Section 1 - General Information Introduction About this Manual Machine Model and Serial Number Finally, please remember above all else safety must come first! This manual provides information for the following model(s) in the JCB machine range: Section Numbering JCB JS360 from serial number 1807000 to 1807299.
Section 1 - General Information Introduction Identifying Your Machine Identifying Your Machine Machine Identification Plate Typical Product Identification Number (PIN) Your machine has a data plate, located on the outside the cab as shown at A. The machine serial number is inscribed at B which is the baseplate of the rear frame.
Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Torque Settings Zinc Plated Fasteners and Dacromet Fasteners T11-002 Introduction Bolts and Screws Some external fasteners on JCB machines are manufactured using an improved type of corrosion resistant finish. This type of finish is called Dacromet and replaces the original Zinc and Yellow Plating used on earlier machines.
Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Torque Settings Zinc Plated Fasteners and Dacromet Fasteners T11-002 Introduction Bolts and Screws Some external fasteners on JCB machines are manufactured using an improved type of corrosion resistant finish. This type of finish is called Dacromet and replaces the original Zinc and Yellow Plating used on earlier machines.
Section 1 - General Information Torque Settings Hydraulic Connections Hydraulic Connections T11-003 'O' Ring Face Seal System Adaptors Screwed into Valve Blocks Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45° seat machined into the face of the tapped port. Table 8. Torque Settings - BSP Adaptors BSP Adaptor Hexagon (A/F) Size 1-11 in. mm Nm kgf m lbf ft 1/4 19.0 18.0 1.8 13.0 3/8 22.0 31.0 3.2 23.0 1/2 27.0 49.0 5.0 36.0 5/8 30.0 60.0 6.
Section 1 - General Information Service Tools Numerical List The tools listed in the table are special tools required for carrying out the procedures described in this manual. These tools are available from JCB Service. Some tools are available as kits or sets, the part numbers for parts within such kits or sets are not listed here. For full Part Number details of all tools, including the content of kits and sets, refer to Tool Detail Reference, Section 1.
Section 1 - General Information Service Tools Tool Detail Reference Tool Detail Reference Section B - Body and Framework Note: Not all service tools are illustrated. Fig 1.
Section 1 - General Information Service Consumables Sealing and Retaining Compounds Service Consumables Sealing and Retaining Compounds T11-001_3 Table 1. Type Description Part No. Quantity JCB Multi-Gasket A medium strength sealant suitable for all sizes of 4102/1212 gasket flanges, and for hydraulic fittings of 25-65 mm diameter. 50 ml JCB High Strength Threadlocker A high strength locking fluid for use with threaded 4102/0551 components.
Section 1 - General Information Terms and Definitions Colour Coding Hydraulic Schematic Colour Codes T11-006 The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications. Red Full Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and MRV operating pressure.
Section 2 - Care and Safety Safety Notices Important Information T1-042 Safety Warnings The Operator Manual !MWARNING You and others can be killed or seriously injured if you operate or maintain the machine without first studying the Operator Manual. You must understand and follow the instructions in the Operator Manual. If you do not understand anything, ask your employer or JCB dealer to explain it.
Section 2 - Care and Safety Safety Notices Safety Check List Safety Check List P11-1008_2 Safety - Yours and Others General Safety INT-1-3-1_3 All machinery can be hazardous. When a machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others. In this manual and on the machine you will find warning messages. Read and understand them.
Section 2 - Care and Safety Safety Notices Safety Labels Safety Labels Introduction T1-014_2 !MWARNING Safety Labels Safety labels on the machine warn you of particular hazards. You can be injured if you do not obey the safety instructions shown. INT-1-3-11 Safety labels are strategically placed around the machine to remind you of possible hazards. If you need eye-glasses for reading, make sure you wear them when reading the safety labels.
Section 3 - Maintenance Routine Maintenance Service Requirements Owner/Operator Support Introduction T3-095 Your machine has been designed and built to give maximum performance, economy and ease of use under a wide variety of operating conditions. Prior to delivery, your machine was inspected both at the Factory and by your Distributor to ensure that it reaches you in optimum condition.
Section 3 - Maintenance Routine Maintenance Service Requirements Fit for Purpose Tests for Lifting Equipment T3-097 All lifting equipment (for example forks, lifting hooks and shackles) need regular inspection and testing by a competent person to ensure they are fit for purpose. This may be needed every six months or at least annually in some countries to meet and comply with legislation and for insurance purposes. Check with your local JCB distributor for further advice.
Section 3 - Maintenance Routine Maintenance Health and Safety Health and Safety Lubricants T3-060_3 Introduction It is most important that you read and understand this information and the publications referred to. Make sure all your colleagues who are concerned with lubricants read it too. Hygiene JCB lubricants are not a health risk when used properly for their intended purposes. However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation.
Section 3 - Maintenance Routine Maintenance Health and Safety Battery !MCAUTION T3-061 !MWARNING Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames. Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear goggles. Handle the battery carefully to prevent spillage. Keep metallic items (watches, rings, zips etc) away from the battery terminals.
Section 3 - Maintenance Routine Maintenance Service Schedules Service Schedules Introduction How to Use the Service Schedules T3-036_3 !MWARNING Maintenance must be done only by suitably qualified and competent persons. T3-012_4 In the example shown, A shows all service requirements to be carried out every 10 hours and B shows the requirements to be carried out every 500 hours. Before doing any maintenance make sure the machine is safe, it should be correctly parked on level ground.
Section 3 - Maintenance Routine Maintenance Service Schedules Pre Start Cold Checks, Service Points and Fluid Levels Operation 10 50 250 500 1000 2000 4000 5000 ENGINE Oil level Oil and Filter (1) Pre Cleaner (if fitted) - Check - Sample/Change - Clean Air Cleaner Outer Element - Change Air Cleaner Inner Element - Change Air Cleaner Dust Valve Fuel Level Fuel Tank - Water and Sediment Coolant Quality/Level - Check and Clean - Check - Drain - Check Coolant - Change Fuel Pump Filter Element
Section 3 - Maintenance Routine Maintenance Service Schedules Functional Test and Final Inspection Operation 10 50 250 500 1000 2000 4000 ENGINE Maximum No-Load Speed - Check Exhaust Smoke (excessive) - Check Coolant System - Leaks - Check Stop Control - Operation - Check Fuel System - Leaks and Contamination - Check All Fuel Hoses - Change TRANSMISSION Slew Brake Operation - Check HYDRAULICS Operation All Services - Check Accumulator (engine stopped) - Check Hoses and Pipework - D
Section 3 - Maintenance Routine Maintenance Service Schedules Service Intervals for Attachments Servicing of the hydraulic oil and filters must be done more frequently according to the percentage of total operating hours involving use of the breaker, crusher or pulverizer. When a breaker, crusher or pulverizer is fitted, ensure that the oil and filters are changed at the intervals shown in the table below.
Section 3 - Maintenance Routine Maintenance Service Schedules Periodic Replacement of Safety Related Components operation the service life of specific parts, so routinely replace them as important parts every 2 years. Routinely replace important parts concerned with safety. It is difficult to determine by visual inspection or from Table 2. Fuel System Important Parts Replacement Interval Fuel Hose (Fuel Tank - Engine) Every 2 years or every 4000 hours, whichever comes first.
Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities Fluids, Lubricants and Capacities JCB recommend that you use the JCB lubricants shown as they have been verified by JCB for use on JCB machines. However, you could use other lubricants that are equivalent to the JCB standards and quality or offer the same machine component protection. JS115 - JS145 and Variants Item Capacity ENGINE 15 litres (3.3 UK gal) (4 US gal) Table 5. Fluid/Lubricant JCB Part No.
Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities JS160 - JS190 and Variants Item Capacity ENGINE - JS160-JS180 15 litres (3.3 UK gal) (4 US gal) ENGINE - JS190 23.5 litres (5.2 UK gal) (6.2 US gal) Table 6. Fluid/Lubricant JCB Part No.
Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities JS200 - JS235 and Variants Item Capacity ENGINE 23.5 litres (5.2 UK gal) (6.2 US gal) Table 7. Fluid/Lubricant JCB Part No. Container Size(1) JCB Engine Oil HP 15W40 4001/1505 -15°C to +40°C (5°F to 104°F) 20 Litres JCB Engine Oil HP 10W30 4001/1705 -30°C to +30°C (-22°F to 86°F) 20 Litres 4006/1120 20 Litres COOLING SYSTEM 28 litres (6.2 UK gal) (7.
Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities JS240/260 and Variants Item Capacity ENGINE 21.5 litres (4.7 UK gal) (5.6 US gal) Table 8. Fluid/Lubricant JCB Part No. Container Size(1) JCB Engine Oil HP 15W40 4001/1505 -15°C to +40°C (5°F to 104°F) 20 Litres JCB Engine Oil HP 10W30 4001/1705 -30°C to +30°C (-22°F to 86°F) 20 Litres 4006/1120 20 Litres COOLING SYSTEM 26.8 litres (5.9 UK gal) (7.
Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities JS290 and Variants Item Capacity ENGINE 38 litres (8.4 UK gal) (10.1 US gal) Table 9. Fluid/Lubricant JCB Part No. Container Size(1) JCB Engine Oil HP 15W40 4001/1505 -15°C to +40°C (5°F to 104°F) 20 Litres JCB Engine Oil HP 10W30 4001/1705 -30°C to +30°C (-22°F to 86°F) 20 Litres COOLING SYSTEM 38 litres (8.4 UK gal) (10.
Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities JS330 and Variants Item Capacity ENGINE 38 litres (8.4 UK gal) (10.1 US gal) Table 10. Fluid/Lubricant JCB Part No. Container Size(1) JCB Engine Oil HP 15W40 4001/1505 -15°C to +40°C (5°F to 104°F) 20 Litres JCB Engine Oil HP 10W30 4001/1705 -30°C to +30°C (-22°F to 86°F) 20 Litres 4006/1120 20 Litres COOLING SYSTEM 38 litres (8.
Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities JS360 and Variants Item Capacity ENGINE 38 litres (8.4 UK gal) (10.1 US gal) Table 11. Fluid/Lubricant JCB Part No. Container Size(1) JCB Engine Oil HP 15W40 4001/1505 -15°C to +40°C (5°F to 104°F) 20 Litres JCB Engine Oil HP 10W30 4001/1705 -30°C to +30°C (-22°F to 86°F) 20 Litres 4006/1120 20 Litres COOLING SYSTEM 38 litres (8.
Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities Typical Lubrication Chart Table 13. Icon Definitions Excavator grease Engine oil change Engine oil filter change Engine coolant change Fig 1. A Table 12.
Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities Coolant Mixtures Fuel T3-009_3 Check the strength of the coolant mixture at least once a year, preferably at the start of the cold period. Replace the coolant mixture according to the intervals shown in the machine's Service Schedule. !MWARNING Antifreeze can be harmful. Obey the manufacturer's instructions when handling full strength or diluted antifreeze.
Section 3 - Maintenance Routine Maintenance Tools Tools Carrying Tools onto the Machine When you carry tools onto the machine you must maintain three points of contact with the machine at all times. Lift tools onto the machine in intervals if necessary. Place the tools down before you adjust your grips on the machine. Do not try to adjust your grips on the machine while holding tools. Locations The machine is equipped with a a grease gun (option) and remote oil-drain tube attachment.
Section 3 - Maintenance Routine Maintenance Tools Tools Carrying Tools onto the Machine When you carry tools onto the machine you must maintain three points of contact with the machine at all times. Lift tools onto the machine in intervals if necessary. Place the tools down before you adjust your grips on the machine. Do not try to adjust your grips on the machine while holding tools. Locations The machine is equipped with a a grease gun (option) and remote oil-drain tube attachment.
Section 3 - Maintenance Routine Maintenance Prepare the Machine for Maintenance Prepare the Machine for Maintenance Introduction How to Make the Machine Safe (Excavator Lowered) !MWARNING Maintenance must be done only by suitably qualified and competent persons. Important: Unless a maintenance procedure instructs you differently, you must lower the Excavator. 1 Before doing any maintenance make sure the machine is safe, it should be correctly parked on level ground.
Section 3 - Maintenance Routine Maintenance Cleaning the Machine Cleaning the Machine Introduction !MCAUTION T3-062_2 Clean the machine using water and or steam. Do not allow mud, debris etc. to build upon the machine. Before carrying out any service procedures that require components to be removed: 1 2 Cleaning must be carried out either in the area of components to be removed or, in the case of major work, or work on the fuel system, the whole engine and surrounding machine must be cleaned.
Section 3 - Maintenance Routine Maintenance Cleaning the Machine Cleaning the Machine Introduction !MCAUTION T3-062_2 Clean the machine using water and or steam. Do not allow mud, debris etc. to build upon the machine. Before carrying out any service procedures that require components to be removed: 1 2 Cleaning must be carried out either in the area of components to be removed or, in the case of major work, or work on the fuel system, the whole engine and surrounding machine must be cleaned.
Section 3 - Maintenance Routine Maintenance Cleaning the Machine Cleaning the Machine 1 Exterior Park the machine on level ground. Open the bucket and swing the boom until it is at 90° to the track. Lower the bucket to the ground. Clean the exterior of the machine using water and/or steam. If steam is used the machine must be completely greased afterwards. K Greasing ( T 3-36) 2 3 !MCAUTION 4 Inspect the Track.
Section 3 - Maintenance Routine Maintenance Checking for Damage Checking for Damage Check the Machine Body and Structure Checking the FOPS Structure T3-063_5 Make sure that all guards and protective devices are in place, attached by their locking devices and free from damage. Inspect all steelwork for damage. Pay particular attention to the following: All excavators are designed so that an operator's protective structure can be fitted.
Section 3 - Maintenance Routine Maintenance Checking for Damage Checking for Damage Check the Machine Body and Structure Checking the FOPS Structure T3-063_5 Make sure that all guards and protective devices are in place, attached by their locking devices and free from damage. Inspect all steelwork for damage. Pay particular attention to the following: All excavators are designed so that an operator's protective structure can be fitted.
Section 3 - Maintenance Routine Maintenance Daily Checking Daily Checking It is vital to check certain machine functions and components daily to ensure that the machine can be operated safely and efficiently. !MWARNING Do not remove the hydraulic tank filler cap or cover plate when the engine is running. The hydraulic system is under pressure. You or others could be injured. First stop the engine and then release the pressure. 1 Prepare the machine. K Prepare the Machine for Maintenance ( T 3-29).
Section 3 - Maintenance Routine Maintenance Greasing Greasing Introduction Slew Ring Teeth and Slew Pinion T3-028_2 You must grease the machine regularly to keep it working efficiently. Regular greasing will also lengthen the machine's working life. Refer to the Service Schedule for the correct intervals. Note: The machine must always be greased after pressure washing or steam cleaning. Greasing should be done with a grease gun. Normally, two strokes of the gun should be sufficient.
Section 3 - Maintenance Routine Maintenance Greasing Greasing Introduction Slew Ring Teeth and Slew Pinion T3-028_2 You must grease the machine regularly to keep it working efficiently. Regular greasing will also lengthen the machine's working life. Refer to the Service Schedule for the correct intervals. Note: The machine must always be greased after pressure washing or steam cleaning. Greasing should be done with a grease gun. Normally, two strokes of the gun should be sufficient.
Section 3 - Maintenance Routine Maintenance Greasing Greasing Points !MWARNING You will be working close into the machine for these jobs. Lower the attachments if possible. Remove starter key and disconnect the battery. This will prevent the engine being started. 8-3-1-3 Table 15. Greasing Points Fig 8. 3 Slew the Machine. Start the engine and slew the machine a few degrees.Stop the engine, remove the starter key and apply grease again. Repeat until the whole ring is greased.
Section 3 - Maintenance Routine Maintenance Electrical System Electrical System Battery Note: Before commencing work on the batteries you must read the following procedure in Health and Safety; K Battery ( T 3-5). Note: If a battery requires replacement then both batteries must be replaced. Battery Isolator T3-101 To disconnect the batteries from the machine electrics a battery isolator has been fitted.
Section 3 - Maintenance Routine Maintenance Electrical System Jump-Starting the Engine a !MWARNING b Connect the positive booster cable to the positive (+) terminal on the front battery of the machine A. In temperatures below freezing, the battery electrolyte may freeze if the battery is discharged or poorly charged. Do not use a battery if its electrolyte is frozen. To prevent the battery electrolyte from freezing, keep the battery at full charge.
Section 3 - Maintenance Routine Maintenance Electrical System Fuses Fuse Identification Table 16. Fuse Circuit(s) Protected !MCAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5 The electrical circuits are protected by fuses. The fuse box is located in the rear stowage area. Open the fuse box cover A to gain access to fuses. Fig 22.
Section 3 - Maintenance Routine Maintenance Bolt and Nut Torque Specifications Bolt and Nut Torque Specifications JS115 - JS360 and Variants Tighten the bolts and nuts after the first 50 hours of the running-in stage and every 250 hours thereafter. Tighten the bolts and nuts according to the tables below. Before and after daily work, check the bolts and nuts for looseness and for those missing. Tighten if loose and renew if missing. For tightening torques for the bolts and nuts not listed K Table 24.
Section 3 - Maintenance Routine Maintenance Engine Engine Oil and Filter Checking the Oil Level 1 Open the Engine Compartment. 2 Check the Oil Level. a A B Locate the dipstick A and remove. Oil should be between the two marks. Add oil if necessary through filler B. Use only the recommended oil K Fluids, Lubricants and Capacities ( T 3-16). Re-check the oil level about 10-15 minutes after refilling. b Make sure that the dipstick and filler cap are secure. T022950 Fig 29.
Section 3 - Maintenance Routine Maintenance Engine Cooling System 6 Checking the Coolant Level - 4JJ Engines (NonPressurized Expansion Bottle Type) Check the radiator is full of coolant to the top of the filler neck. If the level is low: a 1 Park the machine on solid, level ground. 2 Turn the engine OFF and remove the ignition key. 3 Let the engine cool down. Switch the ignition ON and switch the cab heater onto hot and full blower speed.
Section 3 - Maintenance Routine Maintenance Engine Fan Belt Checking the Fan Belt Tension !MWARNING Make sure the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5 1 Prepare the machine. K Prepare the Machine for Maintenance ( T 3-29). 2 Check the fan belt tension. There must be 6-8 mm (0.24-0.31 in) slack at X. Fig 46. Fitting a New Fan Belt Complete steps 1 and 2. Fig 45. 3 Loosen the alternator. Slacken bolts A and B.
Section 3 - Maintenance Routine Maintenance Engine Engine Air Filter changed. As a reminder, mark the inner element with a pen each time the outer element is changed. Changing the Outer Air Filter Element !MCAUTION The outer element must be renewed immediately if the warning light on the instrument panel illuminates. 2-3-3-1 Note: Do not attempt to wash or clean the elements - they must only be renewed. Note: Do not run the engine with the dust valve F removed.
Section 3 - Maintenance Routine Maintenance Fuel System Fuel System Draining Fuel Tank Impurities Introduction !MWARNING 1 Stop the engine and remove the key. Fuel Fuel is flammable; keep naked flames away from the fuel system. Stop the engine immediately if a fuel leak is suspected. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. Completely wipe off any spilt fuel which could cause a fire.
Section 3 - Maintenance Routine Maintenance Fuel System Note: The JS290 and JS360 are fitted with a round access hatch to enable the inside of the tank to be cleaned. Draining the Primary Filter/Sedimenter The filter/sedimenter should be drained at least every 50 hours, but more often if necessary. 1 Park the machine on firm and level ground. Stop the engine and remove the key. 2 Locate filter/sedimenter A K Fig 51. ( T 3-75). Fig 50. JS290 and JS360 7 Remove the 6 x bolts securing the access hatch.
Section 3 - Maintenance Routine Maintenance Fuel System Changing the Primary Filter/Sedimenter Element 1 Park the machine on firm and level ground. Stop the engine and remove the key. 2 Locate filter/sedimenter A. 3 Drain and remove the water separator bowl. 4 To remove the filter element, release locking ring D and discard element. 5 Fit new element and secure in position with locking ring D. 6 Refit water separator bowl.
Section 3 - Maintenance Routine Maintenance Fuel System Draining the Main Filter/Sedimenter The fuel filter housing contains a float which moves up and down in accordance with the amount of separated water. Drain any water in the bowl as follows. 1 Prepare the machine. K Prepare the Machine for Maintenance ( T 3-29). 2 Locate the fuel filter A, K Fig 55. ( T 3-79). A Changing the Main Filter/Sedimenter Element 1 Prepare the machine. K Prepare the Machine for Maintenance ( T 3-29).
Section 3 - Maintenance Routine Maintenance Fuel System Bleeding the System Air in the fuel system could cause misfiring or failure to start. Air will enter the system if any part of it is disconnected or emptied. Note: Running the engine with air in the system could damage the fuel injection pump. After maintenance, remove air from the fuel system as detailed below. 1 Prepare the machine. K Prepare the Machine for Maintenance ( T 3-29). 2 Locate the fuel filter A, K Fig 55. ( T 3-79).
Section 3 - Maintenance Routine Maintenance Hydraulic System Hydraulic System Introduction !MCAUTION !MWARNING The temperature of the hydraulic oil will be high soon after stopping the engine. Wait until it cools (less than 40°C) before beginning maintenance. 8-3-4-10 !MWARNING Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear protective glasses and gloves.
Section 3 - Maintenance Routine Maintenance Hydraulic System Releasing the Hydraulic Pressure Releasing Tank Pressure !MWARNING Do not remove the hydraulic tank filler cap or cover plate when the engine is running. The hydraulic system is under pressure. You or others could be injured. First stop the engine and then release the pressure. 8-3-4-4 1 Prepare the machine. K Prepare the Machine for Maintenance ( T 3-29). 2 Release tank pressure. Use the procedure below to release the hydraulic pressure.
Section 3 - Maintenance Routine Maintenance Hydraulic System Oil and Filters Topping-up Fluid Level Checking the Fluid Level 1 Prepare the machine. K Prepare the Machine for Maintenance ( T 3-29). Prepare the machine. K Prepare the Machine for Maintenance ( T 3-29). 2 Release tank pressure. Pressure ( T 3-81) Position the machine on level ground with the bucket and dipper rams fully extended and the boom lowered to rest the attachment on the ground, as at A. 3 Add Fluid.
Section 3 - Maintenance Routine Maintenance Hydraulic System Draining Water and Sediment from the Hydraulic Tank 1 Prepare the machine. K Prepare the Machine for Maintenance ( T 3-29). 2 Release tank pressure, Pressure ( T 3-81). K Releasing Tank Air Bleeding Procedures After replacing the hydraulic oil or repairing or replacing hydraulic components or removing hydraulic pipes, bleed air from the hydraulic circuit Bleeding Air from the Hydraulic Pump 1 Prepare the machine.
Section 3 - Maintenance Routine Maintenance Hydraulic System Draining Water and Sediment from the Hydraulic Tank 1 Prepare the machine. K Prepare the Machine for Maintenance ( T 3-29). 2 Release tank pressure, Pressure ( T 3-81). K Releasing Tank Air Bleeding Procedures After replacing the hydraulic oil or repairing or replacing hydraulic components or removing hydraulic pipes, bleed air from the hydraulic circuit Bleeding Air from the Hydraulic Pump 1 Prepare the machine.
Section 3 - Maintenance Routine Maintenance Slew Gearbox Slew Gearbox Checking the Slew Gearbox Oil Level Changing the Slew Gearbox Oil 1 Prepare the machine. K Prepare the Machine for Maintenance ( T 3-29). 1 Prepare the machine. K Prepare the Machine for Maintenance ( T 3-29). 2 Locate the slew Description ( T 1-5). K Machine 2 Drain the oil. 3 Check the level. gearbox, a a Remove the dipstick A, wipe it clean and re-fit. b Wipe the drain plug clean. Remove any metallic particles.
Section 3 - Maintenance Routine Maintenance Tracks and Running Gear Tracks and Running Gear !MWARNING Tracks Checking/Adjusting the Track Tension 1 Prepare the Machine. K Prepare the Machine for Maintenance ( T 3-29). When opening the check valve always stand to one side and loosen a little at a time until grease starts to come out. If you over-loosen too much grease could spurt out or the valve cover fly out and cause serious injury. Position the machine on level ground.
Section 3 - Maintenance Routine Maintenance Tracks and Running Gear !MCAUTION Running Gear Oil will gush from the hole when the drain plug is removed. Keep to one side when you remove the plug. Checking the Track Gearbox Oil Level 1 Prepare the machine. K Prepare the Machine for Maintenance ( T 3-29). 2-3-4-2 b Remove filler/level plug A and drain plug B. Allow the oil to drain out. Position the machine on level ground with the level and drain plugs as illustrated K Fig 74. ( T 3-95).
Section 3 - Maintenance Routine Maintenance Bucket Bucket Checking/Adjusting For Side Play 2 It is possible to compensate for lateral wear which leads to sideways play of the bucket. Regular use of this compensating facility leads to less wear on the bucket swivel pin A and the dipper bushes B. Measure the Clearance at C. The clearance should be approximately 0.8 mm K Fig 75. ( T 3-96). 3 Check the clearance. Fig 75. 1 Prepare the machine. K Prepare the Machine for Maintenance ( T 3-29).
Section 3 - Maintenance Routine Maintenance Windscreen Washer Windscreen Washer Checking the Level Locate the front window washer bottle A and fill with clean water. The liquid should contain a de-icing fluid to prevent it freezing. Do not use engine coolant antifreeze. Note: Do not use the washer when there is no liquid in the bottle as it will damage the motor. A Fig 77.
Section 3 - Maintenance Routine Maintenance Fire Extinguisher (If fitted) Fire Extinguisher (If fitted) The fire extinguisher should be inspected daily. !MWARNING Do not use the fire extinguisher in a confined space. Make sure that the area is well ventilated during and after using the fire extinguisher. 4-2-3-1 The fire extinguisher is located in the cab behind the drivers seat at A. Ensure the extinguisher is only used as directed on the canister. A Fig 79.
Section 3 - Maintenance Routine Maintenance Fire Extinguisher (If fitted) Fire Extinguisher (If fitted) The fire extinguisher should be inspected daily. !MWARNING Do not use the fire extinguisher in a confined space. Make sure that the area is well ventilated during and after using the fire extinguisher. 4-2-3-1 The fire extinguisher is located in the cab behind the drivers seat at A. Ensure the extinguisher is only used as directed on the canister. A Fig 79.
Section 3 - Maintenance Routine Maintenance Troubleshooting Troubleshooting To extend the service life and improve the operation of the machine, daily inspection and lubrication are necessary as well as immediately isolating any problem found and dealing with it. If the machine is operated with the problem uncorrected, it may lead to larger trouble and possibly to a big accident. If trouble occurs, search for the cause in the items below and make adjustments, repairs, etc. as necessary.
Section 3 - Maintenance Routine Maintenance Troubleshooting Monitor Display - Fault Messages Note: For further information refer to Monitor Panel. Message WATER TEMP HYD TEMP Table 37.
Section 3 - Maintenance Routine Maintenance Troubleshooting Table 41. Alternator Cause Message ALTERNATOR Belt tension Adjust Wiring fault Repair Defective battery Replace Defective regulator Replace (1) Defective alternator Repair or replace(1) Table 42. Low coolant Cause Message COOLANT LOW Refill Defective sensor Replace(1) Table 43. Engine oil filter Cause Remedy Engine oil dirty Replace engine oil, oil filter Defective sensor Replace(1) Table 44.
Section 3 - Maintenance Routine Maintenance Troubleshooting Hydraulic pump Table 46. Oil not delivered by oil pump Cause Remedy Low hydraulic oil Refill Clogged suction filter Repair Cause Table 47. Hydraulic pump does not build pressure Remedy Oil leakage inside hydraulic pump Replace hydraulic pump(1) Air inside the hydraulic pump Refill oil or check hose on suction side Main relief valve pressure set too low Adjust pressure(1) Table 48.
Section 3 - Maintenance Routine Maintenance Troubleshooting Working Attachments Table 50. Overall low power Cause Remedy Insufficient engine output Refer to Engine Service Manual Function drops due to wear of hydraulic pump Replace hydraulic pump(1) Defective main relief valve Adjust the pressure or replace(1) Low hydraulic oil Refill Viscosity of hydraulic oil incorrect Replace with hydraulic oil of proper viscosity Suction filter clogged Replace suction filter Table 51.
Section 3 - Maintenance Routine Maintenance Troubleshooting Travel Table 55. Insufficient travel force Cause Remedy Pressure setting for main relief valve is too low Adjust the pressure(1) Defective counterbalance valve Replace the counterbalance valve(1) Performance reduction of travel motor Replace travel motor(1) Swivel joint packing damage Replace swivel joint packing(1) Performance reduction of hydraulic pump Replace hydraulic pump(1) Table 56.
Section 3 - Maintenance Routine Maintenance Troubleshooting Slew Table 58. Insufficient slew force Cause Remedy Performance reduction of slew motor Replace slew motor(1) Thermal seizure of slew shaft Supply grease or replace the slew shaft(1) Table 59.
Section 3 - Maintenance Routine Maintenance Troubleshooting Slew Table 58. Insufficient slew force Cause Remedy Performance reduction of slew motor Replace slew motor(1) Thermal seizure of slew shaft Supply grease or replace the slew shaft(1) Table 59.
Section B - Body and Framework Technical Data General Table 1. Item A/C Belt Tension Belt installation tension - 600N. After 30 - 120 min running - 400N. Minimum tension - 250N.
Section B - Body and Framework Technical Data Static Dimensions Static Dimensions JS360 - Monoboom Dimensions in millimetres (ft. in) A Track length on ground 4021 (13 ft 2in) B Undercarriage overall length 4954 (16 ft 3 in) C Track gauge 2600 (8 ft 6 in) D Width over tracks (600 shoes) 3200 (10 ft 6 in) D Width over tracks (700 shoes) 3300 (10 ft 10 in) D Width over tracks (800 shoes) 3400 (11 ft 2 in) D Width over tracks (900 shoes) 3500 (11 ft 6 in) Table 2. Standard Boom 2.21m 2.
Section B - Body and Framework Technical Data Shipping Weight Shipping Weight Approximate weight when equipped with monoboom, medium length dipper, bucket, operator and full fuel tank except where indicated otherwise.
Section B - Body and Framework Technical Data Dig Depth Chart Dig Depth Chart JS360 - Standard Monoboom Standard Boom 6.45 m Dipper 2.21 2.63 3.23 4.03 m (ft in) m (ft in) m (ft in) m (ft in) A Maximum digging reach 10.06 (33 0) 10.46 (34 4) 11.02 (36 2) 11.76 (38 7) B Maximum digging reach (on ground) 9.85 (32 4) 10.25 (33 8) 10.82 (35 6) 11.57 (38 0) C Maximum digging depth 6.25 (20 6) 6.68 (21 11) 7.27 (23 10) 8.07 (26 6) D Maximum digging height 9.51 (31 2) 9.73 (31 11) 10.
Section B - Body and Framework Technical Data Air Conditioning (option) Air Conditioning (option) TB-012 Automatic Temperature Control (ATC) System Pressure Switch Setting Table 3. Bar lbf/in2 Low Pressure Cut In 1.4 (+/- 0.1) 20 (+/- 1.5) Low Pressure Cut Out 0.3 (+/- 0.1) 4 (+/- 1.5) High Pressure Cut In 17.2 (+/- 0.7) 250 (+/- 10) High Pressure Cut Out 27.6 (+/- 0.7) 400 (+/- 10) Table 4. Refrigerant Gas Charge Weight R-134a 1400g +/- 10g Table 5.
Section B - Body and Framework Basic Operation Automatic Temperature Control (ATC) System Basic Operation Automatic Temperature Control (ATC) System TB-011 E F B G H A C D 716480-C3 Fig 1.
Section B - Body and Framework Fault Finding Air Conditioning TB-010_2 Preliminary Checks Before any checks are carried out on the refrigerant circuit the following checks should be made: 1 Check the compressor drive belt is serviceable and correctly tensioned. 2 Check the condenser and engine radiator are not blocked by debris, clean with compressed air or water if necessary. 3 Check that the condenser fins are not flattened or damaged, the fins must allow air to pass freely.
Section B - Body and Framework Fault Finding Air Conditioning TB-010_2 Preliminary Checks Before any checks are carried out on the refrigerant circuit the following checks should be made: 1 Check the compressor drive belt is serviceable and correctly tensioned. 2 Check the condenser and engine radiator are not blocked by debris, clean with compressed air or water if necessary. 3 Check that the condenser fins are not flattened or damaged, the fins must allow air to pass freely.
Section B - Body and Framework Service Procedures HVAC/Air Conditioning Unit TB-009 Removal A Note: Before removing the HVAC/Air Conditioning Unit, the system must be discharged. !MWARNING B The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be disconnected until the system has been discharged by a refrigeration engineer or a suitably trained person. You can be severely frostbitten or injured by escaping refrigerant.
Section B - Body and Framework Service Procedures Air Conditioning Compressor Air Conditioning Compressor Removal and Replacement F E D Removal G A Note: Before removing any of the hoses from the compressor, the system must be discharged. !MWARNING The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be disconnected until the system has been discharged by a refrigeration engineer or a suitably trained person.
Section B - Body and Framework Service Procedures Cab Structure Cab Structure Direct Glazing Removing the Broken Glass and Old Sealant TB-002_5 The following procedures explain how to correctly remove and install panes of glass that are directly bonded to the cab frame apertures. When carrying out the procedures, relevant safety precautions must be taken. 1 Always wear safety glasses during both removal and replacement.
Section B - Body and Framework Cab Panels Cab Panel Removal Cab Panels Cab Panel Removal TB-008 Remove the screws as shown in the following illustrations. Note: Care must be taken not to force the panels away from cab frame, as this could result in breakage of the cab panel Right Hand Cab Panels C006290 Fig 27. C006280 Fig 26. C006300 Fig 28.
Section B - Body and Framework Cab Panels Cab Panel Removal Cab Panels Cab Panel Removal TB-008 Remove the screws as shown in the following illustrations. Note: Care must be taken not to force the panels away from cab frame, as this could result in breakage of the cab panel Right Hand Cab Panels C006290 Fig 27. C006280 Fig 26. C006300 Fig 28.
Section C - Electrics Technical Data Battery Installation C D E B A Fig 1. Item C-1 Table 1.
Section C - Electrics Basic System Operation Circuit Symbols Basic System Operation Circuit Symbols TC-013 The following notations are used in the description circuit, drawings. C005310GB-2 Fig 1. Inputs and Outputs The letters i/p and o/p refer to input and output. The letters in brackets i.e. (C-21) refer to the connector and pin number. C001660-2 Fig 2.
Section C - Electrics Basic System Operation Component Identification Component Identification JS360 The item numbers in the following table are identified on the Wiring schematics in this section. K Fig 5. ( T C-8) Item Part Number Description Location 1 728/80071 Electronic control unit 1 Behind the rear cab panel. 2 728/80073 Electronic monitor system Front of cab. 3 701/80369 Facia switch panel Right hand side of cab. 4 30/927073 Controller (heater) On Right hand console.
C-8 Schematic Diagram 4 25 13U 14U 15U 16U 1 2 3 4 2 1 2 1 3 4 3 1 C32 C33 2 4 3 1 2 1 C26 (0.5)812 59 (0.5)812 SWING SHUT OFF SOL V TRAVEL ALARM SENSOR 0V REF CUSHION SOL V (0.5)406 KEY SW - BATT RELAY (0.5)422D 16 74 32 2 8 7 3 2 30 3 (0.5)425 A/C BINARY P SW (0.5)829 (0.5)811B (0.5)809 (0.5)612A 42 (0.5)423 OVERLOAD (0.5)829 FUEL PUMP 43 44 9 (0.5)836 10 (0.5)600C O/LOAD 11 846B 12 504H (0.5)434 (0.
Section C - Electrics Basic System Operation A.M.S (Advanced Management System) A.M.S (Advanced Management System) TC-011 Operation B The JCB A.M.S system is a whole machine electronic control system. The system controls engine speed, pump power, transmission, excavator functions, lights, wiper, auxiliary circuits, warning lamps, etc. The system is a 'CAN BUS' system which links Electronic Control Units (ECUs) on the vehicle.
Section C - Electrics Basic System Operation Circuit Concepts Circuit Concepts Inputs There are two main types of input, Digital and Analogue. Digital type inputs are on/off type inputs (i.e. switches) and can be Low side inputs or High side inputs. Low side inputs are inputs that provide a ground to the ECU. High side inputs are inputs that provide a positive feed to the ECU.
Section C - Electrics Basic System Operation Pulse Width Modulation (PWM) Pulse Width Modulation (PWM) Ohms law states that, the amount of current flow in a circuit is determined by the voltage, and the resistance. A 24v circuit with a resistance of 6 ohms, would draw a current of 4 amps. This would be the case for a standard solenoid, which is either on or off. Once the voltage is applied to the circuit, it is present 100% of the time. This would be known as a 100% duty cycle.
C-15 ECU1/EMS/FACIA Power Supply and Network 1 14 5A 11 5A IGNITION EY K SWI TCH BATTERY SUPP LY 12 ECU1-B C9 C5 10A 4 C210 STD-WHEELED CAN LINK 4 435 545 304 544 10 612D BATTERY C11 DIAGNOSTIC CONN 2 1 545 MAIN REL AY 612 16 612E A 305 B 545A CAN SHIELD18 544 C 544A D 612F F 24 H J 9803/9880-3 REDUN DANCY SWI TCH C13 1 2 87A GND I/P7,8,15,1623 87 E 612G 85 CHASSIS22 501B CAN LO 21 86 GND I/P9~1417 611E OV 11 CAN HI 15 C250 WR 3 30 BATTERY 6 503B IGNITI
C-16 ECU 1 Supply to Output Drivers 1 ECU1 ECU1-B C9 9803/9880-3 SUPPLY TO O/P17 ~ 22 1 O/P23 ~ 28 2 O/P13 ~ 16 7 O/P13 ~ 16 8 O/P7 ~ 12 13 O/P7 ~ 12 14 O/P1 ~ 6 19 O/P1 ~ 6 20 4 104 105 103B 103 103A 102B 102 301 1 15A 102 2 15A 103 3 15A 104 4 10A 105 5 10A 102A 301B 301 R 301A C6 1 C-16 Section C - Electrics C049120 Fig 18.
Section C - Electrics Basic System Operation Engine Throttle Control Engine Throttle Control Operation Fig 19. The maximum rev/min value for each mode is specified in software. The maximum rev/min value is used as A mode maximum. E mode maximum is 100 rev/min less than A mode maximum. P & L mode maximum is 200 rev/min less than A mode maximum K Fig 20. ( T C-19). During calibration the ECU noted the maximum and mini mum positions of the throttle position sensor.
Section C - Electrics Basic System Operation Pump Control for Each Mode Pump Control for Each Mode Operation Fig 23. The machine can operate in four different modes, depending upon the type of work required K Engine Throttle Control ( T C-18). The pump output horsepower is varied by means of a PWM signal to the pump control solenoid valve which varies for each mode. Tier III machines are required to reduce the "range band" "X to Y" (pump milliamps) K Fig 25.
Section C - Electrics Basic System Operation Hardware Sensing Hardware Sensing TC-012_2 Operation C049900-2 Fig 29. Due to changes in operation of some machine systems and harness from January 06 the ECU1 needs to know what system is fitted to operate the correct outputs. To sense this, machines built from January 06 have permanent live feed to the ECU1 o/p 36 (C-29). This can be viewed on the 5 second menu on "HARNESS TYPE, NEW". Machines previous to January 06 will not have this input.
Section C - Electrics Basic System Operation Auto Boost Pressure Auto Boost Pressure Operation C049920-1 Fig 30. The auto pressure boost function is only available when the excavator is in auto mode. By default it is not available in precision and economy mode and is permanently on (although not indicated on the EMS) in lifting mode. In auto mode, when the boost pressure switch is closed the 2 stage relief valve, ECU1 o/p 24 (C-27) is energised (according to the logic diagram, K Fig 31. ( T C-28)).
Section C - Electrics Basic System Operation Engine Oil Level Warning Engine Oil Level Warning Operation C049930-1 Fig 33. The oil level float switch is positioned in the side of the engine. When the engine oil level is at an acceptable level, the float switch is closed, applying an earth to the ECU1 i/p 35 (A-3) When the engine oil level drops below the acceptable level, the float switch is opened, removing the earth from the i/p. The i/p is only checked on machine ignition on.
Section C - Electrics Basic System Operation Engine Pre Heat (Glow plugs) Engine Pre Heat (Glow plugs) Operation C049890-2 Fig 35. This feature allows the engine cylinders to be pre-heated, before engine cranking to assist cold start performance. When the key switch is turned to the `Ignition' position the ECM detects the temperature to determine whether and for how long preheat is required. The ignition provides a positive feed to the Preheat relay and an input to the ECM at i/p V24.
Section C - Electrics Basic System Operation Engine Automatic Warm Up Engine Automatic Warm Up Operation C031610GB-2 Fig 37. This feature allows the engine to quickly warm up to normal operating temperature if the vehicle is not being used. Automatic warm up will only be performed 15 seconds after the engine is started and provided the following conditions are satisfied: 1 Water temperature is less than 50 ºC (engine coolant temperature is sent from the ECM via the CAN bus).
Section C - Electrics Basic System Operation Engine Automatic Idle Engine Automatic Idle Operation C027250GB-3 Fig 39. When auto idle function has been selected via the switch on the Facia Switch Panel (FSP) the engine will return automatically to the auto idle setting if no services have been selected for 5 seconds (default). This time can be varied between 5 and 30 seconds via the SET menu on the EMS. A second press of this switch will disable the function.
Section C - Electrics Basic System Operation Engine One Touch Idle Engine One Touch Idle Operation C027250GB-2 Fig 40. When one-touch idle is selected via the button on the right hand controller the engine will return to the low idle setting, regardless of any other input, the EMS will display the "LOW IDLE" message to confirm selection. A second press of this switch will disable the function and the engine revs will return to the setting of the throttle dial.
Section C - Electrics Basic System Operation Engine Start/Stop Engine Start/Stop Operation C031471GB-2 Fig 42. Starting/Stopping the engine Pressing the Emergency Stop Button When the ignition key is turned to the crank position, 24v is fed to: If the emergency stop button on the FSP is pressed whilst the engine is running, the 24v from ECU o/p 22, (C-26) to the Emergency Stop Relay is stopped.
Section C - Electrics Basic System Operation Limp Mode system Limp Mode system Operation EMS Limp Mode 16 Ignition 15 Redundancy ECU1 Key Switch Limp mode Switch 1 2A Sys B-5 2 +V ign FSP O/p 22 (C-26) Emer. Stop O/p 21 (C-36) Lever Lock Sol.Valve I/p 32 (A-33) Lever Lock Switch O/p 34 (C-38) Swing Lock Sol. Valve C030750GB-2 Fig 44.
Section C - Electrics Basic System Operation Servo Isolator Servo Isolator Operation C005540GB-2 Fig 47. The operator has the ability to isolate the excavator controls by pressing the isolator switch on the facia switch panel. When the Isolator switch is pressed both the warning lamp and the switch status indicator are illuminated. ECU1 now de-energises the output to the isolator solenoid valve o/p 21 (C-36).
Section C - Electrics Basic System Operation Wiper Wiper Operation C027300GB-2 Fig 49. The wiper has three modes of operation, intermittent, permanently on and off. Timing for the intermittent function is performed by ECU1, and can be varied via the set menu on the EMS. When the wiper switch on the Facia Switch Panel (FSP) is pressed once o/p 12 (C-17) on ECU1 is pulsed for 0.5 seconds to start the wiper stroke. A hold on contact within the motor assembly retains power for the return stroke of the blade.
Section C - Electrics Basic System Operation Lower Wiper (option) Lower Wiper (option) Operation C027310GB-2 Fig 51. The lower wiper is a customer selected option and is fitted to the lower glass panel at the front of the operator's cab. The wiper has three modes of operation intermittent, continuous and off. Timing for the intermittent function is performed by ECU1. The same timer as utilised for the standard wiper is used to synchronise both wipers together.
Section C - Electrics Basic System Operation Washer Washer Operation C027320GB-2 Fig 53. When the washer switch on the facia switch panel is pressed the ECU1 operates the output o/p 23 (C-37) to the washer pump. The ECU output is only energised whilst the facia switch is pressed. Whenever the washer output is energised the wiper output ECU1 o/p 12 (C-17) is also energised. When the washer switch is released the wiper will do three additional strokes and then turn itself off.
Section C - Electrics Basic System Operation Horn Horn Operation C028390GB-2 Fig 55. When the left joystick rear button is pressed, input ECU1 i/ p 24 (A-14) is selected the horn output ECU1 o/p 6 (C-14) is energised whilst the button is pressed.
Section C - Electrics Basic System Operation Travel Alarm Travel Alarm Operation C005590GB-2 Fig 57. The travel alarm is available as an option on the tracked machines. Whenever travel movement is requested travel pressure switch ECU1 i/p 27 (A-16) is selected. When this input is grounded the travel alarm output ECU1 o/p 25 (C23) is energised.
Section C - Electrics Basic System Operation Soft/Hard (Cushion) Soft/Hard (Cushion) Operation C005600GB-2 Fig 59. The soft/hard mode allows the operator to select the response of the hydraulic circuits, soft being controlled and hard being fierce when de-selecting boom and dipper functions. Soft mode is the default setting when starting the machine. To change to hard mode the operator must select the option by pressing cushion switch on the facia switch panel.
Section C - Electrics Basic System Operation Slew Brake (100%) Slew Brake (100%) Operation C028410GB-2 Fig 61. The slew parking brake holds the current slew position of the machine and prevents slew drift. This is the default operation with the engine running. The operator signals for slew movement by moving the left hand joystick. This results in the slew pilot pressure switch being activated. This signals the ECU1 to energise the slew parking brake solenoid valve, thus enabling slew.
Section C - Electrics Basic System Operation Slew lock (100% Slew Brake) Slew lock (100% Slew Brake) Operation C028430GB-2 Fig 63. The slew lock prevents any slew operation of the machine, even if the LH joystick is moved. It acts as 100% slew parking brake and disables the slew pilot circuit, by applying equal pressure on either side of the slew spool in the main valve block (slew shut off). The lock is operated by pressing the slew lock switch on the fascia switch panel.
Section C - Electrics Basic System Operation Slew Brake Solenoid Valve Failure Slew Brake Solenoid Valve Failure Operation In the event of slew brake solenoid or the slew pressure switch failing, the slew brake will still operate. The pilot signal from the hand controller passes through the shuttle block and enters the slew brake valve via port A. When the pressure overcomes the slew brake shuttle, the signal passes through the slew brake valve via port B and is directed to the slew brake.
Section C - Electrics Basic System Operation 3-Speed Travel 3-Speed Travel Operation C005630GB-2 Fig 65. Using a combination of two solenoids (high speed travel solenoid and max flow cut solenoid), pump flow and swash plate position of the travel motor are used to give three travel speeds. The selected travel speed is indicated on the EMS as either a Hare (High), double arrow (Middle), or Tortoise (Low) and is changed by successive presses of the travel change switch.
Section C - Electrics Basic System Operation Work Lamps Work Lamps Operation C028460GB-2 Fig 68. Work lamps are located on the boom and front body (tool box) of the machine. An optional set of three additional work lamps can be fitted to the cab and counter weight. The switch is returned by pressing in the reverse direction boom and tool box work lamps and the optional work lamps are extinguished. When the work light switch is moved to the first position, the input i/p 9 (A-28) to the ECU1 is selected.
Section C - Electrics Basic System Operation Viscous Fan Viscous Fan A ECU 1 EMS FAN DUTY O/p 8 (C-3) B CAN Data I/p 10 (A-38) C I/p 1 (A-19) D I/p 2 (A-18) 865670 Fig 70. Viscous fan solenoid B A/C switch C Hydraulic oil temperature D Engine coolant temperature C 0 10 20 30 40 50 60 70 80 90 100 100 Operation The cooling pack temperature is controlled by an electromagnetically controlled viscous coupling fan.
Section C - Electrics Basic System Operation Fuel Level Sensor/Warning Fuel Level Sensor/Warning Operation C005650GB-2 Fig 72. A float sensor is fitted to the fuel tank to measure the level of fuel in the tank. A magnetic float rises up a tube containing a series of 5 ohm resistors with switches in parallel. The fuel level is displayed to the operator by means of a bar graph gauge. The actual values can be displayed via the EMS SET+MODE menu.
Section C - Electrics Basic System Operation Engine Temperature Sensor/Warning Engine Temperature Sensor/Warning Operation C028490GB-2 Fig 74. The engine is fitted with a thermistor sensor and thermal switch to measure the water temperature. The engine temperature (in ºC) is sent from the ECM to the ECU1 via the CAN bus. The temperature is displayed to the operator by means of a bar graph gauge. The actual values can be displayed via the EMS's SET+MODE menu.
Section C - Electrics Basic System Operation Coolant Level Warning Coolant Level Warning Operation C005680GB-2 Fig 77. A float switch is fitted to the engine coolant reservoir. When the reservoir is empty the float switch ECU1 i/p 37 (A-2) is connected to ground. This causes the EMS to alarm. The buzzer sounds for 1.5 seconds, a "COOLANT LOW" message is displayed on the EMS and flashing low coolant level LED illuminates for 5 seconds. This is followed by a repetitive message and constant LED on.
Section C - Electrics Basic System Operation Air Filter Blocked Warning Air Filter Blocked Warning Operation C005690GB-2 Fig 78. A pressure switch is fitted to the engine air filter. When the filter is blocked the pressure increases, thus triggering the switch and the ECU1 i/p 11 (A-7) is connected to ground. This causes the EMS to alarm. The buzzer sounds for 1.5 seconds, a "AIR FILTER" message is displayed on the EMS and a flashing engine air filter blocked LED illuminates for 5 seconds.
Section C - Electrics Basic System Operation Hydraulic Temperature Sensor/Warning Hydraulic Temperature Sensor/Warning Operation C005700GB-2 Fig 80. The hydraulic system is fitted with a thermistor and a thermal switch to measure temperatures. The temperature is displayed to the operator by means of a bar graph gauge. The actual values can be displayed via the EMS's SET and MODE menu. When the hydraulic oil temperature reaches 97ºC the EMS will illuminate the warning lamp.
Section C - Electrics Basic System Operation Alternator/No Charge Warning Alternator/No Charge Warning Operation C030360GB-2 Fig 82. The output of the alternator is monitored by the ECU1 and a warning alarm sounded if the output voltage falls below a set value. When the value of the alternator input, ECU1 i/p 3 (A-9) falls below 23 volts or above 32 volts, the ECU1 sends a CAN message to the EMS which in turn illuminates the warning lamp.
Section C - Electrics Basic System Operation Quick hitch (option) Quick hitch (option) Operation C005730GB-2 Fig 84. !MWARNING SET + MODE (20 secs) Scroll to Q/H option When using Quick Hitch Type 2, the attachment can become unexpectedly disengaged from the Quick Hitch, when any of the following occurs: Power failure to the Electronic Control Unit (ECU).
Section C - Electrics Basic System Operation Overload Caution (option) Overload Caution (option) Operation C049770GB-2 Fig 86. Overload caution is used as a warning to the operator that the machine is lifting a mass which is exceeding the safe load capacity of the machine. An overload is indicated after the overload pressure switch, ECU1 i/p 13 (A-27) has been activated.
Section C - Electrics Basic System Operation Beacon Beacon Operation C005750GB-2 Fig 88. Beacon is activated by pressing the beacon switch on the facia switch panel and ECU1 o/p 4 (C-22) is switched on. Beacon operation is cancelled by a second press of the facia switch thus disabling the ECU1 output and extinguishing the status LED.
Section C - Electrics Basic System Operation Hammer Only Hammer Only Operation C030430GB-1 Fig 90. The hammer is operated by pressing the foot pedal forward which supplies a pilot pressure signal to close the pressure switch and operate the option spool in the main control valve (MCV). When the pressure switch is closed, ECU 1 i/p 20 (A-11) senses the grounding of the pressure switch, which reduces the engine rpm to a level preset in the SET menu.
Section C - Electrics Basic System Operation Scrap Magnet Option Scrap Magnet Option Operation C030460GB-2 Fig 93. When a scrap handling magnet attachment is fitted to the machine, the high voltage required for its operation is supplied by an engine driven generator. If the minimum engine rpm is too low, the supply voltage to the magnet may decrease to the point where any material on the magnet may drop off.
Section C - Electrics Basic System Operation Cab Interior Lamp Cab Interior Lamp Operation C005790GB-2 Fig 94. A switch near the cab door can be pressed to switch on the cab interior light for access to the machine in the dark. The input i/p 7 (A-30) activates the ECU1 when the ignition is switched off. When the light switch is pressed the cab light will be switched on for 5 minutes or until a second press of the light switch within the 5 minute period.
Section C - Electrics Basic System Operation Refuelling Pump Refuelling Pump Operation +24V Refuel Pump Relay EMS ECU1 O/P5 (C-13) M CAN bus Refuel Pump Motor Ov Ref (A-20) Fuel Level Sensor I/P4 (A-8) I/P16 (A-35) Refuel Pump Switch C030500GB-3 Fig 96. ECU1 Requirements A refuelling pump can also be installed on the machine. This pump can be used in two different modes: automatic or manual.
C-109 Air Conditioning 9803/9880-3 Section C - Electrics Basic System Operation Air Conditioning C049830-2 C-109 Fig 98.
Section C - Electrics Basic System Operation Heated Seat Heated Seat Operation C030500GB-2 Fig 99. When the heated seat switch is selected, an electrical current passes over the seat thermostat to the heating element. The element will then warm the seat. The thermostat is set to 20°C - ON and 30°C - OFF. On initial starting when the heated seat switch is selected, the heated seat element will turn on only if the thermostat is below 30°C. Once the thermostat reaches 30°C the heater will turn off.
Section C - Electrics Basic System Operation Radio and Cigar Lighter Radio and Cigar Lighter Operation Radio The radio has a permanent 12-volt supply from pin 4 of the voltage converter to pin 5 of the radio. The permanent supply is to retain the memory in the radio. The 12-volt switched supply to power the radio is fed from pin 5 of the voltage converter to pin 2 of the radio via a rocker switch (Mute button) in the right hand console of the cab.
Section C - Electrics Basic System Operation Service Required Warning Service Required Warning Operation C005800GB-2 Fig 101. The service warning LED in the EMS will illuminate (no buzzer) when the next service or oil change is due, according to the service schedule. The EMS also displays "SERVICE RQD" and/or "OIL CHANGE". The total elapsed time will be decided by the recorded hours on the hour meter.
Section C - Electrics Basic System Operation EMS Set Menu. EMS Set Menu. When the SET button on the EMS is pressed a sub menu structure appears, enabling the operator to customise the machine operations and confirm the local time/date. The following functions are available: The up/down arrows INT WIPER S X LANGUAGE scroll through the menu and the item is selected by pressing the "ACK" button. Pressing "SET" at any time will return the operator to the normal display. Intermittent wiper speed.
Section C - Electrics Basic System Operation EMS Set + Mode Menu EMS Set + Mode Menu When the SET and MODE buttons on the EMS are pressed together a sub menu appears, enabling the technician to view more detailed data on the machine and to set option configurations. The following functions are available: MODEL NAME Displays the model type. HRDWARE VER Displays the hardware version SFTWARE VER Displays the software version. SCRAP MAG The current status of the scrap magnet function is displayed.
Section C - Electrics Basic System Operation EMS Set+Mode (20 sec) Menu. EMS Set+Mode (20 sec) Menu. When the SET and MODE buttons on the EMS are pressed together for 20 seconds a sub menu structure appears, enabling JCB trained personnel to cancel the intermediate service warning, calibrate the throttle and override the engine speed sensor input to energise solenoids for testing purposes. The up/down arrows scrolls through the menu and the item is selected by pressing the "ACK" button.
Section C - Electrics Fault Finding JCB Servicemaster Fault Finding JCB Servicemaster TC-010 Introduction Servicemaster is a gateway application allowing a large number of vehicle support applications to be linked using one familiar interface. The interface acts as a graphical tool for selecting the target vehicle from a database of vehicle families and triggering the particular service tool application desired.
Section C - Electrics Fault Finding Fault Finding Without Using the JCB Servicemaster Diagnostic Tool Fault Finding Without Using the JCB Servicemaster Diagnostic Tool TC-015 Introduction 6 The AMS system is designed so that all of the components that are connected to the system are able to communicate with each other. This means not only are the machine hours displayed on the Electronic Monitor (EMS) but also they are recorded in the Electronic Control Unit 1 (ECU-1).
Section C - Electrics Service Procedure Testing of ECU Inputs + Outputs TC-014_2 Remove panel behind drivers seat, for access to the ECU A. Testing Low Side Input With the switch open the meter will read 0v. With the switch closed the meter will read 24-28v. ECU Switch (rocker, momentary, pressure, level, etc.) Input Red lead V Black lead C005840GB Fig 2. Testing High Side Input A With the switch open the meter will read 0v. With the switch closed the meter will read 24-28v.
Section C - Electrics Service Procedure Testing of ECU Inputs + Outputs TC-014_2 Remove panel behind drivers seat, for access to the ECU A. Testing Low Side Input With the switch open the meter will read 0v. With the switch closed the meter will read 24-28v. ECU Switch (rocker, momentary, pressure, level, etc.) Input Red lead V Black lead C005840GB Fig 2. Testing High Side Input A With the switch open the meter will read 0v. With the switch closed the meter will read 24-28v.
Section C - Electrics Service Procedure Using a Multimeter Using a Multimeter TC-002 In order to obtain maximum benefit from the fault finding information contained in Section C it is important that the technician fully understands the approach to fault finding and the use of the recommended test equipment, in this case a FLUKE 85 or AVO 2003 digital multimeter, or a moving pointer (analogue) multimeter. The approach is based on a fault finding check list.
Section C - Electrics Service Procedure Using a Multimeter Using a Multimeter TC-002 In order to obtain maximum benefit from the fault finding information contained in Section C it is important that the technician fully understands the approach to fault finding and the use of the recommended test equipment, in this case a FLUKE 85 or AVO 2003 digital multimeter, or a moving pointer (analogue) multimeter. The approach is based on a fault finding check list.
Section C - Electrics Service Procedure Battery Battery TC-001_4 Maintenance !MWARNING To ensure that the battery provides optimum performance the following steps should be observed: 1 Make sure that the electrical connections are clean and tight. Smear petroleum jelly on connectors to prevent corrosion. 2 When applicable - never allow the electrolyte level to fall below the recommended level - 6 mm (1/4 in) above the plates. Use only distilled water for topping up.
Section C - Electrics Service Procedure Wiring Harness Repair Wiring Harness Repair TC-004 !MCAUTION Introduction Instances do occur where it is necessary to incorporate auxiliary electrical components into existing electrical circuits and, although unlikely with present wiring harnesses, repair or replace specific individual wires within a harness. This will also apply to other machines in addition to those of manufacture.
C-177 Harness Data Harness Interconnection Cab Sub Harness Main components connected to this harness: Roof Facia Link Harness Main components connected to this harness: Electronic Monitoring System (EMS) Power Socket Radio Mute Switch Facia Switch Panel HVAC Controller 9803/9880-3 Main Harness Main components connected to this harness: Slew Brake Valve Main Control Valve 8 Spool Solenoid Shuttle Valve Fuse link - Ignition Battery Glow Plugs Alternator Starter Motor Engine Temperature - Sensors Work Ligh
C-178 Main Harness Connector Location For connector identification K Table 1. ( T C-181) C-C 15 16 17 33 3 9803/9880-3 19 Harness Data C-178 Main Harness Fig 2.
Section C - Electrics Harness Data Fascia Link Harness - Type 1 Fascia Link Harness - Type 1 TC-016 Connector Location 2 9 4, 6 11, 12, 13, 14,15 1 5 3 8 7 10 A407772 Fig 11. Connector Identification Table 2. Item Connector Function 1 Location C14 Monitor EMS K Fig 12. ( T C-190) & K Fig 13. ( T C-191) 2 C15 Facia Switch Panel K Fig 12. ( T C-190) & K Fig 13. ( T C-191) 3 C24 Worklamp Switch K Fig 12. ( T C-190) & K Fig 13. ( T C-191) 4 C309 Cigar Lighter K Fig 12.
Section C - Electrics Harness Data Fascia Link Harness - Type 2 Fascia Link Harness - Type 2 Connector Location 2 9 4 11, 12, 13, 14,15 1 5 3 7 8 A407772 Fig 14. Connector Identification Table 3. Item Connector Function Location 1 C14 Monitor EMS K Fig 15. ( T C-193) & K Fig 16. ( T C-194) 2 C15 Facia Switch Panel K Fig 15. ( T C-193) & K Fig 16. ( T C-194) 3 C24 Worklamp Switch K Fig 15. ( T C-193) & K Fig 16. ( T C-194) 4 C309 Power Socket K Fig 15. ( T C-193) & K Fig 16.
Section C - Electrics Harness Data Cab Harness - Type A Cab Harness - Type A TC-017 Connector Location For connector identification K Table 4. ( T C-196) 25 26 27 22 34 13 28 10, 11, 12 32,33 1, 2, 3, 4 29 31 35, 36 16, 17, 18, 20, 21, 22 47 39 14 15 40 41 43 5, 7, 9, 38 8, 50, 51 49 52, 53 48 6 55 37 56 54 Fig 17.
Section C - Electrics Harness Data Cab Harness (includes Engine Harness) - Type B Cab Harness (includes Engine Harness) - Type B Connector Identification Table 6.
Section C - Electrics Harness Data Cab Harness (includes Engine Harness) - Type C Cab Harness (includes Engine Harness) - Type C Connector Identification Table 7.
Section E - Hydraulics Technical Data General Data Technical Data General Data Valve Block Type Table 1. Hydraulic Pilot System Operating System Set pressure relief Main Relief Pressure: Standard 319 bar (4626 lb/in2) at 220 litre/min (48 UK gal) Pressure Raising 343 bar (4975 lb/in2) at 240 litre/min (53 UK gal) Overload Relief Pressure: Bucket open/close 363 bar (5264 lb/in2) at 20 litre/min (4.4 UK gal) Dipper 363 bar (5264 lb/in2) at 20 litre/min (4.
Section E - Hydraulics Basic System Operation Component Identification Item Table 1.
Section E - Hydraulics Basic System Operation Introduction to Hydraulic Schematic Symbols Introduction to Hydraulic Schematic Symbols TE-001 General (Basic and Functional Symbols) Complex hydraulic components and circuits can be described to the engineer by using graphical symbols. The following pages illustrate and give a brief description for some of the more common symbols used. Table 3.
Section E - Hydraulics Basic System Operation Introduction to Hydraulic Schematic Symbols Introduction to Hydraulic Schematic Symbols TE-001 General (Basic and Functional Symbols) Complex hydraulic components and circuits can be described to the engineer by using graphical symbols. The following pages illustrate and give a brief description for some of the more common symbols used. Table 3.
Section E - Hydraulics Circuit Descriptions Hydraulic Schematic JS360 The item numbers in the following table are identified on the Hydraulic Schematic diagrams. K Fig 1. ( T E-17) Table 1.
Section E - Hydraulics Circuit Descriptions Main Servo/Pilot Line Main Servo/Pilot Line Components 1 Cab Manifold 2 8 Station 3 Shuttle Valve 4 Travel pedal 5 Slew Lock Solenoid 6 Cushion Valve 7 Main Control Valve a Dipper 2 b Boom 1 c Bucket d Travel Right hand e Dipper 1 f Boom 2 g Slew h Option i 8 Travel Left hand Tank Return Hose Colour BL Blue BR Brown CI Colourless G Green GR Grey LB Light Blue O Orange P Pink R Red V Violet W White Y Yellow LG Light
Section E - Hydraulics Circuit Descriptions Cab Servo/Pilot Line Cab Servo/Pilot Line Components 1 Right Joystick 2 Travel pedal 3 Left Joystick 4 Cab Manifold 5 Shuttle Valve Hose Colour BL Blue BR Brown CI Colourless G Green GR Grey LB Light Blue O Orange P Pink R Red V Violet W White Y Yellow LG Light Green DG Dark Green E-22 9803/9880-3 E-22
Section E - Hydraulics Circuit Descriptions Servo/Pilot Pressure and Return Line Servo/Pilot Pressure and Return Line Components 1 Slew Motor 2 Rotary coupling 3 8 Station 4 Cushion Valve 5 Tank Manifold 6 Main Pump 7 Main Control valve 8 Cab Manifold 9 Servo Filter Hose Colour BL Blue BR Brown CL Colourless G Green GR Grey LB Light Blue O Orange P Pink R Red V Violet W White Y Yellow LG Light Green DG Dark Green E-26 9803/9880-3 E-26
Section E - Hydraulics Circuit Descriptions Neutral Circuit Neutral Circuit For Schematic, K Fig 8. ( T E-31). With all the controls in the neutral position, flow from pump 1 enters the main control valve 14 at port P2 and flow from pump 2 enters the main control valve 14 at port P1. Oil is allowed to flow across all of the spools via the neutral gallery when all controls are in the neutral position. Oil from pump 1 exits port Ps2 and oil from pump 2, exits port Ps1 at the top of the main control valve.
Section E - Hydraulics Circuit Descriptions Straight Line Travel Straight Line Travel For individual travel and boom circuits, K Fig 9. ( T E-33). To demonstrate the linear travel, both travel spools and boom up spool have been selected, refer to individual circuits. Servo pressure enters the main control valve 14 at Pa1 to select LH travel spool.
Section E - Hydraulics Circuit Descriptions Travel - Middle Speed Travel - Middle Speed For schematic, K Fig 10. ( T E-35). When both tracks are selected forward, servo pressure from port 2 (LH travel lever), and port 4 (RH travel lever) 35 enters the main control valve 14 at Pa6 and Pa1 respectively, selecting the left and right hand travel spools.
Section E - Hydraulics Circuit Descriptions Boom Up Boom Up For schematic, K Fig 11. ( T E-37). Servo pressure from the hand controller 48 enters the servo shuttle valve 46 at port A3 and is distributed to: 1 Boom up pressure switch 45 at port S2 2 Auto mode pressure switch 43 at port C9 3 Port B3 to the cushion control valve 49 at port F and exits at port H, to the main control valve 14 at port Pa8 to select both boom (1), boom (2) spools and upper pilot pressure switch 52.
Section E - Hydraulics Circuit Descriptions Dipper Out Dipper Out For schematic, K Fig 13. ( T E-41) Servo pressure from the hand controller 50 is sent to port A5 of the shuttle valve 46 and is distributed to: 1 Port C9 to activate the auto mode pressure switch 43. 2 Port B5 to port B of the cushion valve 49, through the valve leaving at port D. The signal is sent to port Pa5 on the Main control valve 14 selecting the dipper.(1) spool, Dipper (2) spool and the upper pressure switch.
Section E - Hydraulics Circuit Descriptions Dipper In Dipper In For schematic, K Fig 14. ( T E-43) Servo pressure from the hand controller 50 is sent to port A6 of the servo shuttle valve 46 and is distributed to: 1 Port C9 to activate the auto pressure switch 43. 2 Port B6 to port A on the cushion valve 49, through the valve leaving at port C (if machine is fitted with HBCV, pressure is also sent via port A1 to port P on the HBCV to allow trapped oil in the ram to exit).
Section E - Hydraulics Circuit Descriptions Bucket Opening Bucket Opening For schematic, K Fig 15. ( T E-45). Servo pressure from port 1 of the hand controller 48 selects the bucket open spool position via the pilot shuttle block 46, port A8 and B8. Servo pressure at port Pa7 then selects the bucket spool and upper pressure switch. Flow from pump 2 is available to the bucket spool via the parallel working gallery and boom over bucket priority valve BBV.
Section E - Hydraulics Circuit Descriptions Priority Valves Priority Valves For schematic, K Fig 17. ( T E-49). Boom over Slew Priority (A) This is selected by the operator via switch in the right hand console. When operated the boom priority solenoid on the 8 spool block 60 is energised sending a signal via port C6 to the main control valve 14 at port Pi1. This selects the boom over slew priority. Oil now being fed to the slew spool is restricted to give priority to the boom.
Section E - Hydraulics Circuit Descriptions Slew Circuit Slew Circuit For schematic, K Fig 18. ( T E-51). Slew over Dipper Priority (A) Circuit description is for swing left. This is a non-selectable function automatically carried out within the main control valve 14 when slew and dipper are used together. Servo pressure from the hand controller 50 enters the Servo shuttle valve 46 at port A2 and is distributed to: 1 Port C7 to port A on 8 station solenoid valve 60.
Section E - Hydraulics Circuit Descriptions 100% Slew Lock 100% Slew Lock For schematic, K Fig 19. ( T E-53). When the slew lock button is operated in the cab, the ECU1 give two outputs: 1 To the 2 slew shut off solenoids 44. This puts either side of the slew spool to tank and prevents operation of the circuits. 2 To the CT3 solenoid on the 8 Station solenoid valve 60, allowing any pressure in the slew brake to drain to tank.
Section E - Hydraulics Circuit Descriptions Merged Flow Merged Flow For schematic, K Fig 20. ( T E-55). This option allows the flow of both pumps to come together where the attachment requires high oil flow. When the merged option is selected, using the rocker switch in the cab and the auxiliary pedal 53 is operated, the hammer/auxiliary switch 45 is closed. Once the pressure switch is closed the ECU1 will energise solenoid A, B and C.
Section E - Hydraulics Circuit Descriptions Hammer Circuit Hammer Circuit For Schematic, K Fig 21. ( T E-57) The hammer function only works when the hammer pedal 53 is pressed in a forward direction. In this position pilot pressure from the foot pedal closes the hammer pressure switch 45. The ECM then selects the pre-set hammer RPM on the engine. Pilot pressure from the pedal 53 selects the auxiliary spool via port pa2.
Section E - Hydraulics Main Control Valve Description Table 1.
Section E - Hydraulics Main Control Valve Port Identification Port Identification 11 13 12 14 10 15 9 16 17 8 18 7 19 6 5 20 4 21 3 22 2 1 A B Fig 4. Main Control Valve viewed in Direction of Arrow A For port location, K Table 2. ( T E-65).
Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Operation Hydraulic Pump Regulation The regulator on pump A1 works the same as above. For this description pump A2 has been used. For schematic, K Fig 1. ( T E-17) If Q max cut is selected a 40 bar servo pressure signal from the 8 spool solenoid block enters the pump at port Pm2. This will partly select the Q max cut piston J. which pushed the piston against spring A and reduces the pump to 60% maximum flow.
Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Dismantling and Assembly Hydraulic Pump Dismantling and Assembly The working environment must be clean and the workbench covered with a cloth or rubber sheet to prevent damage to the components. 5 Remove socket head screws 7, 8, 9 to release valve cover 10. The illustration shows both halves of the double axial piston pump. The regulators and the gear pump are not shown. K Fig 14.
Section E - Hydraulics Hydraulic Pump/Regulator Coupling Coupling TE-031 Assembly 1 3 Secure the coupling plate/flywheel A to the engine with bolts B. Note: The mating faces of the coupling plate/flywheel and engine must be clean. 2 Position the 4 x aluminium inserts C onto the coupling plate/flywheel. Ensure the dowels are installed correctly and the inserts are flush with the coupling/ flywheel. Secure the inserts to the coupling plate/ flywheel with bolts D.
Section E - Hydraulics Remote Control Valve (Hand Control) Operation TE-008 The remote control valve is a pressure reduction valve used to control the servo pressure operated system. Four pressure reduction valves used to control the servo pressure are located in the main housing. Direction of the output servo pressure is controlled by selective movement of the control lever. The valves and control levers are mounted in the arm rests on both sides of the operator's seat.
Section E - Hydraulics Remote Control Valve (Hand Control) Removal and Replacement Removal and Replacement 9 !MWARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Make sure the engine cannot be started while the hoses are open.
Section E - Hydraulics Remote Control Valve (Hand Control) Dismantling and Assembly Dismantling and Assembly Dismantling Note: Ensure retaining plate moves freely to prevent sudden release due to spring pressure beneath. Note: All parts are precision made and require the utmost care when being handled. 7 Note: During dismantling, do not use excessive force to separate components which could cause scratches or burrs on bearing surfaces.
Section E - Hydraulics Travel Pedal Valve Dismantling and Assembly TE-007 8 Remove plug 7 with the grease cap 12, packer 13 and `O'-ring attached. 9 Remove piston 14 and damping spring 8 from the casing. 10 Remove spring washer 16 from the casing 10 using tweezers etc. 11 Remove steel balls 17 using a magnet. 12 Fix the lower casing assembly in a vice and remove the `O'-rings 18, 19 from casing 20. 13 Remove pressure reduction valve assembly and return spring 21 from casing 20.
Section E - Hydraulics Solenoid Valve (8 Station) Operation Solenoid Valve (8 Station) Operation TE-026 C4 B A C1 P CT10 CT5 CT6 CT7 CT8 B2 CT11 T1 T2 C13 CT4 CT3 CT1 C9 CT2 C11 C5 C6 C7 C8 C12 C10 T023420 Fig 1.
Section E - Hydraulics Solenoid Valve (8 Station) Operation Solenoid Valve (8 Station) Operation TE-026 C4 B A C1 P CT10 CT5 CT6 CT7 CT8 B2 CT11 T1 T2 C13 CT4 CT3 CT1 C9 CT2 C11 C5 C6 C7 C8 C12 C10 T023420 Fig 1.
Section E - Hydraulics Solenoid Valve (8 Station) Removal and Replacement Removal and Replacement !MWARNING Replacement Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Make sure the engine cannot be started while the hoses are open.
Section E - Hydraulics Solenoid Valve (8 Station) Dismantling and Assembly Dismantling and Assembly F E D L K J H C B G A T023430 Fig 2. Dismantling 8 Using a 5mm Allen key remove valve J, ball K and seat L. 1 Unscrew cap A from solenoid valve. 2 Slide solenoid B, away from the main control valve. 3 Loosen spool C and extract spool from the main control valve. 4 Repeat steps 1-3 to remove all solenoid valves from the valve.
Section E - Hydraulics Shuttle Valve Removal and Replacement TE-025 !MWARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Make sure the engine cannot be started while the hoses are open.
Section E - Hydraulics Shuttle Valve Dismantling and Assembly Dismantling and Assembly Dismantling Table 1. Pressure Switches Port Function Harness Tape Colour K Fig 1. ( T E-123) 1 Remove the pressure switches 1 and plug all orifices to prevent ingress of dirt . 2 Remove plugs 2 from valve. 3 Using a 5mm Allen key remove valve 3, ball 4 and seat 5.
Section E - Hydraulics Cushion Valve Operation TE-024 The machine defaults to cushioned mode on start up. The following descriptions describe only the `dipper in' function but, `dipper out', `boom in' and `boom out' circuits all operate in the same way. T023050-1 Fig 1. A1 C E1 D G H R S T A B E F A406700 Fig 2.
Section E - Hydraulics Cushion Valve Removal and Replacement Removal and Replacement !MWARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Make sure the engine cannot be started while the hoses are open.
Section E - Hydraulics Cushion Valve Dismantling and Assembly Dismantling and Assembly Dismantling K Fig 7. ( T E-132). 1 Remove adapter A and `O'-ring B from valve. 2 Extract spring C, spool D and spring E. 3 Remove adapter F from valve and repeat step 2. Port Hose Colour S Green T Clear Inspection Before assembling the solenoid valve make sure that a thorough inspection of all the components is carried out.
Section E - Hydraulics Slew Motor Motor Operating principles piston expels low pressure hydraulic fluid T via the output side A(b) of the control plate, port b and back to tank. Driving force F2 varies according to the flow rate of the high pressure hydraulic fluid input. The following detailed description explains the operating cycle of an individual piston.
Section E - Hydraulics Slew Motor Slew Brake Operation Slew Brake Operation Cylinder block F is splined to output shaft G. Two friction plates A are splined to the outer edge of the cylinder block and are interleaved between three counter plates B which are fixed to the slew motor casing E. locking cylinder block F and casing E and preventing rotation. The brakes are released when hydraulic pressure is applied to port X.
Section E - Hydraulics Slew Motor Slew Brake Operation Slew Brake Operation Cylinder block F is splined to output shaft G. Two friction plates A are splined to the outer edge of the cylinder block and are interleaved between three counter plates B which are fixed to the slew motor casing E. locking cylinder block F and casing E and preventing rotation. The brakes are released when hydraulic pressure is applied to port X.
Section E - Hydraulics Slew Motor Fault Finding Fault Finding Motor Does Not Rotate Symptom The pressure is low. Cause The relief valve is not set correctly. Remedy Set to the correct value. The relief valve does not work properly. Plunger sticking. The pressure is correct but no rotation. Repair or renew the plunger. Plunger orifice contaminated. Dismantle and clean. Plunger not seating correctly. Renew the plunger seat. Overload protection operating. Remove the cause of overload.
Section E - Hydraulics Slew Motor Removal and Replacement Removal and Replacement TE-027 X C078320 Fig 3. Removal 3 Make an alignment line across the gearbox and motor mounting flanges, to provide a reference during assembly. 4 Remove bolts X. 5 Using suitable lifting equipment carefully lift slew motor until clear of machine, refer to Section E, Technical Data. !MWARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you.
Section E - Hydraulics Slew Motor Dismantling and Assembly Dismantling and Assembly Hydraulic Motor Components 992 123 122 121 116 111 982 706 707 303 124 052 432 171 106 151 161 471 443 304 162 163 985 101 491 433 437 444 301 984 113 106 438 994 117 401 051-1 118 742 469 743 488 114 702 355 351 472 451 131 051 Fig 4.
Section E - Hydraulics Slew Motor Reduction Gear Assembly Removal and Replacement TE-028 Y X C077990 Fig 1. Removal !MWARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Make sure the engine cannot be started while the hoses are open.
Section E - Hydraulics Slew Motor Reduction Gear Assembly Dismantling and Assembly Dismantling and Assembly C068760 Fig 2.
Section E - Hydraulics Rotary Coupling Operation The coupling is located in the centre of the machine between the lower and upper sections and rotates around the slew centreline. The supply and return oil flow to the coupling, piped from the upper to the lower section, is not affected by the rotational movement and allows the machine to slew 360° in both directions. The rotary coupling consists of the inner axle 11 and outer rotor 13 with packing rings, 'O'-rings, thrust plate and cover.
Section E - Hydraulics Rotary Coupling Removal and Replacement Removal and Replacement !MWARNING Removal 1 Jack up the machine by pressing the boom/dipper on the ground. Install wooden blocks under the tracks. K Fig 2. ( T E-172). Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented.
Section E - Hydraulics Rotary Coupling Dismantling Dismantling as a guide to the dismantling and assembly procedures refer to the sectional illustration, K Fig 1. ( T E-171). 1 Remove the bolt 5-B and cover 5-A. 2 Remove the 'O'-ring 5-C. Do not reuse the 'O'-ring 5-C. 3 Remove bolts 5-D and the thrust plate 5-E. 4 Remove seal 5-F. G B A C D H E F C031300-C1 Fig 6. 6 Remove the V-ring 7-J and nylon ring 7-K from the axle 7-H. Note: Do not reuse the V-ring J and nylon ring K.
Section E - Hydraulics Rotary Coupling Assembly Assembly Inspect the parts for signs of wear, pitting, scratching, discolouration etc. Polish out scratches using a fine grade oil stone. Before assembly, thoroughly clean all parts using a suitable solvent: Do NOT use solvents on 'O'-rings, backup rings and seals. Fit new 'O'-rings, backup rings and seals. Lubricate all 'O'-rings, backup rings and seals, with clean hydraulic fluid before fitting. 1 Clean the rotor 10-G with cleaning fluid or compressed air.
Section E - Hydraulics Hydraulic Rams Precautions During Use TE-006 Installation 1 Special seal materials are necessary so check to see if the ram that you are using is suitable or not. Precautions when installing the ram on the machine. a When installing and removing from the machine, suspend the ram safely. c 2 b Suspending the ram by the piping is not only dangerous, but can also cause damage to the cylinder.
Section E - Hydraulics Hydraulic Rams Removal and Replacement Removal and Replacement Typical Bucket Ram P11-E001_2 Removal !MWARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Make sure the engine cannot be started while the hoses are open. 803090 Fig 2.
Section E - Hydraulics Hydraulic Rams Dismantling and Assembly Dismantling and Assembly TE-023 Dismantling the Piston Rod from the Cylinder Tube Refer to Section 1, Service Tools. Before starting work, clean all surfaces with a suitable solvent and dry with compressed air. Each part is precision made, so handle with care. Do not force any part as this may cause damage. Protect the dismantled parts if they are to be left for a period of time. 1 Drain the oil. 2 Disconnect the external piping.
Section E - Hydraulics Hydraulic Rams Maintenance Specifications Maintenance Specifications In order to ensure long life of the hydraulic ram, carry out inspection and maintenance regularly. If an abnormal point Inspection, Maintenance Point is found, repair as soon as possible referring to the troubleshooting chart. Table 5.
Section E - Hydraulics Service Procedures Make the Machine Safe TE-009 Note: You can complete most of the maintenance procedures with the boom lowered. Unless a maintenance procedure instructs you differently, you must lower the boom. You must make the machine safe before you complete any service procedures. 1 Park the machine on firm level ground. 2 Apply the parking brake (if fitted). 3 Lower the equipment or, raise and fit the applicable safety strut. 4 Stop the engine.
Section E - Hydraulics Service Procedures Pressure Testing - General Pressure Testing - General Confirmation of the Oil Temperature Confirm the oil temperature is between 45°C - 55°C using the self check function. If the temperature is low use the following warm-up procedure. Warming-up Procedure 1 Turn the throttle control to mid-range and make sure the work mode is set to E. 2 Run the engine until the coolant temperature gauge reads within the normal (green) range.
Section E - Hydraulics Service Procedures Pressure Relief Valve Location Pressure Relief Valve Location TE-011 2 3 5 4 1 6 9 8 10 7 11 C047240-C1> Fig 2. K Table 2.
Section E - Hydraulics Service Procedures Main Relief Valve (MRV) Pressure Main Relief Valve (MRV) Pressure TE-012 1 Prepare the Machine a Operate the dipper out and lower the boom to set the bucket on the ground. C030150-1 C Fig 3. A b Make the machine safe, refer to Section E, Service Procedures. c Install a 0 - 400 bar (0 - 6000 lb/in2) pressure gauge in TP1 or TP2.
Section E - Hydraulics Service Procedures Servo Relief Pressure Servo Relief Pressure 1 Prepare the Machine a pressure gauge reading should be compared to the technical data at the start of this section. If it is outside the limits adjust the pilot relief valve as below. Operate the dipper out and lower the boom to set the bucket on the ground. 4 Loosen the lock nut B of the pilot Relief Valve.
Section E - Hydraulics Service Procedures Slew Motor Pressure Relief Slew Motor Pressure Relief TE-015 1 Note: If the water-proof slew lock solenoid valve is not removed. Full slew pressure can not be read. Prepare the machine a Operate the dipper out and lower the boom to set the bucket on the ground. Note: Pressure measurement is also possible on the slew motor, upper section. 5 If the readings are outside the limits, continue as below. 6 Pressure Adjustment a C030150-1 Fig 7.
Section E - Hydraulics Service Procedures Auxiliary Relief Valves Auxiliary Relief Valves TE-014_2 General 1 Prepare the machine a Operate the dipper out and lower the boom to set the bucket on the ground. C030150-1 Fig 9. b Make the machine safe, refer to Section E, Service Procedures. 2 Increase MRV Pressure, refer to Section E, Service Procedures. 3 Test the ARVs with the engine at idle using the appropriate test points. 4 Restore Original MRV Pressure, refer to Section E, Service Procedures.
Section E - Hydraulics Service Procedures Travel Motor Relief Pressure Travel Motor Relief Pressure TE-016 1 Prepare the Machine a 4 Start the engine, select MID speed travel, lower the gate lock lever and run the engine at minimum noload speed in the E mode. 5 Slowly engage the locked travel motor and measure the pressure in forward and reverse. 6 The pressure gauge reading (travel motor) should be compared to the technical data at the start of the section.
Section E - Hydraulics Fault Finding Hydraulic Contamination TE-002_3 cleaning unit. K Fig 1. ( T E-233). General Bulletin 011 also refers. Hydraulic Fluid Quality This machine uses a large volume of fluid in the hydraulic system for power transmission, equipment lubrication, rust prevention and sealing.
Section E - Hydraulics Fault Finding Main Control Valve Main Control Valve Symptoms Spool sticking Table 1. Possible Causes Countermeasures 1. Oil temperature is abnormally high. Remove the obstruction. 2. Hydraulic oil is dirty Replace the hydraulic oil and clean the circuit at the same time. 3. Port connector is tightened too much Check the torque. 4. Valve housing is deformed due to Installation Loosen the installation bolt and check. 5.
Section E - Hydraulics Fault Finding Relief Valve Relief Valve Symptoms Pressure does not rise at all Table 2. Possible Causes Countermeasures 1. The main poppet, sleeve or pilot poppets 1 are sticking open or foreign matter is in the valve seat. 2 3 Relief pressure is unstable 1. The pilot poppet seat is damaged. Check whether foreign matter is in each poppet. Check whether each part is sliding smoothly. Clean all the parts. Replace the damaged parts. 2. The piston is sticking to the main poppet.
Section E - Hydraulics Fault Finding Hydraulic System Hydraulic System Symptoms The hydraulic system is not working well or not at all E-237 Table 3. Possible Causes Countermeasures 1. Pump problem. Check the pressure or replace the pump. 2.Foreign matter clogging inside the relief valve. Disassemble the relief valve and clean. 3. Relief valve trouble. Check according to the maintenance procedures. 4. Ram trouble. Repair or replace. 5. Load is too heavy. Check the circuit pressure. 6.
Section E - Hydraulics Fault Finding Slew Motor Slew Motor Symptom Cause Motor does Internal damage to the not run motor. Table 4. External Inspection Countermeasure Repair K Table 5. ( T E-239). Measure the oil drain volume. High possibility of damage to the sliding surfaces if the supply volume is approximately equal to the drain volume. Dismantle and inspect. Internal damage to the motor.
Section E - Hydraulics Fault Finding Hydraulic Pump Hydraulic Pump Often the regulator and attendant valves or pump are combined which makes it very difficult to discover the reason for the trouble. Inspect the following categories which will assist in discovering the abnormal point. 1 Filter and Drain Oil Inspection. Inspect the filter element. Check to see whether there is an abnormally large amount of foreign matter.
Section E - Hydraulics Fault Finding Hydraulic Rams Hydraulic Rams Hydraulic Ram Faults and Remedies It is often not easy to find the part causing the fault. In the table possible problems are listed. K Table 9. ( T E-241). Repair is difficult, refer to the estimated cause and treatment listed in the table. The general phenomenon, estimated causes and treatment are shown. K Table 10. Item E-241 ( T E-242).
Section E - Hydraulics Fault Finding Fault Finding Tests Fault Finding Tests Slow or Underpowered: Additional information Measure the amount of deviation over a 20 metre (165.6 ft) distance and record ground conditions. – boom up operation – bucket service operation – dipper service operation Deviation limit = 1m (39.4 in) deviation in 20m (165.
Section E - Hydraulics Fault Finding Test 001: Testing Negative Control Signal Test 001: Testing Negative Control Signal Pi1 Pi2 C031360 Fig 2. 1 Fit test gauges (0 - 60 bar, 10 - 1000lb in2 ) into hose connections to ports Pi1 + Pi2 with tee piece adapter 2 Warm up machine hydraulic temperature to 50 °c (122 °f) 3 K Table 11.
Section E - Hydraulics Fault Finding Test 002: Test Max Flow Signal Test 002: Test Max Flow Signal Pm2 Pm1 C031360 Fig 3. 1 Fit test gauges 0 - 60 bar (10 - 1000 lb in2) into hose connections to ports Pm1 + Pm2 with tee piece adapter 2 Warm up machine hydraulic temperature to 50 °c (122° f) 3 K Table 12. ( T E-250) Table 12. (expected Pressures) Port Pm1 Port Pm2 0 - 1.5 bar 0 - 1.
Section E - Hydraulics Fault Finding Test 003: Testing Main Pump Pressure Test 003: Testing Main Pump Pressure a2 a1 Fig 4. 1 Fit test gauges 0 - 600 bar (8700 lb in2) into ports a1 + a2. 2 Warm up machine hydraulic temperature to 50°c (122 °F). 3 K Table 13.