213 Piston 1 209 O ring 2 214 Plug 1 215 Plug 2 216 Steel ball 2 217 Back up ring 4 218...

Page 470: ...suitable solvent to remove all dirt and dust Dry using compressed air 1 Loosen but do not remove plug 204 and the two sleeves 202 in relief valve body 212 2 Unscrew the four socket head bolts 170 and...

Page 471: ...Remove O rings 155 from plugs 124 6 Remove two springs 128 two plungers 125 and spool 123 from the rear flange Take care to avoid damaging the mating surfaces of spool and rear flange 7 Remove the tw...

Page 472: ...mating seat in the flange 9 Unscrew adaptor 188 from the rear flange Remove and discard O ring 138 10 Remove spool 186 spring 189 and plunger 187 If necessary use an M5 socket head bolt in the thread...

Page 473: ...lock the hole in valve plate 118 and force out the valve plate using oil pressure directed through the brake pressure port Extract spring 120 and seat 119 Remove and discard O ring 133 Discard ring 12...

Page 474: ...e the two steel balls 216 out of body 212 16 Unscrew one of the sleeves 202 from body 212 Remove and discard O ring 208 and the two back up rings 211 from sleeve 202 Remove and discard O ring 209 and...

Page 475: ...6410 Section F 8 6 Issue 1 Traction Motor Dismantling cont d 17 Unscrew plug 204 from sleeve 202 Remove O ring 210 and shim 205 from plug 204 Discard the O ring 18 Remove spring retainer 203 spring 20...

Page 476: ...112 by applying compressed air through the brake pressure port Place a protective cover over the piston to stop it from flying out CAUTION When using compressed air wear safety glasses and gloves Do n...

Page 477: ...2 cannot be removed from this side of the reduction gear If it is necessary to remove these components refer to Reduction Gear Dismantling 24 Remove the swash plate 103 thrust plate 153 JS130 only ass...

Page 478: ...operation protect the machined surface of the cylinder block with suitable sheeting 26 Remove circlip 145 followed by washer 110 spring 114 and the second washer 110 27 Remove shaft 102 complete with...

Page 479: ...arance to flange 101 bore exceeds 0 025 mm 0 001 in b Outer surface is scratched or unevenly worn a Oil seal 132 contact area is worn b Spline is worn a Evidence of thermal seizure a Spline is worn b...

Page 480: ...surface is scratched b Seat surface is scratched a Pressure marks observed b Flaking is occurring c Unevenly worn a Piston 213 sliding surface is scratched a Clearance to body 212 exceeds 0 025 mm 0...

Page 481: ...04 80 19 59 14 8 2 Plug 214 98 19 72 14 10 2 Plug 215 30 5 4 22 4 3 5 Assembly Clean each part in a suitable solvent and dry using compressed air Inspect all parts and renew as required Care must be t...

Page 482: ...reduction gear assembly on the bench with cover 8 uppermost Remove the two plugs 33 Remove the twelve bolts 35 and super lock washers 36 2 Install eye bolts into the tapped holes vacated by plugs 33...

Page 483: ...res take steps to obtain or manufacture a clamping jig to hold them together Remove the three snap rings 20 from flange 3 identifying each snap ring with its hole in the flange Loosen and remove the t...

Page 484: ...wenty four pins 17 from the inner circumference of hub 1 Remove the clamping jig installed at step 6 9 Fit two eye bolts M16 to spindle 2 Attach suitable lifting gear to the eye bolts and raise spindl...

Page 485: ...ve oil seal 132 unless it needs renewing Do not re use an oil seal that has been removed Remove oil seal 132 by putting a screwdriver against the outer edge of the oil seal inside spindle 2 and striki...

Page 486: ...ring 23 Distance piece 10 Bearing 21 Renew if these conditions exist a Excessive damage or wear a Gear teeth unevenly worn a Crankshaft does not rotate freely in the bearings a Sliding surface scratch...

Page 487: ...spindle 2 align the inner race of bearing 22 with the outer race already installed in the spindle Lower gently to avoid damaging the bearing 3 The outer race of bearing 21 is an interference fit in h...

Page 488: ...If bearing 149 has been removed from shaft 102 it will be necessary to fit a new bearing Heat the bearing to 100 10 C 212 18 F before fitting Smear the outer face of the outer race with molybdenum dis...

Page 489: ...spindle 2 as shown 2 Tighten the special nut F of the jig to a torque of 58 Nm 43 lbf ft 6 kgf m 3 Using a micrometer G through a hole in the clearance measuring jig measure depth A Since dimension B...

Page 490: ...as follows a If D is less than C trim off surface G using a lathe until D C b If D C no further action is necessary c If D is greater than C fit a new spindle 2 and flange 3 then repeat steps 1 to 4...

Page 491: ...feeler gauge between snap ring 20 and bearing 22 to measure the clearance 5 The required snap ring thickness T feeler gauge thickness thickness of snap ring installed 0 05 mm 0 002 in Select a suitabl...

Page 492: ...ace the traction motor reduction gear assembly on the bench with cover 13 uppermost Remove the three plugs 30 and the twenty bolts 32 super lock washers 33 2 Insert eye bolts in the cover holes vacate...

Page 493: ...torque higher than the tightening torque will be required Take extra care that seizures do not occur Match mark the coupling gear 8 and spindle 2 to aid assembly Remove the coupling gear 6 Install fou...

Page 494: ...ove and discard O ring 37 8 Dismantle hub 1 parts as follows a Remove floating seal 31 Note Bearings 24 are a shrink fit onto the hub and should not be removed unnecessarily Having been removed the be...

Page 495: ...t to dismantle the carrier assembly comprising carrier 3 cluster gears 6 shafts 9 thrust collars 14 bearings 25 and parallel pins 34 If damage to any of the individual components is evident renew the...

Page 496: ...exist a Excessive damage or wear a Excessive damage or wear b Uneven tooth wear on cluster gears 6 c Rotation of cluster gears 6 not smooth a Uneven wear or damage to gear teeth a Uneven wear or damag...

Page 497: ...following these notes for details of the components and procedures involved 2 When fitting bearings 24 to hub 1 pre heat the hub to 90 5 C 194 9 F Then tap main bearing press jig A see Service Tools S...

Page 498: ...t up the cluster gears 6 with matching marks positions C as shown Insert sun assembly tool see Service Tools Section 1 to lock the gears relative to each other Install the carrier into ring gear 5 and...

Page 499: ...B see Service Tools Section 1 in spindle 2 in place of distance piece 12 2 Lightly tighten three evenly spaced bolts 35 3 Measure dimension A with depth micrometer as shown 4 Measure dimension C of t...

Page 500: ...r 4 coupling gear 8 cover 13 pin 17 or parallel pins 27 1 Install one of the two thrust bearings 20 into coupling gear 8 Use the thinnest distance piece 12 at this time Install coupling 19 onto shaft...

Page 501: ...earing 20 as follows T C X 0 3 to 0 6 mm 6 Select a suitable thrust bearing from the table below Thrust bearing 20 T Classification Symbol BB 1 5 7 0 05 mm 0 224 0 002 in 2 6 0 0 05 mm 0 236 0 002 in...

Page 502: ...antling 5 1 Assembly 5 2 Grease Cylinder Dismantling 6 1 Assembly 6 1 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 W...

Page 503: ...8 197 230 Idler wheel mounting bolts 267 312 27 2 31 8 197 230 Top roller mounting bolts 267 312 27 2 31 8 197 230 Bottom roller mounting bolts 267 312 27 2 31 8 197 230 Recoil spring installation bol...

Page 504: ...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 505: ...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 link see Track Motor Reduction Gearbox Removal and R...

Page 506: ...e side of the unit only remove the wire clip E or roll pin F and separate the hub C from shaft D 3 Remove O ring I from shaft D Pull out the shaft D from the idler wheel G 4 Remove the wire clip E or...

Page 507: ...ome 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 u...

Page 508: ...ub 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...

Page 509: ...ve 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 pressure of 1 9 bar 28 lbf in2...

Page 510: ...130 19 0 75 Build up or renew JS160 21 0 83 Build up or renew Wheel Width c JS130 68 6 2 70 64 5 2 54 Build up or renew JS160 83 8 3 31 80 3 15 Build up or renew Shaft Diameter d JS130 55 2 17 54 6 2...

Page 511: ...nd cutting through the end of the shaft before slowly releasing the pressure TRACK 1 10 2 Place the recoil unit in the spring compression jig see Service Tools Section 1 yoke E uppermost Raise hydraul...

Page 512: ...guide retainer F then spring B and yoke E Raise hydraulic jack A to compress recoil spring B b Install castellated nut D on the threaded section of spring guide retainer F which protrudes through yoke...

Page 513: ...mbling 1 Before installing grease cylinder C remove check valve E and use a press as shown to fully retract the cylinder and expel the grease Refit the check valve 2 Apply Loctite 262 to the threads o...

Page 514: ...track link see Track Motor Reduction Gearbox Removal and Replacement 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 fal...

Page 515: ...ghten the bolts in a diagonal sequence to a torque of 267 312 Nm 197 230 lbf ft 27 31 kgf m 2 Remove the wooden blocks Connect the track link 3 Apply grease through the check valve to adjust the track...

Page 516: ...it Action mm in mm in Width a JS130 58 9 2 32 53 2 09 Renew JS160 66 2 60 60 2 36 Renew Diameter b JS130 585 23 01 579 22 78 Renew JS160 582 22 93 577 22 70 Renew Diameter c JS130 584 25 67 646 25 43...

Page 517: ...ver 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 track link and side frame 3 Loosen but do not remove the mounting bolts...

Page 518: ...sealant 2 With the track supported as shown under Removal step 2 install the roller Apply Loctite 262 to the threads and fit the mounting bolts 3 Remove the wooden blocks and jack 4 Apply grease throu...

Page 519: ...J Track and Running Gear 9803 6410 Section J 10 1 Issue 1 Top Roller Item Part Name A Roller B Plug C Circlip D Cover E O ring F Bolt G Thrust plate H Shaft I Floating seal J Bush K Bush L Mounting br...

Page 520: ...and drain the oil 2 Remove the circlip 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 roller A from the...

Page 521: ...a 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 usi...

Page 522: ...he roller A Coat the metallic face of the seal with engine oil 4 Install a 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 r...

Page 523: ...event water entering the assembly lower it into a tank of water Apply air pressure of 1 9 bar 28 lbf in2 and check that there are no bubbles leaking from the unit If leakage occurs dismantle and re as...

Page 524: ...spurt out or the valve cover fly out and cause serious injury 8 3 4 5 2 Remove the bolts securing the mounting brackets to the side frame 3 Lift the side of the undercarriage high enough to permit bot...

Page 525: ...es in the mounting brackets with the tapped holes in the undercarriage 2 Lower the undercarriage sufficient to allow the mounting bolts to be installed 3 Apply Loctite 262 to the threads and install t...

Page 526: ...ning Gear 9803 6410 Section J 13 1 Issue 1 JS01590 Bottom Roller Item Part Name A Plug B Locking wires C Shaft D Mounting bracket E Mounting bracket F Floating seal G O ring H Roller outer flange J Ro...

Page 527: ...h end of shaft C Remove mounting brackets D and E from shaft C 3 Using a pry bar remove floating seals F from brackets D and E and discard 4 Remove and discard O rings G from shaft C Pull out shaft C...

Page 528: ...ughly in a 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 roug...

Page 529: ...g A with one thread remaining uncovered Install this plug but leave the other one out until after pressure testing step 6 6 Connect compressed air pipe V to the vacant plug A port Using extreme care t...

Page 530: ...f locking wires B by tapping with a hammer 8 Fill the unit with oil see Fluids and Lubricants Section 3 and install plug A using an appropriate pipe thread sealant Section J Track and Running Gear 980...

Page 531: ...ter flange width d JS130 146 5 75 152 5 98 Renew JS160 173 6 81 179 7 05 Renew Shaft diameter e JS130 50 1 97 49 5 1 95 Renew JS160 60 2 36 58 9 2 32 Renew Bushing diameter e JS130 50 1 97 50 8 2 0 Re...

Page 532: ...Contents Page No Technical Data 1 1 i Engine 9803 6410 i Issue 1 Section K Section K...

Page 533: ...min JS160 Less than 2571 rev min Injection Timing static 12 BTDC Injector Opening Pressure 180 bar 2630 lbf in2 Induction System Air Cleaner Type 2 stage dry element with in cab warning indicator For...

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