JCB 3CX T4F Backhoe Loader Service Repair Manual From 02254521 to 02274521

Service Manual Backhoe Loader Section 1 - General Information Section 2 - Operator Manual Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Electronic Control Systems

Publication No.

9813/0250-07

World Class Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

Section E25 - Hydraulics Rams Dismantle and Assemble

Dismantle and Assemble Typical Ram The procedures described below are applicable for the following rams: – Loader Shovel Ram – Loader Lift Ram

Extract dowel 6 from the piston head using a metric screw (M3, M4, or M6 depending on ram size) threaded into the extractor hole.

Remove piston head from rod using special spanner (see Service Tools).

Remove gland bearing and end cap 1 from piston rod and remove the `O' ring 9, wiper seal 10 and rod seal 11. Check the end cap bearing for damage, scores or nicks. If damaged, the bearing must be replaced as part of the end cap assembly.

– Stabiliser Ram – Bucket Crowd Ram – Boom Ram – Extending Dipper Ram - if fitted

Dismantle

Ensure that metal components are free from scoring, nicks and burrs. A damaged rod will impair the life of the seals.

K Fig 13. ( T E25-23)

Check the bore of the ram cylinder for damage.

K Fig 14. ( T E25-23)

Assemble

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

Place ram assembly on a locally manufactured strip and rebuild bench as shown. K Fig 11. ( T E25-21)

Clean threads of piston rod, piston head, end cap and cylinder using a wire brush. Use JCB Cleaner and Degreaser to ensure that all threads are free from grease, hydraulic oil and sealant. Allow 15 minutes for solvent to dry before applying JCB Threadlocker and Sealer (High Strength).

Ensure that lubricants used during assembly do not come into contact with the JCB Threadlocker and Sealer (High Strength).

For fitting seals to the end cap and piston head refer to the Ram Sealing correct procedure.

K JCB Procedure ( T E25-33) Apply JCB Activator to threads of end cap and cylinder.

Allow Activator to dry for 15 minutes before bringing into contact with the JCB Threadlocker and Sealer (High Strength).

Fig 11.

Slacken end cap 1 using special spanner (see Service Tools), and remove the piston rod assembly 2 from the cylinder.

Fit locking dowel 6 to piston head and rod as follows:

!MWARNING If air or hydraulic pressure is used to force out the piston assembly, ensure that the end cap is securely fitted. Severe injury can be caused by a suddenly released piston rod.

HYD-1-2

Position piston rod assembly on bench in place of ram cylinder. Remove seal 4 and wear rings 3 and 5 from piston head.

E25-21

Note: Neither the JCB Threadlocker and Sealer (High Strength) nor Activator must be allowed to contact seals, bearing rings, or 'O' rings.

1

Fit 'O' ring 8 into piston head 7.

2

Fit piston head to piston rod and torque tighten.

K Table 5. Torque Settings ( T E25-22)

3

New ram Shaft and piston head fitted. If both are required, the following procedure should be followed: a

9813/0250-07 (E-24-04)

Drill through piston head into piston rod. Use an undersized diameter drill first as a guide and then drill with the correct size diameter drill to suit.

E25-21

Section E25 - Hydraulics Rams Dismantle and Assemble K Fig 12. ( T E25-22) K Table 6.

Diameters and Depths ( T E25-22)

Drill

b Remove all swarf and contamination. Insert dowel 6 into drilled hole, make sure tapped extractor hole is to outside.

4

New piston head fitted on a pre-drilled piston rod.

Re-drill and dowel BOTH the piston head and piston rod at 90° from the existing drilled dowel hole in the piston rod. Follow the procedures described in step 3.

5

New piston rod fitted to a pre-drilled piston head.

Use the pre-drilled hole in the piston head. Care must be taken not to elongate the existing hole in the piston head. a

Use a drill the same diameter as the pre-drilled hole in the piston head to make a 'centre mark' in the piston rod. DO NOT drill the piston rod at this stage.

recommended that the rams are operated slowly to their full extent before commencing normal working.

Item

Table 5. Torque Settings Nm kgf m 678

69.2

500

7

405

41.3

300

X

Y

b Use an undersized diameter drill as a guide and drill into the piston rod to the required depth.

K Table 6. Drill Diameters and Depths ( T E25-22) Make sure the drill has centred correctly on the 'centre mark' made at step 5a. c

Use the correct size diameter drill to suit the dowel and drill to the required depth, K Table 6. Drill Diameters and Depths ( T E25-22)

lbf ft

1

Fig 12.

Table 6. Drill Diameters and Depths All Dimensions are in mm Ram Size

Dowel Size

80 x 50

6Ø x 20

4

21

6.02-6.1

22-23

8Ø x 25

5

24

8.02-8.1

27-28

110 x 60 12Ø x 30

8

28

12.02-12.1

32-33

8

33

12.02-12.1

37-38

d Remove all swarf and contamination, insert the dowel.

70 x 40

Position cylinder on bench and install rod assembly into cylinder.

100 x 60

Apply JCB Threadlocker and Sealer (High Strength) to first three threads of cylinder, torque tighten the end cap.

K Table 5. Torque Settings ( T E25-22)

110 x 65

90 x 50

120 x 65 12Ø x 35

Guide Guide Dowel Drill Drill Ø Drill ØX Depth

Dowel Drill Depth Y

130 x 75

Note: If hydraulic oil contacts the uncured JCB Threadlocker and Sealer (High Strength) a weakening of the bond will result. Cure times vary according to the ambient temperature. Allow a minimum of 2 hours between assembly and filling the ram with oil.

Note: Cold weather operation. When operating in conditions which are consistently below freezing, it is

E25-22

9813/0250-07 (E-24-04)

E25-22

Section E25 - Hydraulics Rams Dismantle and Assemble

Fig 13.

5 6

4

9

3

7

1

11 10

Fig 14. Typical Ram Assembly On boom and bucket rams, pivot pin grease seals are fitted.

E25-23

9813/0250-07 (E-24-04)

E25-23

Section E25 - Hydraulics Rams Dismantle and Assemble

Slew Ram

Remove seal 8 and wear rings 7 and 9 from piston head.

Extract dowel 10 from the piston head using a metric screw threaded into the extractor hole.

Dismantle K Fig 17. ( T E25-27)

Remove piston head from rod using special spanner (see Service Tools).

The numerical sequence shown on the illustration is intended as a guide to dismantling.

Remove `O' ring 12.

For assembly the sequence should be reversed.

Place ram assembly on a locally manufactured strip and rebuild bench as shown or alternatively, hold the ram in a suitable vice taking care not to damage machined faces.

Remove cylinder 6 using special spanner (see Service Tools). Tap the cylinder off the piston head assembly using a suitable drift (e.g. nylon).

Position the piston rod assembly in a vice, use soft jaws and stand the assembly vertical whilst clamping on the eye end as shown. K Fig 15. ( T E25-24)

Lift the end cap assembly 13 off the piston rod. Remove `O' ring 14, rod wiper seal 15 and rod seal 16 from the end cap assembly. Check the end cap bearing 13A for damage, scores or nicks.

Item 18 is the metering orifice plate and item 17 its retaining wire, do not remove these items unless problems with the metering are suspected.

Ensure that metal components are free from scoring, nicks and burrs. A damaged rod will impair the life of the seals.

Check the bore of the ram cylinder for damage.

Assemble Clean threads of piston rod, piston head, end cap and cylinder using a wire brush. Use JCB Cleaner and Degreaser to ensure that all threads are free from grease, hydraulic oil and sealant. Allow 15 minutes for solvent to dry before applying JCB Threadlocker and Sealer (High Strength).

Ensure that lubricants used during assembly do not come into contact with the JCB Threadlocker and Sealer (High Strength).

For the correct method of fitting seals to the end cap and piston head. K JCB Ram Sealing Procedure ( T E25-33) Apply JCB Activator to threads of end cap and cylinder.

Allow Activator to dry for 15 minutes before bringing into contact with the JCB Threadlocker and Sealer (High Strength).

Note: Neither the JCB Threadlocker and Sealer (High Strength) nor Activator must be allowed to contact seals, bearing rings, or 'O' rings.

Fit locking dowel 10 to piston head and rod as follows: Fig 15.

E25-24

1

Fit 'O' ring 12 into piston head 11.

9813/0250-07 (E-24-04)

E25-24

Section E25 - Hydraulics Rams Dismantle and Assemble 2

Fit piston head to piston rod and torque tighten.

K Table 7. Torque Settings ( T E25-25)

3

New ram Shaft and piston head fitted. If both are required, the following procedure should be followed: a

Drill through piston head into piston rod. Use an undersized diameter drill first as a guide and then drill with the correct size diameter drill to suit.

K Table 8.

Drill K Fig 16. ( T E25-26) Diameters and Depths ( T E25-26)

b Remove all swarf and contamination. Insert dowel 10 into drilled hole, make sure tapped extractor hole is to outside.

4

5

New piston head fitted on a pre-drilled piston rod.

Re-drill and dowel BOTH the piston head and piston rod at 90° from the existing drilled dowel hole in the piston rod. Follow the procedures described in step 3.

New piston rod fitted to a pre-drilled piston head.

Use the pre-drilled hole in the piston head. Care must be taken not to elongate the existing hole in the piston head. a

Note: If hydraulic oil contacts the uncured JCB Threadlocker and Sealer (High Strength) a weakening of the bond will result. Cure times vary according to the ambient temperature. Allow a minimum of 2 hours between assembly and filling the ram with oil.

Note: Cold weather operation. When operating in conditions which are consistently below freezing, it is recommended that the rams are operated slowly to their full extent before commencing normal working.

Position pipe assembly in correct position and torque tighten probe assembly 2 to 75Nm (55 lbf ft; 7.6 kgf m). DO NOT over-tighten the probe.

Make sure seals 19 and 21 are fitted the correct way as shown.

Item

Table 7. Torque Settings Nm kgf m

lbf ft

6

678

69.2

500

11

405

41.3

300

Use a drill the same diameter as the pre-drilled hole in the piston head to make a 'centre mark' in the piston rod. DO NOT drill the piston rod at this stage.

b Use an undersized diameter drill as a guide and drill into the piston rod to the required depth.

K Table 8. Drill Diameters and Depths ( T E25-26) Make sure the drill has centred correctly on the 'centre mark' made at step 5a. c

Use the correct size diameter drill to suit the dowel and drill to the required depth. K Table 8. Drill Diameters and Depths ( T E25-26)

d Remove all swarf and contamination, insert the dowel.

Install cylinder onto the rod assembly, make sure that the cylinder is fitted square to the rod assembly. Firmly push the cylinder over the piston head seals.

Apply JCB Threadlocker and Sealer (High Strength) to first three threads of cylinder, torque tighten the cylinder.

K Table 7. Torque Settings ( T E25-25)

E25-25

9813/0250-07 (E-24-04)

E25-25

Section E25 - Hydraulics Rams Dismantle and Assemble

X

Y

Fig 16.

Table 8. Drill Diameters and Depths All Dimensions are in mm Ram Size

Dowel Size

Guide Guide Dowel Drill Drill Ø Drill ØX Depth

Dowel Drill Depth Y

80 x 50

6Ø x 20

4

21

6.02-6.1

22-23

8Ø x 25

5

24

8.02-8.1

27-28

110 x 60 12Ø x 30

8

28

12.02-12.1

32-33

8

33

12.02-12.1

37-38

70 x 40 90 x 50 100 x 60 110 x 65 120 x 65 12Ø x 35 130 x 75

E25-26

9813/0250-07 (E-24-04)

E25-26

Section E25 - Hydraulics Rams Dismantle and Assemble 2 3

4

5 1

6

10

9 8 7 11 12

14 16 15

13A

17 13 19 18 20

16 22 15

14

21

2 13 12

9 8

7

6

Fig 17. Slew Ram

E25-27

9813/0250-07 (E-24-04)

E25-27

Section E25 - Hydraulics Rams Dismantle and Assemble

Dipper Ram

Assemble

Dismantle

Clean threads of piston rod, piston head, end cap and cylinder using a wire brush. Use JCB Cleaner and Degreaser to ensure that all threads are free from grease, hydraulic oil and sealant. Allow 15 minutes for solvent to dry before applying JCB Threadlocker and Sealer (High Strength).

K Fig 20. ( T E25-30) The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

Place ram assembly on a locally manufactured strip and rebuild bench as shown. K Fig 18. ( T E25-28)

Ensure that lubricants used during assembly do not come into contact with the JCB Threadlocker and Sealer (High Strength).

For the correct method of fitting seals to the end cap and piston head. K JCB Ram Sealing Procedure ( T E25-33) Apply JCB Activator to threads of end cap and cylinder.

Allow Activator to dry for 15 minutes before bringing into contact with the JCB Threadlocker and Sealer (High Strength).

Note: Neither the JCB Threadlocker and Sealer (High Strength) nor Activator must be allowed to contact seals, bearing rings, or 'O' rings.

Ensure that end damping spring 9 is engaged with collar 10 and piston head 7.

Fig 18.

Slacken end cap 1 using special spanner (see Service Tools), and remove the piston rod assembly 2 from the cylinder.

Fit locking dowel 6 to piston head and rod as follows: 1

Fit 'O' ring 8 into piston head 7.

!MWARNING

2

If air or hydraulic pressure is used to force out the piston assembly, ensure that the end cap is securely fitted. Severe injury can be caused by a suddenly released piston rod.

Fit piston head to piston rod and torque tighten.

K Table 9. Torque Settings ( T E25-29)

3

New ram shaft and piston head fitted. If both are required, the following procedure should be followed: a

Position piston rod assembly on bench in place of ram cylinder. Remove seal 4 and wear rings 3 and 5 from piston head.

Drill through piston head into piston rod. Use an undersized diameter drill first as a guide and then drill with the correct size diameter drill to suit.

K Table 10.

Drill K Fig 19. ( T E25-29) Diameters and Depths ( T E25-29)

Extract dowel 6 from the piston head using a metric screw (M3, M4, or M6 depending on ram size) threaded into the extractor hole.

b Remove all swarf and contamination. Insert dowel 6 into drilled hole, make sure tapped extractor hole is to outside.

HYD-1-2

Remove piston head from rod using special spanner (see Service Tools).

4

Remove gland bearing and end cap 1 from piston rod and remove the `O' rings 11 and 12, wiper seal 13 and rod seal 14. Check the end cap bearing for damage, scores or nicks. If damaged, the bearing must be replaced as part of the end cap assembly.

New piston head fitted on a pre-drilled piston rod.

Re-drill and dowel BOTH the piston head and piston rod at 90° from the existing drilled dowel hole in the piston rod. Follow the procedures described in step 3.

5

New piston rod fitted to a pre-drilled piston head.

Use the pre-drilled hole in the piston head. Care must be taken not to elongate the existing hole in the piston head.

Ensure that metal components are free from scoring, nicks and burrs. A damaged rod will impair the life of the seals.

a

Check the bore of the ram cylinder for damage.

E25-28

9813/0250-07 (E-24-04)

Use a drill the same diameter as the pre-drilled hole in the piston head to make a 'centre mark' in

E25-28

Section E25 - Hydraulics Rams Dismantle and Assemble the piston rod. DO NOT drill the piston rod at this stage.

X

b Use an undersized diameter drill as a guide and drill into the piston rod to the required depth.

K Table 10. Drill Diameters and Depths ( T E25-29) Make sure the drill has centred correctly on the 'centre mark' made at step 5a. c

Y

Use the correct size diameter drill to suit the dowel and drill to the required depth. K Table 10. Drill Diameters and Depths ( T E25-29)

d Remove all swarf and contamination, insert the dowel.

Position cylinder on bench and install rod assembly into cylinder.

Apply JCB Threadlocker and Sealer (High Strength) to first three threads of cylinder, torque tighten the end cap.

K Table 9. Torque Settings ( T E25-29) Note: If hydraulic oil contacts the uncured JCB Threadlocker and Sealer (High Strength) a weakening of the bond will result. Cure times vary according to the ambient temperature. Allow a minimum of 2 hours between assembly and filling the ram with oil.

Note: Cold weather operation. When operating in conditions which are consistently below freezing, it is recommended that the rams are operated slowly to their full extent before commencing normal working.

Item

Table 9. Torque Settings Nm kgf m

Table 10. Drill Diameters and Depths All Dimensions are in mm Ram Size

Dowel Size

Guide Guide Dowel Drill Drill Ø Drill ØX Depth

Dowel Drill Depth Y

80 x 50

6Ø x 20

4

21

6.02-6.1

22-23

8Ø x 25

5

24

8.02-8.1

27-28

110 x 60 12Ø x 30

8

28

12.02-12.1

32-33

8

33

12.02-12.1

37-38

70 x 40 90 x 50 100 x 60 110 x 65 120 x 65 12Ø x 35 130 x 75

lbf ft

1

678

69.2

500

7

405

41.3

300

E25-29

Fig 19.

9813/0250-07 (E-24-04)

E25-29

Section E25 - Hydraulics Rams Dismantle and Assemble

C000480-C1

Fig 20. Dipper Ram

E25-30

9813/0250-07 (E-24-04)

E25-30

Section E25 - Hydraulics Rams Dismantle and Assemble

Power Sideshift Ram

not to allow the piston rod to come into contact with the cylinder bore. Be sure to engage the piston head new wear rings and seal carefully into the cylinder. If the piston head wear rings or seal are damaged during this stage, they must be renewed.

K Fig 21. ( T E25-32) The numerical sequence shown on the illustration is intended as a guide to dismantling.

5

Fit new `O' rings 8 to spacers 7, slide onto the piston head and rod assembly.

6

Apply JCB Activator to threads of the end caps and cylinder. Allow Activator to dry for 15 minutes before bringing into contact with the JCB Threadlocker and Sealer (High Strength).

For assembly the sequence should be reversed.

Dismantle 1

Fix the ram assembly on a locally manufactured strip and rebuild bench as shown at A.

2

Remove both end caps 1, (46mm AF). Pull the piston rod assembly from the cylinder.

Note: Neither the JCB Threadlocker and Sealer (High Strength) nor Activator must be allowed to contact seals, bearing rings or `O' rings.

Note: DO NOT allow the piston rod to come into contact with the cylinder bore. The cylinder bore may be damaged by careless dismantling.

7

Apply JCB Threadlocker and Sealer (High Strength) to threads of the ends caps, fit new `O' rings 6.

3

8

Ensure that there are no burrs at the ends of the piston rod.

Position the piston rod assembly on a bench in place of the ram cylinder. Remove the wear rings 2 and seal 3 from the piston head.

Note: The piston head cannot be removed from the rod. If there is damage to the rod or piston head, replace the complete assembly.

4

Note: If burrs are evident on the ends of the piston rod at positions C or D remove by careful filing.

9

Carefully inspect the bore of the cylinder and the piston rod outer diameter for scoring, nicks and burrs.

If such damage is visible the components must be renewed.

Note: If burrs are evident on the ends of the piston rod at positions C or D remove by careful filing.

5

Remove the end cap seal 4, wiper seal 5 and `O' ring 6, both end caps are the same.

6

Remove spacers 7 and `O' rings 8.

Fit an end cap over the piston rod. Apply light hand pressure to the cap to engage the gland seal on the piston rod. DO NOT use excessive force. Screw on the first end cap and then fix the assembly on the strip and rebuild bench as shown at A. Fit the remaining cap and then torque tighten both caps. K Table 11.

Torque Settings ( T E25-31)

Note: If hydraulic oil contacts the uncured JCB Threadlocker and Sealer (High Strength) a weakening of the bond will result. Cure times vary according to the ambient temperature. Allow a minimum of 2 hours between assembly and filling the ram with oil.

Item

Assemble

1 1

Clean the threads of the end caps and cylinder using a wire brush.

2

Use JCB Cleaner and Degreaser to ensure that all threads are free from grease, hydraulic oil and sealant. Allow 15 minutes for solvent to dry before applying JCB Threadlocker and Sealer (High Strength). Ensure that lubricants used during assembly do not come into contact with the JCB Threadlocker and Sealer (High Strength).

3

For the correct method of fitting seals to the end cap Ram Sealing and piston head.

K JCB Procedure ( T E25-33)

4

Clamp the cylinder vertically and lower the piston rod assembly in from the top, as shown at B. Take care

E25-31

9813/0250-07 (E-24-04)

Table 11. Torque Settings Nm kgf m 400

40.8

lbf ft 295

E25-31

Section E25 - Hydraulics Rams Dismantle and Assemble

C000490-C2

Fig 21. Power Sideshift Ram

E25-32

9813/0250-07 (E-24-04)

E25-32

Section E25 - Hydraulics Rams Dismantle and Assemble

JCB Ram Sealing Procedure TE-005

1

Fit new rod seals.

Use seal fitting tool 22-A to fit rod seals, the size (diameter) and position of pins 22-B is determined by the diameter and radial width of the rod seal being fitted.

Fig 24. b Close the tool. K Fig 25. ( T E25-33). The seal must form a reniform (kidney shape).

Fig 22. Seal Fitting Tool The pins are screwed into threaded holes in the tool body, the spacing of the holes is designed to suit small or large diameter rod seals. a

Open the tool and insert the new rod seal 23-A. The seal must be fitted behind the two front pins but in front of the rear pin as shown.

Fig 25. c

Before fitting the rod seals check the seal grooves are free of contamination and sharp edges.

d Locate the seal in the end cap groove.

K Fig 26. ( T E25-33). When the seal is in position, open the tool to release the seal. Make sure the seal is correctly installed in its grooved and remove the tool.

Fig 23.

Note: Later ram end caps and piston heads are metric threads. The seals are also different, make sure the correct seals are fitted. On metric threaded rams make sure the seals are fitted the correct way round, as shown at 24-A and 24-B. Fig 26. e

Fit rod wiper seal 24-A into seal groove. Make sure the seal is correctly installed as shown.

Note: Some rod wipers, i.e. power track rod, may use a metal encased seal which is pressed into the housing.

E25-33

9813/0250-07 (E-24-04)

E25-33

Section E25 - Hydraulics Rams Dismantle and Assemble Care must be taken to ensure the seal is square before it is pressed in. f

c

Sleeve 27-A must be used to protect the rod seals from damage when fitting end cap onto the piston rod. There are various sizes of sleeve, see Service Tools, Section 1. Make sure the hexagon on the end cap is towards the eye end of the rod.

Ensure the O-ring is fitted into the internal seal groove on the piston head. Screw the piston head onto the thread of the piston rod, refer to the relevant section for torque figure and completion of ram assembly.

d Fit the piston head retaining dowel, refer to the relevant section for torque figure and completion of ram assembly. e

Fit wear rings 29-A and 29-B. Rotate the wear rings so that the piston retention dowel is covered by the wear ring, Not as shown at 29-C.

Fig 27.

2

Fit new head piston seals. a

Use a blunt instrument 28-A (Part no. 892/01027) to lever the inner seal 28-B into the piston head seal groove. Do not let the seal twist. There are identification marks on the outer diameter of the seal, make sure the marks are visible and the seal is free to rotate, if not remove the seal and refit.

Fig 29.

3

Fit the piston rod and head assembly into the cylinder. a

Insert the piston/rod assembly into the cylinder.

Align the rod and head assembly until parallel with the cylinder then push the assembly into the cylinder.

b Fit the end cap, refer to the relevant section for torque figure and completion of ram assembly.

Fig 28. b Fit outer seal 28-C using the same procedure as stated for seal 28-B. Check the external grooves are visible.

E25-34

9813/0250-07 (E-24-04)

E25-34

Section E26 - Hydraulics Excavator Control Levers Introduction

Excavator Control Levers Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device.

Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.

This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T E26-2) K Dismantle ( T E26-3) K Assemble ( T E26-4) K Adjustment ( T E26-5)

E26-1

9813/0250-07 (E-09-05)

E26-1

Section E26 - Hydraulics Excavator Control Levers Related Topics

Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Where applicable the text in this section contains cross references to this page to help you find the correct information.

Sections

Topic Titles

Sub Titles

2

ALL (Care and Safety)(1)

ALL

(1) You must obey all of the relevant care and safety procedures.

E26-2

9813/0250-07 (E-09-05)

E26-2

Section E26 - Hydraulics Excavator Control Levers Dismantle

Dismantle K Fig 1. ( T E26-6) The illustration shows the control rods and linkages for the excavator control valve and is intended as a guide to the dismantling and assembly.

1

Prepare the machine for maintenance. Refer to Section 2.

2

Start the engine and sideshift the excavator to the RH side of the machine and lower to the ground. Stop the engine.

3

Vent the hydraulic pressure. Refer to Section 2.

4

Uncouple the rear horn switch electrical connector and remove the wires from the connector. Use a screwdriver to release the wires and pins from the connector, alternatively cut the wires and re-solder on assembly.

Note: Some machine variants may have additional switches in the control lever knobs which will also need to be uncoupled as above.

5

Working in the cab, remove the control lever knobs and gaiters. Lift off the cover A surrounding the excavator levers.

6

Disconnect the control rods from the excavator valve spools. Remove the bolts securing the complete lever assembly to the excavator valve mounting plate and withdraw the control levers and mounting bracket through the floor aperture.

E26-3

9813/0250-07 (E-09-05)

E26-3

Section E26 - Hydraulics Excavator Control Levers Assemble

Assemble 1

Bolt the mounting bracket B to the excavator valve mounting plate.

2

Assemble the stabiliser levers C to the mounting bracket. Measure the stabiliser lever control rods (2 off) which should be 370 mm (14.57 in) between hole centres, adjust as required. Feed the control rods through the rubber seal D and connect to the stabiliser levers.

Note: If necessary, loosen the lock nuts and rotate the end fittings to give equal amounts of adjustment (thread) at each end of the control rod.

3

Assemble the excavator levers E to the mounting bracket together with the universal joints F. Measure the excavator lever control rods (4 off) which should be 395 mm (15.55 in) between hole centres, adjust as required. Feed the control rods through the rubber seal D and connect to the excavator levers.

4

Connect the control rods to the excavator valve spools with the clevis pins G.

5

Adjust the control rods K Adjustment ( T E26-5)

6

Refit the cover and the gaiters over the control levers.

7

Thread the rear horn switch cable through the control lever and fit the wires and pins into the electrical connector. Couple the connector to the chassis harness and fit the control lever knobs.

8

Connect the battery, check that the controls and rear horn switch operate correctly.

E26-4

if

necessary.

9813/0250-07 (E-09-05)

E26-4

Section E26 - Hydraulics Excavator Control Levers Adjustment

Adjustment Minor adjustment of the control rods may be necessary to align the levers, or to position the levers closer or further from the operator. After adjustment operate the levers and check that there is sufficient travel to give full movement of the excavator valve spools.

Excavator controls that feature a control lever locking pin (option) should be adjusted as follows: 1

Fit the control lever locking pin.

Note: If there is no lever locking pin with the machine use a suitable diameter metal bar.

2

Adjust the control rods until the locking pin is a sliding fit, then tighten the control rods locknuts.

3

Remove the lever locking pin.

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Section E26 - Hydraulics Excavator Control Levers Adjustment

E

E C F F

G

C

B

A

D

C003210

Fig 1. Excavator Valve Controls

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Section E27 - Hydraulics Loader Control Levers Introduction

Loader Control Levers Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device.

Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.

This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T E27-2) K Dismantle and Assembly ( T E27-3)

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Section E27 - Hydraulics Loader Control Levers Related Topics

Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Where applicable the text in this section contains cross references to this page to help you find the correct information.

Sections

Topic Titles

Sub Titles

2

ALL (Care and Safety)(1)

ALL

(1) You must obey all of the relevant care and safety procedures.

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Section E27 - Hydraulics Loader Control Levers Dismantle and Assembly

Dismantle and Assembly The illustrations show typical control lever assemblies: K Manual Controls ( T E27-4)

installed with the levers in the neutral position. Adjust the control rods if necessary.

– Check the function of the electrical switches in the control.

K Easy Controls ( T E27-5)

Dismantling 1

Prepare the machine for maintenance. Refer to Section 2.

2

Vent the hydraulic pressure. Refer to Section 2.

3

Working in the cab, remove the console panels and gaiters surrounding the loader levers as shown at 1.

Note: It is not possible to remove the gaiters completely without removal of the lever control knobs 2 and their electrical switches. Before the switches can be removed their electrical connectors must be removed to allow the cables to pass through the control lever tube 3. Unclip the pins from the connector blocks. Alternatively, cut the wires and re-solder on assembly.

4

Disconnect the control rods from the loader valve spools. Remove the bolts 8 securing the complete lever assembly to the chassis and withdraw the control levers and mounting bracket 11 through the floor aperture. Dismantle the levers as required.

Assembly Assembly is the opposite of the dismantling procedure.

During the assembly procedure do this work also: – Fix the rubber cover 6 to the cab floor after installing and adjusting the control rods.

– Adjust the rod end fittings 4 and 5 so that there is equal adjustment distance at each end of the control rod.

– Install the joint 7 in the correct position.

– Install the control rods 9 with locking flats A at the top.

– Adjust the control rods 9 so that the levers are vertical. Check there is full movement of the control valve spools. Check that the lever lock 10 can be

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