JCB 802 7, 803, 804 PlusSuper Mini Excavator Service Manual - PDF DOWNLOAD by www.heydownloads.com

Service Manual

General Information

Care & Safety

Routine Maintenance

Optional Equipment

Body & Framework

Electrics

Controls

Hydraulics

E F

Plus Super Plus Super Plus Super Published by the TECHNICAL PUBLICATIONS DEPARTMENT of JCB COMPACT PRODUCTS LTD; Harewood Estate Leek Road, Cheadle Stoke-on Trent Staffordshire, England ST10 2JU Tel: 01538 757500, Fax: 01538 757590 Publication No. 9803/3145 Issue 3

Gearboxes Track & Running Gear Engine

J L

Section 1

General Information

Section 1

Introduction This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. It is assumed that these personnel have a sound knowledge of workshop practice, safety procedures and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Therefore, these basic subjects generally are omitted from this manual, the intention being to convey only more specialised information concerning particular aspects of a machine or component. For example, renewal of oil seals, gaskets etc., and any component showing obvious signs of wear or damage is expected as a matter of course and, therefore, information of this nature is included only in the context of specialised procedures or where a range of wear tolerances is required. Similarly, it is expected that components will be cleaned and lubricated where appropriate, also that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all SAFETY MUST COME FIRST! The manual is compiled in sections, the first three are numbered and contain information as follows: 1 2 3 machine.

= = =

General Information - includes torque settings and service tools Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. Routine Maintenance - includes service schedules and recommended lubricants for the

The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: A B

= =

Optional Equipment Body & Framework ... etc.

The page numbering in each alphabetically coded section may not be continuous. This allows for the insertion of new items in later issues of the manual. Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section. All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid reference. Illustrations which show a dismantled component are numbered as a guide to the dismantling sequence, which generally can be reversed for assembly. Torque settings are given as a 'mean' figure which may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third. 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine. References to alternative servicing intervals are to be treated on a 'whichever occurs first' basis.

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General Information

Section 1

Contents

Page No.

Identification ............................................................................................ 1 - 1 Storing your machine .............................................................................. 2 - 1 Operation Introduction ................................................................................................ B1 Before entering the cab ....................................................................... B2 - B3 Entering/exiting the cab ...................................................................... B4 - B5 Cab ..................................................................................................... B6 - B7 Opening the windscreen ............................................................................. B8 Opening the side window ........................................................................... B9 Heater controls ................................................................................ B10 - B11 Seat .......................................................................................................... B12 Seat belt (when fitted) .............................................................................. B13 Engine and track controls Switches and instruments ............................................................... B14 - B15 Track controls ........................................................................... B16 - B17 Engine controls ................................................................................. B19 Switches ................................................................................... B20 - B21 Instruments .............................................................................. B24 - B25 Dozer controls ................................................................................. B26 - B27 Excavator controls .......................................................................... B28 - B23 Slew cab ............................................................................................ B30 Swing boom ...................................................................................... B31 Boom swing stop ........................................................................ B32-B33 Raise / Lower boom ................................................................... B34-B35 Dipper................................................................................................ B36 Bucket ............................................................................................... B37 Refuelling the machine ............................................................................ B39 Before starting the engine ............................................................... B40 - B41 Starting the engine .......................................................................... B42 - B43 Jump starting the engine ................................................................. B44 - B46 Cold climate warm up .............................................................................. B47 Operating in high / low temperatures ....................................................... B48 Stopping and parking the machine .................................................. B50 - B51 Preparing for road / site travel ......................................................... B52 - B53 Getting the machine moving ........................................................... B54 - B55 Working with the dozer .................................................................... B56 - B57 Working with the excavator ............................................................. B58 - B43 Installing a bucket - non Quickhitch models ............................. B58 - B59 Replacing bucket teeth...................................................................... B59 Removing a bucket ........................................................................... B37 Bucket selection ................................................................................ B60 Removing a bucket - non Quickhitch models ................................... B61 Installing a bucket on a Quickhitch .......................................... B62 - B63 Removing a bucket from a Quickhitch ..................................... B64 - B65 Working on a slope ......................................................................... B66 - B67 Digging ..................................................................................... B68 - B69 Moving the machine while digging on the level ................................ B70 Digging near walls ............................................................................. B71 Lifting ................................................................................................ B72 Safe working loads ............................................................................ B73 Using the attachments and site safety ............................................ B74 - B77 Single/double acting circuits .................................................... B78 - B79 Removing a Quickhitch Rockbreaker ....................................... B80 - B83 Using hand held tools ............................................................... B84 - B85 Moving a disabled machine ............................................................ B86 - B87 Transporting the machine ................................................................ B88 - B89 Securing for Transport ..................................................................... B90 - B91

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Section 1

1-1

Identifting Your Machine The machine has a Data Plate attached to the left hand front face of the machine. The serial numbers of the machine, engine and gearboxes are stamped on this plate. If the engine is replaced, stamp the new serial number in place of the old one.

Explanation of Vehicle Identification Number (VIN)

Explanation of Engine Identification Number

Code Example

SLP A

0803 B

T C

E D

A B

World Manufacturer Identification Machine Model

Year of Manufacture R = 1994 W = 1998 S = 1995 X = 1999 T = 1996 Y = 2000 V = 1997 1 = 2001

D E

Manufacturers Location Machine Serial Number

0765607 E SLP = JCB 0803 = 803

A B C D E

2 = 2002 3 = 2003 4 = 2004 5 = 2005

A KE

B 50390

C J

D 000001

E y

Engine Type Engine Parts List Country of Manufacture Engine Serial Number Year of Manufacture

E = England 0765607

OSEN ISO9001

J C BAMFORD EXCAVATORS LTD ROCESTER, STAFFS, ENGLAND CONSTRUCTOR

VIN Vehicle Identification Number

Product Identification Number

FM 14063

ENGINE SERIAL NUMBER

LH TRACK GEARBOX SERIAL NUMBER

SLEW GEARBOX SERIAL NUMBER

RH TRACK GEARBOX SERIAL NUMBER

WEIGHT kg

ENGINE POWER kW

RPM

YEAR OF MANUFACTURE H04343

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2-1

Section 1 2-1

Preparation for Storage

Preparation after Storage

The operations to place a machine into storage (-15째C to 44째 C) are given below.

The operations to remove a machine from storage (15째C to 44째C) and prepare it for use are given below.

Lower the fuel level to ensure that sufficient air space exists in the tank.

Check all oil and water levels, adjust contents to correct levels as necessary.

Switch off the engine. Operate controls to release pressure from the rams.

Ensure the battery is fully charged.

Disconnect battery to prevent discharge.

Reconnect battery.

Ensure the fuel tank is filled to a maximum, leaving no air space.

Remove electrical contact from fuel injection pump solenoid.

Ensure hydraulic tank is filled to maximum on the sight gauge.

Crank engine for 20 seconds or until oil pressure warning light goes out.

Spray exposed ram rods with Waxoyl.

Reconnect electrical supply to the fuel injection pump solenoid.

Slacken off rubber tracks until no visible spring tension exists.

Start the engine. If the engine fails to start after several attempts, bleed the fuel system.

Adjust track tensions.

Park the machine safely with the bucket and dipper rams retracted and the dig end outstretched. Lower the boom until the bucket rests on the ground. Lower the dozer to the ground.

10 Grease all lubrication points.

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Section 1

OPERATION

Introduction This chapter is arranged to guide you step-by-step through the task of learning how to use the machine. Read it through from beginning to end. By the end of the chapter you should have a good understanding of the machine and how to operate it. Pay particular attention to all safety messages. They are there to warn you of possible hazards. Do not just read them-think about what they mean. Understand the hazards and how to avoid them. If there is anything you do not understand, ask your JCB dealer, he will be pleased to advise you.

Move on to the attachment controls only when you can drive the machine confidently and safely. Take great care when practising with the attachment controls. Practise in an open space, keep people clear. Do not jerk the controls: operate them slowly until you understand the effect they have on the machine. Finally, do not rush the job of learning. Take you time and take it safely. Remember

When you have learned where the driving controls are and what they do, practise using them. Practise driving the machine in a safe, open space clear of other people.

BE CAREFUL BE ALERT SAFE

Get to know the "feel" of the machine and its driving controls.

BEFORE ENTERING THE CAB

WARNING Walking or working under raised attachments can be hazardous. You could be crushed by the attachments or get caught in the linkages.

The following checks should be made each time you return to the machine after leaving it for any period of time. We advise you also to stop the machine occasionally during long work sessions and do the checks again. All these checks concern the serviceability of the machine. Some concern your safety. Get your service engineer to check and correct any defects.

Lower the attachments to the ground before doing these checks. If you are new to his machine, get an experienced operator to lower them for you. If there is nobody to help you, study this handbook until you have learned how to lower the attachments. Also make sure that the swing lock is fitted before doing these checks. HOP26

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BEFORE ENTERING THE CAB

Machine walk round inspection

d Inspect the windows for cracks and damage

e Check for oil, fuel and coolant leakages beneath the machine.

Check for cleanliness: a Clean the windows and light lenses. b Remove dirt and debris, especially from around the linkages, rams, pivot points and radiator. c Make sure the cab and handrails are clean and dry.

WARNING You could be killed or injured with damaged tracks. Do not use the machine with damaged or excessively worn tracks. HOP27

Check the Tracks (Rubber) Check for cut rubber and penetration by sharp objects. Do not use a machine with damaged tracks.

Check the engine cover/panels and fuel filler cap a Make sure the engine cover / panels are fitted and securely locked.

d Clean all safety decals. Replace any that are missing or cannot be read. 2

Check for damage: a Inspect the machine generally for damaged and missing parts. b Make sure that the bucket teeth are secure and in good condition c Make sure that all the pivot pins are secured correctly in place

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b Make sure the fuel filler cap is tightly closed (we also recommend that you lock it).

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General Information

Section 1

ENTERING/EXITING THE CAB

WARNING Do not enter or exit the cab unless the arm rest or lever lock is fully engaged. To give sufficient clearance to enter or leave the cab, the left lock must be raised. When the lock is in the raised position the excavator controls cannot be operated. Lowering the lock to the normal position connects the excavator controls and allows the normal operation of the levers.

WARNING Always face the machine when entering or leaving the cab. Use the step(s) and handrails. Make sure the step(s), handrails and your boot soles are clean and dry. Do not jump from the machine. Do not use the machine controls or lever locks as handholds, use the handrails. Failure to follow these instructions could result in unexpected movement of the machine.

Note: When entering or leaving a canopy machine, both LH and RH locks must be raised.

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CAB

H50250

CAB

B7 The cab is bolted on top of the mainframe and is a welded steel construction. The cab has a sliding window on the right side, a hinged door and an up and over windscreen. All windows are of toughened glass. The cab is fitted with a windscreen wiper, heater fan, seat and all operating controls and instruments.

CAUTION Do not drive the machine with the door unlatched. It must be correctly closed or secured fully open. HOP29

Opening and closing the door To open a door from the outside, unlock it with the key provided and press the lock barrel to release the catch. To open a door from inside, push lever A Close the door from the inside by pulling it firmly, it will latch itself.

Securing the door in the open position Swing the door fully open until the spigot E on the side of the cab locates securely in the socket F on the door. To release the door when it is secured fully open, operate the button G on the inside of the door.

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Section 1 B8

General Information

Section 1

OPENING THE WINDSCREEN

To open the up and over window, disengage the latch pins A on both handles and lift the screen to a position parallel with the roof. Secure in place with the latch pins A. Note: Care must be taken when lowering the window not to bump the top edge of the lower front window.

H14080

OPENING THE SIDE WINDOW

The side window is held closed by catch A operated from inside the cab. To open the window, operate the catch A and slide the window to the desired position. To close the window, slide the window fully shut and check that the catch A has located on the frame.

H50260

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HEATER CONTROLS

B10

C B

H14041

HEATER CONTROLS

B11

Hot air can be directed to the cab floor by closing / opening flap A. Hot air is directed to the windscreen via. a fixed vent system B. For the summer use, the heater element can be turned off at the water valve C on the engine.

WARNING Stop the engine before lifting the engine cover to operate valve C. HOP30

Heater fan Press the rocker switch D located on the right hand instrument console, down to switch the fan on. Return the switch to the first position to turn the fan off.

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Section 1

SEAT CONTROL

B12

Suspension seat - when fitted

WARNING Do not adjust the seat with the engine running otherwise your legs could knock the control levers. HOP31 Depending on the type of machine various adjustments can be made to the positions of the control levers and the seat consoles/armrests. The operators seat can be adjusted for your comfort. A correctly adjusted seat will reduce operator fatigue. Position the seat so that you can comfortably reach the controls with your feet on the cab floor. The seat is adjustable for height and reach.

WARNING Whilst seated, adjust the dial below the seat until your weight in kgs. appears in the red shaded area. Failure to set the weight adjustment dial will reduce the beneficial isolation effect of the seat suspension and may result in personal discomfort or injury. 2-2-1-12

CAUTION Having adjusted the seat position, ensure the seat locking lever has engaged fully.

B13

SEAT BELT - when fitted

B13

Fasten the seat belt Sit correctly in the seat. Make sure the belt is not twisted. Push the male fitting A into the buckle B until it latches.

Release the seat belt Press button C and pull the recoil side of the belt outwards.

Note: If your machine is fitted with a seat belt, USE IT.

H26160

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Section 1

ENGINE AND TRACK CONTROLS, SWITCHES AND INSTRUMENTS

B14

16 12 7

8 3 9

6 11

H50810

B15

ENGINE AND TRACK CONTROLS, SWITCHES AND INSTRUMENTS

1 2 3 4 5 6 7 8 9 10 11 12 13 15 16

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B15

Left Track Control Lever Right Track Control Lever Hand Throttle Lever Starter Switch Working Lights Switch Windscreen Wiper Switch Horn Button Warning Lights Hourmeter Fuel Gauge Heater Fan Two Speed Tracking Switch Slew Switches Beacon Socket Boom Boost Switch (optional)

Issue 3*

Section 1 B16

General Information

Section 1

ENGINE AND TRACK CONTROLS, SWITCHES AND INSTRUMENTS - continued

B16

A C

H50280

B17

ENGINE AND TRACK CONTROLS, SWITCHES AND INSTRUMENTS - continued

B17

Track controls

Forward

The two tracks are controlled by a pair of control levers A in front of the seat. Each lever controls one track and is spring loaded to a central position. In this position the track does not operate. The left side lever controls the left track. The right side lever controls the right track. The two levers can be operated individually or together as necessary to move the machine as required. This can be done using one hand or both. An increase in speed can be achieved by operating the push button switch C located in the dozer lever if fitted.

To move the machine forward, push both levers forward. Release the levers to stop.

WARNING Make sure that all persons are clear before moving.

Reverse To move the machine backward, pull both levers backward. Release the levers to stop.

Turn To turn the machine whilst travelling, move the lever back towards the central position on the side towards which you want to go e.g. move the left lever back to turn left. This causes one of the tracks to move slower than the other. The faster moving track will push the machine around. Release the lever to stop.

Spin WARNING The track controls operate as described when the dozer is located in front of the windscreen. If the dozer is positioned behind the cab, the lever operation will be reversed. It is advisable when tracking to always position the dozer to the front of the machine.

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To spin the machine around though 360ยบ, without moving it, operate one lever, in a forward position and the other in a reverse position. This will cause the tracks to drive in opposite directions and hence push the machine around.

Issue 3*

Section 1 B19

General Information

Section 1 B19

ENGINE AND TRACK CONTROLS, SWITCHES AND INSTRUMENTS - continued

Engine Controls Engine speed A hand operated throttle lever in the cab, controls the speed of the engine. Move the lever to increase or decrease the engine speed. The lever can be left in any position between idle and maximum as required.

Engine start / stop To start and stop the engine use the starter switch, see Switches on the following page.

H50290

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Section 1 B20

General Information

Section 1

ENGINE AND TRACK CONTROLS, SWITCHES AND INSTRUMENTS - continued

B20

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H50300

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General Information

Section 1

ENGINE AND TRACK CONTROLS, SWITCHES AND INSTRUMENTS - continued

B21

Switches Starter Switch A This is operated by the starter key. It has four positions. The key can only be removed when in the 'O' position. O

Off/Stop Engine Turn the key to this position to stop the engine. Make sure the controls are in neutral and the excavator and dozer are lowered before stopping the engine.

On Turning the key in this position connects the battery to the electrical circuits The key will spring back to this position when released from ll.

Heat Position Holding the key in this position switches on the glow plugs. The glow plugs warm the engine combustion chambers for cold weather starting. Do not hold in this position for more than 15 seconds. The key will spring back to O when released.

lll

Start Operates the starter motor to turn the engine.

Note: Do not operate the starter for more than 20 seconds at one time.

B23

ENGINE AND TRACK CONTROLS, SWITCHES AND INSTRUMENTS - continued

B23

Switches - continued Working Light Switch B Press the switch down to switch the working lights on. Press the switch again to switch the working lights off. Windscreen Wiper Switch C Press the switch down once to switch the windscreen wiper on to the slower speed. Press the switch down again to switch the windscreen wiper on to the fast speed. Put the switch to the off position to switch off the windscreen wiper, which will then self park. Functions only with the starter switch at I.

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Horn Button D This is a push button switch located in the R.H. excavator control lever or positioned in the instrument console. Press the switch to activate the horn. Cab Light E A cab light is situated on the right side of the cab, above the rear window. It is operated by pressing either end of the light lens.

Issue 3*

Section 1 B24

General Information

Section 1

ENGINE AND TRACK CONTROLS, SWITCHES AND INSTRUMENTS - continued

B24

D E F

C B

H50860

B25

ENGINE AND TRACK CONTROLS, SWITCHES AND INSTRUMENTS - continued

B25

Instrument cluster Indicators for the engine and related systems are mounted in the instrument cluster in the R.H. console. Hourmeter (A) Indicates the accumulative machine operating hours. Blocked Air Cleaner (B) Optional Illuminated when the air flow through air cleaner is restricted Coolant Temperature (C) Illuminated when the engine coolant becomes overheated.

Glow Plug (E) Illuminated with the starter key at positions II and III. Extinguished at all other times. Engine Oil Pressure (F) Illuminated when the pressure of the oil in the engine is too low, and initially with the starter at position I before the engine is cranked. Fuel Gauge (G) Indicates the amount of fuel in the tank.

Alternator (D) Illuminated when the alternator supply current to the battery is defective and/or the fan belt is broken. It will also illuminate initially with the starter key at position I before the engine is cranked.

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Section 1 B26

General Information

Section 1

DOZER CONTROLS

B26

DOZER CONTROLS

B27

The dozer is operated by a single control lever on the right side of the cab. This lever is spring loaded to the central position. In this position the dozer will not move.

CAUTION Before operating the dozer, make sure that large rocks or other objects are not between it and the tracks that can jam the mechanism. HOP34

CAUTION Before stopping the engine lower the dozer blade to the ground. HOP35

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H50310

B27

Raise dozer 'A' To raise the dozer pull the lever backward. At the required position release the lever.

Lower dozer 'B' To lower the dozer push the lever forward until an increased resistance is felt and the blade moves. At the required position release the lever.

Dozer float position 'C' The float operation is selected by pushing and holding the lever fully forward.

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Section 1

B28

EXCAVATOR CONTROLS

B28

B29

EXCAVATOR CONTROLS

B29

The slew lock is situated forward of the seat. Lift and turn it through 90ยบ to unlock. Ensure it is UNLOCKED before operating the excavator controls. The excavator controls consist of those levers which operate the boom, dipper and bucket and swing the machine. There are two excavator controllers A and B which control all the functions. The controls are situated in the operators seat armrests. Raising the left armrest when leaving the cab prevents the services operating. When re-entering the cab, ensure the armrest is replaced firmly to ensure correct operation. The left side controller A controls swing, and dipper functions. The right side controller B controls boom and bucket functions as standard. It is possible to specify SAE style operating functions i.e. left controller A controlling swing and boom. The right hand controller B controlling dipper and bucket operation. Both controllers are spring loaded to the central position. In this position related services will not operate.

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Most excavating movements are achieved using a combination of both controllers at the same time. Practise such movements until you are familiar with the operations that can be achieved safely.

WARNING When using the boom and dipper fully extended, take the following precautions, otherwise the machine could get damaged or become unstable and a danger to you and other people. Make sure you do not exceed the working capacity of the boom at maximum reach. Swing the boom slowly to prevent any chance of the machine becoming unstable. For the same reason avoid dumping downhill if possible. HOP36

CAUTION Do not excavate on hard or rocky ground with the boom set diagonally across the undercarriage. This induces a rocking motion that can cause damage to the track gearbox sprockets and tracks. HOP37

Issue 3*

Section 1 B30

General Information

Section 1

EXCAVATORS CONTROLS - continued

Before slewing the cab ensure the slew lock D is disengaged, (the up position).

B30

The machine should be set for slew operation. Ensure you are in slew mode by carefully operating the left hand control lever and noting the movement.

Select Slew on the Slew/Swing switch A on the left hand controller.

Slew cab left To slew the cab to your left, move the left controller to the left B. Release the controller when you have moved to the desired position.

Slew cab right To slew the cab to your right, move the left controller to the right C. Release the controller when you have moved to the desired position. B

H50820

B31

EXCAVATORS CONTROLS - continued

Select Swing on the Slew/Swing switch A on the left hand controller.

Swing boom left To swing the boom to your left, move the left controller to the left B. Release the controller when you have reached the desired position.

CAUTION When the requirement for boom swing has finished, position boom to the straight ahead configuration and reset machine to 360 deg. slew by operating switch A.

Swing boom right

To swing the boom to your right, move the left controller to the right C. Release the controller when you have reached the desired position. B B

B31

H50820

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EXCAVATOR CONTROLS - continued

B32

EXCAVATOR CONTROLS - continued

B33

WARNING Before repositioning swing stop, lower the boom until the bucket is on the ground. Stop the engine.

Boom swing stop The boom swing can be adjusted to allow an increased swing to the left from 60º to 90º by repositioning the swing stop.

60º Operation (normal operation) Set the swing stop to position A this enables the machine to operate in an arc of 60º to the left and 50º to the right.

H24230

B33

CAUTION With certain digging configurations with the boom stop set to 90º the bucket can contact the cab. Care should be taken whenever operating with the boom stop set to 90º especially at the extremes of position. The machine can become unstable with a fully laden bucket. HOP39

CAUTION The boom stop should only be used in the 90º position for the duration of the job. Return the boom stop to the 60º position for normal operating.

90º Operation (for specific jobs only) Set the swing stop to position B this enables the machine to operate in an arc of 90º to the left and 50º to the right.

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Section 1

EXCAVATOR CONTROLS - continued

B34

SAE

ISO

B34

H50340

EXCAVATOR CONTROLS - continued

B35

WARNING Thoroughly warm the hydraulic oil before operating the excavator services. To ensure smooth boom operation damping is incorporated into the boom lift circuit, this means when boom raise is released, the boom may continue to rise for a fraction of a second. Before selecting boom up, check there are no overhead obstructions or electric power cables. HOP40

Note: Boom damping is an option and not fitted as standard.

CAUTION The boom service is operated by the R.H. controller on standard ISO control machines or by the L.H. controller on the optional SAE control pattern machines. HOP41

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B35

Raise boom To raise the boom pull the respective controller backwards A. Release the controller when the boom has reached the desired position. The boom ram incorporates damping at the limit of boom raise, reducing the speed of the ram, eliminating shock loadings.

Boom boost Partial selection of the controller will limit the speed of boom raise. Boom Boost is automatically engaged when controller is fully selected. An optional switch is available on the LH controller which will disable the boom boost operation.

Lower boom To lower the boom, push the respective controller forwards B. Release the controller when the boom has reached the desired position.

Issue 3*

Section 1

General Information

Section 1

EXCAVATOR CONTROLS - continued

B36

CAUTION The dipper service is operated by the L.H. controller on standard ISO control machines or by the R.H. controller on the optional SAE control pattern machines. HOP42

ISO

SAE

Dipper In To bring the dipper in, pull the respective controller backward A. Release the controller when the dipper is at the desired position.

Dipper Out To push the dipper out, push the respective controller forward B. Release the controller when the dipper is at the desired position.

B A

H50350

B37

EXCAVATOR CONTROLS - continued

B37

Close bucket To close the bucket (to gather a load), move the right controller to the left A. Release the controller when the bucket is closed sufficiently. A

Open bucket

To open the bucket (to dump a load), move the right controller to the right B. Release the controller when the bucket is open far enough.

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H50360

Issue 3*

Section 1

General Information REFUELLING THE MACHINE

B39

Section 1 B39

WARNING Diesel fuel is flammable. Keep flames away from the machine. DO NOT smoke while fuelling the machine or working on the engine. Do not refuel with the engine running. There could be a fire and injury if you do not follow these precautions. INT-3-2-2

CAUTION Spilt fuel may cause skidding and therefore accidents. Clean any spilt fuel immediately. Do not use fuel to clean the machine. When filling with fuel, choose a well aired and ventilated area. At the end of every working day, fill the tank with the correct type of fuel. This will prevent overnight condensation from developing in the fuel. Do not fill the tank completely, leave some space to allow the fuel to expand

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Section 1

General Information BEFORE STARTING THE ENGINE

B40

Note: Read Operating in Low Temperatures or Operating in High Temperatures in operation section if you will be using the machine in very hot or cold climates.

Before lowering the attachments to the ground, make sure that the machine and the area around it are clear of other people. Anyone on or close to the machine could fall and be crushed by the attachments, or get caught in the linkages.

Do a pre-start inspection. For your own safety (and others) and for a maximum service life of your machine, do a prestart inspection before starting the engine.

b Remove dirt and rubbish from the cab interior, especially round the pedal and control levers.

HOP43

Lower the attachments to the ground. Lower the excavator bucket and dozer to the ground, if they are not already there. They will lower themselves under their own weight when you operate the controls. Operate the controls carefully to control the rate of descent.

B40

a If you haven't already done it, do a walkround inspection of the outside of the machine. See before entering the cab in operation section

WARNING

Section 1

c Remove oil, grease and mud from the pedals and control levers.

WARNING Keep the machine controls clean and dry. Your hands and feet could slide off slippery controls. If that happens you will lose control of the machine. HOP44 d Make sure that your hands and shoes are clean and dry

BEFORE STARTING THE ENGINE - continued

B41

WARNING Loose articles can fall and strike you or roll on the floor. You could be knocked unconscious, or the controls could get jammed. If that happens you will lose control of the machine. HOP45

e Remove or secure all loose articles in the cab, such as lunch boxes, tools etc. f

Adjust the Seat Adjust the seat so that you can comfortably reach all driving controls. You should be able to operate the control pedal with your back against the seat back. Ensure the seat locking lever has engaged fully.

Set the hand Throttle Lever Set the hand throttle lever to idle.

Check round the cab for loose or missing bolts, screws etc. Fit new ones or tighten where necessary.

g Inspect the seat belt (if fitted) and its mountings for damage and excessive wear. h Check that the following are in working order: Lights, Horns all Switches and Wiper j

Check the excavator lever gaiters are not damaged or loose, replace or secure as required with new fasteners.

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Issue 3*

Section 1

General Information

Section 1

STARTING THE ENGINE

B42

817

Start the engine Move the throttle lever to full speed position. Turn the starter key to the glow plug position A for approximately 6 seconds to warm the engine combustion chambers.

Note: outside temperatures below 32Â°F (0Â°C) will require extended times. Turn the starter key further to position lll and hold it there until the engine starts; do not exceed 20 seconds. If the engine does not start, turn the starter switch to position A and repeat step 1. 2

H04431

STARTING THE ENGINE

B43 1

/ 03310

Check the indicators

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B43

CAUTION Once the engine has started, move the throttle lever to the idle position. Check that all the warning lights have gone out. Do not race the engine until the oil pressure low light has extinguished. If any indicator fails to extinguish, or if they illuminate while the engine is running, make the machine safe, stop the engine and investigate the cause. HOP46 3

Warm up the engine and hydraulics Allow the engine to warm up at idle speed for five minutes. If the engine has been jumpstarted, remove the booster cables (see jump starting the engine). Operate the excavator a few times to help warm up the hydraulic system.

Issue 3*

Section 1 B44

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General Information JUMP STARTING THE ENGINE

Section 1 B44

Issue 3*

Section 1

General Information

Section 1

JUMP STARTING THE ENGINE

B45

Note: Read battery pages in section C of this handbook before carrying out any work with the battery. Follow the instructions on this and the following page to start the engine using booster cables. Your machine has a 12V starting system. The negative (-) terminal on the battery is connected to frame earth.

B45

Lower the Attachments to the Ground Lower the excavator bucket and dozer to the ground. If they are not already there. They will lower themselves under their own weight when you operate the control. Operate the control carefully to control the rate of descent.

Set all switches in the cab to off

CAUTION WARNING If you try to charge a frozen battery, or jump start and run the engine, the battery could explode. Do not use a battery if its electrolyte is frozen. To prevent the battery electrolyte from freezing, keep the battery at full charge.

WARNING Before lowering the attachments to the ground make sure the machine and the area around it are clear of people. Anyone on or close to the machine could fall and be crushed by the attachments, or get caught in the linkages.

The booster supply should not be higher than 12V. Using a welder or higher voltage supply will damage your machine's electrical system.

CAUTION Do not connect two batteries together to give 24V. This could burn out the glow plugs and damage the starter motor. 3

Open the engine cover

HOP43

JUMP STARTING THE ENGINE - continued

B46 4

Connect the Booster Cables a Remove battery cover if fitted.

b Connect the positive booster cable to the positive (+) terminal on the machine battery. Connect the other end of this cable to the positive (+) terminal of the booster supply. c Connect the negative (-) booster cable to a good frame earth on the machine, away from and below the battery. Note: A good frame earth is part of the machine frame, free from paint and dirt. Do not use a pivot pin for an earth. d Connect the other end of this cable to the negative (-) terminal on the booster supply. 5

Do the pre-start checks See before starting the engine Start the engine - see starting the engine

B46

Disconnect the Booster Cables a Disconnect the cable from the machine frame earth, then disconnect if from the booster supply. b Disconnect the positive booster cable from the positive (+) terminal on the battery, then disconnect it from the booster supply.

Fit battery cover (if required).

Refit items removed to gain access to the battery.

WARNING Keep metal watch straps and any metal fasteners on your clothes, clear of the positive (+) battery terminal. Such items can short between the terminals and nearby metal work. If this hapens you can get burned. Make sure that the fuel filler cap is tightly fitted. Make sure that all spilt fuel is cleaned away from the battery area. HOP48

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Issue 3*

Section 1

General Information COLD CLIMATE WARM UP

B47

Section 1 B47

Before starting work in temperatures below -15Â°C, hydraulic fluid must be warmed. 1

Warm up Engine After starting the engine (see starting engine) set the throttle lever to mid position and run for 10 minutes. DO NOT operate any services. After the warm up period make sure that everyone is clear of the machine.

b Raise and lower boom from ground level to full height five times. c Stroke the dipper fully in both directions, five times

Warm up Hydraulic Oil a Increase engine speed to maximum. Warm the hydraulic oil by repeatedly selecting bucket crowd by moving the right hand lever to the left for 5 seconds. Repeat for several minutes.

d Rotate the bucket fully in both directions, five times e Swing the upper structure clockwise for one revolution and stop. Swing the upper structure anti-clockwise for one revolution and stop.

b Select dozer up by moving dozer control lever backwards, keep selected for one minute.

f 4

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Warm up Hydraulic Circuit a Reduce engine speed by moving throttle lever to mid position.

Repeat step 3c three times

The machine should now operate correctly. Should operation still appear slow, then steps 3b and 3c may be repeated.

Issue 3*

Section 1

General Information OPERATING IN LOW TEMPERATURES

B48

Section 1 B48

In low temperature situations, take the following precautions. They will make for easier starting and prevent possible damage to your machine. 1

Use the correct viscosity engine lubricating oil See fluids and lubricants - Capacities and Specifications in Maintenance section

Use a low temperature diesel fuel If available. See fuel system in Maintenance section

Use the correct coolant mixture See Coolant Mixture in Maintenance section

Keep the battery at full charge

Fill the fuel tank at the end of each work period

Protect the machine when not in use Park the machine inside a building or cover it with a tarpaulin.

Install cold weather starting aids In very low temperatures, say -18Â°C and below, additional starting aids may be needed. Examples are fuel, oil and coolant heaters and extra batteries. Ask your JCB Dealer for advice

Note: Do not connect two batteries in series to give 24 volts for starting. This could burn out the glow plugs and starter motor. 8

Remove snow from around the engine cover before starting Otherwise snow could get into the air filter.

OPERATING IN HIGH TEMPERATURES

B49

In high temperature situations, take the following precautions to prevent possible damage to the machine. 1

Use the correct viscosity engine oil See Fluids and Lubricants-Capacities and Specification in Maintenance section.

Use the correct coolant mixture See coolant mixtures in Maintenance Publication

Check the coolant system regularly Keep the coolant at the correct level. Make sure there are no leaks.

Keep the radiator/oil cooler clean. Regularly remove dirt and debris from between the radiator /oil cooler and the engine.

Check ventilation grilles Ensure the ventilation grilles to and from the engine compartment are not blocked.

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Issue 3*

Section 1

General Information

Section 1

STOPPING AND PARKING THE MACHINE

B50

H27190

STOPPING AND PARKING THE MACHINE

B51

Whenever possible, stop the machine on dry and level ground. 1

Stop the machine Release the two track levers A then push the hand throttle lever B to the idle position.

Lower the Bucket and Dozer to the ground.

3 4

Stop the Engine and reset ignition key to position I, Vent the Hydraulic System

Note: Hydraulic pressure is retained in an accumulator which must be vented when leaving the machine.

Switch off all unnecessary Switches If you are leaving the machine, make sure that all switches are set to off.

WARNING Ensure that the excavator is in a safe condition HOP49

Leave and Secure the machine Raise the left armrest or engage the lever lock(s).Use the handrail to leave the cab. If you are leaving the machine for a long period, close and latch the window and lock the door. Make sure that the fuel filler cap is locked.

Operate the control levers C to vent the hydraulic system residual pressure. 5

Remove the Starter Key Ensure the waterproof cover is closed on canopy machines.

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Issue 3*

Section 1

General Information

Section 1

PREPARING FOR SITE TRAVEL

B52

150mm (6 in.) H50390

PREPARING FOR SITE TRAVEL

B53

CAUTION Always travel the machine with the excavator positioned at the same end as the dozer, especially on hard and rocky ground.

Travelling position (level site conditions)

Travelling position (uneven site conditions)

(Activate warning beacon if fitted)

Cab facing forward over dozer, excavator as shown, dozer blade fully up.

Lower the boom so that the bucket or attachment is approximately 150mm (6in) from the ground.

Position boom fully up, operate dipper fully in and bucket fully crowded, i.e. bucket rotated fully towards cab.

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Issue 3*

Section 1

General Information

Section 1

GETTING THE MACHINE MOVING

B54

After you have warmed up the engine, move off as described below. Read Operating Hints and Warnings first.

Operating hints

WARNING

The machine does not have gears. Do not overwork the engine unnecessarily. Operate at an engine speed suitable for the duty being carried out. Note: Too low an engine speed may result in lack of dipper control. When moving the machine, keep it under control at all times. Stay alert for obstructions and possible hazards.

You and others could be killed or injured if you reverse direction on the move, because the change in direction will be sudden and without warning to others. Always stop the machine and drop engine speed to idle before changing from forward to reverse or vice versa. HOP51

Approach deep mud slowly.

GETTING THE MACHINE MOVING

B55 1

Check your seat. Make sure that the seat is secure and correctly adjusted. Fasten the seat belt if fitted.

Cab Swing Lock Make sure that the cab swing lock is disengaged and the swing switch is pressed.

Start the Engine See starting the engine in Operation section

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B55

Move the machine a Check that the attachments are in the travel position. Make sure that it is safe to move off. b Take hold of both track control levers in one hand c Move the levers forward or backward as required and pull the throttle lever slowly backward until the desired speed is attained. To increase tracking speed operate the two speed tracking switch. See 'Engine and Track Controls' page.

Issue 3*

Section 1 B56

General Information WORKING WITH THE DOZER

Section 1 B56

H50400

B57

WORKING WITH THE DOZER

B57

Remember that you will be driving the machine while you are using the dozer. Keep alert for bystanders, animals and possible hazards. Ensure the slew lock is engaged when working with the dozer.

Dozing and Grading

Backfilling

Keep the bottom of the dozer parallel to the ground. When grading a site remove high spots first, then use this soil to fill in troughs. Do not use excessive downward pressure on the dozer or machine traction could be lost. When working with the dozer, set the excavator straight with the machine, as for road travel. Keep the dozer high when travelling as this increases the machines ground clearance.

When backfilling on a slope, pile the material on the high side of the trench whenever possible. Set the dozer level to the ground. Work at right angles to the trench filling a dozer's width at a time. Leave any spillage until the trench is filled. Use the spillage to finish the job by driving the length of the trench with the dozer low to the ground.

Scraping and Cutting If a deep cut is to be made, do it in steps of about 50mm (2in). Do not forget to adjust the dozer height when the machines tracks enter the cut.

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Issue 3*

Section 1

General Information

Section 1

B58

WORKING WITH THE EXCAVATOR

B58

B59

WORKING WITH THE EXCAVATOR

B59

Installing a bucket - non Quickhitch models

Replacing bucket teeth

(See Bucket Selection)

Position the Bucket Make sure that the bucket is resting flat on the ground.

Switch off the Engine Remove the starter key.

Remove a Tooth Remove the nut and bolt C and the tooth D.

Install a Tooth Position the tooth D and fit the bolts C.

Note: This job is easier done by two people - one to operate the controls and one to line up the pivots. 1

Position the Bucket Set the bucket flat on level ground, using a suitable lifting device.

WARNING DO NOT use your fingers through the holes to align the links HOP65

Engage the Dipper If necessary move the machine to align the pivot pin holes. Carefully align the holes in the dipper and bucket link with the bucket. Fit the pivot pins B and lynch pin A.

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Issue 3*

Section 1

General Information

Section 1

WORKING WITH THE EXCAVATOR - continued

B60

Bucket selection WARNING The bucket selected should be the correct width to suit the hole/trench to be excavated. However, if the hole width demands the larger bucket, consideration should be given to the density/weight of the material to be moved affecting the stability of the machine especially if working on a slope. If there is danger of the machine's stability being compromised, then select a smaller bucket or reposition the machine. Use the 300mm (12 in.) wide bucket for narrow excavations or for maximum penetration when digging in hard, rocky or clay soils. Larger buckets are ideally suited to bulk shifting light or loose materials.

WARNING When buckets 750mm or wider are fitted to the machine, use extreme caution in operation to avoid contact with the cab.

WORKING WITH THE EXCAVATOR - continued

B61

Removing a bucket - non Quickhitch models 1

Position the Boom Swing the boom so that it is straight in front of the machine. Rest the bucket on level ground, with the dipper approximately vertical and the bucket flat to the ground. Block the bucket to prevent its movement.

WARNING Stand clear and to one side of the bucket while the pivot pins are removed: the bucket could roll over.

WARNING If two people are doing this job, make sure that the person working the controls is competent. A person can be killed or seriously injured if the controls are moved violently or incorrectly. HOP64

Withdraw the Dipper Using the controls, carefully lift the dipper clear of the bucket.

HOP63

Detach the Bucket Remove the lynch pin A and the pivot pins B.

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Issue 3*

Section 1

General Information

Section 1

WORKING WITH THE EXCAVATOR - continued

B62

Installing a bucket on a Quickhitch (See Bucket Selection) 1 G F

2 B A

Position the Bucket Set the bucket on firm level ground. Use safe and correct lifting equipment to move the bucket . Position the Machine a Position the machine so that the Quickhitch and bucket are correctly aligned for connection as shown. b Use the excavator controls to engage jaw A of the quickhitch with the pivot pin B of the bucket.

C E

H25960

WORKING WITH THE EXCAVATOR - continued

B63

c Use the excavator controls to roll the Quickhitch in the direction of arrow C until the latch hook D has fully engaged the pivot pin E on the bucket . Due to the light weight of some bucket it may be necessary to apply a load on the bucket teeth to achieve Quickhitch connection. Alternatively, use the tommy bar to lever the latch off, allowing the attachment pivot pin E, to locate in jaw D of the Quickhitch.

CAUTION Make sure that the latch hook has fully engaged. 2-4-4-3

d Fit the latch hook locking pin F and secure with lynch pin G.

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B63

WARNING Always fit the Quickhitch latch hook locking pin. Failure to fit the pin will result in possible failure of the latching mechanism. Such a failure would result in the sudden release of an attachment from the machine, you or others could be killed or seriously injured.

CAUTION When the Quickhitch is installed and its attachment fitted, there is a danger of the attachment hitting the underside of the boom. Operate the boom and dipper carefully when the Quickhitch and its attachment are fitted. 2-4-4-2

Issue 3*

Section 1

General Information

Section 1

WORKING WITH THE EXCAVATOR - continued

B64

H F

H25970

WORKING WITH THE EXCAVATOR - continued

B65

Removing a bucket from a Quickhitch Note: Deposit Quickhitch attachments on firm level ground whenever possible. This will make later refitting easy and safe. 1

Park the machine on firm level ground.

Position the bucket so that it is approximately 150mm (6 in) above the ground.

WARNING The attachment will roll forward when released. Stand clear and to one side when releasing the attachment.

Apply a downward pressure on the bar to release the bucketsâ&#x20AC;&#x2122; rear pivot pin from the latch hook, as shown at Z. Remove the tommy bar from the Quickhitch.

Rest the bucket on the ground.

Slowly roll the Quickhitch back and simultaneously raise the dipper arm to release the bucketsâ&#x20AC;&#x2122; front pivot pin, as shown at Y.

2-4-4-1

Remove lynch pin H, and locking pin F.

Insert the tommy bar J into the hole K of the latch hook.

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Note: Quickhitch procedure applies to most attachments. See your attachments instructions for specific procedures.

Issue 3*

Section 1

General Information

Section 1

WORKING WITH THE EXCAVATOR - continued

B66

25°

10°

9 H05500

WORKING WITH THE EXCAVATOR - continued

B67

Working on slopes WARNING

CAUTION

Failure to observe these precautions may cause the machine to become unstable and in extreme circumstances will overturn with potential serious injury to the operator.

When excavating on level ground, the dozer may be positioned at either end of the machine to improve stability. Always lower the dozer blade to the ground.

HOP64

The machine can operate without detriment to its systems on inclines of up to 25º. However, on slopes greater than 10º the operator must use his discretion and proceed with extreme caution. When working on inclines, position the dozer for maximum stability. This may mean the dozer and the boom are at the same end of the machine, especially if digging down hill, lower the dozer sufficiently to bring the machine level. If necessary, to prevent an instability problem, cut a level platform for the machine to stand on. If your machine is fitted with a seat belt, USE IT.

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Issue 3*

Section 1

General Information

Section 1

WORKING WITH THE EXCAVATOR - continued

B68

2 3 H50410

WORKING WITH THE EXCAVATOR - continued

B69

Digging It is possible when excavating, to use either full machine slew when discharging a loaded bucket, or if conditions dictate, swinging the excavator end only to the required dumping area. 1

To start the dig, reach out with the boom and dipper and position the bucket as shown.

Slowly close the bucket at the same time bring the dipper in. Make sure the bucket stays at the same angle to the ground while it travels. If necessary, at the same time apply a downward pressure on the boom, to increase the digging force on the bucket. 2

When the bucket is full, close it fully and at the same time move the dipper out a little way. This will keep soil from building up under the machine.

Slew the machine or swing the bucket to the dump area.

Start dumping as the bucket approaches the pile. Do not waste time by dumping too far from the excavation. Dump close to the start dig position. Swing the bucket back to the excavation and start the next dig.

CAUTION If machines are fitted with the extra long dipper (1660mm) option or long dozer (standard on 804 machines) then care must be taken when digging up to machine as it is possible for the dig end to contact the dozer.

CAUTION Do not use the side of the excavation to stop the bucket. This could damage the machine and cause the sides of the trench to collapse. Backfill the excavation by loading the bucket with soil from the pile. Do not push the soil with the side of the bucket. Note: Take extra care if extended swing is utilised (see Excavator Controls - Extended Operation).

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Issue 3*

Section 1

General Information

Section 1

WORKING WITH THE EXCAVATOR - continued

B70

Moving the machine while digging on the level When digging a trench or hole which is longer than the excavator's reach, dig to the required depth and width A until it is not possible to dig any closer without contacting the machine. When this position is reached, move the machine a suitable distance away from the excavation. Lower the dozer blade until the machine is level, then continue digging B.

B A

Tracking on uneven ground As for the travelling position, except that the bucket should be lowered to approximately 150 mm (6 in.) above ground.

150mm (6in) H05370

WORKING WITH THE EXCAVATOR - continued

B71

Digging near walls WARNING When digging near a wall, take care not to undermine the foundations. The wall could collapse. HOP66 Position the machine close to the wall as shown. Set the machine at an approximate angle of 45Â° to the wall.

B71

Digging up against obstructions 1

Swing left or right as required

Position the machine so that the bucket is up against the obstruction when fully rotated.

When swinging away from the obstruction the rear of the machine may contact the obstruction if care is not taken.

H50830

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Issue 3*

Section 1

General Information

Section 1

WORKING WITH THE EXCAVATOR - continued

B72

Lifting (Craning) regulations and safe working loads Lifting regulations

B72

WARNING Do not use the Excavator as a 'Crane'. Consult National Lifting Regulations.

The factories Act Construction (Lifting Operations) Regulations 1961 defines 'Excavators' as 'Lifting Appliances'. As such the JCB Mini Excavators are subject to these regulations. The owner and/or operator must make sure that he fully understands the laws and regulations concerning the use of the JCB Excavator. Consult your JCB dealer for further information.

Note: The machine is fitted with an eye on the tipping link. This is for securing the machine for transport or lifting buckets and attachments for safe storage only.

WORKING WITH THE EXCAVATOR - continued

B73

Safe working loads WARNING The safe working load indicated on lifting accessories such as cranes etc. is not the safe working load of the machine. When loads are to be lifted by the excavator, a bucket must be fitted. The maximum load which may be lifted depends on the equipment fitted to the excavator and the laws and regulations in force at the time and in the country in which the excavator is being used. If your machine is equipped to be operated under 'Exemption Certificate' rules, your Exemption Certificate will specify the Safe Working Loads. Note: In certain countries Safety Regulations in force call for the application of specific safety factors. Consult your dealer for information.

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Issue 3*

Section 1

General Information

Section 1

USING THE ATTACHMENTS AND SITE SAFETY

B74

This section explains some techniques for efficient and safe use of the machine and its attachments. Attention is also drawn to the various safety aspects of operating on site. Read and understand this section before you start working with the machine. Practice using the attachments until you are completely familiar with the controls and what they do. Before using the attachments, study the lifting and digging diagrams in the Specification section of the maintenance publication. Before you start using the machine, tell your workmates what you will be doing and where you will be working. On a busy site, use a signalman. Remember that your machine is mobile. Whenever possible, manoeuvre your machine into a position which combines safety with efficiency. If you have to choose remember that

SAFETY MUST COME FIRST!

B75

Electrical power cables You could be electrocuted or badly burned if you get the machine or its attachments to close to electrical power cables. You are strongly advised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near electric power lines. HOP54

WARNING Buried electric power cables Before you start using the machine, check with your electricity supplier if there are any buried power cables on the site. HOP55

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Choose the correct attachment for the job. Do not use an oversize bucket for rocky material. It could overload the system and shorten service life.

WARNING General site safety Before you start using this machine, inspect the job sites. You could be killed or injured if the ground gives way under your machine or if piled material collapses onto it. Check for potholes and hidden debris, logs, ironwork etc. Any of these could cause you to lose control of your machine. HOP52

CAUTION Legal liability You and/or your company could be legally liable for any damage you cause to public utilities. Make sure that you know the locations of all public utility cables or pipes on the site which could be damaged by your machine. HOP53

USING THE ATTACHMENTS AND SITE SAFETY - continued WARNING

B74

B75

WARNING Overhead electric power cables There is a minimum clearance required for working beneath overhead power cables. You must obtain details from you local electric company. HOP56

WARNING If you will be working with a labourer, make sure that you both understand what each other will be doing. Learn and use the recognised signalling procedures. Do not rely on shouting he will not hear you! HOP58

Issue 3*

Section 1 B76

General Information

Section 1

USING THE ATTACHMENTS AND SITE SAFETY - continued

B76

WARNING Underground gas pipes Before you start using the machines, find out from your local gas company if there are any buried gas pipes on the site. Some modern gas pipes cannot be detected by metal detectors. So it is essential that you get an accurate map of buried gas pipes before you begin any excavation work. Hand-dig trial holes to obtain precise pipe locations. If you find any cast iron pipes, assume they are gas pipes until you can prove otherwise.

If a gas leak is suspected, contact the local gas company immediately and warn everyone on the site. Ban smoking, ensure that all naked lights are extinguished and switch off any engines which may be running. You are strongly advised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near buried gas pipes. HOP57

Older gas pipes can be damaged by heavy vehicles driving over this ground above them. Mechanical digging must not take place within 500mm (20in) of a gas pipe. Leaking gas is highly explosive.

B77

USING THE ATTACHMENTS AND SITE SAFETY - continued WARNING

CAUTION Do not travel with the track motors leading particularly on hard and rocky ground. The recoil units will not absorb the shocks and damage could result to the track running gear. Do not excavate on hard or rocky ground with the boom positioned diagonally across the undercarriage. This can produce a rocking motion that could cause damage to the track gearbox sprockets.

WARNING Hill sides Operating on hillsides can be hazardous, especially moving across a slope. If the slope is too steep, your machine could roll over. If you must drive across a slope keep the attachments close to the ground. Remember that loose surface material and mud will change the ground conditions. In any event do not drive across a slope of greater than 17 deg.

B77

Reworking old sites There could be hazardous materials such as asbestos, poisonous chemicals or other harmful substances buried on the site. If you uncover any containers or if you see any signs of toxic waste, stop the machine and inform the site manager immediately.

WARNING Water supplies and drains Before you start using the machine, check with your local public water company if there are buried pipes and drains on the site. If there are, obtain a map of their locations and follow the advice given by the water supplier. You are strongly advised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near buried water pipes and drains. HOP62

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Issue 3*

Section 1 B78

General Information

Section 1

USING THE ATTACHMENTS - continued

B78

D B

H20170

B79

USING THE ATTACHMENTS - continued

There are two types of hydraulic attachment circuits available. Single acting or double acting. Both types are operated by a floor mounted pedal.

Single acting circuit This type powers a dipper mounted breaker A.

Double acting circuit This type powers reversible attachments such as an auger B. The double acting circuit can be switched to single acting operation by means of a valve C located to the right of the radiator in the engine compartment. Rotate the valve fully anti-clockwise for single acting operation or fully clockwise for double acting operation. Operate the pedal in the required direction for correct tool operation. In non-operating conditions the pedal must be locked in position D.

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B79

WARNING Hydraulic Fluid Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid. If hydraulic fluid penetrates your skin, get medical help immediately. INT-3-1-10/1

Issue 3*

Section 1

General Information

Section 1

USING THE ATTACHMENTS - continued

B80

H F

H27200

USING THE ATTACHMENTS - continued

B81

Removing a Quickhitch Rockbreaker Note: Deposit Quickhitch attachments on firm level ground whenever possible. This will make later refitting easy and safe. 1

Park the machine on firm level ground.

CAUTION The rockbreaker must be positioned correctly before attempting to release it from the quickhitch. if incorrectly positioned, the rockbreaker could swing or fall suddenly from the machine when releasing the quickhitch latch hook. 2

Position the rockbreaker just clear of the ground and at an angle such that the rockbreaker does not detatch from the front pivot pin when the Quickhitch is unlatched. Typically shown at V.

B81

Stop the Engine.

Operate the auxiliary attachment control pedal, this will release any hydraulic pressure trapped in the system.

Disconnect the hydraulic hoses.

WARNING The attachment will roll forward when released. Stand clear and to one side when releasing the attachment. 2-4-4-1

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Issue 3*

Section 1

General Information

Section 1

USING THE ATTACHMENTS - continued

B82

H F

H27200

USING THE ATTACHMENTS - continued

B83

Removing a Quickhitch Rockbreaker continued 6

Remove lynch pin H, and locking pin F.

Insert the tommy bar J into the hole K of the latch hook.

Apply a downward pressure on the bar to release the rockbreakersâ&#x20AC;&#x2122; rear pivot pin from the latch hook, allowing the attachment to swing forward as shown at Z. Remove the tommy bar from the Quickhitch.

11 Slowly roll the Quickhitch back and simultaneously raise the dipper arm to release the rockbreakersâ&#x20AC;&#x2122; front pivot pin, as shown at Y. 12 Remember to remove the lynch pin H and locking pin F before fitting another attachment.

Installing a Quickhitch Rockbreaker Procedure is as installing a bucket.

Refit the locking pin F and lynch pin H. Failure to refit the pin will result in the rockbreaker relatching as it is lowered to the ground. Make sure that the hydraulic hoses do not become trapped under the attachment.

10 Start the engine and carefully lower the attachment to the ground as shown at Y.

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Issue 3*

Section 1

General Information

Section 1

USING THE ATTACHMENTS - continued

B84

B A C

E H26040

USING THE ATTACHMENTS - continued

B85

Using hand held tools Hand held tools operate from the machines auxiliary circuit via a valve A.

Stop the Engine.

Operate the auxiliary attachment control pedal, this will release any hydraulic pressure trapped in the system.

Attach the valve A to the bucket ram protection plate B.

Connect the hydraulic hoses C to the auxiliary connectors D, making sure they are clean.

Connect the hand held attachment to the connectors E, making sure they are clean.

Lock the auxiliary pedal F in the operating position.

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Issue 3*

Section 1

General Information

Section 1

MOVING A DISABLED MACHINE

B86

A H50420

MOVING A DISABLED MACHINE

B87

CAUTION Do not tow a disabled machine. Permanent damage to the track motors will occur if the machine is towed. HOP68

If the machine becomes disabled, it must not be towed or otherwise moved on its tracks.The machine should be made safe, lifted onto a transporter and moved to a location where maintenance can be carried out.

Lifting points have been provided on the machine as follows: 1

On each end of the dozer blade at points A.

On the boom at point C.

The correct method for 3-point lifting is shown in the illustration opposite. When the machine is totally disabled, the boom should be set to the fully raised position and lifted using the 3-point lifting method.

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Issue 3*

Section 1

General Information

Section 1

TRANSPORTING THE MACHINE

B88

Preparing for road travel Before loading the machine on to its trailer (see transporting the machine), remove all loose dirt that may otherwise come off and obstruct the highway and damage other vehicles.

Note: The transport position height does not include the truck/trailer height, add the two figures together for the clearance height.

Note: Before transporting the machine make sure you will be obeying the local rules and laws regarding machine transportation of all the areas that the machine will be carried through.

Make sure that the two speed tracking selector is set to low speed before loading or unloading the machine.

CAUTION

Make sure that the transporting vehicle is suitable. See Maintenance section for the dimensions and weight of your machine. There is a travel height label fitted to the cab. Try to make sure that the truck driver knows the clearance height before he drives away. See section D for machine height figures.

BEFORE USING THE TRAILER

B89

WARNING Before moving the machine onto the trailer, make sure that the trailer and ramp are free from oil, grease and ice. Remove oil, grease and ice from the machine tracks. Make sure the machine will not foul on the ramp angle. HOP69 1

Remove any dirt or debris from the trailer.

Check the operation of the parking brake.

Check the trailer bodywork for signs of damage.

Check the tyre pressures are correct (consult the Manufacturer's handbook).

Check the lights are working and are the correct voltage for the towing vehicle (consult the Manufacturer's handbook).

Check the breakaway cable is serviceable.

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B89

WARNING The safe transit of the load is the responsibility of the transport contractor and driver. Any machine, attachment or parts that may move during transit must be adequately secured. 5-2-5-3

Issue 3*

Section 1

General Information

Section 1

SECURING THE MACHINE

B90

B H27220

SECURING THE MACHINE

B91

WARNING The machine must be securely tied down to the trailer to prevent lateral movement, fore-and-aft movement, and slewing of the superstructure. Failure to do so could cause injury to yourself or others. 1

Engage slew lock. Ensure by operating the slew control that the slew lock is engaged.

Close the bucket. Position the dipper vertically and lower the boom until the bucket rests on a wooden block on the trailer bed.

Position a wire rope A of suitable breaking strain over the bucket and secure to the trailer shackles.

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Place skids B under each track at front and rear to prevent movement of the machine in the foreand-aft direction.

Position a wire rope C of suitable breaking strain around each track at front and rear and secure to the trailer shackles to prevent lateral movement of the machine.

Attach wire ropes D of suitable breaking strain to the lifting points on the superstructure and secure to the trailer shackles to prevent the superstructure from swinging.

Issue 3*

Section 3

Routine Maintenance

Section 3

Contents

Page No.

Fluids, Lubricants, Capacities and Specifications ......................... 1 - 1 Engine Lubrication Chart ............................................................... 1 - 2 Torque Settings ............................................................................. 1 - 3 Hydraulic Fittings .......................................................................... 1 - 5 Fuel Systems ................................................................................ 1 - 6 Coolant Mixtures ........................................................................... 1 - 7 Service Schedules ........................................................................ 2 - 1 Greasing ........................................................................................ 3 - 1 Hydraulic Fluid Level .................................................................... 4 - 1 Track Gearbox .............................................................................. 5 - 1

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Section 3

Fluids, Lubricants, Capacities and Specifications

1-1

Note: New engines DO NOT require a running-in period. The engine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).

ITEM

CAPACITY Litres (UK/US Gal)

Engine Oil 100 Series KR Builds First 100 hours only

4.5 (1.0) [1.2]

Engine Oil 400 Series HP Builds

4.5 (1.0) [1.2]

FLUID/LUBRICANT

JCB 10W/30 Multigrade above - 15OC (5OF) JCB 5W/20 Multigrade -15OC to - 25OC (5 OF to - 13OF) JCB Extreme Performance Engine Oil 15W/40 -10°C to +50°C (14°F to 122°F)

INTERNATIONAL SPECIFICATION MIL-L-46152, API CC/SF API CC/SE (recommended) CH4/SJ (ACEA E5-B3-A3)

Engine (Coolant) Canopy Cab

4.5 (1.0) [1.2] 5.0 (1.1) [1.3]

JCB Universal Antifreeze/water ( See Coolant Mixtures)

ASTM D3306-74

Track Gearbox (each)

1.2 (0.26) [0.3]

JCB SAE 30 Engine Oil ( NOT Multigrade )

API CD/SF, MIL-L-46152B MIL-L-2104B

Slew Gearbox

Lubricated from hydraulic system

Track Idler Wheels

Sealed Unit

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105D

Track Rollers (bottom) (top)

Sealed Unit Sealed Unit

JCB HD90 Gear Oil JCB HD90 Gear Oil

API-GL-5, MIL-L-2105D API-GL-5, MIL-L-2105D

Hydraulic Tank 802.7 803 804 to M734833 804 M734834 on

48 (10.6) [12.7] 48 (10.6) [12.7] 46 (10.1) [12.2] 48 (10.6) [12.7]

Hydraulic System 802.7 to M747210 802.7 M747211 on 803 to M827239 803 M827240 on 804 to M734833 804 M734834 on

81 (18.0) [21.5] 70 (15.7) [18.6] 81 (18.0) [21.5] 70 (15.7) [18.6] 81 (18.0) [21.5] 70 (15.7) [18.6]

Fuel Tank 802.7 to M747210 802.7 M747211 on 803 to M827239 803 M827240 on 804 to M734833 804 M734834 on

43 (9.5) [11.4] 48 (10.6) [12.7] 43 (9.5) [11.4] 48 (10.6) [12.7] 42 (9.25) [11.0] 48 (10.6) [12.7]

#Slew Ring Bearings Gear Teeth All Other Grease Points

JCB Hydraulic fluid 46 -10°C to +40°C (14°F to 104°F) JCB Special Hydraulic fluid -10° JCB Hydraulic fluid 68 Above +40°C (Above 104°F)

Diesel Oil (See Types of Fuel)

ASTM D975-66T Nos. 1D, 2D

JCB MPL Grease JCB Slew Pinion Grease ##

Lithium based, No. 2 consistency.

JCB MPL Grease

Lithium based, No. 2 consistency.

## WARNING JCB Slew Pinion Grease is harmful. It contains bitumen compounds 2811 with possible risks of irreversible effects. Excessive contact may lead to dermatitis or skin cancer. Always use a barrier cream or wear gloves. Wash contaminated skin thoroughly with soap and water. In the event of contact with the eye, immediately wash with plenty of water and seek medical advice. 9803/3145

Issue 3

Section 3

Routine Maintenance

Section 3

Fluids, Lubricants, Capacities and Specifications

1-2

Engine Lubrication Chart

JCB Super Universal Agricultural First 100 Hours only 100 SERIES ENGINE

JCB Extreme Performance Engine Oil 15W/40

5W/20

-30

-20

-10

0 10 20 AMBIENT TEMPERATURE (DEGREES C)

Safety Notice Care must be taken when handling fluids and lubricants. Refer to Product Safety Information (COSHH) leaflet.

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Routine Maintenance

Section 3

1-3

Torque settings Only use following when no setting is specified in text of manual. CAUTION: All bolts used on JCB equipment are high tensile and must not under any circumstances be replaced with bolts of a lesser tensile specification. Metric Grade 8.8 Bolts Bolt Size (mm) M5 M6 M8 M10 M12 M16 M20 M24 M30 M36

(5) (6) (8) (10) (12) (16) (20) (24) (30) (36)

Hexagon (A/F) mm

8 10 13 17 19 24 30 36 46 55

7 12 28 56 98 244 476 822 1633 2854

Torque Settings kgf m 0.7 1.2 3.0 5.7 10 25 48 84 166 291

lbf ft 5 9 21 42 72 180 352 607 1205 2105

Table of important tightening torques Tightening Points Track motor to undercarriage Retaining bolts Track roller Idler yoke Rotary coupling mounting Rotary coupling torque arm Slew ring Slew gearbox case Hydraulic oil tank Fuel tank Hydraulic filter cover Rod end - controls Silencer bolt Exhaust tail pipe Engine shock absorber (to slew frame) Engine shock absorber (to engine) Engine bracket Engine support (to bell housing) Counterweight Track gearbox cover Slew ring to superstructure (802.7 / 803) Slew ring to superstructure (804)

Nm 113 250 244 98 56 35 120 244 56 56 28 56 28 56 56 98 118 98 98 56 100 160

Tightening Torque kgf m 11.5 25.5 25 10 5.7 3.6 12.3 25 5.7 5.7 3.0 5.7 3.0 5.7 5.7 10 12 10 10 5.7 10.2 16.3

lbf ft 83 184 180 72 41 26 89 180 41 41 21 41 21 41 41 72 87 72 72 41 74 118

Rams: See Section E

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1-4

Table of important tightening torques (cont'd) Tightening Points Tightening Torque

kgf m

lbf ft

Valve Block Tie rod (large diameter) Tie rod (small diameter) Spool spring retainer End cap screw Servo retaining cap screws

45 19 TBA 7 TBA

4.6 2.0 TBA 0.7 TBA

33 14 TBA 5 TBA

Track Motor Motor to undercarriage bolts Drive sprocket to motor bolts

98 98

10 10

72 72

Drive coupling Tie bolts (main) Tie bolts (servo)

54 43-46 24-27

5.5 4.4-4.7 2.4-2.8

40 32-34 18-20

Engine Bearing holder bolts Rear plate Bolts Flywheel Housing bolts Flywheel bolts Connecting rod nuts Oil suction filter bolts Sump bolts Crankshaft pulley nut Cylinder head bolts (oiled) Injection pump bolts Injection pump nuts Rocker arm nuts Head cover nuts Cooling fan bolts Oil pipe banjo bolt Oil sump drain bolt Injector nozzle Injector nozzle clamp Injector pipe Thermo switch Oil pressure switch Glow plug Stop solenoid Oil relief valve Adjusting screw nut

49-54 13-18 24-28 58-68 49-54 9-12 9-12 275-333 88-93 9-12 9-12 20-24 8-12 9-12 10-13 30-39 59-69 20-24 15-24 26-30 15-20 15-20 15-20 57-69 6-16

5.0-5.5 1.4-2.4 2.5-2.9 6.0-7.0 5.0-5.5 1.0-1.2 1.0-1.2 28-46 9.0-9.5 1.0-1.2 1.0-1.2 2.0-2.5 0.8-1.2 1.0-1.2 1.0-1.3 3.1-4.0 6.0-7.0 2.0-2.5 1.5-2.5 2.6-3.1 1.5-2.0 1.5-2.0 1.5-2.0 6.0-7.0 1.0-1.6

36-40 10-13 18-21 43-51 36-40 7-9 7-9 203-246 65-69 7-9 7-9 14.5-18.1 6-9 7-9 7.2-9.4 22-29 44-51 14.5-18.1 11-18 19-22 11-15 11-15 11-15 44-51 7-12

Pump 802.7 - 803

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Section 3

1-5

Hydraulic fittings & torque settings O-ring Face Seal All the hydraulic fittings on the JCB Plus Series of Tracked Excavators use the O-ring face seal system which achieves a leakproof, non loos-ening connection.

Adapters screwed to valve blocks etc. seal onto an O-ring which is compressed into a 45O seal machined in the face of the tapped port. Adaptor (A) SAE Tube Size

SAE Port Thread Size

4 6 8 10 12 16 20

7/16 - 20 9/16 - 18 3/4 - 16 7/8 - 14 1.1/16 - 12 1.5/16 - 12 1.5/8 - 12

A/F mm 15.9 19.1 22.2 27.0 31.8 38.1 47.6

in 0.625 0.750 0.875 1.063 1.250 1.500 1.875

Tightening Torque Nm lbf ft 20-28 46-54 95-105 130-140 190 - 210 290 - 310 280 - 380

16.5 - 18.5 34 - 40 69-77 96 - 104 141-155 216 - 230 210 - 280

Outer sleeve nut (B) SAE Tube Size

Hose/pipe Thread Size

Tightening Torque Nm lbf ft

4 6 8 10 12 16

9116 - 18 11/16 - 16 13116 - 16 1-14 1.3/16 - 12 1.7/16 - 12

17.5 20.6 23.8 28.6 35.0 41.5

0.688 0.813 0.937 1.125 1.375 1.625

20-30 31-39 45 - 55 80 - 90 105-125 155-175

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A/F

15-21 23-29 33 - 41 59-67 77 - 93 114 - 130

Issue 1

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Routine Maintenance

Section 3

1-6

Fuel system Types of Fuel Use good quality diesel fuel to get the correct power and performance from your engine. The recommended fuel specification for Perkins engines is given below. Cetane Number: Viscosity: Density: Sulphur: Distillation:

45(minimum) 2.5/4.5 centistokes at 40OC(104OF) 0.835/0.855 kg/litre (0.872/0.904 lb./pint) 0.5% of mass (maximum) 85% at 350OC (662OF)

Cetane Number Indicates ignition performance. Fuel with a low cetane number can cause cold start problems and affect combustion Viscosity Is the resistance to flow. If this is outside limits, the engine performance can be affected. Density Lower power will reduce engine power. Higher density will increase both engine power and exhaust smoke. Sulphur High sulphur content can cause engine wear, (High sulphur fuel is not normally found in North America, Europe or Australia). If you have to use high sulphur fuel you must also use a highly alkaline engine lubricating oil: or change the normal oil more frequently. Distillation This indicates the mixture of different hydrocarbons in the fuel. A high ratio of lightweight hydrocarbons can affect the combustion characteristics.

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Fuel Standards Consult your fuel supplier, JCB distributor or Perkins dealer about the suitability of any fuel you are unsure of. Low Temperature Fuels Special winter fuels may be available for engine operation at temperatures below 0OC (32OF). These fuels have a lower viscosity. They also limit wax formation in the fuel at low temperatures. (Wax forming in the fuel can stop the fuel flowing through the filter). Flow improvers may also be available. These can be added to the fuel to reduce wax formation. Petrol

WARNING Do not use petrol in this machine. Do not mix petrol with the diesel fuel. In storage tanks the petrol could rise to the top and form flammable vapours. INT3-1-6

Advice If you have to use nonstandard fuels, contact your JCB distributor for advice on engine adjustments and oil change periods.

WARNING Diesel fuel is flammable; keep naked flames away from the machine. Do not smoke while refuelling the machine or working on the engine. Do not refuel with the engine running. There could be a fire and injury if you do follow these precautions INT3-2-2

Issue 1

Section 3

Routine Maintenance

Section 3

1 - 6A

Fuel system (cont'd) Bleeding the Fuel System 802.7 to M747158 803 to M766870 804 to M734750

WARNING Air in the fuel system can cause misfiring or failure to start. Air will enter the system if any part of it is disconnected or emptied.

WARNING When you turn the engine to bleed the fuel lines, do not operate any of the hydraulic control levers. 4

Loosen the unions at C, D and E. If you are working with an assistant warn him that you are about to turn the engine.

Open the throttle a little and turn the starter key to rotate the engine.

When air-free fuel flows from all three points, tighten the unions.

WARNING To bleed the air from the system, the engine must be turning. When the engine is turning, there are parts rotating in the engine compartment. Before starting this job, make sure you have no loose clothing (cuffs, ties etc.) which could get caught in rotating parts. Keep clear of rotating parts. 1

Raise the engine cover.

To bleed air from the filter, slacken bleed screw A. Operate lift pump lever B until air-free fuel flows from the union.

The fuel injection pump is self bleeding as the engine is cranked.

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Section 3

1 - 6B

Fuel system (cont'd) Bleeding the Fuel System (cont'd) 802.7 M747159 on 803 M766871 on 804 M734751 on

WARNING Air in the fuel system can cause misfiring or failure to start. Air will enter the system if any part of it is disconnected or emptied.

WARNING When you turn the engine to bleed the fuel lines, do not operate any of the hydraulic control levers. 4

Loosen the unions at C, D and E. If you are working with an assistant warn him that you are about to turn the engine.

Open the throttle a little and turn the starter key to rotate the engine.

When air-free fuel flows from all three points, tighten the unions.

Raise the engine cover.

To bleed air from the filter, slacken bleed screw A. Squeeze the priming bulb B repeatedly until airfree fuel flows from the union.

The fuel injection pump is self bleeding as the engine is cranked.

Note: The illustration shows a typical model; your machine may look different from the model shown.

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Routine Maintenance

1-7

Section 3 1-7

Coolant mixtures The protection provided by JCB Universal Antifreeze is shown below. If any other antifreeze is used, refer to the manufacturers' instructions and ensure that a corrosion inhibitor is included. DO NOT use solutions of more than 60% or less than 50% or damage to the cooling system will occur. Solution

55%

Maintains circulation down to

Protects against damage down to

deg C

deg F

deg C

deg F

-36

-33

-41

-42

The strength of the antifreeze solution must be checked at least once a year, preferably at the beginning of the cold period. It is an advantage to leave the antifreeze in all the year round as it gives continued protection against corrosion. Always renew the antifreeze every two years. A 50% antifreeze mixture must be used even if frost protection is not needed. This gives protection against corrosion and raises the coolant's boiling point. Note: In climates where antifreeze is not necessary, a reputable inhibitor must be used. Renew the mixture every 6 months.

WARNING Antifreeze can be harmful. Obey the manufacturers instructions when handling neat or diluted antifreeze. 7-3-4-4

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Routine Maintenance

2-1

Section 3

SERVICE SCHEDULES

Every 10 operating hours or daily

Every 50 operating hours or weekly

whichever occurs first

Clean 1 Machine generally

Do the daily jobs plus:

Check and adjust where necessary (engine stopped) 2 Generally for damage 3 Hydraulic oil level 4 Engine oil level 5 Engine coolant 6 Fuel system for leaks 7 Engine air filter pre-cleaner 8 Track adjustment Check and adjust where necessary (engine running) 9 Operation of horn 10 Operation of all other electrical equipment 11 Exhaust (excessive smoke) 12 Dozer operation 13 Excavator operation 14 Track and running gear operation 15 Hourmeter operation

2-1

Clean 1 Drain and clean fuel filter 2 Drain fuel sediment bowl 3 Radiator matrix Check and adjust where necessary (engine stopped) 4 Fan belt adjustment Note: Failure to maintain correct fan belt adjustment can result in damage to timing case cover. First 100 hours only Do the jobs listed in 50 hours (above) plus: Change 1 Engine oil and filter canister Check 2 Track tension (rubber tracks only)

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Routine Maintenance

2-2

Section 3

SERVICE SCHEDULES

2-2

Every 100 operating hours or 2 weeks

Every 250 operating hours or monthly

whichever occurs first

Do the daily jobs through to 50 hours plus:

Do the daily jobs through to 100 hours plus:

Clean 1 Battery terminals

Change 1 Engine oil 2 Engine oil filter canister

Check and adjust where necessary (engine stopped) 2 Hose and pipework for security and damage 3 Condition of ram piston rods 4 All grease seals 5 Track, plate condition/rubber condition 6 Engine mounting bolts 7 Air cleaner hose security 8 Wiring for damage 9 Track tension First 250 operating hours only Do the daily jobs through to 100 hours plus: Change 1 Track gearbox oil Check 2 Kingpost pivot pins retaining bolt torque.

Grease 3 Slew ring grease nipples

Every 500 operating hours or 6 months whichever occurs first Do the daily jobs through to 250 hours plus: Clean 1 Fuel lift pump Change 2 Fuel filter element 3 Hydraulic fluid return filter element 4 Outer air cleaner element (very dusty conditions only) Check and adjust where necessary (engine stopped) 5 Exhaust system security 6 Track gearbox oil levels 7 Injectors and test 8 Tighten cylinder head 9 Valve clearances 10 Engine mounting bolts Check and adjust where necessary (engine running) 11 Main relief valve pressure 12 Auxiliary relief valve pressure 13 Slew crossline relief valve 14 Engine idle speed 15 Engine maximum speed

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Routine Maintenance

2-3

Section 3 2-3

SERVICE SCHEDULES

Every 1000 operating hours or yearly

Every 2000 operating hours or 2 years

whichever occurs first

Do the daily jobs through to 500 hours plus:

Do the daily jobs through to 1000 hours plus:

Clean 1 Air filter dust valve

Change 1 Air cleaner element (inner) 2 Hydraulic fluid and clean suction strainer 3 Engine coolant

Change 2 Air filter element (outer) 3 Track gearbox oil 4 Idler wheel and track rollers, oil and seals Check 5 Cab frame 6 Check security of all major component mounting bolts, gearboxes, slew motor, track motors, rotary joint etc. 7 Check, clean and replace if damaged, filter adaptors fitted in pressure maintenance valve

Check (engine stopped) 5 Battery electrolyte level (low maintenance) 6 Starter motor and alternator brush gear 7 Valve clearance and lubrication

Grease 8 Slew pinion and slew ring gear teeth

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3-1

Section 3 3-1

Greasing WARNING You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the starter key. This will prevent the engine being started.

For the types of grease to use at each point, see the Lubricants and Capacities chart at the start of the Routine Maintenance section. Do not mix different types of grease, keep them separate.

8-3-1-3

You must grease the machine regularly to keep it working efficiently. Regular greasing will also lengthen the machine's working life. Greasing should be done with a grease gun. Normally two strokes of the gun should be enough. Stop greasing when fresh grease appears at the joint.

H23630

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Issue 2*

Section 3

Routine Maintenance

Section 3

3-2

Greasing - every 250 hours Slew Ring Bearings Ensure the slew ring is kept full of grease. Grease point on left hand side of mainframe. To ensure distribution of grease, use the following procedure: 1

Grease, rotate 180Â°

Grease.

H23640

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Section 3

Routine Maintenance

Section 3

3-3

Greasing - every 1000 hours Slew Ring Gear Teeth WARNING JCB Slew Pinion Grease Is harmful as It contains bitumen compounds 2811. Excessive contact may lead to dermatitis or skin cancer. Always use a barrier cream or wear gloves; wash contaminated skin thoroughly with soap and water. In the event of eye contact, Immediately wash with plenty of water and seek medical advice. 8-1-1-2

WARNING A machine can sink Into soft ground. Never work under a machine on soft ground. INT-3-2-1

WARNING A machine can roll off jacks and crush you. Do not work under a machine supported only by jacks. MD-1-6-1

Raise machine and support the undercarriage.

Stop the engine and remove the starter key.

Remove the bolts A and plate B in the underside of the undercarriage.

Apply the grease to the pinion using an applicator.

Insert the starter key and start the engine.

Rotate the main frame twice fully.

Stop the engine and remove the starter key.

Repeat step 4 as necessary.

Refit the plate B and bolts A.

10 Put the machine back on the ground.

B H23650

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Section 3

4-1

Hydraulic fluid level Check Level - For interval see Service Schedule.

WARNING Fine jets of hydraulic oil at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic oil leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leak and then inspect the cardboard for signs of hydraulic oil. If hydraulic oil penetrates your skin, get medical help immediately. HYD-001

Position the machine on firm level ground with the rams half extended. Check that the hydraulic level is to the correct mark A (804) A1 (802.7 / 803 / 804 Super*). Remove hydraulic tank cover, unscrew cap B1 from return filter and top up tank as necessary. Replace cap and cover.HYDRAULIC FILTER

C D E

Renew Filter - For interval see Service Schedule. 1

Remove hydraulic tank cover B (and filter cap B1 802.7 / 803 / 804 Super*).

Withdraw spring C, filter element D and seal E from body.

Clean all metal parts. Reassemble using new filter element D and seal E.

Replace and secure filler cap B1 and hydraulic tank cover

B B1 C D

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Section 3

5-1

Track Gearbox Check Level - For interval see Service Schedule

Drain& Refill - For interval see Service Schedule

Position the machine on firm level ground with the drain plug B at the lowest point and with safe access to the level plug A and filler plug C.

Position the machine on firm level ground with safe access to the level plug A, and the drain plug B at the lowest point.

Remove the level plug A. Oil should flow from the hole.

Remove plugs B and C and allow oil to drain completely.

If necessary, remove filler plug C and top up the oil.

Fit the drain plug B.

4 4

Refit the filler plug C.

Fill the gearbox through the filler hole at C to the correct level at A.

Fit the level plug A.

Fit the plugs A and C.

Note: There is a track gearbox on each track.

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Note: There is a track gearbox on each track.

Issue 1

Section A

Optional Equipment

1-1

Section A 1-1

General Description This section lists the options available on the Mini-Excavators and, where appropriate, details the procedures necessary to carry out the installations or conversions.

Options Cab Working Lights Twin roof-mounted working lights. Double Acting Auxiliary Pipework Enables forward or reverse operation of various hydraulic attachments. 3CX Hand Controller Pattern To change the standard ISO hand controller pattern to the 3CX pattern. Hose Burst protection Valves To fit lock valves to both the dipper ram and the boom ram to prevent uncontrolled descent if an hydraulic hose fails. Radio Kit Radio cassette, twin speakers and antenna. Long, Standard or Short Dipper Refer to Section B, Body and Framework for dismantling and assembly of Dipper. Long or Short Dozer Dozer blade length conversion. Rubber or Steel Tracks Refer to Section J, Track and Running Gear for removal and replacement of tracks.

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Section B

Body & Framework

Section B

Contents

Page No.

General Description .................................................................... 1 - 1 Bucket Linkage - Removal and Replacement ........................................... 2 - 1 Bucket Ram Pivot and Linkage - Removal and Replacement ........................................... 3 - 1 Dipper - Removal and Replacement ........................................... 4 - 1 Boom - Removal and Replacement ........................................... 5 - 1 Upper Structure - Dismantling and Assembly ............................................ 6 - 1 Kingpost - Removal and Replacement ........................................... 7 - 1

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Section B 1-1

Body & Framework

Section B 1-1

General Description The Mini-Excavator body and framework is of fabricated steel construction and comprises the upper structure and front attachment. The upper structure comprises a fabricated steel base that provides housing and mounting for the machine controls and services above and below a floorplate. The machine cab is mounted on the floorplate. The engine is mounted behind the cab. The front attachment comprises a bucket, dipper and boom assembly attached to the front of the upper structure through a kingpost. The front attachment is pivoted on the kingpost enabling movement right and left. The bucket dipper and boom are connected through pivots enabling a full range of bucket, or other attachment operations

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Section B

Body & Framework

2-1

Section B 2-1

Front attachment Bucket Removal and Replacement When Removing 1 Set up the machine in the posture shown, with the bucket lightly grounded. 2

Shut down the machine and post WARNING notices to prevent operation during maintenance.

Remove the lynch pins A. Drive out the bucket pivot pins B.

Separate the bucket from the machine.

Check the wear on the bucket teeth. Remove and renew as necessary.

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Section B

Body & Framework

2-2

Section B 2-2

Front attachment - cont. Bucket Removal and Replacement When Replacing 1 Check the bucket pivot pins and the bushing in the bucket linkage are within the permitted tolerances. Renew the pivot pins as necessary. Remove and inspect the bucket ram pivot linkage before refitting the bucket. Tolerances - Pivot Pin/Pivot Bush Reference value Allowable limit 2

Pin 35mm 34mm

Bush 35mm I/D 36mm I/D

Locate the bucket onto the dipper arm and adjust to align the bores of the bucket bosses, the dipper arm end boss and link.

WARNING DO NOT align pivot pin holes with your fingers. 3

Fit the bucket pivot pins B and secure by fitting the lynch pins A.

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Section B

Body & Framework

3-1

Section B 3-1

Bucket - Ram pivot and linkage Removal and Replacement Removal 1 Remove the bucket. 2

Remove the self-locking nut C and the bolt D. Support the link H. Drive out the pivot pin E and remove the link H. Lower the piston rod end of the bucket ram F clear of the link G.

Clean all old grease from the links G and H and pivot pin E.

Inspection 1 Check that the link bushes and the pivot pin are within permitted tolerances. Renew pivot pin and/ or remove and replace link bushes as necessary. Tolerances - Pivot Pin/Pivot Bush Pin Bush Reference value Allowable limit

30 mm dia. 30 mm I/D 29 mm dia. 31 mm I/D

Replacement

WARNING DO NOT align pivot pin holes with your fingers. 1

Locate the fork end of the link H into the fork of the dipper end link G. Locate the rod end of the bucket ram F into the fork of the link H.

Fit the pivot pin E through both links and the ram end. Secure using bolt D and new self-locking nut C.

Grease the linkage through the grease nipple on the ram end boss, for grease specification and quantity see Section 3 1-2.

9803/3145

Issue 1

Section B

Body & Framework

Section B

4-1

Dipper Removal and Replacement Removal 1 Remove the bucket. 2 If necessary remove the bucket ram. 3 Remove the locknut A and bolt B. Drive out the dipper ram pivot pin C. Separate the dipper ram eye end D from the dipper pivot E. Position a block of timber on which to rest the dipper ram eye end. Note: The machine will be fitted with one of the three dipper options. Apart from dimensions and weight the removal/replacement sequence is identical. 4 5 6

Attach suitable lifting equipment through the dipper ram pivot pin location and support the dipper J. Remove the locknut F and the bolt G. Drive out the pivot pin H. Using suitable lifting equipment, remove the dipper from the machine.

Inspection 1 Check that the dipper pivot bushes and the pivot pin are within permitted tolerances. Renew pivot pin and/or remove and replace dipper pivot bushes as necessary. Tolerances Reference value Allowable limit

Pivot pin 30mm dia. 29mm dia.

Pivot bush 30mm I/D 31mm I/D

802.7 803 804 804

Overall Length 1100 mm 1400 mm 1400 mm 1660 mm

Weight 55 kg 74 kg 74 kg 84 kg

Replacement 1 Using suitable lifting equipment, locate the dipper J onto the boom. 2 Fit the pivot pin H and secure with bolt G and a new locknut F. 3 Locate the dipper ram end D into the dipper pivot E. Fit the pivot pin C and secure with the bolt B and new locknut A. 4 Fit the bucket ram. 5 Fit the bucket.

9803/3145

H15680

Issue 2*

Section B 5-1

9803/3145

Body & Framework

Section B 5-1

Issue 1

Section B

Body & Framework

Section B

5-2

Boom Removal and Replacement Removal 1 Remove the bucket, bucket link and dipper.

Replacement Note: The boom weighs 100kg.

Remove the dipper and boom rams.

Using suitable lifting equipment, locate the boom D onto the kingpost E.

Disconnect the hydraulic hoses at the base of the boom. Blank off the open ends of hoses and pipes.

Fit the pivot pin C and secure with the bolt B and a new locknut A.

Fit the dipper and boom rams.

Fit the dipper, bucket link and bucket.

Remove the blanks and connect the hydraulic hoses at the base of the dipper.

Restore the hydraulic supply and set up the hydraulic circuit.

Connect the boom working lights.

Disconnect the boom working light harness.

Note: The boom weighs 100kg. 5 6

Attach suitable lifting equipment to the boom D and take up the slack. Remove the locknut A. Remove the bolt B and drive out the pivot pin C. Remove the boom from the machine.

Inspection 1 Check that the boom pivot bushes and the pivot pin are within permitted tolerances. Renew pivot pin and/or boom pivot bushes as necessary. Tolerances Reference value Allowable limit 2

Pivot Pin 30 mm dia. 29 mm dia.

Pivot Bush 30 mm I/D 31 mm I/D

Examine the boom structure for wear, damage or corrosion. Renew as necessary.

9803/3145

Issue 1

Section B

Body & Framework

Section B

6-1

Upper structure - all machines Dismantling and Assembly When Dismantling Note: The upper structure encompasses all equipment and structure located above the track and running gear with the exception of the front end attachment. 1

Remove the excavator assembly.

Disconnect the interior light and windscreen wiper motor in the cab/canopy structure.

11 Remove the track control lever(s), see B/6-3, step 2. 12 Remove the slew motor and gearbox and the valve blocks, if required.

Remove the cab/canopy floor.

Disconnect all electrical cables and hydraulic pipes to the seat.

14 Remove the bolts from the rotary joint.

Remove the seat.

15 Remove the engine assembly, if necessary.

Drain and remove the fuel tank.

Remove the dozer control lever, see B/6-3, step 1.

Drain the hydraulic system. Remove the hydraulic pipework.

16 Attach lifting equipment to the upper structure frame. Take up slack in the slings 17. Remove the nuts A securing the upper structure frame to the slew ring. Lift the upper structure frame clear of the machine. Take care not to foul the rotary coupling.

Remove the hydraulic tank.

13 Remove the hydraulics from the rotary coupling.

10 Disconnect the instrument panel electrical cables.

18 Remove the rotary coupling, if necessary. Remove dowels D. 19 Remove the nuts B and the bolts E securing the slew ring C to the machine undercarriage. 20 Remove the slew ring from the machine.

9803/3145

Issue 1

Section B

Body & Framework

6-2

Section B 6-2

Upper Structure (cont'd) Dismantling and Assembly (cont'd) When Assembling 1 Fit the bolts F into the slew ring from below and fit the slew ring to the machine, ensuring that the soft spot (marked 'S') is towards the right hand side of the machine. Line up dowel holes and fit dowels D. 2

Secure the slew ring using the nuts B and bolts E.

Fit the rotary coupling.

Refit the hydraulics to the rotary coupling if necessary.

Refit and secure the upper structure.

If necessary, refit the engine assembly.

Refit the slew motor and gearbox. Refill the gearbox with oil.

Refit the valve blocks if necessary.

Refit the hydraulic tank. Fit the hydraulic hoses as necessary. Remake all hydraulic connections.

10 Top up the hydraulic tank. 11 Reconnect the machine electrics. 12 Refit the dozer control lever. 13 Refit the track control levers. 14 Refit the floor plate. 15 Refit and fill the fuel tank. 16 Refit and secure the seat assembly. 17 Connect the seat equipment electrical connections. 18 Refit the cab/canopy. 19 Connect the cab/canopy electrical cables. 20 Refit the excavator assembly.

9803/3145

Issue 1

Section B

Body & Framework

Section B

6-3

Upper Structure, Control Mechanism all machines Removal and Replacement When Removing 1 Remove bolt H and nut J. Remove the dozer control lever G.

When Replacing 1 Replace the controls in reverse order of disassembly

Remove bolts K and nuts L. Remove bolts N and M.

Set up the hydraulic system.

3 3

Remove the track control levers Q and P.

Set up the control system by slackening locknuts R and adjusting rods S until all control levers are set at 90O in both planes, to the line of the floor.

Fit and secure the floor plate(s) and seat.

Inspection 1 Check all linkages for security and excessive movement. 2

Remove and replace defective components.

9803/3145

Issue 1

Section B

Body & Framework

Section B

7-1

B C A

J E

J A G

9803/3145

Issue 1

Section B

Body & Framework

7-2

Section B 7-2

Kingpost Removal and Replacement Removal 1 Remove the boom, ensure the boom working light is disconnected. 2

Remove both outer hose clamps A.

Remove the bolts securing the central hose clamp B.

Remove the swing ram locking plate C and drive out the rod side pivot pin.

WARNING The kingpost weighs 42 kg. Take care when lifting or handling it. 5 6

Support the weight of the kingpost with suitable lifting equipment. Undo the top mounting securing bolt D and washer and remove them; drive out the upper pivot pin E in a downward movement, avoiding contact with the hydraulic hoses.

Remove the king pin lower protective cap F.

Undo the lower mounting securing bolt and washer G and remove; drive out lower pivot pin H in an upward movement, avoiding contact with the hydraulic hoses.

9803/3145

Replacement 1 Clean paint and loose scale from the pin abutment area J on both the upper and lower kingpost pivot pins and from the kingpost abutment areas. 2

Using suitable lifting equipment, locate the kingpost onto the mainframe, threading the hoses through the centre of the kingpost.

Fit both the lower and upper pivot pins, locating the abutment areas into the kinpost.

Fit the attaching parts to the upper and lower pivot pins and torque tighten to 250 Nm (26 kgf m, 184 lbf ft).

Fit the swing ram pivot pin and secure with the locking plate.

Arrange the boom hoses in the central kingpost clamp and tighten the clamp.

Fit both the outer hose clamps.

Fit the boom and working light.

Issue 1

Section C

Electrics

Section C

Contents

Page No.

Technical Data .............................................................................. 1 - 1 Battery ........................................................................................... 2 - 1 Fan Belt ......................................................................................... 3 - 1 Alternator ...................................................................................... 4 - 1 Starter Motor ................................................................................. 5 - 1 Beacon .......................................................................................... 8 - 1 Circuit Diagram ........................................................................... 10 - 3 Wiring Harness (802.7 / 803) ...................................................... 10 - 5 Wiring Harness (804) .................................................................. 10 - 7 Harness Specifications ............................................................... 10 - 9 - Main Harness .................................................................. 10 - 10 - Radio Harness ................................................................ 10 - 16 - Cab Harness ................................................................... 10 - 17 - Instrument Panel Adaptor Harness ................................ 10 - 18 - Fuel Sender Adaptor Harness ........................................ 10 - 19 - Slew Frame to Cab Adaptor Harness ............................. 10 - 20 - Slew/Swing Change-over Harness ................................. 10 - 21

9803/3145

Issue 1

Section C

Electrics

Section C

1-1

Technical Data System Type Battery -

Type 058, (802.7 / 803) Type 643, (804) Voltage Capacity

12Volt negative earth

Specific Gravity (fully charged)

12V 75 ampere/hour (Wet charged) 802.7 / 803 60 ampere/hour (Dry charged) 802.7 / 803 103 ampere/hour (Wet charged) 804 96 ampere/hour (Dry charged) 804 Between 1.285 and 1.310 at 15Â°C

Function Cab lights Working lights Indicator Power Glowplug Working lights on/off (indication at switch )

Rating 18W 55W N/A N/A N/A 1.2W

Bulbs

Circuit Protection The electrical circuits are protected by fuses located in a fuse box below the instrument panel, with an extra main harness protection line mounted 50A fuse (clipped to the top of the engine rocker cover). Fuse A 6 5 4 3 2

Circuit Main harness (not shown) Horn, Beacon (optional), Radio (optional) Seat Microswitch, Slew/Swing, Servo Supply Solenoid Working Lights Working Lights plus Cab Lights (optional) Wipers, Heater Instrument Panel (Hourmeter, Engine Oil Pressure Switch, Coolant Temperature Switch, Blocked Air Filter Switch), Two Speed Switch/Solenoid, Auxiliary Power Socket (optional) Cab Light RADIO removed

Rating 50A 15A 5A 10A 20A 15A

6 5 4 3 2

10A 5A

1 H50770

9803/3145

Issue 2*

Section C

Electrics

Section C

2-1

Battery Negative Earth Electrical System 1 Always connect the negative terminal of the battery to EARTH. 2 When connecting the battery, connect the earth lead LAST. 3 When disconnecting the battery, disconnect the earth lead FIRST.

High Rate Discharge Test This test is to determine the electrical condition of the battery and to give an indication of the remaining useful ‘life’

Inspection Check the level of the electrolyte (low maintenance). Make sure that the terminals are tight and clean. Coat them with petroleum jelly to prevent corrosion.

Disconnect both terminals of the battery.

Adjust the discharge tester to 3 x amp/hour rating of the battery.

Testing the Specific Gravity The specific gravity of the electrolyte gives an indication of the state of charge of the battery. Readings should be taken using a hydrometer, when the electrolyte temperature is 15°C (60°F). If the battery has recently been charged, wait approximately one hour, to dissipate the ‘surface charge’ before testing.

Connect the tester to the battery terminals, observing the polarity.

Note the voltmeter reading. The battery should be capable of maintaining at least 9 volts for 1 0 seconds. A rapidly falling voltage indicates a fault in one or more of the battery cells.

Readings should not vary between cells by more than 0.04. A greater variation indicates an internal fault on that particular cell.

Before testing, ensure that the battery is at least 75% charged.

Note: Do not leave the discharge tester connected to the battery for longer than is necessary to complete the test.

If the electrolyte temperature is other than 15°C (60°F) a 'correction factor’ must be applied to the reading obtained. Add 0.0007 per 1°C higher than 15°C, and subtract the same if the temperature is lower.

9803/3145

Issue 1

Section C

Electrics

3-1

Section C 3-1

Fan belt Removing, Inspection and Fitting Removing 1 Park the machine on firm, level ground and remove the starter key.

Fitting 1 Install the fan belt so that it passes around the fan, crankshaft, water pump and alternator pulleys.

Open the engine cover.

Remove the engine access panel.

Use a wooden lever and move the alternator away from the engine block. Apply pressure at the drive end bracket only.

Adjust the position of the alternator, so that when the belt is depressed at the mid-point C between the crankshaft and alternator pulleys, the deflection is 5 mm (0.2 in). Use a finger force of approximately 10 N (1 kgf, 0.51 lbf) for this check.

Tighten the mounting bolts A and the adjusting bolt B.

Reconnect the battery. Connect the earth lead last.

WARNING Make sure that the engine cannot be started. Disconnect the battery. Disconnect the earth lead first. ENG 6-3

Loosen the alternator mounting bolts A and the adjusting bolt B.

Move the alternator towards the engine block.

Remove the fan belt from the alternator pulley, water pump pulley and the crankshaft pulley.

Remove the fan belt over the fan.

Inspection 1 Examine the fan belt and pulleys for damage. Renew as necessary.

9803/3145

Issue 1

Section C

Electrics

Section C

4-1

Alternator Removing and Fitting Removing 1 Raise the engine cover. 2

Remove the interior access panel.

Disconnect the battery. Disconnect the earth lead first.

Disconnect the electrical connections.

Fitting 1 Put the alternator in position and align with the fan belt. 2

Fit the mounting nut A and bolt B and the adjusting bolts C.

Adjust the fan belt tension, see page 5/7 - 3, and tighten the mounting nut A and bolt B, and the adjusting bolt C.

Support the alternator and remove the mounting nut A and bolt B.

Connect the electrical connections.

Remove the adjusting bolt C.

Reconnect the battery. Connect the earth load last.

Remove the alternator. 6

Refit the interior access panel.

Close the engine cover.

9803/3145

Issue 1

Section C

Electrics

Section C

5-1

Starter Motor Removing and Fitting Removing 1 Raise the engine cover. Remove the interior access panel.

Refitting 1 Engage the starter pinion with the engine flywheel gear teeth.

Disconnect the battery. Disconnect the earth lead first.

Support the starter A motor while refitting and tightening the securing bolts B.

Disconnect the starter electrical connections.

Reconnect the starter motor electrical connections.

Support the starter motor A, loosen and remove the securing bolts B.

Refit and secure the access panel behind the driverâ&#x20AC;&#x2122;s seat in the rear of the cab.

Disengage the pinion from the flywheel gear teeth and remove the starter motor.

Reconnect the battery terminals.

Close the rear engine cover.

Fitting 1 Put the starter motor in position and align the pinion in the flywheel gear teeth. 2

Fit and tighten the securing bolts B.

Connect the electrical connections.

Connect the battery terminals. Connect the earth terminal last.

Fit the interior access panel.

Close the engine cover.

9803/3145

Issue 2*

Section C

Electrics

Section C

5-2

Starter Motor (cont'd) Inspection and Testing 1 Check torque settings for all connections, and connections are free from contamination caused by arcing or sparking, Clean and re-torque as required. Note: Do not over tighten connections, this could result in damaged threads or internal damage to the starter motor.

CAUTION Never remove the inner lock nut on either the Starter Motor A or Solenoid B. Removal will cause permanent internal damage to the Starter Motor and Solenoid. 2

If the starter will still not start, disconnect electrical connections and remove the starter from the engine.

For the following tests, a 12V battery, (in a good state of charge), two heavy duty battery jump leads fitted with crocodile clips and a 5 amp lead, with open circuit in line push button switch are required. 3

Secure the motor in a vice or similar.

Connect the battery positive lead to the heavy duty solenoid connection, using one of the battery jump leads. Connect the second jump lead to the starter motor case terminal and battery negative pole. There should be NO operation of the starter motor, if there is any buzzing, smoking or sparking from the starter motor it is faulty and should be replaced.

A H28000

With the existing connections in place, connect the 5 amp capacity wire between battery positive and solenoid lucar blade. Operate the push button switch C, the solenoid should engage moving the starter pinion out. The starter motor will rotate, releasing the push button will allow the pinion to retract and the starter to stop rotating. If there is any abnormal noise, electrical buzzing, smoke, the starter does not rotate or the pinion does not move forward or back, the starter motor is faulty and should be replaced.

If the starter motor operates correctly investigate the machine electrical system.

H28010

9803/3145

Issue 2*

Section C

Electrics

8-1

Section C 8-1

Beacon Mounting The rotating beacon relies on the force of a magnet to hold it in position on the machine. A cable and plug from the beacon fits into a socket located on a panel in the cab of the machine. The panel is wired to provide a beacon operating switch and warning light. The intended beacon mounting position must be flat, clean and dry. When mounted, particularly ensure beacon positioning conforms to the following: - Is in accordance with National and local legal requirements. - The light is visible from any point at a reasonable distance from the machine. - Beacon base parallel to the ground and on the machine longitudinal centre line. - If radio equipment is fitted to the machine, there should be a minimum distance of 500 mm (20 in.) between the beacon and the radio antenna.

CAUTION The beacon must be removed before the machine is towed or loaded onto a trailer for towing. The beacon must not be fitted if the machine is moved at speeds exceeding 80 kph (50 mph). Bulb Change 1 Remove the lens latch locking screw A. 2

Push down the lens latch B. Turn lens C anticlockwise to release and remove it.

Taking care not to touch the bulb glass, release the bulb retaining clip D and lift bulb E and attached clip from the connector F. Disconnect bulb E.

Remove the unserviceable bulb from clip D.

Fit a new bulb and assemble the beacon in reverse order of dismantling. Do not tighten the lens latch locking screw A to more than 0.65Nm (5.75 lbf in.).

Note: Ensure the drive motor is fitted with the red pulley for correct operation on 12V systems.

9803/3145

Issue 1

Section C

Electrics

Section C

10 - 3

36 34 10

51 2

41 4

5 17

F1 F2 F3 F4 F5 F6

19 18

M 22

23 48

46 47 49 50

28A

28B

29 32 31 9803/3145

H03661

Issue 1

Section C

Electrics

10 - 4

Section C 10 - 4

Circuit diagram Main Components 1 Battery 2 Alternator 3 Starter Motor 4 Starter Switch 5 Fuse Block 5B 50 amp Main Harness Fuse 6 Warning Buzzer 7 Diode Bank 8 Glow Plugs 9 Fuel Gauge 10 Fuel Gauge Sender 11 Fuel Solenoid 12 Hourmeter 13 Engine Oil Pressure Switch 14 Engine Coolant Temperature Switch 15 Blocked Air Filter Switch 16 Radio - Optional 17 Interior Light Switch 18 Windscreen Wiper Motor 19 Wiper Motor Parking Switch 20 Heater Motor 21 Resistor 22 Heater Switch 23 Working Light Switch 25 Seat Microswitch 26 Servo Supply Solenoid 27 Slew/Swing Switch 28A Swing Solenoid 28B Swing Solenoid 29 Horn Switch 30 Horn 31 Low hydraulic oil temperature sender (804 m/c only) 32 Beacon 34 Cigarette Lighter 35 Two Speed Switch 36 Two Speed Solenoid

9803/3145

Lamps 40 Alternator Warning 41 Engine Oil Pressure Warning 42 Engine Coolant Temperature Warning 43 Blocked Air Filter Warning 44 Glowplug Warning 45 Interior 46 Boom 47 Mainframe working (if fitted) 48 Working Light Switch 49 Cab Roof - Optional 50 Cab Roof - Optional 51 Fuel Gauge 52 Hourmeter 53 Low hydraulic temperature warning (804 m/c only)

Issue 1

Section C

Electrics

Section C

10 - 5

10 - 5 22 45 35 40

124 39B 65 70

41 61

34 63

81 82

8 39 SP11 39B 41 71

44 69 66A

10, 60, 61, 62 63, 64, 65, 66 66A, 67, 68, 70, 73, 74, 260, 262, 272

46/47 GN/BL 48/49 W/BN 50 BN/PK 51/52 LT.GN/R 43 W/OR 53 BN/BK

32, 33 36 31 23, 24 25, 37 22

SP8

SP5

POSITION 1, 42 GR/BK POSITION 2, 64 BK

66 BK 67 BK 54 GN 8 BL/BK 26 GN

R CAB CONNECTOR 22 BL 45 R/GN 35 R/BL 40 R/BN 124 GN 39B BL/BK 65 BK 70 BK

13, 15, 16, 17 18, 19, 20, 21

19 18 17 16 15 5

32 262

48 51 49 52 53

56 59 20

66,67,54,8,42,26

74 82

46 50 43 47

SP9

25, 26 54, 80 81

SP7

35, 36

38 138 238

272 38

SP10

7,7a,9 12,12a

60 138

260 238 55 56

52,72,9,47,-,49,-,50

12 12a

AIR CLEANER 52 LT.GN/RED GLOW PLUG 72 BK GLOW PLUG 9 BN/BL WATER TEMP 47 GN/BL ENGINE OIL 49W/GN ALTERNATOR WARNING 50 BN/PK

31 39 39 BL/BK

71 68 72 71 BL/BK 68/72 BK

23 44 69

4 6 4a 14 14a 3 3a

45 24/124 35 40

69 GN/GY 23 GN 44 GN/Y

SP1

1,2,4,4a 5,14,14a

45 R/GN 24/124 GN 35 R/BL 40 R/GN

46 48

10 58 59

7 7a

3 3a

1, 2 6

53 21

58 51

9803/3145

H18560

Issue 2*

Section C

Electrics

10 - 6

Section C 10 - 6

Wiring Harness - 802.7 / 803 1 2 3 3a 4 4a 5 6 7 7a 8 9 10 12 12a 13 14 14a 15 16 17 18 19 20 21 22 23 24 25 26 31 32 33 34 35 36 37 38 39 39B 40 41 42 43 44 45

Starter Motor Feed to SP1 Starter Motor Feed to SP1 Starter Solenoid to Fuse Starter Solenoid to Fuse Ignition Switch to SP1 Ignition Switch to SP1 Fuse Block to SP1 Ignition Switch to Starter Solenoid Glow Plug to SP10 Glow Plug to SP10 SP11 to Instrumentation Illumination Glow Plug Warning Lamp to SP10 Earth to SP5 Ignition Switch to SP10 Ignition Switch to SP10 Ignition Switch to SP8 Fuse to SP1 Fuse to SP1 Fuse Block to SP8 Fuse Block to SP8 Fuse Block to SP8 Fuse Block to SP8 Fuse Block to SP8 Warning Buzzer to SP8 Alternator to SP8 Fuse Block to Cab Connector Fuse Block to Blower Motor Fuse Block to Wiper Motor Fuse Block to SP9 Fuel Gauge to SP9 Boom Lamps To Fuse Block Fuse Block to Beacon Feed Fuse Block to Horn Feed Horn to Horn Switch Wiper Motor to Cab Connector Fuse Block to Slew/Swing Switch Fuse Block to Fuel Solenoid Slew/Swing Switch to SP7 Boom lamps to SP11 SP11 to Cab Connector Wiper to Cab Connector Boom Lamps to SP11 Fuel Gauge to Fuel Gauge Sender Diode Connector to Warning Buzzer Blower Motor to Heater Windscreen Wiper Motor to Cab Connector

9803/3145

46 47 48 49 50 51 52 53 54 55 56 58 59 60 61 62 63 64 65 66 66A 67 68 69 70 71 72 73 74 80 81 82 124 138 238 260 262 272

Engine Coolant Temperature Switch to Diode Connector Engine Coolant Warning Lamp to Diode Connector Engine Oil Pressure Switch to Diode Connector Engine Oil Pressure Warning Lamp to Diode Connector Alternator Warning Lamp to Diode Connector Blocked Air Filter Switch to Diode Connector Blocked Air Filter Warning Lamp to Diode Connector Alternator to Diode Connector Hour Meter to SP9 Slew/Swing Switch to Seat Micro - Switch Seat Micro - Switch to Servo Supply Solenoid Blocked Air Filter Switch to Earth Pilot Solenoid to Earth Swing Solenoid to SP5 Boom Lamp to SP5 Tube to Earth Horn to SP5 Fuel Gauge Sender to SP5 Cab Connector to SP5 Hour Meter to SP5 Heater to SP5 SP5 to Instruments SP5 to Boom Lamp Warning System Heater to Blower Motor Cab Connector to SP5 Boom Lamp Warning System to Boom Lamp Relay Glow Plug Lamp to Boom Lamp Warning System Cigarette Lighter to SP5 2 - Speed Solenoid to SP5 Cigarette Lighter to SP9 2 - Speed Switch to SP9 2 - Speed Switch to 2 - Speed Solenoid Cab Connector to Wiper Motor Swing Solenoid to SP7 Swing Solenoid to SP7 Swing Solenoid to SP5 Beacon Feed to SP5 Slew Swing Switch to SP5

Issue 1

Section C 10 - 7

9803/3145

Electrics

Section C 10 - 7

Issue 1

Section C

Electrics

10 - 8

Section C 10 - 8

Wiring Harness - 804 1 2 3 3a 4 4a 5 6 7 8 9 10 11 11a 12 12a 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 39B 40 41 42 43

Starter Motor Feed to SP1 Starter Motor Feed to SP1 Starter Solenoid to Fuse Starter Solenoid to Fuse Ignition Switch to SP1 Ignition Switch to SP1 Fuse Block to SP1 Ignition Switch to Starter Solenoid Glow Plug to SP10 Glow Plug to SP10 Glow Plug Warning Lamp to SP10 Earth to SP5 Fuse to SP1 Fuse to SP1 Ignition Switch to SP10 Ignition Switch to SP10 Ignition Switch to SP8 Ignition Switch to SP8 Fuse Block to SP8 Fuse Block to SP8 Fuse Block to SP8 Fuse Block to SP8 Fuse Block to SP8 Warning Buzzer to SP8 Alternator to SP8 Fuse Block to Cab Connector Fuse Block to Blower Motor Fuse Block to Wiper Motor Fuse Block to SP9 Fuel Gauge to SP9 Water Temperature Lamp to SP9 Engine Oil Lamp to SP9 Alternator Warning Lamp to SP9 Air Cleaner Lamp to SP9 Boom Lamps To Fuse Block Fuse Block to Beacon Feed Fuse Block to Horn Button Horn to Horn Button Wiper Motor to Cab Connector Fuse Block to Slew/Swing Switch Fuse Block to Fuel Solenoid Slew/Swing Switch to SP7 Boom lamps to SP11 SP11 to Cab Connector Wiper to Cab Connector Boom Lamps to SP11 Fuel Gauge to Fuel Gauge Sender Diode Connector to Warning Buzzer

9803/3145

44 45 46 47 48 49 50 51 52 53 54 55 56 58 59 60 61 62 63 64 65 66 66A 67 68 69 70 71 72 73 74 80 81 82 124 138 238 260 262 270 271 272 273

Blower Motor to Heater Windscreen Wiper Motor to Cab Connector Engine Coolant Temperature Switch to Diode Connector Engine Coolant Warning Lamp to Diode Connector Engine Oil Pressure Switch to Diode Connector Engine Oil Pressure Warning Lamp to Diode Connector Alternator Warning Lamp to Diode Connector Blocked Air Filter Switch to Diode Connector Blocked Air Filter Warning Lamp to Diode Connector Alternator to Diode Connector Hour Meter to Alternator Warning Lamp Slew/Swing Switch to Seat Micro - Switch Seat Micro - Switch to Servo Supply Solenoid Blocked Air Filter Switch to Earth Pilot Solenoid to Earth Swing Solenoid to SP5 Boom Lamp to SP5 Tube to Earth Horn to SP5 Fuel Gauge Sender to SP5 Cab Connector to SP5 Hour Meter to SP5 Heater to SP5 Fuel Gauge to Hour Meter Fuel Gauge to Boom Lamp Warning System Heater to Blower Motor Cab Connector to SP5 Boom Lamp Warning System to Boom Lamp Relay Glow Plug Lamp to Boom Lamp Warning System Cigarette Lighter to SP5 2 - Speed Solenoid to SP5 Cigarette Lighter to SP9 2 - Speed Switch to SP9 2 - Speed Switch to 2 - Speed Solenoid Cab Connector to Wiper Motor Swing Solenoid to SP7 Swing Solenoid to SP7 Swing Solenoid to SP5 Beacon Feed to SP5 Boom Boost Switch to SP5 Boom Boost Switch to SP12 Slew Swing Switch to SP5 SP12 to Fuse Block

Issue 1

Section C

Electrics

Section C

10 - 9

8 7 6 5

4 3 2 1

2 1

NH NJ 2 1

1 2 3 4 5 6 7 8

1 2 3 4 5 6

MR 2 1

2 1

NC MT

8 6 42

2 1

7 5 31

8 6 42

7 5 31

NB 6 5 4

3 2 1

1 1U

2 2U 3 3U 4 4U 5 5U

ND NM

6 6U

B A

NL B A 3 2 1

MC B

60A 2

MA MJ

MG MH

2 1

9803/3145

H27570

Issue 1*

Section C

Electrics

Section C

10 - 10

Harness specifications Main Harness Refer to the Reference Tables on Page 10-14 for the Unit Items, Related Items and wire colour information.

Unit (Unit Items)

Wire ID No (Colour)

Plug ID

Plug Terminal

Wire Size

Wire Destination

Related Items

3 (N) 14 (N/R)

1 2

6.0 6.0

MB1 S1

Starter Solenoid

3 (N)

6.0

MA1

M,BP

Starter Solenoid

6 (W/R) (D, E)

3.0

MX4

Alternator (N, P)

1 (N) 2 (N) 53 (N/B)

1 2 3

4.0 4.0 1.0

S1 S1 NB6

R R S

Temp Sender (BH)

46 (G/U)

1.0

Earth Ring

10 (B)

6.0

M,K

Fuel Cut-off

37 (W/G)

1.0

S12

A,D,E

7 (N/R)

4.0

L,K

Oil Pressure

48 (W/N)

1.0

S10

G,H

Fuel Sender (AV)

42 (G/B) 64 (B)

1 2

1.0 1.0

NA2 S5

AW,AX AW,AX

Boom Light (AB, AC)

41 (U/B) 61 (B)

1 2

1.4 1.4

S7 S5

Z,AA Z,AA

Horn (AZ,BA)

34 (P/B) 63 (B)

1 2

1.4 1.4

MZ2 S5

BB,BC BB,BC

22 (U) 45 (R/G) 35 (R/U) 40 (R/N) 124 (G) 39B (U/B) 65 (B) 70 (B)

1 2 3 4 5 6 7 8

1.4 1.4 1.4 1.4 1.4 1.4 2.0 2.0

MS1U MT1 MT5 MT7 S13 S7 S5 S5

Z,AA Z,AA Z,AA Z,AA Z,AA Z,AA Z,AA Z,AA

1 2

1.0 1.0

S12 NKA

V,W V,W

Maxi-Fuse (AY)

Glow Plug

Cab Connector (X,Y)

Dozer Lever (2 Speed) (AB, AC)

9803/3145

Issue 1*

Section C

Electrics

Section C

10 - 11

Harness specifications Main Harness - cont'd Refer to the Reference Tables on Page 10-14 for the Unit Items, Related Items and wire colour information.

Unit (Unit Items)

Wire ID No (Colour)

Plug ID

Plug Terminal

Wire Size

Wire Destination

Related Items

Fuse Box (AG, AH)

5 (N) 22 (U) 15 (W) 25 (G) 16 (W) 24A (G) 17 (W) 31 (P) 18 (W) 36A (W/G) 19 (W) 32 (P) 33 (P)

1 1U 2 2U 3 3U 4 4U 5 5U 6 6U

1.4 1.4 1.0 1.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 1.0 1.4

S1 MP1 S6 S12 S6 S13 S6 MV5 S6 S4 S6 ND1 MZ1

BE BE BD BD BE BE BD BD BE BE BE BF BF

Wiper Switch (AM)

45 (R/G) 24 (G) 35 (R/U) 40 (R/N) -

1 2 3 4 5 6 7 8

1.4 1.4 1.4 1.4 -

MP2 S13 MP3 MP4 -

AP AP AP AP -

Blower Switch (AM)

69 (G/S) 23 (G) 44 (G/Y) -

1 2 3 4 5 6 7 8

1.4 1.4 1.4 -

NE2 S13 NE3 -

AP AP AP -

Boom Lights (AM)

39 (U/B) 31 (P) -

1 2 3 4 5 6 7 8

2.0 2.0 -

S7 MS4U -

AP AP -

Boom Lights (Warning) (AL)

71 (U/B) 68 (B)

9 10

0.6 0.6

S7 S5

AN AN

Ignition Switch

4 (N) 13 (W) 12 (N/R) 6 (W/R)

1 2 3 4

6.0 3.0 4.0 3.0

S1 S6 S9 MC1

J,K C,D J,K C,D

9803/3145

Issue 1*

Section C

Electrics

Section C

10 - 12

Harness specifications Main Harness - cont'd Refer to the Reference Tables on Page 10-14 for the Unit Items, Related Items and Wire Colour information.

Unit (Unit Items)

Wire ID No (Colour)

Plug ID

Plug Terminal

Wire Size

Wire Destination

Related Items

Indicator Lamps (AT)

50 (N/K) 49 (W/N) 47 (G/U) 9 (N/R) 72 (B) 52 (LG/R)

1 2 3 4 5 6 7 8

0.6 0.6 0.6 0.6 0.6 0.6

NB3 S10 S8 S9 S5 S11

AU AU AU AU AU AU

Horn Button (D)

33 (P) 34 (P/B)

1 2

1.4 1.4

MS6U MN2

B B

Fuel Gauge/ Hourmeter (AS)

26 (G) 42 (G/B) 8 (U/B) 54 (G) 67 (B) 66 (B)

1 2 3 4 5 6

0.6 1.0 0.6 0.6 0.6 0.6

S12 ML1 S7 S12 S5 S5

AU AU AU AU AU AU

Diode Connector (T, U)

46A (G/U) 48A (W/N) 50 (N/K 51A (LG/R) 43 (W/O) 53 (N/B)

1 2 3 4 5 6

0.6 0.6 0.6 0.6 0.6 1.0

S8 S10 MY1 S11 NC1 MD3

V,W V,W V,W V,W V,W V,W

Buzzer

43 (W/O) 20 (G/N)

1 2

0.6 0.6

NB5 S12

E,F A,D

Beacon Feed

32 (P) 262 (B)

1 2

1.0 1.0

MS6U S5

A,D A,D

Heater

66A (B) 69 (G/S) 44 (G/Y)

1 2 3

1.4 1.4 1.4

S5 MU1 MU5

B,D B,D B,D

Cigarette Lighter

73 (B) 80 (G)

1 2

1.4 1.4

S5 S4

B,D B,D

Slew Swing Switch

36 (W/G) 38 (W/G) 272 (B)

1 2 3

1.0 1.0 1.0

S4 S3 S5

B,D,E B,D,E A,D,E

Micro Switch (AB, AC)

55 (B/R) 56 (B/R)

1 2

1.0 1.0

S4 NRA

V,W V,W

Solenoid (2 Speed) (AF)

82 (W/U) 74 (B)

A B

1.0 1.0

MR2 S5

BJ,BK BJ,BK

Swing Solenoid (AF)

138 (W/G) 60 (B)

A B

1.0 1.0

S3 S5

BJ,BK BJ,BK

Swing Solenoid (AF)

238 (W/G) 260 (B)

A B

1.0 1.0

S3 S5

BJ,BK BJ,BK

9803/3145

Issue 1*

Section C

Electrics

Section C

10 - 13

Harness specifications Main Harness - cont'd Refer to the Reference Tables on Page 10-14 for the Unit Items, Related Items and wire colour information.

Unit (Unit Items)

Wire ID No (Colour)

Plug ID

Plug Terminal

Wire Size

Wire Destination

Related Items

Pilot Solenoid (AF)

56 (B/R) 59 (B)

A B

1.0 1.0

NJ2 S5

BJ,BK BJ,BK

Air Filter (AV)

51 (LG/R) 58 (B)

1 2

1.0 1.0

S11 S5

AW,AX AW,AX

9803/3145

Issue 1*

Section C

Electrics

Section C

10 - 14

Harness specifications Main Harness - cont'd Reference Table - Unit and Related Items Item Ref. A B C D E F G H J K L M N P R S T U V W X Y Z AA AB AC AF AG AH AL AM AN AP AS AT AU AV AW AX AY AZ

9803/3145

Description Faston Terminal, 6.35 mm (0.35 - 1.0 mm²) Faston Terminal, 6.35 mm (1.0 - 3.0 mm²) Faston Terminal, 6.35 mm (3.0 - 5.0 mm²) Individual Faston Housing Block Cover for 6.35 mm Tab Male Tab Terminal, 6.35 mm (0.6 - 3.0 mm²) Ring, 4.3 mm dia. 0.5 - 1.0 mm² CSA Heatshrink Sleeve, 30 mm x 6.4 mm Fastin Terminal, 9.5 mm (2.0 - 6.0 mm²) Heatshrink Sleeve, 12/4 x 40 mm Ring, 5.4 mm dia. 2.5 - 6.0 mm² CSA Ring, 10.5 mm dia. 6.0 - 10.0 mm² CSA Alternator Housing, Left Hand, Three Way Alternator Housing Cover Fastin-Faston Terminal, 90 deg., 9.5 mm (3.0 - 4.5 mm²) Fastin-Faston Terminal, 90 deg., 6.3 mm (0.65 - 1.0 mm²) Socket Housing, Six Way, HW090 Socket Retainer, Six Way, HW090 Socket Terminal, HW090, 0.3 - 1.25 mm Blue Cable Seal, 1.4 - 2.2 mm OD Socket Housing, Eight Way, HW090 Socket Retainer, Eight Way, HW090 Socket Terminal, HW090, 1.4 - 2.0 mm Brown Cable Seal, 2.2 - 2.9 mm OD Socket Housing, Two Way, HW090 Socket Retainer, Two Way, HW090 W/Pack Shd Housing 10, Two Way Fusebox Housing, Six Way Fusebox Cover, Six Way Illumination Housing, Two Way Switch Base, Eight Way Fastin-Faston Terminal, 6.35 mm 0.5 - 1.0 mm², LIF Fastin-Faston Terminal, 6.35 mm 0.8 - 2.0 mm², LIF PCB 3.96 mm Pitch Connector, Female, Six Way PCB 3.96 mm Pitch Connector, Female, Eight Way Terminal, Female, 3.96 and 5.08 Pitch Junior Timer Socket Housing with A/B Block, Two Way Junior Timer Socket Terminal Cable Entry Seal, Junior Timer Maxi-Fuse Kit, 60 Amp Econoseal Socket Housing, Two Way

Item Ref. BA BB BC BD BE BF BG BH BJ BK BP

Description Econoseal Socket Housing Retainer, Two Way Econoseal Socket Terminal, (0.75 - 2.0 mm²) Econoseal Cable Seal, 2.0 mm², Max Ins, 2.7 mm dia. Fusebox Terminal, 6.35 mm Fusebox Terminal, 6.35 mm Fusebox Terminal, 6.35 mm Socket Terminal, 4.0 mm Socket Terminal Cover, 4.0 mm W/pack Cable Entry Seal, 1.0 - 2.0 mm W/pack Pin Terminal, 1.0 - 3.0 mm Heatshrink Sleeve, Red, 12/4 x 40 mm

Reference Table - Wire Colours Wire Code

Wire Colour

N N/R N/B N/K G G/ G/U G/S G/Y G/N LG/R U U/B W W/G W/N W/U W/R W/N W/O P P/B B B/R R/G R/U R/N

Brown Brown/Red Brown/Black Brown/Pink Green Green/Black Green/Blue Green/Slate (Grey) Green/Yellow Green/Brown Light Green/Red Blue Blue/Black White White/Green White/Brown White/Blue White/Red White/Brown White/Orange Purple Purple/Black Black Black/Red Red/Green Red/Blue Red/Brown

Issue 1*

Section C

Electrics

Section C

10 - 15

8 6 4 2

10 - 15

7 5 3 1

8 6 4 2

7 5 3 1

AA TERM 1

AB 4 3

2 1

3 4

1 2

RHS SPEAKER

860

LHS SPEAKER

602

859

601

32P 3

262B 8

32P 32AP

262B 262AB 32AP 2

RADIO

BEACON

SPEAKER

POWER

CIRCUIT DIAGRAM

9803/3145

WIRE 32P 32AP 262B 262AB

AB TERM 1 2

WIRE 32AP 262AB

AC TERM 1 2 3 4 5 6 7 8

BEACON POWER SIZE DEST 1,0 AC7 1,0 AB1 1,0 AC8 1,0 AB2 BEACON SIZE 1,0 1,0

TYPE L,M L,M

DEST AA1 AA2

TYPE N,P N,P

WIRE 32P 262B

RADIO POWER SIZE DEST 1,0 AA1 1,0 AA2

A TYPE C C

AD TERM 1 2 3 4 5 6 7 8

WIRE 860 602 859 601 -

RADIO SPEAKERS SIZE DEST 1,0 AE1 1,0 AE2 1,0 AE3 1,0 AE4 -

B TYPE C C C C -

AE TERM 1 2 3 4

WIRE 860 602 859 601

SPEAKER SOCKET SIZE DEST 1,0 AD3 1,0 AD4 1,0 AD5 1,0 AD6

D,E TYPE H,K H,K H,K H,K

AF TERM 1 2 3 4

WIRE 860 602 859 601

SPEAKER PLUG SIZE DEST 1,0 AG1 1,0 AG2 1,0 AH1 1,0 AH2

F,G TYPE J,K J,K J,K J,K

AG TERM 1 2

WIRE 860 602

RHS SPEAKER SIZE DEST 1,0 AF1 1,0 AF2

TYPE N,P N,P

AH TERM 1 2

WIRE 859 601

LHS SPEAKER SIZE DEST 1,0 AF3 1,0 AF4

TYPE N,P N,P

262AB 2

BEACON

Issue 1*

Section C

Electrics

10 - 16

Section C 10 - 16

Harness Specifications Radio Harness Item Reference Table Item Ref. A B C D E F G H J K L M N P

9803/3145

Description Radio Power Plug Radio Speaker Plug Socket Terminal Socket Housing, Four Way Socket Retainer, Four Way Pin Housing, Four Way Pin Retainer, Four Way Socket Terminal, 0.3 - 1.25 mm Pin Terminal, 0.3 - 1.25 mm Wire Seal (Blue) Faston Tab Terminal, 6.3 mm Housing Shroud Pos-Lok Receptacle, 6.3 mm (0.6 - 2.0 mm) Pos-Lok Sleeve

Issue 1*

Section C

Electrics

Section C

10 - 17

Harness Specifications - cont'd Cab Harness DC 2 4

1 3

DA DB

12 3 4 56 7 8 H27580

WIPER MOTOR

WIRE

WORKLIGHT CONN. SIZE

DEST

TYPE

TERM

WIRE

SIZE

DEST

TYPE

TERM

600T

1,0

K,N

225C

2,0

DA5

J,M

600R

2,0

DA8

J,M

DB TERM

INTERIOR LIGHT WIRE

SIZE

DEST

UPPER CAB CONN.

TYPE

TERM

WIRE

SIZE

A,B

DEST

TYPE

208

1,0

DA1

H,J

208

1,0

DB1

C,D

600P

1,0

H,J

832

1,0

DC2

C,D

217

1,0

DC1

C,D

833

1,0

DC3

C,D

TYPE

225C

2,0

DD1

E,F

1,0

DC4

C,D

DC TERM

WIPER MOTOR WIRE

SIZE

DEST

217

1,0

DA3

832

1,0

DA2

600N

1,0

C,D

600R

2,0

DD2

E,F

833

1,0

DA4

1,0

DA6

L SA

Item Reference Table Item Ref. A B C D E F G H J K L M N

9803/3145

Description Pin Housing, Eight Way Pin Retainer, Eight Way Wire Seal (Blue) Pin Terminal, 0.3 - 1.25 mm Pin Terminal, 2.0 mm Wire Seal (Brown) Fastin-Faston Housing, Four Way Pos-Lok Terminal, 6.3 mm (0.5 - 1.0 mm) Pos-Lok Single Housing Ring Terminal, M5 Fastin-Faston Terminal, 6.3 mm (0.5 - 1.0 mm) Pos-Lok Terminal, 6.3 mm (1.4 - 2.0 mm) Heatshrink Sleeving

EARTH SPLICE WIRE

SIZE

DEST.

600N

1,0

DA7

600P

1,0

DB2

600T

1,0

DE1

Issue 1*

Section C

Electrics

Section C

10 - 18

Harness Specifications - cont'd Instrument Panel Adaptor Harness

87 65 432 1

7 8 9 10 11 12 1 2 3 4 5 6 65 432 1

H27600

TERM

WIRE

PANEL IND. LAMPS SIZE

DEST

TYPE

TERM

WIRE

NEW PANEL SIZE

DEST

TYPE

0,6

AC9

0,6

AB1

0,6

AB6

0,6

AC7

0,6

AB2

0,6

AC10

0,6

AC8

0,6

AB4

0,6

AA3

0,6

AC11

0,6

AA6

PANEL FUEL/HOUR

0,6

AA1

0,6

AA5

0,6

AA8

TERM

WIRE

SIZE

DEST

TYPE

0,6

AC1

0,6

AC4

0,6

AC6

0,6

AC2

Item Reference Table Item Ref. A B C E F

9803/3145

Description Friction Lock Header, Eight Way Friction Lock Header, Six Way Mini-Fit Receptacle, 12 Way Mini-Fit Female Terminal (5556) Heatshrink Sleeving, Adhesive Lined

Issue 1*

Section C

Electrics

Section C

10 - 19

Harness Specifications - cont'd Fuel Sender Adaptor Harness

AB H27620

FUEL SENDER

A,B

MAIN HARNESS

E,F

TERM

AA WIRE

SIZE

DEST

TYPE

TERM

WIRE

SIZE

DEST

TYPE

408

1,0

AB1

C,D

408

1,0

AA1

600

1,0

AB2

C,D

600

1,0

AA2

Item Reference Table Item Ref. A B C D E F G

9803/3145

Description Econoseal Socket Housing, Two Way Econoseal Socket Retainer, Two Way Econoseal Socket Terminal, 0.75 - 2.0 mm Econoseal Cable Seal Junior Timer Pin Housing, Two Way Heatshrink Sleeving, Adhesive Lined Junior Timer Pin Terminal

Issue 1*

Section C

Electrics

Section C

10 - 20

Harness Specifications - cont'd Slew Frame to Cab Adaptor Harness

1 2 3 4

4 3 2 1

5 6 7 8

8 7 6 5

H27590

PLUG

A,B

SOCKET

C,D

TERM

WIRE

SIZE

DEST

TYPE

TERM

WIRE

SIZE

DEST

TYPE

22U/208

1,0

NB1

J,L

22U/208

1,0

NA1

K,L

1,0

NB6

J,L

35RU/832

1,0

NA3

K,L

35RU/832

1,0

NB2

J,L

124G/217

1,0

NA5

K,L

40RN/833

1,0

NB4

J,L

40RN/833

1,0

NA4

K,L

124G/217

2,0

NB3

J,L

39BU/225

2,0

NA6

E,G

39BU/225

1,0

NB5

E,F

1,0

NA2

K,L

65B/600N

1,0

NB7

J,L

65B/600N

1,0

NA7

K,L

70B/600R

2,0

NB8

E,F

70B/600R

2,0

NA8

E,G

Item Reference Table Item Ref. A B C D E F G H J K L

9803/3145

Description Pin Housing, Eight Way Pin Retainer, Eight Way Socket Housing, Eight Way Socket Retainer, Eight Way Wire Seal (Brown) Pin Terminal, 2.0 mm Socket Terminal, 2.0 mm Dummy Terminal Pin Terminal, 1.0 mm Socket Terminal, 1.0 mm Wire Seal (Blue)

Issue 1*

Section C

Electrics

10 - 21

Section C 10 - 21

Harness Specifications - cont'd Slew/Swing Change Over Harness Wire identification There are two types of latching relays fitted to the slew/ swing switch in the left hand console. One has coloured wires and the other has yellow coded wires. The wires are arranged in two groups of three. It is important that the wires are identified and fitted correctly when replacing/ refitting. Coloured wires

Yellow wires (codes)

Black Yellow Green/White

1-B 3-Y 4-G/W

Red Blue Yellow

8-R 7-U 9-Y

9803/3145

Issue 1*

Section D

Controls

Section D

Contents

Page No.

Servo Hand Controllers - Description and Operation ............................................... 4 - 1 - Port Identification ............................................................. 4 - 3 - Switchable ISO/SAE Mode .............................................. 4 - 4 - Changing the Excavator Control Mode ............................ 4 - 5 Track Levers ......................................................... See section B 6 - 3 Dozer Lever ........................................................... See section B 6 - 3

9803/3145

Issue 2*

Section D

Controls

Section D

4-1

8 7

11 4

6 2

1 P

9803/3145

Issue 1

Section E

Hydraulics

Section E

i Contents

Page No.

Technical Data ....................................................................................... 1 - 1 Hydraulic Circuit (Schematic) 802.7 / 803 .............................................. 2 - 2 Hydraulic Circuit (Schematic) 803 Super / 804 ...................................... 2 - 4 Servo Circuit Description .................................................................................... 2 - 10 Hydraulic System General Fault Diagnosis ......................................... ...................... 3 - 1 Hydraulic Pump 802.7 / 803 Operation ........................................................................................ 4 - 1 Hydraulic Pump 804 Operation ........................................................................................ 4 - 3 Track Motor Description and Operation .............................................................. 5 - 2 Slew Motor Description ...................................................................................... 6 - 1 Hydraulic Pump(s) Flow Testing .................................................................................... 7 - 2 Hydraulic Pump 802.7 / 803 Removal and Replacement ............................................................. 7 - 4 Hydraulic Pump 804 Removal and Replacement ............................................................. 7 - 6 Hydraulic Pump 802.7 / 803 Dismantling and Assembly .............................................................. 7 - 8 Hydraulic Pump 803 Super / 804 Dismantling and Assembly ............................................................ 7 - 10 Track Motor Dismantling and Assembly .............................................................. 8 - 1 Control Valves, MRV and Spool Locations .......................................... 12 - 2 Control Valve(s) Removal and Replacement ........................................................... 12 - 4 Control Valve Sections Dismantling and Assembly ............................................................ 13 - 1 Main Relief Valves Removal and Replacement ........................................................... 14 - 2 Servo Relief Valve Removal and Replacement ........................................................... 14 - 3 Dipper Boost Dump Valve Removal and Replacement ........................................................... 14 - 4 Auxiliary Relief Valve Removal, Dismantling and Assembly, Inspection ......................... 15 - 1

9803/3145

Issue 3*

Section E

Hydraulics

Section E

ii Contents

Page No.

Boom, Dipper and Bucket rams Removal and Replacement ........................................................... 16 - 1 Dozer ram Removal and Replacement ........................................................... 16 - 4 Swing ram Removal and Replacement ........................................................... 16 - 6 Dismantling and Assembly ............................................................ 16 - 9 Inspection .................................................................................... 16 - 16 Rotary Coupling Removal and Replacement ........................................................... 17 - 2 Dismantling and Assembly ............................................................ 17 - 2 Main Relief Valves Pressure Testing Description ........................................................ 18 - 2 Pressure Testing Procedure .......................................................... 19 - 2 Auxiliary Relief Valves Pressure Testing ........................................................................... 19 - 3 Servo Relief Valves Pressure Testing ........................................................................... 19 - 4 Cross-line Relief Valves Pressure Testing ........................................................................... 19 - 5 Dipper Boost Dump Valve Pressure Testing` .......................................................................... 19 - 6 Hydraulic Oil Cooler Removal and Replacement ........................................................... 21 - 2

9803/3145

Issue 3*

Section E

Hydraulics

Section E

1-1

Technical data Pump Type 802.7 / 803 Plus Hydraulic triple gear type, driven directly from the engine crankshaft. Pump Flow Rates 802.7 Rated at 2350 rev/min. and at M.R.V. pressure:Section P1 at 172bar (2500 lbf/in2). New 12.3 litres/min (2.7 UK gal/min. 3.25 US gal/min.) Service Limit 11.5 litres/min (2.5 UK gal/min. 3.0 US gal/min.) Section P2 & P3 at 190 bar (2750 lbf/in2). New 19.2 litres/min. (4.2 UK gal/min.5.0 US gal/min.) Service Limit 18.0 litres/min (4.0 UK gal/min.4.8 US gal/min.) Pump Flow Rates 803 Plus Rated at 2200 rev/min. and at M.R.V. pressure:Section P1 at 172 bar (2500lbf/in2). New 17.3 litres/min (3.8 UK gal/min. 4.6 US gal/min.) Service Limit 15.8 litres/min (3.6 UK gal/min.4.3 US gal/min.) Section P2 & P3 at 190 bar (2750 lbf/in2). New 26 litres/min. (5.7 UK gal/min. 6.9 US gal/min.) Service Limit 23.75 litres/min (5.3 UK gal/min.6.3 US gal/min.) Pump Type 804 Plus and Super Single variable displacement piston type with two equal outlet flows in tandem with single gear type, driven directly from the engine crankshaft. Pump Flow Rates 804 Plus and Super Rated at 2110 rev/min. and at neutral circuit pressure:Pump P1 22 litres/min. (4.8 UK gal/min., 5.8 US gal/min.). Pumps P2 and P3 35 litres/min., 9.6 US gal/min.). Relief Valve Operating Pressures Machines to Serial No. xxxxxx

Main Relief Valves (M.R.V.) *Swing/Slew/Dozer/Dipper Boost Tracks/Dipper/Boom/Bucket/Auxiliary

802.7 Plus

803 Plus

804 Plus

*804 Super

bar

lbf/in2

bar

lbf/in2

bar

lbf/in2

bar

lbf/in2

172 190

2500 2750

172 185

2500 2670

172 190

2500 2750

172 190

2500 2750

802.7 Super M747211 on bar lbf/in2

803 Plus M827240 on bar lbf/in2

803 Super M827240 on bar lbf/in2

804 Super M734834 on bar lbf/in2

172 185

172 2500 185 2700

172 2500 207 3042

172 2500 185 2700

802.7 Plus

803 Plus

804 Plus

*804 Super

bar

lbf/in2

bar

lbf/in2

bar

lbf/in2

bar

lbf/in2

Servo Pressure Maintenance Valve

360

Auxiliary Relief Valves (A.R.V.) Boom rod and head side Dipper rod and head side *Dozer head side *Swing rod side

248 3600 248 3600 200 2900 Anti cavitation valve

248 3600 248 3600 200 2900 (all machines)

248 248 200

3600 3600 2900

248 248 200

3600 3600 2900

Slew Crossline Relief Valves

165

2400

165

2400

165

2400

165

2400

Dipper Boost Dump Valve

110

1600

110

1600

110

1600

Main Relief Valves (M.R.V.) *Swing/Slew/Dozer/Dipper Boost Tracks/Dipper/Boom/Bucket/Auxiliary

9803/3145

2500 2700

to M734508 160 2320 M734509 on 110 1600

Issue 3*

Section E

Hydraulics

Section E

1-2

Rams

-Boom -Dipper -Bucket -Swing -Dozer

802.7 / 803 Plus/Super*

804 Plus*

Bore mm in

Rod Dia mm in

Stroke mm in

Bore mm in

Rod Dia mm in

Stroke mm in

80 70 75 80 90

40 40 50 40 45

465 570 374 520 165

90 75 80 80 90

45 45 50 40 45

475 645 374 520 165

3.15 2.76 2.95 3.15 3.54

1.57 1.57 1.97 1.57 1.77

18.31 22.44 14.72 20.47 6.50

3.54 2.95 3.15 3.15 3.54

1.77 1.77 1.97 1.57 1.77

18.7 25.39 14.72 20.47 6.50

804 Super* Bore mm in

Rod Dia mm in

Stroke mm in

-Boom -Dipper -Bucket -Swing -Dozer

90 75 80 80 90

45 45 50 40 45

475 646 377 520 165

Motors Track

802.7 Plus/Super*

803 Plus/Super*

804 Plus*

-Maximum tractive effort -Motor displacement -Final displacement -Weight (w/out g/box) -Ratio

2300 kgf (5071 lbf) 30.6/16.6cc per rev 1019/553cc/rev 32 kg (70 lb) 19.3 : 1

2560 kgf (5645 lbf) 30.6/16.6cc per rev 1019/553cc/rev 47 kg (104 lb) 33 : 1

2489 kgf (5487 lbf) 30.6/16.6cc per rev 1242/674cc/rev 47 kg (104 lb) 40.6 : 1

Slew Slew Speed

Piston 9.5 rev/min.

Piston 10.3 rev/min.

3.54 2.95 3.15 3.15 3.54

1.77 1.77 1.97 1.57 1.77

18.7 25.43 14.84 20.47 6.50

804 Super* Track -Maximum tractive effort -Motor displacement -Final displacement -Weight -Ratio

2450 kgf (5401 lbf) 30.6/16.6cc per rev 1242/674 cc/rev 47 kg (104 lb) 40.6 : 1

Slew Slew Speed

Piston 9.5 rev/min.

Filtration all machines -Main Bypass pressure

9803/3145

1.5 bar (22 lbf/in2)

Issue 3*

Section E

Hydraulics

Section E

2-1

16B

15B

11 9

15A

16A

11A

14 13 11B 13A

18A

c 3D

1D j

1D 1D

a b c d

1D 1A

7 7B

e f

g h j k

4B 4F 4

4A 4E

19 P P3 T 9803/3145

4F 5

20 21

H17700

Issue 2*

Section E

Hydraulics

Section E

2-2

Hydraulic Circuit Schematic - 802.7 / 803 Machines

*Hydraulic Circuit Schematic - 802.7 / 803

Component Key

*Note: Circuit and description are for ISO machines.

P1 P2 P3 T E 1 1A 1B 1C 1D 1E 1F 1G 1H 1J 2 2A 2B 3 3A 3B 3C 3D 3E 3F 3G 3H 4 4A 4B 4C 4D 4E 4F 5 6 6A 6B 7 7A 7B 8 9 10 11 11A 11B 12 13 13A

Pump Section 1 Pump Section 2 Pump Section 3 Tank Engine Five Spool Valve Block Main Relief Valve Dozer Spool Auxiliary Relief Valves Load Hold Check Valves Swing Spool Slew Spool Dipper Boost Spool Auxiliary Spool Anti-cavitation valves High Pressure Carry-over Tube Non-Return Valve Quick Release Couplings Six Spool Valve Block Bucket/Boom/RH Track - MRV L.H. Track/Dipper/Boom Boost - MRV R.H. Track Spool Boom Spool Bucket Spool L.H. Track Spool Dipper Spool Boom Boost Spool Pressure Maintenance Valve Pressure Reducing Valve Shuttle Valves Servo Isolation Solenoid Two Speed Tracking Solenoid Accumulator Non-Return Valve Pressure Test Point Accumulator R.H. Joystick Controller Boom Control Bucket Control L.H. Joystick Controller Dipper Control Swing / Slew Control Slew / Swing Change-over Dozer Ram Swing Ram Slew Motor Cross-line Relief Valves Slew anti-cavitation Valves Dipper Ram Dipper Boost Dump Valve Relief Valve

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14 15 15A 15B 16 16A 16B 17 18 18A 19 20 21 22

Rotary Coupling L.H. Track Motor Counterbalance Valve L.H. Two Speed Tracking R.H. Track Motor Counterbalance Valve R.H. Two Speed Tracking Boom Ram Bucket Ram Restrictor Oil Cooler Return Filter with By-pass Valve Suction Strainer Check Valve

The mini-excavator hydraulic circuit is fed from a hydraulic oil tank T, located to the right of the operator’s cab. The system is powered by a three section gear pump P, connected directly to the engine crankshaft. When the engine is running, the pump draws fluid from the tank and routes it through the two main control valve blocks 1 and 3. Pump section P1 supplies the control valve sections for: - Dozer ram, 1B - Swing ram, 1E - Slew motor, 1F - Dipper Boost, 1G - Auxiliary, 1H Pump section P2 supplies the control valve sections for: - Right hand track motor, 16 - Boom ram, 17 - Bucket ram, 18 Pump section P3 supplies the control valve sections for: - Left hand track motor, 3F - Dipper ram, 3G - Boom boost, 3H Supply from all three pumps is also directed to the Pressure Maintenance Valve 4, fitted with a single adjustable pressure reducing valve 4A, Servo Isolation Solenoid Valve 4C and Two Speed Tracking Solenoid 4D. Supply from the pumps is via a servo signal hose directed into shuttle valves 4B. Main relief valves (M.R.V.) 1A, 3A and 3B are fitted in the main control valve blocks to vent hydraulic pressure, venting excess flow to tank T. Auxiliary relief valves (A.R.V.) 1C are fitted to protect the dipper, boom and the head side only on the dozer ram from damage that might be generated through overpressure conditions during operation. When the A.R.V.’s are open, over pressure fluid is routed to the control valve exhaust chamber and back to tank T.

The service lines to the dozer ram, the track motors and the pilot line from the high speed selector to the track motors are routed through a rotary coupling 14. This device allows the machine upper structure to turn without damaging hoses connected to services mounted on the undercarriage. The remaining service lines connect directly to their relevant devices. Return fluid from services or from the neutral pressure circuit is routed back to tank through an exhaust line and return filter 20.

Neutral Pressure Circuit With the engine running, but no service selected, the pump flows are routed from pump sections P1, P2 and P3 to respective valves. The valve spools are spring loaded to the neutral position, allowing fluid to pass through the valve’s neutral circuit and returned to tank through the return line. Excess pressure in the selected circuit opens the M.R.V. associated with the valve section supplied and vents excess pressure back to tank T.

Dipper Boost Dipper speed is increased by an automatic dipper boost system. Dipper boost is achived by adding a fifith spool 1G between the slew and auxiliary spools in the rear valve block 1, the spool is arranged in series to the slew spool to maintain ‘preferred’ slew operation. The boost supply from pump P1 via this fifth spool is piped through a line mounted relief valve 13 and joins the main dipper spool 3G flow to the ram L. Relief valve 13 limits the boost pressure to 110 bar (1600 lbf/in2) and is pilot operated from pressure developing in the main dipper feed pump P3. This dump valve ensures that when dipper tearout is utilised the boost supply is off-loaded back to tank by relief valve 13A enabling full system pressure to be generated at the main excavator pumps P2 and P3 without overloading the engine.

Main Relief Valves The main relief valves 1A, 3A and 3B are incorporated into the respective control valve blocks

Issue 2*

Section E

Hydraulics

Section E

2-3

2-3 16

17 11 16B

17B

17A 16A

9 11A

13 19

11B

6 6A

19A

2 1

1C 3B

1G 1F g

d 23 j

1E h 1B

a b c

14A 14

7 7B

3C 1J

e f

g h j k

4B 4F

P P3 P2 T 9803/3145

4D 21 22

4F 5

4C H17710

Issue 2*

Section E

Hydraulics

Section E

2-4

*Hydraulic Circuit Schematic - 802.7 Super / 803 Super / 804Plus & Super

*Hydraulic Circuit - 802.7 Super / 803 Super / 804Plus & Super

Component Key

Note: Circuit and description are for ISO machines.

P P1 P2 P3 T E 1 1A 1B 1C 1D 1E 1F 1G 1H 1J 2 2A 3 3A 3B 3C 3D 3E 3F 3G 3H 4 4A 4B 4C 4D 4E 4F 5 6 6A 6B 7 7A 7B 8 9 10 11 11A 11B 12 13

Pump Pump Section 1 (variable displacement) Pump Section 2 (variable displacement) Pump Section 3 (fixed displacement) Tank Engine Five Spool Valve Block Main Relief Valve Dozer Spool Auxiliary Relief Valves Load Hold Check Valves Swing Spool Slew Spool Dipper Boost Spool Auxiliary Spool Anti-cavitation valve High Pressure Carry-over Tube Non-Return Valve Six Spool Valve Block Bucket/Boom/RH Track - MRV L.H. Track/Dipper/Boom Boost - MRV R.H. Track Spool Boom Spool Bucket Spool L.H. Track Spool Dipper Spool Boom Boost Pressure Maintenance Valve Pressure Reducing Valve Shuttle Valves Servo Isolation Solenoid Two Speed Tracking Solenoid Non-return Valve Pressure Test Points Accumulator R.H. Joystick Controller Boom Control Bucket Control L.H. Joystick Controller Swing / Slew Control Dipper Control Dual Solenoid Valve Dozer Ram Swing Ram Slew Motor Cross-line Relief Valves Slew anti-cavatation Valves Dipper Ram Dipper Boost Dump Valve

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14 14A 15 16 16A 16B 17 17A 17B 18 19 19A 20 21 22 23

Auxiliary Couplings (Double Acting) Auxiliary Coupling (Single Acting) Rotary Coupling L.H. Track Motor Counterbalance Valve Two Speed Tracking Valve R.H. Track Motor Counterbalance Valve Two Speed Tracking Valve Boom Ram Bucket Ram Restrictor Oil Cooler Return Filter with By-pass Valve Suction strainer Check Valve

The mini-excavator hydraulic circuit is fed from a hydraulic oil tank T, located to the right of the operator’s cab. The system is powered by a three section pump P, connected directly to the engine crankshaft. Sections P1 and P2 are constant horsepower variable displacement pumps, section P3 is a fixed displacement gear pump When the engine is running, the pump draws fluid from the tank and routes it through the two main control valve blocks 1 and 2. Pump section P1 supplies the control valve sections for: - Dozer ram, 1B - Swing ram, 1E - Slew motor, 1F - Dipper Boost, 1G - Auxiliary, 1H Pump section P2 supplies the control valve sections for: - Right hand track motor, 17 - Boom ram, 18 - Bucket ram, 19 Pump section P3 supplies the control valve sections for: - Left hand track motor, 3F - Dipper ram, 3G - Boom boost, 3H Supply from all three pumps is also directed to the Pressure Maintenance Valve 4, fitted with a single adjustable pressure reducing valve 4A, Servo Isolation Solenoid Valve 4C and Two Speed Tracking Solenoid 4D. Supply from the pumps is via a servo signal hose directed into shuttle valves 4B. Main relief valves (M.R.V.) 1A, 3A and 3B are fitted in the main control valve blocks to vent hydraulic pressure, venting excess flow to tank T. Auxiliary relief valves (A.R.V.) 1C are fitted to protect the dipper, boom and the head side only on the dozer ram from damage that might be generated through overpressure conditions during operation. When the A.R.V.’s are open, over pressure fluid is routed to the control valve exhaust chamber and back to tank T.

The service lines to the dozer ram, the track motors and the pilot line from the high speed selector to the track motors are routed through a rotary coupling 15. This device allows the machine upper structure to turn without damaging hoses connected to services mounted on the undercarriage. The remaining service lines connect directly to their relevant devices. Return fluid from services or from the neutral pressure circuit is routed back to tank through an exhaust line and return filter 21.

Dipper Boost Dipper speed is increased by an automatic dipper boost system. Dipper boost is achived by adding a fifth spool 1G between the slew and auxiliary spools in the rear valve block 1, the spool is arranged in series to the slew spool to maintain ‘preferred’ slew operation. The boost supply from pump P1 via this fifth spool is piped through a line mounted relief valve 13 and joins the main dipper spool 3G flow to the ram L. Relief valve 13 limits the boost pressure to 160 bar (2320 lbf/in2) and is pilot operated from pressure developing in the main dipper feed pump P3. This dump valve ensures that when dipper tearout is utilised the boost supply is off-loaded back to tank by relief valve 13A enabling full system pressure to be generated at the main excavator pumps P2 and P3 without overloading the engine.

Main Relief Valves The main relief valves 1A, 3A and 3B are incorporated into the respective control valve blocks

Issue 3*

Section E

Hydraulics

Section E

2-9

4B 4G 4A

4C 4 H18410

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Issue 1*

Section E

Hydraulics

2 - 10

Section E 2 - 10

Servo circuit Description The Servo Pressure Maintenance Valve 4 is fitted with a single adjustable pressure reducing valve 4A and solenoid valves for servo isolation 4C and two speed tracking selection 4D. The system is supplied from all three pumps P1, P2 and P3 via a servo signal hose from each of the pump pressure pipes, into a shuttle valve system 4B. With the isolator solenoid energised, neutral circuit pressure from the pumps connects to the hand controllers 6 and 7. As the hand controllers are operated, the neutral circuit pressure is directed to and begins to select the desired excavator spool, which in turn pressurises the supplying pump flow. This increase in pressure is available in the servo system via. shuttle valves 4B to enable full excavator operation, but is limited and maintained to correct servo levels by the relief valve cartridge 4A. Servo pressure can be measured at pressure point 4F which is located in the forward position on the top face of the valve. Because the signal lines from all three pump flows are capable of being pressurised to full system pressure, a single pressure test tapping 4G (rear test point on top face of valve) is fitted which can be used to monitor all main hydraulic pump pressures. Boom selection restrictors 6A fitted in servo hose terminations on the boom boost spool are optional on 802.7 / 803, they cushion selection and deselection of the boom to smooth operation. However when the hydraulic system is cold an operating delay may occur.

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Issue

Section E

Hydraulics

Section E

3-1

Hydraulic System - General Fault Diagnosis Before carrying out the following checks, ensure that where applicable :1 2 3 4 5

The correct hydraulic fluid is used and the system filled to the correct level. The hydraulic fluid, filter and suction strainer are clean. There are no visible leaks in the system. Engine maximum speed and condition is as specification Hydraulic pressures for each service are correct to specification

If possible the machine should be operated to identify the fault and to bring the systems to their normal working temperature. After completing these initial checks, proceed as follows :A B C D

If If If If

all the hydraulic services are at fault start at check 1. servo controllers only are at fault start at check 13. tracking services only are at fault start at check 16. slew service only is at fault start at check 21.

Check

Action

Is the fault in all services or one only?

ALL : Check 2 ONE : Check 6

Are the hydraulics inoperative or lacking in power?

INOPERATIVE : Check 4 POOR PERFORMANCE :Check 3

Is the servo pressure to specification?

YES : Check 4. NO : Adjust

Is the pump operating correctly?

YES : Check M.R.V's. NO : Check 5.

Is the pump noisy in operation? (803 Super & 804 Super only).

YES : Purge air from pump casing. NO : Check 6

Is the pump drive broken?

YES : Renew NO : Check 7.

Is one service only down on pressure?

YES : Check 8. NO : Check 9.

Is the cable adjustment correct? (Dozer control only)

YES : Check 9. NO : Adjust cable see Section D.

Is the control valve spool sticking?

YES : Overhaul valve block section NO : Check 10.

10 Is the service A.R.V. operating correctly?

YES : Check 11. NO : Reset or renew

11 Is the valve block section cracked?

YES : Renew section and check valve block mounting

12 Are the rams faulty?

YES : Overhaul or renew

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Issue 1*

Section E

Hydraulics

Section E

3-2

Hydraulic System - General fault diagnosis - cont. Check

Action

13 Is the fault in all servo operated services or only one?

ALL :

14 Is the servo system operating correctly?

YES : NO :

Check 15 Check servo pressure maintenance valve

15 Is the hand controller plunger leaking/sticking?

YES :

Service hand controller, see Section D.

16 Is the tracking fault in both tracks and in one or both directions?

ONE : Check control linkage, check 17. BOTH : Check 4.

17 Is the tracking fault in one track in one or both directions?

ONE : Swap hoses between pumps P2 & P3, If the fault changes to other track, service pump. If fault stays check 18. Check for sticking motor counterbalance spool. BOTH : Check 18.

18 Is the fault in one track only and in both directions?

YES :

With track stalled measure lubrication return to tank flow (1) at top of rotary joint and (2) out of track motor. If (1) high and (2) normal service rotary joint. If (1) high and (2) high check track motor.

19 Is high speed engaging?

YES : NO :

Check 20. Check operation of high speed solenoid valve, rotary joint seals or motor high speed selector spool.

20 Is the track motor high speed selector servo hose crossed with motor lubrication drain hose?

YES :

Correct connections

21 Is the slew motor performance/braking poor?

YES :

Check for correct pressure settings of cross line relief valves. Check slew motor anti-cavitation check valves are closing.

22 Does the slew motor performance improve if bucket service stalled?

YES :

Check servo pressure maintenance valve non return valves are closing.

9803/3145

Check servo isolator microswitch, check servo solenoid valve, check 14. ONE : Check 15.

Issue 1*

Section E

Hydraulics

4-1

Section E 4-1

Hydraulic pump - operation 802.7 and 803 Machines 802.7 machines and 803 machines are fitted with a three section gear pump. Drive is transmitted through the sections of the pump via. a drive shaft, linked by splined bushes between each pump section P1, P2, P3.

In each pump section the drive shaft carries a gear wheel, which meshes with a second gear, carried below the drive shaft on an independent idler shaft. The pump is gravity fed from the hydraulic tank which is mounted higher on the machine than the pump. Fluid is carried by the rotating gears to the outlet side of the pump. As the gear teeth 'remesh' on the outlet side, pressure increases and fluid flows from the pump into the machine neutral circuit and servo circuit.

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Issue

Section E 4-2

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Hydraulics

Section E 4-2

Issue

Section E

Hydraulics

4-3

Section E 4-3

Hydraulic Pump 804 Variable Displacement Operation The hydraulic pump is a small lightweight compact unit containing single piston pump A components, which is able to supply two equal flows to the hydraulic system. Mounted on the back of the pump body is a gear pump B supplying oil to the dozer, slew and swing circuits.

C The piston pump rotating group of components seal against a fixed valve plate C in the pump casing. The valve plate has a single groove S machined for suction, but two concentric pressure grooves P1 & P2 both bridging the piston bores in the rotating barrel D, the outer groove supplies one hydraulic circuit whilst the inner groove supplies the second, both circuits receive equal flows. The piston pump has a constant horsepower control E which responds to hydraulic system pressure demands, as pressure in the circuits rise so the volume of oil being pumped into the circuits decreases, maintaining the horsepower demands within the power output of the engine and preventing an engine stall situation.

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The constant horsepower control, or summator, is a simple design incorporating a trunnion mounted 'swash plate' F which governs the stroke of the pistons in the pump barrel. This swash plate is spring loaded to an angle matching the maximum piston stroke hence maximum flow position. As the pistons G and barrel D rotate, driven by the engine, the swash plate draws the pistons out of the barrel, filling the vacated space on top of the piston with oil, once past top dead centre the swash plate pushes the pistons back into the barrel displacing the oil out into the hydraulic circuits of the machine. When the machine starts to dig the pressures in the circuits begin to rise, this is sensed back to the pump and registers against the crown of the pistons G as the barrel rotates. The force of the pressure felt on the piston crowns is transmitted onto the swash plate and once the spring force of the summator is exceeded, the swash plate angle progressively decreases. This in turn decreases the piston stroke reducing the volume of oil pumped into the hydraulic circuits. The gear pump is a fixed displacement pump, and should this come under pressure whilst the machine is digging, the horsepower demands on the engine will increase. However, there is a pilot gallery H sensing gear pump pressure, running through the main pump housing to a plunger J behind the swash plate. This increases the load against the summator springs E decreasing the angle of swash plate further and so reducing the piston pump flows thus maintaining a constant horsepower demand on the engine.

Issue

Section E 5-1

9803/3145

Hydraulics

Section E 5-1

Issue

Section E

Hydraulics

Section E

5-2

Track Motor Description The track motor consists of a fixed section, made up of a hydraulic motor and valve unit, and a rotary section which is a simple double-step planetary speed reduction. When both tracks are selected to operate, the pump section P2 feeds the valve block section for the RH travel motor, P3 feeds the valve block section for the LH travel motor. Track feeds from the selected spools flow through the rotary coupling to the respective track motors. The motor valve plate A has two sets of ports B and C and is in contact with the swash plate D. B and C are connected to the motor inlet and outlet lines via the counterbalance valve. When pressurised fluid is introduced through A, pistons E, on the B side are forced against the swash plate D. Reaction force from the swash plate generates radial force causing rotation of the cylinder block F. Torque generated at the cylinder block is transmitted to the output shaft G, through splines on the cylinder block. The end of the output shaft G has a spline connected gear which drives two sets of planetary gears H. These reduce output speed in two steps and transmit rotation to the rotary section of the motor via an integral ring gear J.

Operation When the track is driving forwards, pressure is fed from the main pump via the control valve to port C on the motor, this causes a spool to move downwards and the check valve to open. Flow is then allowed to enter the motor, oil is returned through P1 back to the tank Counterbalance Operation When the machine is on an incline ft will tend to travel under gravity. Under such conditions the motor overspeeds, acting as a pump, increasing outlet pressure and lowering inlet pressure. Differential pressure causes the counterbalance plunger K to shift and restrict flow from the counterbalance valve. Restricted flow from counterbalance valve to motor causes motor inlet pressure to rise and balance outlet pressure compensating for gravitational action. Braking When control valve is reset to neutral circuit P1 and P2 are connected to return line and the motor counterbalance valve re-centres and integral check valves close P1 and P2. The low travel inertia of the machine and the notched shape of the valve spool gradually limit the flow of return fluid and the machine motion is stopped smoothly.

Working fluid is discharged from C . When the control valve, on the main valve block, is selected to opposite position, C becomes inlet port, B becomes outlet and rotation is reversed. For low speed operation, the 2-speed control valve supplies fluid to all ports on the port B side (or port C side), producing maximum torque. *When high speed operation is selected, the 2-speed control valve spool AA is moved across by servo pressure against its spring. This masks off gallery BB consequently supplies pressurised fluid to only one port on side B (or C). The same volume of oil from the pump is now acting on two motor pistons instead of 5 increasing the speed of the motor/gearbox but reducing it's torque. The other port on side C (or B) are open to drain returning oil to tank via the selected track motor spool in the valve block.

C BB AA

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Issue 2*

Section E

Hydraulics

Section E

5-3

E A

H50220

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Issue 1*

Section E

Hydraulics

5-4

Section E 5-4

Track Motor - cont. Motor Low Speed, High Traction Selected With the high speed button deselected on the dozer lever, the return spring A above two speed selector spool B returns the spool to the low speed position. Service ports C and D are connected via the rotary coupling to the track spool in the valve block. Depending on whether track forward or track reverse is selected either port C or D may be pressurised, the other port then returns exhaust oil back to tank via the rotary coupling and the track spool. The illustration shows the upper service port A pressurised. Because the two speed tracking selector is not selected, the return spring A holds the selector spool B down allowing this pressurised oil to cross the spring cavity and on to two inlet ports in the valve plate E as well as across the top waisted section of the spool into the centre port of the valve plate. This means that at least four of the motor pistons receive high pressure oil, driving the motor at maximum torque (tractive effort) although at the lower speed. The opposite four pistons of the track motor are connected to tank via the lower waisted section of the two speed selector spool.

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Issue 1*

Section E

Hydraulics

Section E

5-5

h50230

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Issue 1*

Section E

Hydraulics

5-6

Section E 5-6

Track Motor - cont. Motor High Speed, Low Traction Selected With the high speed button selected on the dozer lever, servo pressure from the servo pressure maintenance valve via the rotary coupling fills the cavity under the two speed selector spool B and lifts it against the return spring A. Service ports C and D are connected via the rotary coupling to the track spool in the valve block. Depending on whether track forward or track reverse is selected either port C or D may be pressurised, the other port then returns exhaust oil back to tank via the rotary coupling and the track spool. The illustration shows the upper service port A pressurised. Because servo pressure has lifted spool B, pressurised oil crosses the top waisted section only of the spool into the centre port of the valve plate E, supplying a maximum of two of the motor pistons, driving the motor at maximum speed (minimum torque/tractive effort). The opposite two pistons of the track motor displace the oil to tank via the lower waisted section of the two speed selector spool.

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Issue 1*

Section E

Hydraulics

Section E

6-1

Slew Motor Description The slew motor consists of a reduction gearbox A, hydraulic motor B and hydraulic cross-line relief valve assembly C.

The motor located by dowels D to the mainframe and secured by setscrews E which may be used as jacking screws when removing the motor from the mainframe.

The hydraulic motor is an axial piston type and converts hydraulic energy supplied from the hydraulic pump into a rotary motion. The hydraulic valve consists of cross-line relief valves, which in conjunction with a D/A spool fitted to the valve block ensures that the inertia produced when stopping the machine is absorbed through the cross-line relief valves producing a smooth machine stop also preventing the hydraulic motor becoming overloaded. The gearbox is a single step planetary type, the gearing converts high speed rotary motion from the hydraulic motor into low-speed high torque transmitted to the pinion shaft. C

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Issue

Section E 7-1

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Hydraulics

Section E 7-1

Issue

Section E

Hydraulics

7-2

Section E 7-2

Hydraulic Pump Pump Flow Testing To achieve accurate flow figures it is recommended that the following procedure is adopted. When gear pump testing (802.7 & 803 machines), the two main pumps P2 & P3 are equal capacity, it may therefore only be necessary to compare the flows one to another. When variable displacement pump flow testing (804 machines) the results are critical to assessing the pumps performance and therefore the flow meter must be checked for accuracy.

WARNING Accurate pump performance can only be measured with the hydraulic system at normal operating temperature. Consequently various hose connections may be required with HOT hoses, pipes and fittings. Care must be taken to avoid touching metallic fittings with bare hands and prevent hot oil dripping onto the skin.

804 Variable Displacement Pumps Before the following flow testing is attempted all hydraulic pressures should be checked for accuracy. It may be an incorrectly set relief valve causing engine over load or poor machine performance. If during normal excavating duties the engine excessively lugs down and black smokes or the hydraulic system appears to be slow, it may be due to incorrect calibration of the variable displacement pump. To prove this, the pump must be accurately flow tested as follows. With the hydraulic system at the correct working temperature, park the machine with the excavator end resting on the ground. Stop the engine, leave the isolator lever in the 'down' position and ignition switch 'on', operate all excavator services to vent residual pressure.

802.7 and 803 Gear Pumps With the hydraulic system at the correct working temperature, park the machine with the excavator end resting on the ground. Stop the engine, leave the isolator lever in the 'down' position and ignition switch 'on', operate all excavator services to vent residual pressure.

Remove ignition key for safety, open the engine cover and disconnect pumps P1 and P2 pressure hoses from the pressure testing steel pipes. Connect suitable lengths of hose to both steel pipes and join together with a Tee piece A. Run another 1 metre (36 in) length of hose B (to prevent oil turbulence interfering with the flow meter). Connect a suitably accurate reading flow meter C ideally with an inbuilt pressure gauge and manual pressure loading restrictor valve. Run a length of hose from the meter to a second Tee D piece then divide the flows along the correct neutral circuit paths E & F of pumps P1 and P2.

Remove ignition key for safety, open the engine cover and disconnect pump P1 pressure hose from the pressure testing steel pipe. Insert flow meter (See Service Tools Catalogue) into pump P1 pressure line ensuring there is a least 1 metre (36 in) of straight hose with straight fittings from pump to flow meter, this will prevent oil turbulence interfering with the recorded flow on the flow meter.

Ensure load valve on the flow meter is released so that no hydraulic pressure is imposed on engine start. Start the engine and set the throttle to rated speed as detailed in Technical Data, slowly and progressively screw load valve in until 190 bar (2750 lbf/in2) is recorded on the pressure gauge, check engine speed and reset if necessary. Note recorded flow figure on meter.

Start the engine and run at rated speed as detailed in Technical Data. Operate the dozer service to maximum M.R.V. pressure and check engine speed, readjust if necessary. Note maximum flow recorded on meter. Refer to Technical Data for correct flow limit, if pump output falls below service limit, renew pump.

With 190 bar (2750 lbf/in2) still loaded on system, raise and stall dozer service, again record flow meter reading. Release dozer service and reduce system pressure imposed by the load valve to 170 bar (2465 lbf/in2), reset engine speed, and record flow. Stall dozer service and record flow.

Move flow meter to pumps P2 and P3 in turn, to measure pump P2 the bucket service should be operated to maximum ram travel and held at maximum M.R.V. pressure. Similarly, to measure pump P3 output the dipper service should be operated and stalled to M.R.V. pressure, ensuring engine speed is readjusted.

Continue these flow checks through 150 bar (2175 lbf/in2) and 100 bar (1450 lbf/in2) pressure settings always rechecking engine speed and adjusting.

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Contact Service department of JCB Compact Products Ltd for calibration instructions.

Issue

Section E

Hydraulics

Section E

7-3

G F A

1 5

B 2

H15780

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Issue

Section E

Hydraulics

Section E

7-4

Hydraulic Pump 802.7 and 803 Gear Pumps Removal and Replacement

Removal Gain access to the engine compartment.

Replacement Replacement is the reverse of the removal procedure.

Select the starter switch to the ON position.

Renew filtered adaptor B fitted to pump P1.

Relieve pressure from the hydraulic system.

Refill the hydraulic tank to the correct level.

Select the starter switch to the OFF position and remove the key. Disconnect the battery.

Before connecting the pipework, fill each pump section with JCB Hydraulic Fluid.

Drain the hydraulic tank into a clean container of suitable capacity, for reuse.

Running-in (All machines) A new pump is correctly bedded in by the manufacturer and will require no further running in after fitting.

Disconnect hydraulic hoses and pipes 1, 2, 3 and 4 from the pump, cap open ports to prevent dirt ingress. Remove the screws and washers 5 securing the pump to the engine flywheel housing. Withdraw the pump including drive coupling gear and remove to a clean working area. Note: Crankshaft drive gear F is Loctited to flywheel plate G and will be difficult to dismantle. If the gear requires renewal, the gear and plate are supplied under one part number. Remove the pump drive gear A retaining nut from the pump shaft, use a suitable puller if necessary to remove drive gear.

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Issue

Section E 7-5

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Hydraulics

Section E 7-5

Issue 3*

Section E

Hydraulics

Section E

7-6

Hydraulic Pump 802.7 Super, 803 Super & 804 Variable Displacement Pump Removal and Replacement

Removal Gain access to the engine compartment. Select the starter switch to the ON position. Relieve pressure from the hydraulic system. Select the starter switch to the OFF position and remove the key. Disconnect the battery. Drain the hydraulic tank into a clean container of suitable capacity, for reuse. Disconnect hydraulic hoses and pipes 1, 2, 3 and 4 from the pump, cap open ports to prevent dirt ingress. Remove the screws and washers 5 securing the pump to the engine flywheel housing. Pump flywheel housing adaptor plate C must NOT be removed. The adaptor plate C is jig mounted to the flywheel housing during machine manufacture, any misalignment of plate will result in premature failure of pump drive coupling K. Pump Drive Renewal If the pump drive has failed prematurely due to pump misalignment. A new flywheel housing will be necessary complete with jig aligned adaptor plate.

Replacement When refitting drive gear D to pump shaft dimension X measured from rear face of gear pinch bolt boss to front face of pump body as illustrated, must be maintained at 6.5 mm (0.25 in.). Pinch bolt E should then be torque set to 49 Nm (36 lb ft). Renew filtered adaptor B fitted to gear pump. Fill pump body with clean hydraulic fluid through suction port adaptor A. Cap adaptor to prevent oil draining whilst pump is refitted to flywheel housing. Enter the pump drive gear through adaptor plate C ensuring correct meshing of gear teeth with spline of coupling K. Torque set bolts 5 (see Technical Data). Replace pump connections 1, 2, 3 and 4. Refit suction hose 1 to adaptor A as quickly as possible to prevent oil loss, tighten worm drive clips. Refill Hydraulic tank with oil to the correct level. Ensure maximum no load engine speed does not exceed the figure specified in Engine Technical Data. Running-in (All machines) A new pump is correctly bedded in by the manufacturer and will require no further running in after fitting.

Note: Crankshaft drive gear F is Loctited to flywheel plate G and will be difficult to dismantle. If the gear requires renewal, the gear and plate are supplied under one part number. *Note: 804 Super has circlip H and two capscrews fitted from Machine number M734471 on.

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Issue 3*

Section E

Hydraulics

Section E

7-7

7-7 C

9803/3145

Issue

Section E

Hydraulics

7-8

Section E 7-8

Hydraulic Gear Pump 802.7 & 803 Machines Dismantling and Assembly When Dismantling Note: It is not possible to renew individual components of the pump. External leaks can be repaired as can, in some circumstances, the pump's performance be improved by the renewal of seals. Before starting, mark the pump sections, flange and end cover to ensure correct alignment on reassembly. 1

Unscrew and remove the tie bolts B, bolts C and washers D.

Using a soft-faced hammer, separate the pump sections. Do not use levers of any kind to separate pump components.

Remove bushes, gears and seals, keeping components together in their relative positions.

Inspection It is normal for the gears to have cut a slight track in the body bore on the inlet side. The gear track cannot be measured accurately but will be related to bearing wear. Examine the bores of the bearing blocks E which are coated during manufacture with PTFE. If the grey PTFE is worn through so that large areas of the bronze base are visible, the complete pump must be renewed. Renew pump if faces of bearing blocks E are scored or if side faces of gears F are chipped or damaged. DO NOT use any abrasive on the bearing blocks or gears as this would destroy critical manufacturing dimensions. When Assembling Note: New seals, tie bolts and nuts are to be fitted on assembly. Apply Loctite to the threads before assembly. 1

Assemble in reverse order of stripping, maintaining parts in their relative positions.

Tighten the tie bolts B, bolts C and drive coupling nut A to torque settings specified (see torque setting table).

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Issue

Section E 7-9

9803/3145

Hydraulics

Section E 7-9

Issue

Section E

Hydraulics

7 - 10

Section E 7 - 10

Hydraulic Pump 802.7 Super, 803 Super & 804 Variable Displacement Pump Dismantling and Assembly When Dismantling Remove screws 1 retaining gear pump to piston pump body Remove locknut 2 and count the number of turns to remove pump calibration screw 3 from the pump body to ensure it can be accurately repositioned on assembly. Follow numerical sequence to continue pump dismantling. Do not use levers of any kind to separate pump components. Use a soft-faced hammer to separate pump sections. Rotating components 13 should be renewed as a complete assembly. Gear pump components 42 to 49 should be renewed as a complete assembly. Inspection Check pump barrel A and pistons B for wear or damage. Also inspect bearing faces of valve plate 13 renew if there is any sign of erosion or damage caused by debris. When Assembling Note: New seals 'O' rings and gaskets are to be fitted on assembly. Apply Loctite to the threads before assembly. Assemble in reverse order of dismantling, maintaining parts in their relative positions.

9803/3145

Issue 2*

Section E

Hydraulics

Section E

8-1

Track Motor - (Nachi) Dismantling and Assembly Dismantling Note: Cover all open orifices to prevent dirt entering the hydraulic system. Brake Valve Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed.

Assembling Renew the O-rings 3, 4, 6, 22, and 26. O-rings 11 and 18 need only be renewed if the valve plugs 10 and 17 are disturbed. Torque Settings Item 1 5, 10, 12 & 17 21 & 25

Nm 26-29 167-196 49-68

kgf m 2.6-3.0 17-20 5-7

lbf ft 18-21 123-145 36-50

When removing the valve spools, note their orientation; they must be refitted correctly or the valve will not operate properly.

9803/3145

Issue

Section E

Hydraulics

8-2

Section E 8-2

Track Motor Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. When Assembling Renew the O-ring 3, spring pin 5 and oil seal 22. Before fitting the oil seal 22, fill the inside of the lip with grease. Install the oil seal 22 and the bearing 20 with a compression force of approximately 500 kgf (1 1 00 lbf). Before fitting the body 2 to body 23 , pour hydraulic fiuid into body 23. Torque Settings Item Nm 1 51-64

9803/3145

kgf m 5.2-6.6

lbf ft 38-47

Issue

Section E

Hydraulics

Section E

12 - 2

Control Valves, MRV & Spool Locations

16 15 14 18 13 12 11

22 19 21

4A 4B

9 8

6 17

1 2 3 4 4A 4B

Six Spool Valve Block Five Spool Valve Block Dipper Boost Dump Valve Servo Pressure Maintenance Valve Two Speed Tracking Solenoid (Lower) Servo Isolation Solenoid (Upper)

Valve Block Spool Locations

Relief Valves

Five 6 7 8 9 10

17 18

Spool Dozer Spool Swing Spool Slew Spool Dipper Boost Spool Auxiliary Spool

Six Spool 11 R.H. Track Spool 12 Boom Spool 13 Bucket Spool 14 L.H. Track Spool 15 Dipper Spool 16 Boom Boost

20 21 22 23 24

9803/3145

M.R.V. Five Spool Valve Block M.R.V. Six Spool Valve Block R.H. Track Boom Bucket M.R.V. Six Spool Valve Block L.H.Track Dipper Boom Boost A.R.V. Five Spool Valve Block Dozer (head side only) A.R.V. Six Spool Valve Block Boom (rod and head sides) A.R.V. Six Spool Valve Block Dipper (rod and head sides) Servo Pressure Maintenance Relief Valve Dipper Boost Relief Valve Issue

Section E

Hydraulics

Section E

12 - 3

G F

E D

C A M N

10 mm 9803/3145

M Issue

Section E

Hydraulics

12 - 4

Section E 12 - 4

Control Valve Removal and Replacement The sequences illustrated are typical and refer to all valve blocks.

WARNING Fine jets of hydraulic oil at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic oil leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic oil. If hydraulic oil penetrates your skin, get medical help immediately.

Inspection 1 Check the mating faces of the valve sections for scratching, pitting, burrs and/or corrosion. Renew valve sections as necessary. 2

HYD-001

Remove the floor plate.

Note: If the five spool valve block requires removal, the engine sump guard should be removed to give access to the valve block rear fittings. 2

In order to avoid draining the complete hydraulic system, remove and blank the three feed hoses from the main pump and release the hydraulic filter cover to avoid syphoning.

Disconnect and blank the hydraulic pipes and hoses from the appropriate valve.

Remove old control cables and discard, retain fixing screws A.

Remove bolts B and C securing the control valve to the frame. Remove the valve(s) from the machine to a clean working area.

Check the O-ring seatings, check valve locations and check valves for scratching, pitting, burrs and/ or corrosion. Renew control valve sections or check valves as necessary.

When Assembling Note: Smear all O-rings with hydraulic fluid on assembly. 1

Slide the valve sections onto the tie rods E in the correct order and orientation, fitting new O -rings H, new springs F and check valves G as necessary.

Fit the nuts D to the tie rods E. Torque tighten.

Fit the valve to the machine.

Cable Fitting Adjustment 4 Screw threaded inner end of new cable J 10mm into spool end K and tighten locknut L against spool. 5

Slide cast sleeve M into position, ensure seal retainer N and circular nut P locate correctly. Using retaining screws A, secure sleeve to valve block

Dismantling and Assembly

When Dismantling Caution: Absolute cleanliness is essential when stripping and assembling hydraulic components.

Set cable position appropriate for the spool. Check all cable cables operate freely and without binding.

Assemble removed components in reverse order of Removal section.

Set up the hydraulic circuit.

Note: It is not necessary to separate valve sections to remove valve spools, connections, relief valves etc. from the valve block. 1

Remove nuts D from tie rods E and remove the end cover from the valve.

Withdraw the valve sections from the tie rods E. Collect the springs F and check valves G.

Note: Ensure check valves are replaced into sections from which they were removed. 3

Remove and discard O-rings H

9803/3145

Issue

Section E

Hydraulics

13 - 1

Section E 13 - 1

Control Valve Sections Dismantling 1 Remove the control valve. 2

Assembly 1 Lubricate new O-rings and seals with hydraulic fluid before assembly.

Remove spools one at a time, label the spools and mark the relevant sections to ensure assembly to the correct location

Inspection 1 Examin the spool for signs of distortion, cracking and/or corrosion. 2

Replace the spring if necessary.

Discard used O-rings.

DOZER

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Issue

Section E

Hydraulics

Section E

13 - 2

BOOM BOOST and DIPPER BOOST

DIPPER and BOOM

TRACK

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Issue

Section E

Hydraulics

Section E

13 - 3

BUCKET and SLEW

AUXILIARY

SWING

9803/3145

Issue

Section E

Hydraulics

Section E 14 - 2

14 - 2

Main Relief Valves

Removal

WARNING Fine jets of hydraulic oil at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic oil leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic oil. If hydraulic oil penetrates your skin, get medical help immediately. HYD001

1 Slew machine across tracks to gain access to the appropriate valve. 2

Relieve hydraulic pressure, if necessary disconnect and blank hydraulic hoses from the valve block.

Unscrew the M.R.V.(s) from the valve block, covering the port(s) to prevent the ingress of dirt. Remove to a clean working area.

Replacing Note: Seals are made from special material, ensure correct replacements are used. 1

Screw the M.R.V. into the appropriate valve block.

Reconnect hydraulics and set the valve.

Refit the components removed to gain access to the valve(s).

M.R.V. Location and Identification

P3 P2 P1

Six section valve block A Bucket, Boom and R.H. Track (P2) B Boom Boost, Dipper and L.H. Track (P3) Five section valve block (All machines) C Aux., Dipper Boost, Slew, Swing and Dozer (P1) Dipper boost dump valve block D Dipper Boost Relief Valve Servo pressure maintenance valve E Servo Relief (P1)

9803/3145

Issue

Section E

Hydraulics

Section E

14 - 3

Servo Pressure Relief Valve Removal

WARNING Fine jets of hydraulic oil at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic oil leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic oil. If hydraulic oil penetrates your skin, get medical help immediately.

Note: It is possible to remove the relief valve cartridge for cleaning or resealing without removing the complete valve from the machine. 3

To remove the valve, mark hoses for correct replacement and remove. plug hoses to prevent the ingress of dirt.

Remove bolts holding the valve to the slew frame.

HYD001

Stop the machine on level ground with the bucket resting on the ground. Stop the engine and vent residual pressure from the servo accumulator by turning the ignition on and lowering the L.H. arm rest to the excavator operate position. Operate both excavator control levers in all directions until stored servo pressure in the accumulator has been exhausted. Remove the key. Open the engine canopy to gain access to the pressure maintenance valve.

If there is evidence of damage to the valve or its seat caused by debris then the cartridges will require renewing. If a cartridge or valve complete is renewed it is recommended that the filtered adapters in the feed ports of the valve are also renewed. PT - MRV Test Point PV - Servo Test Point PT

P3 PT

ACC PV

Note:- Filter adaptors P1, P2 and P3 should be checked and cleaned or replaced every 1000 hours, or if the hydraulic system has been contaminated.

9803/3145

H18250

Issue

Section E

Hydraulics

Section E

14 - 4

Dipper Boost Dump Valve Removal

WARNING Fine jets of hydraulic oil at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic oil leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic oil. If hydraulic oil penetrates your skin, get medical help immediately. HYD001

Stop the machine on level ground with the bucket resting on the ground. Stop the engine and vent residual pressure from the servo accumulator by turning the ignition on and lowering the L.H. arm rest to the excavator operate position. Operate both control levers in all directions until stored servo pressure in the accumulator has been exhausted.

Remove floor plates as required to gain access to the valve. Remove and blank hoses connected to the valve.

P4 P1

Undo securing bolts and remove valve to a clean area.

PT P3

PT P1 P4 P3 P2

Pressure test point Dipper boost supply from spool Dipper boost supply from spool Dipper boost valve to main dipper spool Dipper boost valve to main dipper spool

9803/3145

Issue

Section E

Hydraulics

15 - 1

Section E 15 - 1

Auxiliary Relief Valve Removal

WARNING Fine jets of hydraulic oil at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic oil leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic oil. If hydraulic oil penetrates your skin, get medical help immediately. HYD001

Obtain access to the control valve.

Relieve hydraulic pressure, disconnect and blank any hoses or pipes which may interfere with the removal of the relief valve(s).

Unscrew the auxiliary relief valve(s) from the control valve and remove to a clean working area.

Dismantling and assembly When Dismantling 1 Remove acorn nut A, locknut B and O-rings C. Discard O-rings. 2

Remove washer D.

Remove pressure setting plug E.

Tip the valve and remove: - Thrust washers G - Spring F - Poppet H

9803/3145

Inspection 1 Check valve components for scratching, pitting, distortion and/or corrosion. Note: If any part other than O-rings C and washer D are damaged the entire valve must be renewed. When Assembling 1 Clean the valve body and components in an appropriate solvent. 2

Assemble in the reverse order of dismantling.

Pressure test the valve.

Issue

Section E

Hydraulics

Section E

16 - 1

Rams - Boom, Dipper and Bucket 802.7 and 803 Machines with: Boom Ram Part No.: 903/16600 Dipper Ram Part No.: 903/16500 Bucket Ram Part No.: 903/16400 Removal & Replacement

When Removing 1 With the engine idling, set the machine with the bucket on the ground. 2

Support the excavator under the angle between the dipper and boom to ensure it will not move when the ram is removed.

On boom and bucket rams, remove the protection plate. Support the ram under the gland bearing and remove locknut A and bolt B from the pivot at the eye end of the ram. Drive out the pivot pin C.

With the engine idling, gently retract the ram rod into the cylinder by operating the relevant service.

On manual control machines, stop the engine. Operate the lever controlling the ram to be removed, in both directions to vent any trapped pressure. Remove the hoses, plug and cap any open hydraulic ports to prevent ingress of dirt. On servo machines, run the engine at idle and with the servo isolator lock in the operate position move the control lever rapidly in both directions to vent any trapped pressure. Stop the engine.

HYD001

WARNING A raised and badly supported machine can fall on you. Position the machine on a firm, level surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it. Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN001

WARNING 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. HYD002

CAUTION This operation may not fully release all the trapped pressure. Consequently, when removing the hoses, progressively slacken the fittings to vent any residual pressure to atmosphere. 6

9803/3145

Support the ram and remove the locknut D and the bolt E from the pivot at the base of the piston. Drive out the pivot pin F. Remove the ram from the machine.

Issue 2*

Section E

Hydraulics

Section E

16 - 2

Rams - Boom, Dipper and Bucket (cont'd) 802.7 and 803 Machines with: Boom Ram Part No.: 903/16600 Dipper Ram Part No.: 903/16500 Bucket Ram Part No.: 903/16400 Removal & Replacement (cont'd) When Replacing 1 Locate the pivot point on the ram into the location on the machine structure. Fit the pivot pin F and secure using the bolt E and new locknut D. 2

Support the ram under the gland end of the cylinder, reconnect the hoses. With the engine idling, slowly extend the ram until the eye end locates correctly in the machine structure. Fit pin C. Secure using the bolt B and new locknut A.

Apply grease to the pivot points through the grease nipples G. For grease specification see Lubricants and Capacities.

Connect the hoses to the cylinder, see Hydraulic Fittings and Torque Settings.

On the bucket and boom rams, fit the protection plate and secure using the bolts.

B A

G D E

F G

H18790

9803/3145

Issue 2*

Section E

Hydraulics

16 - 3

Section E 16 - 3

Rams - Boom, Dipper and Bucket - cont. Removal and Replacement

WARNING Fine jets of hydraulic oil at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic oil leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic oil. If hydraulic oil penetrates your skin, get medical help immediately. HYD001

WARNING A raised and badly supported machine can fall on you. position the machine on a firm, level surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it. Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-001

When Replacing 1 Locate the pivot point on the ram into the location on the machine structure. Fit the pivot pin C and secure using the bolt B and new locknut A. 2

Fit the pivot point on the ram into its location on the machine structure. Fit pin F. Secure using the bolt E and new locknut D.

Apply grease to the pivot points through the grease nipples G. For grease specification and quantities see page 3 /1 -1.

Connect the hoses to !he cylinder, see page 3/1-5 for sealant and torque information.

On the bucket and boom rams, fit the protection plate and secure using the bolts.

WARNING 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. HYD002 When Removing 1 Set the machine with the bucket grounded. 2

Locate supporting structure under the boom/dipper pivot.

With the starter switch ON, shut down the hydraulic circuit and relieve residual pressure by operating the servo controls.

On the boom and bucket rams, remove the protection plate

Disconnect the hydraulic hoses from the pivot end of the ram to be removed. Blank off the hoses and the open ports of the ram.

Remove the locknut A and the bolt B from the pivot at the rod end of the piston. Drive out the pivot pin C.

Lower the rod end of the ram onto a suitable support.

Remove the locknut D and the bolt E from the pivot at the base of the piston. Drive out the pivot pin F. Remove the ram from the machine.

Note: For ram dismantling see pages E/16-4 to E/16-7. 9803/3145

Issue 2*

Section E

Hydraulics

16 - 4

Section E 16 - 4

Rams (cont'd) - Dozer 802.7 / 803 and 804 Machines with: Ram Part No.: 557/60024 Removal and Replacement When Removing 1 Set the machine in the posture shown with the dozer grounded onto suitable supports.

When Replacing 1 Locate the pivot point on the base of the ram into the dozer frame.

With the starter switch turned OFF, relieve residual hydraulic pressure by operating the hydraulic controls.

Fit the pivot pin H and secure using the locking plate G and new screws and spring washers F.

Remove the bolts A and take off the protection plate B.

Fit the pivot point at the rod end of the ram to the machine.

Disconnect the hydraulic hoses from the pivot end of the ram. Blank off the hoses and the open ports of the ram.

Fit the pivot pin E and secure using the bolt D and new locknut C

5 5

Remove the locknut C and the bolt D from the pivot at the rod end of the ram. Support the ram and drive out the pin E. Lower the ram end onto a suitable support.

Apply grease to the pivot points through the grease nipples J. For grease specification see Lubricants and Capacities.

6 6

Remove the screws and spring washers F and locking plate G from the pivot at the dozer end of the ram. Support the ram and drive out the pivot pin H. Remove the ram from the machine.

Connect the hoses to the cylinder, see Hydraulic Fittings and Torque Settings.

Fit the protection plate B and secure using the bolts A.

9803/3145

Issue 2*

Section E

Hydraulics

16 - 5

Section E 16 - 5

Rams (cont'd) - Dozer Removal and Replacement When Removing 1 Set the machine in the posture shown with the dozer grounded on suitable supports.

When Replacing 1 Locate the pivot point on the base of the ram into the dozer frame.

With the starter switch turned OFF, relieve residual hydraulic pressure by operating the control levers.

Fit the pivot pin H and secure the bolt G and new locknut F.

Remove the bolts A and take off the protection plate B.

Fit the pivot point at the rod end of the ram into the machine.

Disconnect the hydraulic hoses from the pivot end of the ram. Blank off the hoses and the open ports of the ram.

Fit the pivot pin E and secure using the bolt D and new locknut C.

5 5

Remove the self-locking nut C and the bolt D from the pivot at the rod end of the ram. Support the ram and drive out the pivot pin E. Lower the ram end onto a suitable support.

Apply grease to the pivot points through the grease nipples J.

Connect the hoses to the cylinder.

Fit the protection plate B and secure using the bolts A.

Remove the locknut F and bolt G from the pivot at the dozer end of the ram. Support the ram and drive out the pivot pin H. Remove the ram from the machine.

9803/3145

Issue 3*

Section E

Hydraulics

Section E

16 - 6

Rams (cont'd) - Swing 802.7 / 803 and 804 Machines with: Ram Part No.: 576/60038 Removal & Replacement When Removing 1 Position the machine with upper structure slewed at 900 right to the tracks. 2

Swing the machine dig end through 450 to the left and lower the excavator to the ground.

Remove the bolts B and spring washers C securing the pivot keep plate D at the rod end of the cylinder.

Support the cylinder A and drive out the pivot pin E. With the engine idling, slowly retract the ram until the eye end clears the king post H. Stop the engine.

Operate the swing pedal in both directions to vent any residual pressure.

Remove floor mat and floorplates. Disconnect the ram feed hoses at the valve block, Plug the hoses and cap the open ports of the valve.

Locate the ram from underneath the upper structure. Remove the bolts and the spring washers F securing the keep plate at the base end of the cylinder.

Remove the pivot pin G.

Withdraw ram with hoses attached.

When Replacing 1 Connect hoses to new/serviced ram. Locate the ram into the machine upper structure and align the base pivot point with the mating location in the machine frame. 2

Fit the pivot pin G. Refit and secure with bolts, spring washers F and keep plate.

Reconnect the hoses.

With the engine idling, slowly extend the ram until the eye end locates into the kingpost H, stop the engine

Fit the pivot pin E. Refit and secure keep plate D with bolts B and spring washers C.

Note: See section 1 for torque tightening and sealant information.

G E H

B C

9803/3145

Issue 3*

Section E

Hydraulics

16- 7

Section E 16 - 7

Rams (cont'd) Removal and Replacement When Removing 1 Position the machine with upper structure turned at 90Â° right to the track. 2

Swing the machine dig end through 90Â°.

Locate the ram from underneath the upper structure.

When Replacing 1 Locate the ram into the machine lower structure and align the eye end pivot point with the mating location in the machine frame. 2

Fit the pivot pin G. Refit and secure with bolts, spring washers F and keep plate.

Disconnect the hoses from the ram. Blank off the hoses and the ram.

Fit the rod end of the ram into the location in the kingpost H.

Remove the bolts B and spring washers C securing the pivot keep plate D at the rod end of the ram.

Fit the pivot pin E. Refit and secure keep plate D with bolts B and spring washers C.

Support the cylinder A and drive out the pivot pin E.

Connect the hoses to the ram.

Remove the bolts and the spring washers F securing the keep plate at the eye end of the ram, located underneath the slew frame.

Note: See section 3 for torque tightening and sealant information.

Remove the pivot pin G.

Free the rod end of the ram from the kingpost H and remove the ram from the front of the machine.

9803/3145

Issue 2*

Section E 16 - 8

Hydraulics

Section E 16 - 8

Rams (cont'd) 804 Machines with: Ram Part No.: 576/60038

Typical - Dismantling and Assembly

9803/3145

Issue 2*

Section E

Hydraulics

16 - 9

Section E 16 - 9

Rams (cont'd) 802.7 / 803 and 804 Machines with: Ram Part No.: 576/60038

Typical - Dismantling and Assembly WARNING 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. HYD002

Pivot Pin Bush Clearances 1 Using an internal micrometer measure the internal diameter (I.D.) of the pivot pin bushes S in the piston rod and cylinder ends. 2

The numerical sequence shown in the figures are intended as a guide to dismantling.

Compare the readings with the permitted tolerances shown. Remove and replace pin bushes as necessary.

Note: The only renewable parts for these rams are the pivot bearings 12 and 14, piston rod 2, ram cylinder and seals. If any of the other internal components of the ram are damaged, then the complete ram assembly must be renewed. When Dismantling 1 Support the ram as shown. 2

Slacken the end cap 1 using C-spanner part no. 892/ 00296 (68/75 mm) or 892/00297 (80/90 mm) for dozer.

Pull out the end cap and piston rod assembly.

Remove the piston head nut 4.

Remove the piston head 3 and collar 7 from the piston rod 2.

Remove piston head seals 3 and discard, remove also 'O' ring 6 from piston rod and discard.

Remove the end cap 1 from the piston rod.

Remove and discard all seals, back-up rings and 'O' rings from the end cap.

Inspection Piston Rod Warp 1 Support the bear piston rod on a pair of 'V' blocks. 2

Set a dial test indicator (D.T.I.) at the approximate centre of the rod. Set the D.T.I. to zero.

Rotate the piston rod in its blocks, noting any variation in D.T.I. reading.

If warp (half the difference between maximum and minimum readings) exceeds 0.5 mm (0.02 in) the piston rod must be replaced.

9803/3145

Issue 2*

Section E

Hydraulics

16 - 10

Section E 16 - 10

Rams (cont'd) 802.7 / 803 and 804 Machines with: Ram Part No.: 576/60038 When Assembling 1 Thoroughly remove all oil, grease, dirt and hardened locking compound frm the threads of the piston head nut C, piston rod B, end cap A and cylinder. Remove all traces of rust using a wire brush. 2

Lubricate the new seals with clean hydraulic fluid. Fit rod seal L, back up ring M, dust seal K, 'O' rings H and J to the end cap A.

Fit the end cap to the piston rod. Take care not to damage the end cap seals when passing the end cap over the threads and shoulder of the rod.

Fit collar E to the piston rod.

Fit new hydraulic fluid lubricated 'O' ring G to the piston rod and seals F to the piston head D.

Fit the piston head D to the piston rod B with the chamfered end outermost.

Fit the piston head nut C to the piston rod B and torque tighten nut to 314 Nm (232 lbf/ft) for all excavator rams and 345 Nm (255 lbf/ft) dozer ram.

Load the piston rod assembly, piston end first, into the cylinder.

Screw the end cap A into the cylinder and torque tighten to 610 Nm (450 lbf/ft) all excavator rams and 400 Nm (195 lbf/ft) for the dozer ram.

10 Fit the ram to the machine.

9803/3145

Issue 1*

Section E

Hydraulics

16 - 11

Section E 16 - 11

Rams (cont'd) Dismantling and Assembly

WARNING If air or hydraulic pressure is used to force out of the piston assembly, ensure that the end cap is securely fitted. Severe injury can be caused by a suddenly released piston rod. HYD002

Illustrations for the Dismantling and Assembly sequences are of typical rams, slight variations may occur in parts used. The numerical sequence shown in the figures are intended as a guide to dismantling. For assembly the sequence should be reversed. Try to lay out the parts in the correct sequence for assembly. Support the ram as shown. Discard all seals and O-rings. See inspection page E/16-8 Fit new O-rings and seals on assembly. Make sure that the wiper A and gland B seals are fitted the correct way around as shown. Torque tighten the end cap and piston nut, see page 3/13

9803/3145

Issue 1*

Section E

Hydraulics

Section E

16 - 12

16 - 12 *Ram

Machine

Swing 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. HYD002

802.7/803 300 221 31 804 300 221 31 804 Super 678 499 70

400 295 41 400 295 41 450 331 46

Dipper

802.7/803 300 221 31 804 325 240 33 804 Super 678 499 70

400 295 41 400 295 41 450 331 46

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

Boom

When Dismantling Use a 4.75 mm (0.187 in) drill to remove hollow aluminium dowel (where fitted) from the gland end cap before the end cap can be unscrewed.

802.7/803 300 221 31 804 325 240 33 804 Super 678 499 70

400 295 41 400 295 41 450 331 46

Dozer

802.7/803 325 240 33 804 325 240 33 804 Super 678 499 70

400 295 41 400 295 41 450 331 46

Bucket

802.7/803 350 258 36 804 350 258 36 804 Super 678 499 70

400 295 41 400 295 41 450 331 46

Rams (con't) Typical - Dismantling and Assembly

WARNING

*Note: Drill depth must not exceed 10 mm (0.39 in). Use a 'C' spanner located in the end cap slots to remove end cap, except for 804 Super; these use ordinary A/F Spanner. The piston head is locked to the rod with a hardened steel dowel, this dowel is located under the wear ring and must be removed before the piston nut can be unscrewed. The dowel is drilled and tapped M3 X 0.5 for ease of removal, retain the dowel and reuse on assembly.

Ram

Machine

Swing

802.7/804 5.95 mm (0.234 in) 803 6.0 mm (0.236 in)

26.0 mm (1.02 in) 31.0 mm (1.22 in)

Dipper

802.7/803 5.95 mm (0.234 in) 804 6.0 mm (0.236 in)

21.0 mm (0.82 in) 26.0 mm (1.02 in)

Boom

802.7

5.95 mm (0.234 in) 803 6.0 mm (0.236 in) 804 6.0 mm (0.236 in) 804 Super 8.0mm (0.315in)

26.0 mm (1.02 in) 31.0 mm (1.22 in) 31.0 mm (1.22 in)

802.7/803 5.95 mm & 804 (0.234 in) 804 Super 8.0mm (0.315)

26.0 mm (1.02 in)

802.7/803 5.95 mm 804 6.0 mm (0.236 in)

26.0 mm 26.0 mm (1.02 in)

When Assembling For assembly the sequence should be reversed. Torque set the piston head until the dowel hole aligns with the hole in the rod. Replace the dowel but do not attempt to peen it in place, the dowel will be held in position by the wear ring. If a new piston rod is fitted the dowel hole drill size and depth is as tabulated opposite. Fit new 'O' rings and seals on assembly lubricated with hydraulic fluid. Refit piston rod assembly to the cylinder, fully tighten end cap. Drill through the same hole in the cylinder using a 4.75 mm (0.187 in) dia drill to a maximum depth of 10 mm (0.39 in). Insert new dowel and peen in position to retain.

Dozer

*804 Super - End Cap A/F Sizes Swing - 70mm (2 3/4 in) Dipper 70mm (2 3/4 in) Boom - 70mm (2 3/4 in) Dozer - 75mm (2 15/16 in) Bucket - 75mm (2 15/16 in)

Bucket

9803/3145

Piston Head Nm lbf ft kgf m

*Piston Head Dowel

Discard all seals and 'O' rings. Try to lay out the parts in the correct order for assembly.

End cap Nm lbf ft kgf m

Drill Dia

Dowel hole depth

N/A

Issue 1*

Section E

Hydraulics

Section E

16 - 13

Rams (con't) Boom 9

3 4 5 6 1

H24990 10

9803/3145

Issue 1*

Section E

Hydraulics

Section E

16 - 14

Rams (cont'd) Swing

8 9

Bucket

3 5

6 1 7

9 9803/3145

Issue 1*

Section E

Hydraulics

Section E

16 - 15

Rams (cont'd)

Dipper

3 4 6 5 1 7

DOZER 8 10 6

3 4

9 10

9803/3145

H19620

Issue 1*

Section E

Hydraulics

16 - 16

Section E 16 - 16

Rams (cont'd) 802.7 / 803 and 804 Machines with: Ram Part No.: 576/60038

Typical - Inspection Piston rod warp 1 Support the piston rod on a pair of 'V' blocks. 2

Set a dial test indicator (D.T.I.) at the approximate centre of the rod at top dead centre.

Rotate the piston rod and read off any variation on the D.T.I.

If warp (half the difference between the minimum and maximum readings) exceeds 0.5 mm (0.02 in.) the piston rod must be replaced.

Piston rod / Rod bush clearance 1 Using internal and external micrometers measure the piston rod outside diameter (O.D.) and the rod bush inside diameter (I.D.). 2

Piston/Cylinder clearances 1 Using internal and external micrometers measure the piston O.D. and the cylinder I.D. 2

Compare the readings taken with the permitted tolerances. If necessary replace the piston and/or the cylinder with new.

Pin bush clearances 1 Using internal micrometers measure the I.D. of the pin bushes in the piston rod and cylinder ends. 2

Compare the readings with the permitted tolerances shown.

Compare the readings taken with the permitted clearances. If necessary replace the piston rod and or remove the rod bush and replace with new.

9803/3145

Issue 1*

Section E

Hydraulics

16 - 17

Section E 16 - 17

Rams (cont'd) Inspection Piston rod warp 1 Support the piston rod A on a pair of â&#x20AC;&#x2DC;Vâ&#x20AC;&#x2122; blocks. 2

Set a dial test indicator (D.T.I.) at the approximate centre of the rod at top dead centre.

Rotate the piston rod and read off any variation on the D. T. I.

If warp (half the difference between the minimum and maximum readings) exceeds 0.5 mm ( 0.02 in) the piston rod must be replaced.

Piston/Cylinder clearances 1 Using internal and external micrometers measure the piston outside diameter (O.D.) and the cylinder inside diameter (I.D.) 2

Piston rod / Rod bush clearance 1 Using internal and external micrometers measure the piston rod outside diameter (O.D.) and the rod bush B inside diameter (I.D.) 2

Compare the readings taken with the permitted tolerances. If necessary replace the piston and/or the cylinder with new.

Pin Bush Clearances 1 Using internal micrometers measure the inside diameter (I.D.) of the pin bushes C in the piston rod and cylinder ends. 2

Compare the readings with the permitted tolerances shown. Remove and replace pin bushes as necessary.

Compare the readings taken with the permitted clearances. If necessary replace the piston rod and/ or remove the rod bush B and replace with new.

9803/3145

Issue 1*

Section E

Hydraulics

Section E

17 - 3

A A E

B G

B H18920

9803/3145

Issue 2*

Section E

Hydraulics

17 - 4

Section E 17 - 4

Rotary Coupling Removal & Replacement

Dismantling & Assembly

Removal Note: Before removing a suspected leaking coupling, ensure that the leak is from the coupling core and not a hose adaptor. Ensure all adaptors are tight.

Dismantling 1 Note the positions and remove the adaptors A and B from the coupling. Discard the O-rings.

WARNING Fine jets of hydraulic oil at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic oil leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic oil. If hydraulic oil penetrates your skin, get medical help immediately. HYD001

WARNING A raised and badly supported machine can fall on you. Position the machine on a firm level surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it. Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN001

Remove the floor plate

Disconnect the hydraulic hoses from the rotary coupling adaptors A, blank off the hoses and adaptors.

From under the machine, remove the rotary coupling cover plate.

Disconnect the remaining hydraulic hose from the rotary coupling adaptors B, Blank off the hoses and adaptors.

Remove the bolts, washers and nuts C securing the coupling flange to undercarriage.

Lift the coupling, allowing the reaction peg D to clear the reaction bracket E on the mainframe floor, turn the coupling 90 deg. and lower clear of the machine to a clean working surface.

9803/3145

Remove the four capscrews retaining cover plate F.

Remove the external circlip and spacer ring G from the base of the coupling.

From the top of the coupling carefully withdraw the coupling core H from the shell J.

Remove and discard back-up rings and O-rings K from the core.

Inspection 1 All rotary coupling core O-rings and back-up rings K must be replaced with new and are only available as a set. 2

If the core H or shell J show signs of wear replace the complete rotary coupling.

Assembly 1 Assemble in reverse order of dismantling, fitting new O-rings and back-up rings, lightly lubricate with hydraulic fluid. 2

Fit lip seals L in the positions and attitudes shown.

Replacement 1 Replace in reverse order of removal. 2

Reconnect hydraulic hoses using new lightly lubricated O-rings.

Issue 2*

Section E

Hydraulics

Section E

18 - 1

802.7 / 803 machines MRV Pressure Variation Against Oil Temperature 245 (3600)

235 (3400)

MRV Pressure bar (lbf in2)

220 (3200)

207 (3000)

195 (2800)

Excavator MRV

180 (2600) Dozer MRV 165 (2400) Slew MRV 152 (2200)

138 (2000)

125 (1800)

110 (1600) 15

804 machines 245 (3600)

235 (3400)

MRV Pressure bar (lbf in2)

220 (3200) Excavator MRV

207 (3000)

195 (2800)

180 (2600) Dozer MRV 165 (2400)

152 (2200)

138 (2000)

125 (1800) Slew MRV 110 (1600) 15

Hydraulic Oil Temperature (Â°C) H15750

9803/3145

Issue

Section E

Hydraulics

Section E

18 - 2

Pressure testing - Main Relief Valves Description The correct digging performance of these machines can only be achieved with the Main Relief Valves (M.R.V.'s) accurately set. On production they are carefully set with the hydraulic oil temperature at the correct operating level. If the pressure setting is attempted with 'cold' hydraulic oil the pressure drops away as the hydraulic oil warms up with the machine operating and the power of the excavator is significantly reduced. The graphs show the pressure to which the machine should be set depending on oil temperature. Select the graph to suit the M.R.V. to be tested and measure the hydraulic oil temperature. Read off the correct pressure relating to the recorded oil temperature and set the relief valves accordingly. Always test the main relief valves in the following sequence:A B C D E

Servo Pressure Maintenance Slew - Swing - Dozer (P1) L.H. Track, Dipper R.H.Track, Boom, Bucket Dipper Boost Dump Valve

C B

9803/3145

Issue

Section E

Hydraulics

Section E

19 - 2

Pressure testing - Main Relief Valves 1

Remove blanking cap and connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to port PT on the pressure maintenance valve, for the circuit to be tested.

With the engine running at maximum speed, and hydraulic fluid at normal working temperature, operate the circuit served by the valve under test.

Check the gauge reading is as detailed in Technical Data. If incorrect, remove cap nut. With the ram held at full travel, undo locknut F, use an allen key to adjust the M.R.V. by means of the screw E until the gauge reads the correct pressure.

Tighten locknut F. Check gauge reading is correct. Repeat procedure as necessary.

Switch off engine. Remove pressure gauge and refit blanking cap.

C B

A B C D

Servo - Pressure maintenance valve Slew - Swing - Dozer L.H. Track, Dipper R.H.Track, Boom, Bucket

F E

9803/3145

Issue

Section E

Hydraulics

Section E

19 - 3

Pressure testing Auxiliary Relief Valve(s) 1

Remove the auxiliary relief valve from the control valve and plug the valve port.

Install the auxiliary relief valve to test block number 892/00252.

Connect a 0 - 400 bar (0 - 6000lbf/in2) pressure gauge and hand pump, number 892/00223, to test block.

Operate pump and adjust pressure setting plug C until valve opens at correct pressure, refer to Technical Data.

Lock the pressure setting plug with the locknut D and re-test. Remove auxiliary relief valve from test block and refit to control valve.

9803/3145

Dozer (Head side)

B1 B2

Boom (Rod side) Boom (Head side)

C1 C2

Dipper (Rod side) Dipper (Head side)

Issue

Section E

Hydraulics

19 - 4

Section E 19 - 4

Pressure testing Servo Pressure Maintenance Valve All pressure testing must be carried out with the machine hydraulic system within the range 30 - 40oC. Servo Pressure Relief Valve 1 Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to test point PV on the servo pressure maintaining valve block. 2

With the engine running at maximum speed, fully select dipper in and hold whilst checking gauge reading, if pressure is incorrect, remove cap from relief valve A, slacken locknut and slowly adjust valve until gauge reading is correct. Tighten locknut and replace cap, recheck the pressure.

Note: If the relief pressure cannot be achieved then engine should be shut down and all stored servo pressure vented from the accumulator. The relief cartridge removed and inspected for failed seals or other damage. Prior to installing a repaired or new relief cartridge remove and discard the three filtered adaptors in the maintenance valve and replace with new.

9803/3145

Issue

Section E

Hydraulics

Section E

19 - 5

Pressure testing - Crossline Relief Valves There is a single relief valve A and B for each direction of slew. These valves are located in the head of the slew motor. The pressures should be checked to the values quoted (refer to Technical Data) using the method described below.

Ensure the hydraulic system is at correct operating temperature. Crossline Relief Valves A and B 1 Remove floor mat and necessary floor plates to gain access to the slew motor. 2

Connect a 0 - 400bar (0 - 6000lbf/in2) pressure gauge at test point PT on the pressure maintenance valve.

Engage slew lock. With the engine running at maximum speed and the hydraulic fluid at working temperature (refer to Technical Data), fully select slew left and hold whilst checking the pressure gauge reading.

Check that the pressure gauge reading equals the crossline relief setting (refer to Technical Data). The relief valve cartridges are not pressure adjustable, if the recorded pressure is low, remove the valve from the motor and check for debris or failed seals. Clean valve components and renew seals if necessary, refit to motor and retest. if the correct pressure is still not obtainable the relief valve should be changed for a new one.

Repeat the test fully selecting slew right.

Stop the engine, remove the pressure gauge and fit blanking cap. PT

9803/3145

Issue

Section E

Hydraulics

Section E

19 - 6

Pressure testing Dipper Boost Dump Valve

Remove blanking cap and connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge A to test point PT on the pressure maintenance valve B, connect a second 0 - 400 bar (0 - 6000 lbf/in2) gauge C to test point PT on the dipper boost dump valve D.

Run the engine at maximum speed, slowly and progressively operate dipper IN. The pressure recorded on gauge C connected to the dipper boost valve D will suddenly fall back to zero, at this point the pressure recorded on the gauge A connected to the pressure maintenance valve B will be the setting of the dipper boost dump valve.

Note:- The pressure on the pressure maintenance valve gauge A will continue to rise, for accurate valve setting the reading MUST be taken at the exact point the pressure in the dump valve begins to fall to zero.

PT B

9803/3145

Issue

Section E

Hydraulics

Section E

21 - 1

G C

B F D

9803/3145

Issue 2*

Section E

Hydraulics

21 - 2

Section E 21 - 2

Hydraulic Oil Cooler Removal and Replacement Note: The hydraulic oil cooler is mounted directly in front of the radiator, and under normal circumstances should require no attention. However, periodically debris collected between the radiator and cooler should be removed. In this event the cooler can be dismounted and carefully moved clear of the radiator without disconnecting the hydraulic pipework. Whilst dismounted, the cooler should be inspected for damage and leaks.

WARNING Fine jets of hydraulic oil at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic oil leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic oil. If hydraulic oil penetrates your skin, get medical help immediately. HYD001

Removal 1 Position the machine on firm level ground with the bucket resting on the ground. Stop the engine and vent residual pressure from the system by fully operating all control levers. 2

Remove the hydraulic oil filler cap and drain the hydraulic tank.

Disconnect the top and bottom hoses A from the cooler.

Remove bolts and washers B securing the upper C and lower D oil cooler mounting lugs to the top radiator bracket E and lower mount F.

If a new cooler is to be fitted, remove screws, washers and nuts G to release the upper C and lower D oil cooler brackets from the old cooler.

Replacement 1 If installing a new cooler, fit top C and bottom D lugs removed from the old cooler using screws, washers and nuts G. 2

Secure the cooler to the radiator using bolts and washers B.

Connect the top and bottom hoses A to the cooler.

Fill the hydraulic tank. Run the engine and check for leaks.

Note: Take care to ensure that the breather hose from the hydraulic tank is routed clear of the radiator, and vents into the slew frame on the engine side. If incorrectly positioned, oil mist venting from the hose is drawn through the radiator matrix coating it with oil. As a consequence, dust picked up by the cooling air passing through the radiator and sticking to the oil may cause the engine to overheat.

Note: Ensure the space between the radiator and oil cooler is clean and free from debris.

9803/3145

Issue

Section F

Gearboxes

Section F

Contents

Page No.

Technical Data........................................................... 1 - 1 General Description ................................................... 1 - 1 Track Gearbox - Operation ........................................................... 2 - 1 - Check Oil Level .................................................. 2 - 2 - Drain and Refill .................................................. 2 - 2 - Removal and Replacement ................................ 2 - 3 - Dismantling and Assembly ................................. 2 - 5 Slew Gearbox - Removal and Replacement ................................ 3 - 3 Slew Motor - Dismantling and Assembly ................................. 3 - 4

9803/3145

Issue 2*

Section J

Track & Running Gear

Section J

Contents

Page

General Description ..................................................................... 1 - 1 Tracks Clean and Inspection ......................................................... 2 - 1 Removal and Replacement................................................ 2 - 2 Changing ............................................................................ 2 - 4 Track Rollers Removal and Replacement................................................ 3 - 1 Dismantling and Assembly ................................................. 3 - 2 Track Idler and Recoil Unit Dismantling and Assembly ................................................. 4 - 2 Driven Sprocket Dismantling and Assembly ................................................. 5 - 1 Track Roller Metallic Face Seals Removal and Replacement................................................ 6 - 1

9803/3145

Issue 1

Section J

Track & Running Gear

1-1

Section J 1-1

General Description The Mini-Excavator track and running gear comprises the tracks fitted to the machine, these may be either of steel or rubber construction depending on the option selected, the associated sprockets that transmit drive from the track gearboxes to the tracks and the equipment that provides and maintains the tension of the tracks. The track and running gear is located on and within the machine undercarriage track boxes.

9803/3145

Issue 1

Section J

Track & Running Gear

2-1

Section J 2-1

Tracks Clean

WARNING If two people are doing this job make sure that the person operating the controls is a competent operator. If the wrong control lever is moved, or if the controls are moved violently, the other person could be killed or injured. If you will be working with another person, make sure that you both understand what is to be done. Learn and use the recognised signalling procedures. Do not rely on shouting - he will not hear you. To clean the tracks you must turn them. When the tracks are turning, keep clear of rotating parts. Before starting this job, make sure you have no loose clothing (cuffs, ties etc.) which could get caught in moving parts. Keep people not involved with this job well away!. MD3-3-2

Park the machine on firm level ground. Operate the controls to slew the cab around as shown, lower the bucket to the ground.

Raise the track to be cleaned clear of the ground by operating the dipper controls with the bucket grounded.

WARNING Rotating the tracks off the ground may cause stones and other debris to be thrown with considerable force. If you are on the outside, keep well clear. Keep other people well clear. 8-3-3-2

Rotate the raised track in both directions until all mud is shaken off. If necessary hose down the track during rotation to aid cleaning.

Inspect 1 Track rollers, Track wheel sprockets and Idler wheels for damage or oil leaks. Repair parts as required. 2

Tracks for damage or wear. Replace tracks as required.

On machines fitted with rubber track option, visually inspect the track and replace if: - one or more metal cores are missing. - steel cord is exposed. - more than half the track is missing. - the track comes off although fully tensioned.

9803/3145

Issue 1

Section J

Track & Running Gear

2-2

Section J 2-2

Tracks (cont'd) Removal & Replacement Steel Track 1 Position the machine so that the master pin B is at the front of the track, as shown. 2

Remove the fastener A and drive out the master pin B.

WARNING Ensure that all persons are clear of the track and especially of the driven sprocket during the following operations. TRACK 1-6

Slowly reverse the machine until the track is laid on the ground.

WARNING The following operations must only be undertaken by persons familiar with track changing operations and who are qualified to perform the operations. All persons must keep clear of the driven sprocket. TRACK 1-7

Lay out the replacement track C, behind the machine. Drive the machine onto the new track, guiding the track over the idler wheel D and roller E, until the ends can be joined.

Fit the master pin B and lock using a new fastener A.

Refer to 'Track Tensioning'.

9803/3145

Issue 1

Section J

Track & Running Gear

Section J

2-3

Tracks (cont'd)

Fit replacement track to the machine. If marked the 'M' should be in the position indicated. Replace the grease adaptor C.

Tension the track, see 'Track Tensioning'.

Replace the access plate B and secure using the bolts A.

Remove the machine supports and lower the track to the ground.

Removal & Replacement Rubber Track

Track Tensioning (Steel and Rubber) 1 Set the machine in the posture shown, with the track to be tensioned raised from the ground and the undercarriage supported.

GEN-001

Remove the bolts A and the access plate B.

Check the tension clearance D. The tension clearance should be between 15mm and 20mm for a rubber track or 40mm and 45mm if a steel track is fitted.

Using a 28mm socket, unscrew and remove the grease adaptor C.

Apply grease (See Lubricants and Capacities) to the grease adaptor C, to achive the correct tension.

Fully release the track tension by pushing the track idler inwards.

Pull the track clear of the machine.

Replace and secure the access plate. Remove the machine supports and lower the machine to the ground.

Position the machine in the posture shown. Fit suitable supports under the machine lower structure.

Remove bolts A and take off access plate B.

9803/3145

Issue 1

Section J

Track & Running Gear

2-4

Section J 2-4

Tracks (cont'd)

Track Guides

Converting Tracks

Removal and Replacement

CAUTION When converting a machine from steel tracks to rubber tracks, the track guides must be removed. When converting from rubber tracks to steel tracks the track guides must be fitted.

Track guides are fitted to both sides of each track at the idler wheel position. At the drive hub position they are fitted to the outer side of the track. 1 Remove the bolts A securing the guide brackets B to the subframe, remove the bracket from the subframe.

Damage to the tracks may result if this is not carried out. TRACK 1-8

Track change

Guides

Steel to rubber Rubber to steel

OFF ON

9803/3145

Issue 1

Section J

Track & Running Gear

Section J

3-1

Track Rollers Removal and Replacement When Removing

Set the machine in the posture shown. Fit suitable supports under the machine lower structure. If necessary adjust the track tension to allow the track to become clear of the rollers.

Upper Roller 2 Gain access to the roller by removing or splitting the track. 3

Undo the nut A securing the roller B to its mounting bracket.

Lower Roller 4 Remove the bolts C, D and washers E. Lower the roller assembly F from the machine. When Fitting 1 Fit the rollers in the reverse sequence to removal. Torque tighten the fittings. 2

Refit and tension the track.

Remove the supports and lower the tracks to theground.

Torque Settings Item Nm A 160 C 244 D 244

kgf m 16.3 25.0 25.0

lbf ft 118 180 180 C E

9803/3145

D Issue 1

Section J

Track & Running Gear

Section J

3-2

Track Rollers (cont’d) Dismantling and Assembly Upper Rollers When Dismantling 1 Remove the bolt C and washer D.

When Assembling 1 Press the bearing R into the roller E and fit the circlip Q.

Remove the circlip F, O-ring G and plate H. 2

Install the plate N and seal P on the pin K.

Remove the circiip J and partly withdraw the pin K assembly.

Install the pin K assembly through the bearing R.

Remove the bearing L.

Install the circlip M on the pin K.

Remove the circlip M and withdraw the pin K assembly fully.

Press the bearing L onto the roller E.

Fit the circlip J to the pin K.

Remove the plate N and seal P from the pin K, 7

Turn the assembly so that the opening is uppermost and fill the assembly with 27cc of JCB Gear Oil HD90.

Install the O-ring G on the plate H and install the assembly in the roller E.

Secure the plate H with the circlip F.

7 Remove the circlip Q and then the bearing R. Inspection 1 Check that the roller diameter at the outer edge and dimension ‘X’ are within permitted limits, see page 7/1 -1 Renew as necessary. 2

Check that the roller bearings run freely and smoothly and there is no discoloration, scratching, pitting or corrosion. Renew as necessary.

9803/3145

10 Fit the washer D and bolt C.

Issue 1

Section J

Track & Running Gear

Section J

3-4

Track Rollers (Cont'd.) Dismantling and Assembly

Lower Rollers Inspection 1 Check that the roller diameter at the outer edge are within permitted limits, see page 7/1-1. Re-new as necessary.

When Dismantling 1 Remove semi circular clips 1 from grooves in end of shaft. 2 3

Remove 'O rings 2 from roller shaft 3 and remove shaft.

Check that the roller bearing bushes 6 are not marked or worn oval. Renew as necessary.

Check contact area of metallic face seals 5, refer to page J/6-1.

Pry off end caps 4 and drain roller of oil.

Maintain metallic face seals 5 in original pairs.

If necessary remove bearing bushes 6.

When Assembling 1 Install bearing bushes 6 into roller shell. 2

Fit one pair of metallic face seals 5 to end cap and roller shell.

Replace roller shaft 3 through roller end cap. Renew 'O' rings 2 on roller shaft.

Replace semi circular clip 1 in roller shaft groove.

Remove filler plug 7 in end cap, fill roller casing with 75cc of JCB Special Gear Oil.

4 5 2 3 2

7 6

5 4 1

9803/3145

H13180

Issue 1

Section J 4-1

9803/3145

Track & Running Gear

Section J 4-1

Issue 1

Section J

Track & Running Gear

Section J

4-2

Idler and Recoil Unit Dismantling and Assembly When Dismantling

WARNING The recoil unit spring can cause serious injury if suddenly released. Take care when removing and replacing the spring retaining nut. Scrap recoil units must be dismantled before transfer from the workshop. Do not use flame cutting equipment unless precautions are taken to release the spring pressure slowly. Note: If smooth faced idlers are to be rebuilt it is recommended that they are changed in pairs for the later sprocket type. 1

Set the machine to remove the track.

Undo the recoil adjusting valve nut A to relieve the grease pressure.

10 Withdraw the piston rod N from the tensioner P. Remove and discard the wiper seal Q and seal R.

Carefully raise and support the dozer clear of the track to give sufficient clearance for the removal of the idler wheel.

11 Ensure all old grease is removed from the tensioner P. Remove the cotter pin S from the nut T.

Support the dozer ram and disconnect the dozer from the ram.

Lift the idler and recoil assembly clear of the machine undercarriage.

14 Carefully release the pressure on the unit. Remove the cap V and the spring U from the spring support W.

Remove bolts B and spring washers C, separate the idler wheel assembly from the tensioner assembly.

Inspection 1 Examine the spring U for cracks and distortion. Renew if necessary.

Drive out the tension pins D and remove the idler supports E.

Examine the spring support W for wear or damage. Renew if required.

Remove the lip seals F circlips G and the bearings H.

Examine the cap V for wear or damage. Renew if necessary.

9803/3145

Withdraw the idler shaft J from the idler K.

13 Using a 2.5 to 3.0 tonne press, compress the spring U and remove the nut T.

Issue 1

Section J 4-3

9803/3145

Track & Running Gear

Section J 4-3

Issue 1

Section J

Track & Running Gear

Section J

4-4

Idler and Recoil Unit (cont'd) When Assembling 1 Install the idler shaft J into the idler K. 2

Fit new bearings H in the idler K over the idler shaft J.

Secure the bearings H with the circlips G.

Fit new lip seals F to the idler K over the idler shaft J.

Fill the idler assembly with 72ml of JCB gear oil HD90 through the capscrew L hole.

13 Remove the grease nipple from the valve nut A and fit valve nut A into the tensioner P. Ensure that grease flows from the tensioner P then fit the grease nipple to valve nut A. 14 Attach the idler assembly to the tensioner assembly with the spring washers C and bolts B. 15 Slide the spring U and cap V over the spring support W. 16 Use the 2.5 to 3.0 tonne press to compress the spring to a length of 213mm at X. Check compression load equals 2216Kgf.

Fit a new bonded washer M and the capscrew L into the idler K.

Position the idler supports E over the idler shaft J with the tension pin D holes aligned.

18 Release the spring assembly from the press

Drive in the tension pins D to secure the idler supports to the idler shaft J.

19 Install the idler and recoil assembly into the machine undercarriage.

Lubricate the new seal R and new wiper seal Q with MPL grease and install them in the tensioner P.

20 Reconnect the dozer to the dozer ram.

17 Install the nut T and secure with a new cotter pin S.

10 Fully pack the tensioner P with JCB MPL grease.

21 Fit the track to the machine. 22 Set the track tension.

11 Remove the valve nut A. 12 Prime the piston N with JCB MPL grease to ensure that there are no trapped air pockets. Carefully install in the tensioner P until grease is emitted continuously from the valve nut orifice.

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Issue 1

Section J

Track & Running Gear

Section J

5-1

Driven Sprocket Dismantling and Assembly When Dismantling 1 Set up the rnachine and remove the track, see page J/2-2, J/2-3. Clean off all dirt and accumulated debris. 2

Remove the bolts A.

Remove driven sprocket C from the track gearbox D.

When Assembling 1 Install the driven sprocket C onto the track gearbox D. 2

Fit bolts A.

Torque tighten the bolts, see page 3 / 1 - 3

Fit the track, see page J/2-2, J/2-3.

Inspection 1 Check that the driven sprocket conforms to permitted tolerances.

9803/3145

Issue 1

Section J

Track & Running Gear

6-1

Section J 6-1

Track Roller metallic face seals Removal and Replacement When Removing

CAUTION Avoid skin contact with surface 'A' as corrosion may be caused. Retain face seals in pairs when they are removed. Fit as matched pairs if suitable for further use. Inspection If contact area A is undamaged, estimate remaining life wear as follows: New seals

Contact area is a narrow band at outer edge.

Partly worn seals Contact area is wider but does not extend full width. Scrap seals

Contact area is worn to full width.

Renew pair of seals if contact surface is scratched, pitted or corroded. Examine outer edges B, housing ramp C and lip D. Carefully polish away light damage or corrosion. When Replacing Thoroughly clean and dry seals, 'O' rings and housings before fitting seals as follows: Note: Do not allow oil to come into contact with the 'O' rings or housings until the assembly is complete. Fit 'O' rings onto the seals, check that they seat evenly and are not twisted. Press 'O' ring past lip D. Check that dimension is constant around the circumference of seal. Immediately before final assembly, clean dust etc. from surface A and lightly coat with clean oil of the appropriate grade.

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Issue 1

Section L

Engine

Section L

Contents ...................................................................................... Page Technical Data .............................................................................. 1 - 1 Engine Oil Drain and Refilling .................................................................. 2 - 1 Oil Filter Renewing ................................................................................ 2 - 2 Oil Cooler Removing and Fitting ............................................................. 2 - 3 Oil Pressure Relief Valve Removing and Fitting ............................................................. 3 - 1 Oil Sump, Suction Pipe and Strainer Removing and Fitting ............................................................. 4 - 1 Fuel Filter Renewing ................................................................................ 5 - 1 Fuel Lift Pump Removing, Inspecting and Fitting ........................................... 5 - 2 Dismantling, Inspecting and Assembly ................................... 5 - 3 Fuel Injection Pump Removing and Fitting ............................................................. 5 - 4 Fuel Injection Timing Checking and Adjusting .......................................................... 5 - 5 Fuel Injectors and Fuel Pipe Assemblies Removing, Dismantling and Inspecting .................................. 5 - 6 Fuel System Bleeding .................................................................................. 5 - 8 Air Filter Renew Outer / Inner Element ................................................. 6 - 1 Engine Coolant Draining and Filling ................................................................. 7 - 1 Water Pump, Thermostat Housing Assemblies Removing, Inspecting and Fitting ........................................... 7 - 2 Engine Removing and Replacing ....................................................... 9 - 2 Cylinder Head Removing, Inspecting and Fitting ......................................... 10 - 1 Piston and Connecting Rods Removing, Inspecting and Fitting ......................................... 11 - 1 Timing Gear Case Removal and Replacement .................................................. 12 - 1 Idler Gear and Oil Pump Assembly Removing, Dismantling, Inpecting and Fitting ...................... 13 - 1 Camshaft Assembly and Tachometer Drive Removing, Inspecting and Fitting ......................................... 14 - 1 Crankshaft Removing ............................................................................. 15 - 1 Dismantling and Inspecting .................................................. 15 - 2 Assembling ........................................................................... 15 - 4

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Issue 1

Section L

Engine

Section L

1-1

Technical Data General Model Type Swept Volume

KE 103-15 IDI Vertical in-line, 3 cylinder, normally aspirated, 4 stroke, water cooled diesel. 1.493 litre (91.29 in3)

Power Output

802.7 - to M747210 803 - to M827239 804 - to M734833 802.7 - M747211on 803 - M827240 on 804 - M734833 on

20.9 kW (27 hp) @ 2345 rev/min. 20.1 kW (26.8 hp) @ 2200 rev/min. 19.2 kW (25.6 hp) @ 2110 rev/min. 21 kW (28 hp) @ 2200 rev/min. 21 kW (28 hp) @ 2200 rev/min. 21 kW (28 hp) @ 2200 rev/min.

Bore Stroke Firing Order Valve Clearance (cold) Compression Ratio Compression Pressure Injection Timing / Injection Pump Injector Setting

84 mm (3.31 in.) 90mm (3.54in.) 1-2-3 0.2 mm (0.008 in.) 22.5:1 29.4 bar (30 kgf/cm2, 427 lbf/in.2) 220 - 230 B.T.D.C. 152 - 161.7 bar (155 - 165 kgf/cm2, 2204 - 2346 lbf/in2)

Oil Capacity (min - max) Oil Pressure Weight (dry) Idling Speed

4.5 - 5.7 litres (1.0 - 1.3 U.K. gallons 1.2 - 1.56 US Gal) 1.7 - 4.1 bar (1.8 - 4.2 kgf/cm2, 25 - 60 lbf/in.2) 135 kg (297 lb) 1050 rev/min.

Maximum No load Speed

802.7 Plus 802.7 Super

- 2580 rev/min - 2420 rev/min*

803 Plus 803 Super

- 2420 rev/min - 2420 rev/min*

804 Plus 804 Super

- 2320 rev/min - 2420 rev/min*

Note: All American machines have JCB low emission (EPA) diesel engines fitted. European machines are being progressively fitted with the EPA engines. On the EPA engines, it is not possible to adjust the engine idle speed, other than throttle cable adjustment. Note: * indicates that the engine fitted to these machines is a sealed unit. Do not attempt to adjust the engine idle speed. You must seek the advice of a registered JCB distributor to rectify this type of problem. For complete engine servicing refer to Perkins 100 Series Service Manual. Coolant Capacity

9803/3145

2.65 litres (0.6 U.K. gallons 0.72 US Gals)

Issue 2*

Section L

Engine

Section L

1-2

Technical Data (contâ&#x20AC;&#x2122;d) Torque Settings Cylinder Head Bolts Connecting Rod Nuts Flywheel Bolts Injector Nozzle Main Bearing Bolts Big-end Bearing Bolts Cooling Fan Bolts

Nm 88 to 93.5 49 to 54 58.3 to 69 58.3 to 69 24.5 to 29.4 49 to 54 9.5 to 12.2

kgf m 9.0 to 9.5 5.0 to 5.5 6.0 to 7.0 6.0 to 7.0 2.5 to 3.0 5.0 to 5.5 0.9 to 1.3

lbf ft 65 to 69 oiled 36 to 40 43 to 51 43 to 51 18 to 22 36 to 40 7 to 9

Camshaft and Timing Gears Cam Height (inlet and exhaust) Cam Height (injection pump) Cam Height (fuel feed pump) Timing Gear Backlash Connecting Rod Gudgeon Pin O.D. Gudgeon Pin Small End Bush Clearance Crankshaft End-float

9803/3145

(new) (service (new) (service (new) (service (new) (service

limit) limit) limit) limit)

34.065 to 34.12 mm (1.341 to 1.343in.) 33.7 mm (1.327in.) 41.94 to 42.06mm (1.6512 to 1.6559in.) 41.8mm (1.6457in.) 31.9 to 32.0mm (1.2559 to 1.2598in.) 30.0mm (1.1811in.) 0.08mm (0.003in.) 0.25mm (0.010in.)

(new) (service limit)

27.996 to 28mm (1.1022 to 1.1024in.) 27.98mm (1.1016in.)

(new) (service limit)

0.01 to 0.025mm (0.0004 to 0.001in.) 0.08mmm (0.003in.)

(new) (service limit)

0.10 to 0.40mm (0.004 to 0.016in.) 0.5mm (0.020in.)

Issue 2*

Section L

Engine

Section L

1-3

Technical Data (contâ&#x20AC;&#x2122;d) Crankshaft Alignment

(new) (service limit)

0.03 mm (0.0012 in) or less 0.06 mm (0.0024 in)

Main Journal Diameter

(new) (service limit) (nominal 0.25 mm u/s) (service limit)

67.957 to 67.970mm (2.6755 to 2.6760 in) 67.9 mm (2. 673 in) 67.707 to 67.72 mm (2.6656 to 2.6661 in) 67.65 mm (2.6634 in)

2nd Re-grind Diameter

(nominal 0.5 mm u/s) (service limit)

67.457 to 67.470 mm (2.6557 to 2.6563 in) 67.40 mm (2.6535 in)

Big-end Journal Diameter

(new) (service limit)

51.964 to 51.975 mm (2.0458 to 2.0463 in) 51.90 mm (2.0433 in)

1st Re-grind Diameter

(nominal 0.25 mm u/s) (service limit)

51.714 to 51.725 mm (2.0360 to 2.0364 in) 51.65 mm (2.0335in)

2nd Re-grind Diameter

(nominal 0.5 mm u/s) (service limit)

51.464 to 51.475 mm (2.0261 to 2.0266 in) 51.40 mm (2.0236 in)

Crankshaft Bearing (bush) Diameter

(new)

67.957 to 67.97 mm (2.6755 to 2.6760 in)

1 st Re-grind Diameter 2nd Re-grind Diameter

(nominal 0.25 mm u/s) (nominal 0.5 mm u/s)

67.707 to 67.720 mm (2.6656 to 2.6661 in) 67.457 to 67.470 mm (2.6558 to 2.6563 in)

Main Bearing Oil Clearance

(new) (service limit)

0.044 to 0.102 mm (0.0017 to 0.004 in) 0.2 mm (0.0078 in)

Big-end Bearing Oil Clearance

(new) (service limit)

0.035 to 0.083 mm (0.0010 to 0.0030 in) 0.2 mm (0.0078 in)

(new) (service limit)

0.044 to 0.116 mm (0.0017 to 0.0046 in) 0.2 mm (0.0078 in)

lst Re-grind Diameter

Crankshaft Bearing (bush) Oil Clearance Fillet Radius (mains) Fillet Radius (big-ends) Surface Finish of Journals and Thrust Faces Oil Hole Radius Cylinder Head Distortion of Head Surface

2.8 to 3.2 mm (0.11 to 0.126 in) 2.8 to 3.2 mm (0.11 to 0.126 in) 1.6 Z (0.064 in) 2 to 5 mm (0.0787 to 0. 1960 in) (max)

Piston Protrusion above cylinder block 0.8 mm (0.020 to 0.031 in) Gasket Thickness (tightened) Gasket No. Valve Seal Angle Valve Seat Width (intake) (new) (service limit) Valve Seat Width (exhaust) Valve to Valve Guide Clearance - intake -exhaust 9803/3145

0.12 mm (0.005 in) 0.5 to 1.4 mm (0.055 in) 111147001 45Â° 1.66 to 1.87 mm (0.065 to 0.074 in) 2.5 mm (0.098 in)

(new) (service limit)

1.66 to 1.73 mm (0.065 to 0.068 in) 2.5 mm (0.098 in)

(new) (service limit) (new) (service limit)

0.03 to 0.06 mm (0.0012 to 0.0024 in) 0.2 mm (0.008 in) 0.050 to 0.075 mm (0.002 to 0.003 in) 0.25 mm (0.010 in) Issue 2*

Section L

Engine

Section L

1-4

Technical Data (cont’d) Cylinder Block Distortion of Block Surface Cylinder Bore Diameter Ist Re-bore Diameter 2nd Re-bore Diameter

(new) (service limit)

0.05 mm (0.002 in) 0.12 mm (0.005 in)

(new) (service limit) (nominal 0.5 mm o/s) (service limit) (nominal 1.0 mm o/s) (service limit)

84.000 to 84.019 mm (3.307 to 3.308 in) 84.2 mm (3.315 in) 84.500 to 84.51 9 mm (3.327 to 3.328 in) 84.70 mm (3.335 in) 85.00 to 85.019 mm (3.347 to 3.348 in) 85.20 mm (3.355 in)

Fuel Injectors Nozzle Opening Pressure Dry Nozzle at Valve Seat Pressure Tightness Oil Pump Rotor Lobe Clearances Rotor-to-Cover Clearance Pistons and Rings Gudgeon Pin Boss I.D. Gudgeon Pin Boss I.D. to Pin Clearance Ring Gap - No. 1 ring - No. 2 ring - Oil ring Ring to Groove Side Clearance - No. 1 ring - No. 2 ring - Oil ring

152 - 162 bar (155 - 165kg/cm2, 2204 - 2346 lbf/in2) 98.07 bar (100 kg/cm2, 1422.4 lbf/in2) (new) (service limit) (new) (service limit)

0.01 to 0.15 mm (0.0004 to 0.006 in) 0.25 mm (0.01 in) 0.1 to 0.15 mm (0.004 to 0.006 in) 0.2 mm (0.008 in)

(new)

27.999 to 28.003 mm (1.1023 to 1.1025 in)

(new) (service limit)

- 0.001 to + 0.007 mm (- 0.00004 to + 0.0003 in) 0.02 mm (0.0008 in)

(new) (service limit) (now) (service limit) (now) (service limit)

0.20 to 0.35 mm (0.008 to 0.014 in) 1.0 mm (0.039 in) 0.20 to 0.40 mm (0.008 to 0.016 in) 1.0 mm (0.039 in) 0.20 to 0.40 mm (0.008 to 0.016 in) 1.0 mm (0.039 in)

(new) (service limit)

0.07 to 0.11 mm (0.0028 to 0.0043 in) 0.25 mm (0.01 in)

(new) (service limit) (new) (service limit)

0.04 to 0.08 mm (0.0015 to 0.0031 in) 0.25 mm (0.01 in) 0.02 to 0.06 mm (0.0008 to 0.0023 in) 0.15 mm (0.006 in)

Radiator Cap Opening Pressure

0.73-0.93 bar (0.75 -0.95 kg/cm2, 6.5-10.8 lbf/in2)

Thermostat Opening Temperature - Starts to open - Fully open Lift

69 to 73°C (156-163°F) 82°C (180°F) 8.0 mm (0.315 in)

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Issue 2*

Section L

Engine

Section L

1-5

Technical Data (contâ&#x20AC;&#x2122;d) Valves and Springs Valve Stem Diameter

(inlet) (exhaust)

6.955 to 6.97 mm (0.2738 to 0.2744 in) 6.94 to 6.95 mm (0.273 to 0.274 in)

(new) (service limit)

0.03 to 0.06 mm (0.001 to 0.002 in) 0.2 mm (0.008 in)

-exhaust

(new) (service limit)

0.05 to 0.075 mm (0.002 to 0.003 in) 0.25 mm (0.01 in)

Valve Head Thickness

(new) (service limit)

0.925 to 1.075 mm (0.0364 to 0.0423 in) 0.5 mm (0.02 in)

(new) (service limit)

45Â° 0.85 to 1.15 mm (0.034 to 0.045 in) 1.8 mm (0.071 in)

(new) (service limit)

35 mm (1.4 in) 33.5 mm (1.32 in)

Valve Stem to Guide Clearance -inlet

Valve Face Angle Valve Recessing Spring Free Length Spring Fitted Length Load to Compress to Fitted Length

30.4 mm (1.197 in) (new) (service limit)

79.43 N (8.1 kgf, 17.9 lbf) 68.65 N (7.0 kgf, 15.4 lbf)

Spring Squareness

(new) (service limit)

3.4% 6.0%

Rocker Shaft Diameter

(new) (service limit)

11.65 to 11.67 mm (0.4587 to 0.4594 in) 11.57 mm (0.456 in)

Rocker Arm Running Clearance

(new) (service limit)

0.032 to 0.068 mm (0.0013 to 0.0027 in) 0.2 mm (0.008 in)

9803/3145

Issue 1*

Section L

Engine

2-1

Section L 2-1

Engine Oil Note: The illustration shown below is for an 803 machine, however, the procedure for the remaining machines is similar Draining and Filling for interval see Service Schedule

WARNING Used engine oil contains carbon deposits and is hazardous to health, do not allow excessive contact with the skin. Thoroughly wash hands with a good quality cleanser after this operation.

CAUTION The engine and its oil will be hot and may burn, take necessary precautions. Deposit old oil in the correct manner in accordance with the local authority. Draining 1 Run the engine to thoroughly warm the lubricating oil 2

Park the machine on firm level ground. Lower the excavator to the ground.

Stop the engine and remove the starter key.

Open the engine cover.

Place a suitable container beneath the engine oil drain plug to catch the oil, (see page 3 / 1 - 1 for capacity).

Remove the drain plug A and let the oil drain out.

Filling 1 Clean the drain plug A and refit it. Make sure it is tight. 2

Fill the engine slowly with new oil through the filler cap B (see page 3/1 - 1 for capacity). Do not pour the oil in too quickly as it may blow back and flow over theengine.

Disconnect the electrical lead from the fuel solenoid and crank the engine until the oil pressure warning light goes out.

Check for leaks and top up if necessary with new oil. (See page 3/1 - 1 for capacity.)

Reconnect the electrical lead to the fuel solenoid.

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Issue 1

Section L

Engine

2-2

Section L 2-2

Engine Oil Filter Note: The illustration shown below is for an 803 machine, however, the procedure for the remaining machines is similar. Renewing for interval see Service Schedule 1

Drain the engine oil, see page L/2-1.

Unscrew the filter canister A. If necessary use a chain or strap wrench.

Clean the filter mounting head B.

Smear the new seal C with oil.

Screw in the new filter canister - hand tight and then one quarter turn.

Fill the engine with new oil. (See page3/1-1 for capacity).

Motor the engine until the oil pressure warning light goes out.

Check for leaks and top-up the engine with oil.

9803/3145

Issue 1

Section L

Engine

Section L

2-3

Engine Oil Cooler (If fitted) Removing and Fitting Removing 1 Drain the engine oil, see page L/2-1. 2

Drain the engine coolant, see page L/7-1.

Disconnect and plug hoses A and B from the engine oil cooler C. Make a note of the connections to ensure correct refitting.

Disconnect engine coolant hoses D, remove retaining bolt E and remove the engine oil cooler.

Remove engine oil filter H.

Remove oil supply hoses from cooler sandwich block F and associated adapters.

Unscrew sandwich block F from engine cylinder block. Remove seals G and discard

Fitting 1 Renew seals G between engine cylinder block and oil cooler sandwich block F, replace sandwich block ensuring correct phasing of oil cooler oil supply hose ports. Replace hose adaptors and hoses. 2

Renew/replace filter H.

Connect engine coolant hoses D to the engine oil cooler C.

Connect engine oil hoses A and B to the engine oil cooler as noted during removal.

Refill the engine cooling system, see page L/7-2.

Refill the engine with oil, see page L/2-1.

9803/3145

C A

Issue 1

Section L

Engine

3-1

Section L 3-1

Oil Pressure Relief Valve Note: The illustration shown below is for an 803 machine, however, the procedure for remaining machines is similar Removing and Fitting Removing 1 Loosen and remove the relief valve A. Fitting 1 Fit a new 0-ring to the relief valve A. 2 Insert the valve in the cylinder block and tighten. Torque Settings Item Nm A 59-69

9803/3145

kgf m 6.0-7.0

lbf ft 44-51

Issue 1

Section L

Engine

Section L

4-1

Oil Sump, Suction Pipe and Strainer Removing and Fitting Removing 1 Drain the engine oil, see page L/2 - 1. 2

Remove all the sump bolts and remove the sump and gasket.

Loosen and remove the bolts A and remove the strainer B.

4 5

Rotate the pipe C and remove the pipe from the cylinder block. Remove and discard the 0-ring D from the pipe C.

Fitting 1 Fit a new O-ring D to the pipe C and insert the pipe into the cylinder block. 2

Fft the strainer B to the pipe C.

Fit the bolts A and tighten.

Fit the sump with a new gasket. Tighten the bolts diagonally and evenly.

Torque Settings Item Nm A 9-13

kgf m 0.9-1.3

lbf ft 6.5-10

Note: Engine is shown inverted.

9803/3145

Issue 1

Section L

Engine

5-1

Section L 5-1

Fuel Filter Renewing for interval see Service Schedule 1

Disconnect the battery.

Support the bowl A.

Unscrew bolt B.

Remove the bowl and element C.

Wash the bowl in clean fuel.

Install the element C with new seals D. Make sure they seat correctly.

Tighten bolt B.

Check for leaks.

Bleed the fuel system, (see page L/5 - 8).

10 Reconnect the battery.

9803/3145

Issue 1

Section L

Engine

5-2

Section L 5-2

Fuel Lift Pump Removing, Inspecting and Fitting Removing 1 Loosen the clamp A and remove the fuel lines. 2

Remove the two securing bolts B complete with washers.

Remove the fuel lift pump C.

Remove the gasket D.

Drain any fuel from the lift pump.

Inspecting 1

Examine for damage, cracks etc.

Make sure that the bottom body E and the piston F are not seized.

Check the top body G as follows: - draw air from the IN side using a vacuum and blow air into the OUT side - if the air stops in both cases, the body is normal.

Fitting 1 Install a new gasket D on the fuel lift pump. 2

Insert the fuel lift pump C in its bore.

Fit the two securing bolts B and washers and tighten them.

Fit the fuel lines and tighten the clamps A.

9803/3145

Issue 1

Section L

Engine

5-3

Section L 5-3

Fuel Lift Pump (cont'd) Dismantling, Inspecting and Assembly Dismantling Note: Before dismantling the fuel pump make sure that the bottom body E and piston F are not seized. 1

Make a note of the reference marks on the cap G, top body H and bottom body E.

Remove the bolts J and separate the top body H and cap G from the bottom body E. Discard the gasket K.

Remove the swivel couplings L and M from the cap G.

Turn the piston F until the pin N aligns with the groove in the bottom body E.

Hold the diaphragm P and piston F in position against the spring pressure and remove the pin N.

Take care with the springs Q and R, remove diaphragm P, piston F and springs Q and R.

Inspecting Note: If the lift pump is found to be unserviceable, a new lift pump will have to be fitted. The new lift pump will not have a lift pump lever. Therefore, a priming bulb will also have to be installed to the fuel system to permit fuel system priming. 1

Examine the fuel pump components for damage or wear. Check that the diaphragm P is not cracked or damaged.

Inspect the check valves located in body H and clean as required.

Assembly 1 Assemble the fuel pump in the reverse order of dismantling. 2

Make sure that the reference marks align and fit a new gasket K.

9803/3145

Issue 2*

Section L

Engine

5-4

Section L 5-4

Fuel Injection Pump Assembly Removing and Fitting Removing 1

Remove fuel pipe assembly from injectors and fuel pump, see page L/5 - 6.

Remove the two mounting bolts A and nuts B.

Carefully lift the fuel injection pump until access to the link snap pin C is gained.

Disconnect the link D and remove the fuel injection pump.

Remove the shim(s) E. Record the number and thickness of the shim(s) for re-assembly.

Fitting 1 Put the shim(s) E in position. 2

Position the fuel pump and connect the link D. Fit the snap pin C.

Install the fuel pump and fit the mounting bolts A and nuts B.

Tighten the mounting nuts and bolts.

Adjust the fuel injection timing, see page L/5 - 5.

Fit the fuel pipe assembly, see page L/5 - 6.

9803/3145

Issue 1

Section L

Engine

Section L

5-5

Fuel Injection Timing Checking and Adjusting - for interval see Service Schedule

Piston Position and Crankshaft Angle (BTDC) Crankshaft Angle (°BTDC) 21 22 23 24 25 26 27 28 29

This procedure provides the correct injection timing. If the fuel injection pump, the camshaft assembly, or the cylinder block have been renewed carry out this check. When renewing the fuel injection pump start with a shim of 0.5 mm (0.0197 in) thickness. 1

Remove the fuel pipe assembly. See page L/5 - 6.

Remove the delivery valve holder A at the front (radiator side) of the fuel injection pump B.

Remove the delivery valve (IN) C.

Refit the spring D and the delivery valve holder A in the injection pump B.

Note: When re-assembling the delivery valve holder A, use a length of wire to align delivery valve E.

Piston Position mm (in) 3.895 (0.1533) 4.267 (0.168) 4.655 (0.1833) 5.058 (0.1991) 5.477 (0.2156) 5.912 (0.2328) 6.361 (0.2504) 6.826 (0.2687) 7.304 (0.2876)

Move the governor control lever to maximum fuel position. Slowly turn the crankshaft clockwise until No. 1 piston is a little before ‘X’ degrees BTDC on its compression stroke and continue turning until fuel starts to flow from the delivery holder.

Then slowly turn the crankshaft clockwise until fuel flowing from delivery holder is stopped. Check the piston position at this point. If the position is later than ‘Y’ BTDC, use a thinner shim. If the position exceeds ‘Z’ BTDC, use a thicker shim.

Note: Changing the shim thickness by 0.1 mm (0.004 in) will change the timing by approximately one degree. Increasing the shim thickness makes the timing later (i.e. decreases the angle) while decreasing the shim thickness makes the timing earlier (i.e. increases the angle). When no shims are needed, assemble with coating of liquid sealant. Shims are available in the following thicknesses (for part numbers see parts microfiche): 0.2mm, 0.3mm, 0.4mm, 0.5mm. Injection Timing and Crankshaft Positions Engine Model No

KE 103-151DI

9803/3145

Piston Position mm (in) 2.278 (0.0897) 2.569 (0.1011) 2.875 (0.1132) 3.199 (0.1259) 3.539 (0.1393)

Injection Timing

22-23

Remove the delivery valve holder A and fit the delivery valve (IN) C.

Refit the delivery valve holder A and torque tighten.

Refit the fuel pipe assembly, see page L/5-6.

Piston Position and Crankshaft Angle (BTDC) Crankshaft Angle (°BTDC) 16 17 18 19 20

Degrees Crank BTDC

Torque Settings Item Nm A 39-45

kgf m 4-4.5

lbf ft 29-33 Issue 1

Section L

Engine

5-6

Section L 5-6

Fuel Injectors and Fuel Pipe Assembly Removing, Dismantling/Inspecting Removing 1 Loosen the fuel pipe nuts H from the injectors and the fuel injector pump.

Dismantling/Inspecting 1 Carefully place the nozzle holder (body) A in a vice and turn the nozzle nut B to disassemble.

Remove the fuel pipes as an assembly.

Note: Care should be taken the needle valve does not fall when the nozzle C is removed.

Remove the spring clamp J and the fuel return hose K.

Loosen and remove the Banjo bolt and three securing nuts L. Remove the leak-off rail M. Remove and discard the three aluminium washers N.

Wash the nozzle body and needle valve and inspect the nozzle for seizure, sticking and fuel leakage on the seat surface. If fuel leakage is detected, replace the nozzle.

Inspect the upper and lower contact surfaces of the distance piece D and correct so that positive contact can be obtained.

Check the nozzle needle valve-contact surface on the push rod E for wear, and spring seat for cracks.

Remove the injectors and discard the cap P and gaskets Q.

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Section L

Engine

Section L

5-7

Fuel Injectors and Fuel Pipe Assembly (cont’d) Reassembling/Adjusting and Fitting Reassembling/Adjusting 1 Before fitting a new nozzle assembly, soak it in heated light oil (50° - 60°C, 122° - 140°F) to remove anti-corrosive agent from the nozzle. Then slide the body on the needle valve so that they slide smoothly. 2

Turn the nozzle body upside down, fit the shims F, spring G, rod E, spacer D and nozzle C, in this order, and torque tighten to 78 - 98Nm (8 - 10kgf m, 58 -72lbf/ft). using nozzle nut B.

Fitting 1 Fit new cap P and gaskets Q on injector body. 2 Fit the injector and torque the body to 59 - 69Nm (6 - 7 kgf m, 44 - 51 lbf ft). 3 Fit the leak off rail M with new washers N and securing nuts L. 4 Fit the spring clamp J and the return hose K. 5 Fit the fuel pipe assembly and tighten the nuts H.

After reassembly, check the injection pressure of the nozzle, adjust as required. Torque Settings

WARNING Avoid contact with the fuel spray and do not inhale the fumes. Keep naked flames away and do not smoke while working on the injector. There could be a fire and injury if you do not follow these precautions.

Item B H

Nm 59-69 15-25

kgf m 6-7 1.5-2.5

lbf ft 44-51 11-18

8-3-4-8

Adjust the pressure with adjusting shims using a nozzle tester so that the injection starts at 152 bar (155 - 165 kg/cm2, 2204 - 2346lbf/in2). Note that the pressure increases or decreases about 10 bar (10 kg/cm2, 142 lbf/in2) with a shim of 0.1 mm (0.004 in) thick.

Spray condition: a Fuel drops should not be mixed in the spray pattern. b Fuel should be sprayed in conical shape with respect to the nozzle axis. c Check that the fuel is sprayed in a circular shape when tested. d Hold the pressure at 132 bar (134kg/cm2, 1914 lbf/in2) - i.e. lower by 20 bar (20 kg/cm2, 284.5 lbf/in2) than specified and check that no test oil drops from the nozzle tip. 5

When the adjustment is correct torque tighten the nozzle nut B on the body A.

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Issue 1

Section L

Engine

5-8

Section L 5-8

Fuel System Bleeding

WARNING To bleed the injectors you must turn the engine. When the engine is turning, there are parts rotating In the engine compartment. Before starting this job, make sure that you have no loose clothing (cuffs, ties etc) which could get caught In rotating parts. When the engine Is turning, keep clear of rotating parts. 2-3-3-8

Should the engine fail to start, misfire, or if any part of the system has been disconnected or become empty, bleed the system as follows:Note: The fuel injection pump is self-bleeding when the engine is cranked. 1

Loosen vent screw A on top of the fuel filter.

Operate the fuel lift pump priming lever X until airfree fuel flows from the filter vent point. Tighten the vent screw A.

Note: If the lift pump priming lever does not operate, turn the crankshaft one revolution to place the follower on the back of the cam. 3

Loosen connecting union nuts B, C and D at the injectors.

Open the throttle a little, use the starter key to turn the engine until air-free fuel flows from the connections.

Tighten the union nuts.

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Issue 1

Section L

Engine

Section L

6-1

Air Filter Renew Outer Element - for interval see Service Schedule

Renew Inner Element - for interval see Service Schedule

Unscrew the wingnut H. Pull out the element G. Take care not to tap or knock the element as you remove it.

To prevent dust getting into the engine, remove the induction hose A. Cover the hose to prevent rain and dirt getting into the engine.

Clean the inside of the canister C and dust valve D.

Unscrew wingnut H. Pull out the outer element G.

Unscrew nut F. Pull out the inner element E.

Insert the new element into the canister. Make sure it seats correctly, by smearing the seal J with grease and checking for a witness mark on the canister base. Fit and tighten the wingnut H. Check all hoses for condition and tightness.

Clean the inside of the canister C and dust valve D.

Carefully insert the new inner element into the canister. Make sure it seats correctly, by smearing the seal B with grease and checking for a witness mark on the canister base. Fit and tighten nut F.

66 Carefully insert the new outer element. Make sure it seats correctly, by smearing the seal J with grease and checking for a witness mark on the canister base. Fit and tighten nut H. 7

Connect the induction hose. Check all hoses for condition and tightness.

Note: In a dusty working environment, the outer element may have to be changed more frequently than the service schedule recommendation. A new inner element must be fitted at latest, every third time the outer element is changed. As a reminder, mark the inner element with a felt tip pen each time you change only the outer element.

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Issue 1

Section L

Engine

Section L

7-1

Engine Coolant WARNING The cooling system is pressurised when the coolant is hot. Hot coolant will burn you. Make sure that the engine is cool before checking the coolant level or draining the system.

Filling 1 Check the radiator, hoses and clips for security and damage. Renew if necessary. 2

Clean the radiator drain plug C and refit it. Make sure it is tight.

Draining and Filling - for interval see Service Schedule

Close the engine block drain tap B.

Draining 1 Park the machine on level ground. Remove the starter key.

Fill the radiator with the correct coolant mixture. (See page 3 /1 - 1 for capacity.) Do not fill faster than 10 litres/min (2 UK Gal/min 2.4 US Gal/min) as this may induce an air lock under the thermostat.

Do not fit radiator cap at this stage. Run engine at fast idle for five minutes or until all trapped air is expelled. Top up radiator with coolant to 20 mm (3/ 4 in) below neck. Ensure there is at 50 mm (2 in) of coolant in expansion bottle D.

Refit the radiator filler cap A and make sure it is tight.

Start the engine and run it until engine working temperature is reached.

Stop the engine and check for leaks.

2-3-3-3

Open the engine cover.

Make sure that the radiator is cool and remove the filler cap A.

Undo the tap B on the engine block.

WARNING Keep your face away from the drain hole when removing the drain plug. 2-3-3-4

Remove the radiator drain plug C.

Allow the coolant to drain.

If necessary flush the system with clean water.

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Issue 1

Section L

Engine

7-2

Section L 7-2

Water Pump/Thermostat Housing Assemblies Removing, Inspecting and Fitting Water Pump 1 Drain the coolant. 2

Remove the radiator shroud. Slacken the fan belt at the alternator.

Inspecting 1 Place the thermostat into water. Raise the water temperature gradually and make sure that the valve opening temperature and the valve lift are correct (see Technical Data). it not, replace the thermostat.

Remove the cooling fan mounting bolts A and remove the fan and pulley.

Note: 3 to 5 minutes will be required before the valve starts to open.

Remove the fan belt.

Loosen hose clamps B and remove them with hoses C.

Loosen the securing bolts D and remove the water pump assembly E, set plate F and gaskets G.

Examine the water pump for wear, leaks and damage. Check the bearing for roughness. If defective, replace the assembly.

Thermostat Housing 1 Loosen hose clamps B and remove them with hoses C. 2

Disconnect wiring from the temperature sender unit.

Loosen the securing bolts H and remove the thermostat upper housing J and gasket K.

Remove the thermostat L from the lower thermostat housing M.

Loosen bolts N and nut P and remove the lower thermostat housing and gasket Q.

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Issue 1

Section L

Engine

Section L

7-3

Water Pump/Thermostat Housing Assemblies (cont'd) Removing, Inspection and fitting Fitting Thermostat Housing 1 Fit a new gasket Q to the cylinder head using a Silicon RTV type liquid packing.

Water Pump 1 Fit new gaskets G and set plate F using a Silicon RTV type liquid packing.

Secure the lower thermostat housing to the cylinder head with attaching parts N and P.

Fit the thermostat L in the lower thermostat housing M.

Place the water pump assembly E in position using a Silicon RTV type liquid packing. Rotate the fan holder to ensure it is not fouling. Secure evenly with bolts D.

Replace hoses C and secure with clamps B.

Fit the gaskets K to the lower thermostat housing using a Silicon RTV type liquid packing.

Fit the cooling fan and pulley to the water pump assembly. Torque tighten bolts A to 9 - 13 Nm (0.9 - 1.3 kgf m, 6.5 - 9.5 lbf ft).

Fit the fan belt and adjust.

Fit the radiator shroud.

Refill with coolant (see page 3/1-1 for capacity).

Run and test.

Place the upper thermostat housing J in position and secure evenly with bolts H.

Replace hoses C and secure with clamps B.

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Issue 1

Section L

Engine

10 - 1

Section L 10 - 1

Cylinder Head Removing, Inspecting and Fitting Removing Note: For clarity, the illustrations show the engine removed from the machine. If the cylinder head is removed with the engine in situ, first carry out the following operations: -

Drain the cooling system, remove the radiator and heater hoses.

Disconnect the air cleaner and exhaust silencer from manifolds.

Disconnect the water and oil sender units.

The following procedure applies if the engine is either in situ or has been removed:1

Loosen the fuel pipe nuts from the fuel injection pump and the injectors. Remove the pipes as an assembly.

Remove the injectors, K required, by removing the three securing nuts. Remove the three aluminium washers and discard them.

Remove the cooling fan and pulley.

Remove the water pump assembly and set plate, see page L/7 - 2.

Remove the breather hose B. Loosen and remove three cap nuts C with washers D. Lift the rocker cover assembly E.

Remove the oil-ring gasket F.

Loosen and remove three nuts G, lock washers H and flat washers J from the rocker pillar studs. Lift the rocker assembly K.

Remove the push rods L and the valve stem caps.

Loosen and remove the two banjo bolts N at the cylinder block main oil gallery and cylinder head assembly. Remove the oil pipe P.

10 Remove the clamp Q from the fuel injection pump. 11 Loosen the cylinder head bolts starting from the centre, in a circular pattern, using several steps of equal torque. Remove the head.

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Issue 1

Section L

Engine

10 - 2

Section L 10 - 2

Cylinder Head (contâ&#x20AC;&#x2122;d) Inspecting 1 Using a valve spring compressor, compress the valve spring A and remove the valve collets B, retainer C, spring A and valve D. 2

Clean off all the carbon from the cylinder head face, valves and parts.

With a straight edge and a thickness gauge, check for warping of the cylinder head lower face.

Check six positions, as shown at X, for distortion. If the distortion is excessive (see Technical Data), this must be corrected using a surface grinder.

Check the valve stem for excessive wear or damage. If it is found to be excessive, renew the valve.

Check the valve stem diameters at positions I, II and Ill with a micrometer. If the diameter is less than the permitted value (see Technical Data), renew the valve.

Check the thickness of the valve head Y. If it is less than the permitted value, renew the valve.

Insert the valves into the valve guides and check the clearance between the valve stem and the valve guide. If the clearance is excessive (see Technical Data), renew the guide, recut the valve seat and renew the valve.

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Issue 1

Section L

Engine

10 - 3

Section L 10 - 3

Cylinder Head (cont’d) Inspecting 9 Check the condition and width of the valve seats. If the width Z is more than specified in Technical Data or if the seat is excessively pitted, recut the seat as shown. 10 Check the recess dimension of the valves Z1. If the recess exceeds the limit specified in Technical Data, renew the valve seat insert (if fitted). 11 Renewal of valve seat insert (where fitted): -

Either 1 . Using a gas burner (700-800°C,12921443°F) heat diagonally across the valve seat insert. Leave in air for 3 to 5 minutes and remove the valve seat insert by light tapping (ensuring head is not damaged).

Or 2. Machine the insert out taking care not to damage the head.

Clean up the insert bore and fit a new insert using a press (9800-14710N, 1000-1500 kgf, 22043306 lbf) and a suitably smooth surface tool. To assist the process, chill the valve seat insert with liquid nitrogen etc. or heat the head to between 60-100°C (140-212°F).

12 Correct the valve seat contact using a valve lapper and lapping compound. When using a new cylinder head, obtain correct seat contact width and seat recess using the seat cutter. Then carry out lapping. 13 Check the valve springs as follows and renew if outside the limits specified in Technical Data: -

measure the free length.

Check the squareness by placing the spring against a set square positioned on a surface plate and rotating to obtain maximum dimension E. Measure dimension E and express as a percentage of free length F. i.e. squareness E x 100%. F

check the spring tension by measuring the load required to compress the spring to its fitted length.

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Issue 1

Section L

Engine

10 - 4

Section L 10 - 4

Cylinder Head (contâ&#x20AC;&#x2122;d) Fitting 1 Insert the valves D in the cylinder head and fit the spring A (using a spring compressor), the cotter B and the retainer C. Take care not to damage the valve guide seat. 2

Set each piston to T.D.C. and measure the amount of protrusion above the cylinder block with a depth gauge or dial gauge. Take the measurement by pressing the piston lightly. Use the highest reading as the reference.

Check that the cylinder head gasket meets the tolerance levels (see Technical Data). The last four digits of the code number are stamped on the head gasket.

Install the head gasket with the code numbers at the top.

Install the cylinder head.

Lubricate the cylinder head bolts with a molybdenum disulphide based grease and install them.

Tighten the cylinder head bolts in a three step procedure in the order shown.

Torque the cylinder head bolts to 88-93 Nm (9.09.5 kgf m, 65-69 lbf ft).

Put the oil pipe P in position and fit the banjo bolts N at the cylinder block main gallery and cylinder head assembly (see page L/10-1). Torque the banjo bolts to 10-13 Nm (1.0-1.3 kgf m, 7.2-9.4 lbf ft).

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10 Fit the caps on the valve stems. 11 Install the push rods L. 12 Fit the rocker arm assembly on the rocker pillar studs. Fit the flat washers J, new lock washers H and the nuts G on the rocker pillar studs. 13 Tighten the nuts G and torque to 20-24 Nm (2.02.5 kgf m, 14.5-18.1 lbf ft).

Issue 1

Section L

Engine

10 - 5

Section L 10 - 5

Cylinder Head (contâ&#x20AC;&#x2122;d) Fitting 14 Adjust the valve clearances (cold) of the inlet and exhaust valves to 0.2 mm (0.0078 in) as follows: -

loosen nut Z and adjust the screw X on each tappet. When the clearance is correct, tighten the nut Z.

15 Adjust the valves in this sequence: -

Set the No.1 piston to T.D.C. (compression stroke) and adjust both No.1 cylinder valves, No.2 cylinder inlet valve and No. 3 exhaust valve.

Turn the crankshaft counter-clockwise through 360Â° (viewed from the front).

Adjust the No.2 cylinder exhaust valve and No.3 cylinder inlet valve.

16 Put the rocker cover oil-ring gasket F in position. 17 Carefully put the rocker cover E in position. Make sure the oil-ring gasket F stays in position. 18 Fit the washers D and the cap nuts C on the rocker pillar studs and tighten them evenly. Torque to 812 Nm (0.8-1.2 kgf m, 6-9 lbf ft). 19 Fit the breather hose B. 20 Fit the water pump assembly, radiator and heater hoses. 21 If necessary, fit the injectors with new aluminium washers. Torque the injectors to 59-69Nm (6-7 kgf m, 44-51 lbf ft). Fit the return pipe and the injection pipes. Torque the injection pipe unions to 15-25Nm (1.5-2.5 kgf m, 11 -18 lbf ft). 22 Fit the cooling fan pulley and fan to the water pump assembly. Torque the bolts to 9-13 Nm (0.9-1.3 kgf m, 6.5-9.5 lbf ft). 23 Fit the fan belt and adjust to the correct tension, see page C/3 - 1

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Issue 1

Section L

Engine

11 - 1

Section L 11 - 1

Piston and Connecting Rods Removing, Inspecting and Fitting Removing 1 Drain the coolant, see page L/7 - 1. 2

Drain the engine oil, see page L/2 - 1.

Remove the cylinder head assembly, see page L/ 10 - 1.

Remove the oil sump, suction pipe and strainer, see page L/4 - 1.

Remove the big-end nuts F and bolts G and remove the big-end cap H.

Remove any carbon from the cylinder bore. Push the piston and connecting rod through the cylinder block.

Refit the big-end cap on the removed piston and connecting rod. Attach a label to each of these assemblies to ensure replacement in the original bore.

Remove the piston rings A.

Remove the circlips B and drive out the gudgeon pin C.

10 Repeat for each cylinder.

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Issue 1

Section L

Engine

Section L

11 - 2

Piston and Connecting Rods (contâ&#x20AC;&#x2122;d) Inspecting 1 Examine the outer surface of the piston D for cracks, scores and burns. If excessive, renew the piston. Âˇ

Check the larger diameter of the piston skirt (1 0 mm (0.4 in) from the bottom) and check the inside diameter (thrust direction) of the cylinder bore. Calculate the clearance between the cylinder and the piston. If this clearance is more than the permitted value, or the piston diameter is less than the permitted value (see Technical Data) renew the piston.

12 Check the oil clearance, using plastigauge, as follows: -

Remove oil or foreign matter from the bearing and crankshaft F.

Cut the plastigauge to the same width as the bearing. Place it on the crankshaft. Avoid the oil hole G.

Assemble the connecting rod and connecting rod cap and torque tighten to 49-54Nm (5.0-5.5 kgf m, 36-40 lbf ft).

Note: If the cylinder bore is oversized, make sure that an oversized piston is used. 3

Measure the inside diameter of the gudgeon pin hole and the outside diameter of the gudgeon pin. Calculate the difference. If the clearance is excessive (see Technical Data), renew as necessary.

Measure the outside diameter of the gudgeon pin. If less than permitted value (see Technical Data) renew it.

Clean out the carbon from the piston ring grooves.

Examine the piston rings and renew as necessary.

Insert the rings into the cylinder bore at right angles to the bore and measure the clearance. If the clearance is excessive (see Technical Data), renew as necessary.

Measure the clearance between the piston ring groove and the ring. If the clearance is excessive (see Technical Data), renew the ring. Check the connecting rod E for distortion between the large and small ends. If the distortion is excessive (see Technical Data), renew the connecting rod.

Note: Never rotate the connecting rod. -

Remove the connecting rod cap. Measure the oil clearance with the scale printed on the gauge bag.

Note: Measure the widest area. If oil clearance exceeds the permitted value (see Technical Data), renew the bearing. Or, grind the crankshaft and use underside bearings as follows (see Microfiche for part numbers): Bearing Size

Crankshaft Pin O.D.

10 Measure the inside diameter of the connecting rod small-end bush and calculate the clearance between the small-end bush and the gudgeon pin. If the clearance is excessive (see Technical Data), renew as necessary.

Standard

51.964 - 51.975 mm (2.0458 - 2.0463 in)

0.25 mm (0.0098 in)

51.714 - 51.725 mm (2.0360 - 2.0364 in)

11 Assemble the connecting rod to the crankshaft and measure the play in the shaft direction. If the play is excessive (see Technical Data), renew the connecting rod.

0.50 mm (0.0196 in)

51.464 - 51.475 mm (2.0261- 2.0266 in)

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Note: When grinding the outside diameter of the crankshaft, make sure that the oil clearance is correct before reassembly. Issue 1

Section L

Engine

Section L

11 - 3

Piston and Connecting Rods (cont’d) Cylinder Block, Inspecting 1 Inspect the cylinder block top face for cracks, damage and warping in the same way as for the cylinder head. If outside limit, replace cylinder block. 2 3

Visually inspect cylinder bore. There should be no scoring, rust or corrosion. Using a cylinder gauge, measure the cylinder bore at the upper, middle and lower areas (piston ring contact area) in the direction of the crankshaft and at right angle to the crankshaft.

Note : The upper area described in 3 corresponds to the top ring when the piston is at the T.D.C., (about 10mm below the cylinder block top surface). The lower area corresponds to the piston oil ring when the piston is at the B.D.C. (about l00mm from top face).

Fitting 1 Heat the piston to approximately 100°C (212°F). 2

Align the set marks X and the marks Y on the piston, as shown.

Insert the gudgeon pin C and fit the circlips B.

Fit the piston rings on the piston with the scribe mark towards the piston crown. Make sure that the rings are in the correct position as shown.

When the connecting rod, piston or gudgeon pin has been renewed, the difference in weight of the complete assemblies should not exceed 10 grams between cylinders.

Refit the oil suction pipe and strainer and the sump, see page L/4 - 1.

Refit the cylinder head assembly, see page L/10 1.

Fill the engine with oil, see page L/2 - 1.

Fill the cooling system with coolant, see page L/7 1.

Cylinder Bore Sizes Size

Inside Diameter

Allowable Limit

Standard

84.00 - 84.019 mm (3.307 - 3.308 in)

84.2 mm (3.315 in)

1st Re-bore 0.5 mm (0.02 in)

84.50 - 84.519 mm (3.327 - 3.328 in)

84.7 mm (3.335 in)

2nd Re-bore 0.5 mm (0.02 in)

85.00 - 85.019 mm (3.346 - 3.347 in)

85.2 mm (3.354 in)

After the second re-bore, replace the cylinder block.

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Issue 1

Section L

Engine

Section L

12 - 1

Timing Gear Case Removal and Replacement Removal 1 Remove nut A and washer B.

Fitting 1 Install the start spring J.

Pull the crankshaft pulley C from the crankshaft D.

Insert the link through the hole in the cylinder block.

Remove the securing bolts E and lift the case off the locating dowels

Rotate oil pump cover F to position spring pin hole to the centre position.

Install the cover locating pin G in the oil pump cover plate.

Note: Ensure the engine is not rotated.

Note: Take care not to damage the oil seal.

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Turn the mechanical stop lever H clockwise to assist assembly.

Fit the securing bolts E and tighten them evenly.

Align the key way and key on the crankshaft pulley C and the crankshaft D.

Fit the washer B and nut A. Torque to 275 - 334 Nm (28 - 34 kgf m, 203 - 246 lbf ft).

Issue 1

Section L

Engine

Section L

13 - 1

Idler Gear and Oil Sump Assembly Removing, Dismantling, Inspecting and Fitting

13 - 1 Inspecting 1 Check all the components for damage and wear and replace as necessary.

Removing 1 Remove the Timing Gear Case, see Page L/12 - 1.

Measure the clearance between the rotor L and the vane G. If the clearance is excessive (allowable limit 0.25mm (0.01 in) replace the vane and rotor.

Remove the circlip A.

Remove the idler gear and oil pump assembly B complete.

If the idler gear needs replacing contact Perkins service department.

Fitting Note: Coat both faces of the rotor and vane with grease for assembly. DO NOT TURN the crankshaft with the timing gear case removed.

Dismantling 1 Remove the snap ring C. 2

Remove the collar D, the spring E and the shim F.

Remove the idler gear vane G and the oil pump cover H together.

Remove the spring J and the pin N.

Remove the rotor L from the idler gear M.

Insert the rotor L in the idler gear M. Fit the pin N and the spring J.

Insert the thrust washer K.

Align the set marks on the idler gear M, crankshaft gear P and camshaft gear Q and fit on to the idler gear shaft R.

Install the vane G, the cover H, the shim F, the spring E, the collar D and the snap ring C.

Adjust with shim 0.10, 0.15, 0.20, 0.50 mm (0.004, 0.006, 0.008, 0.02 in) so that side clearance of the oil pump, rotor and vane is between 0.1 - 0.15 mm (0.0004 - 0.006 in).

Fit the timing gear case, see page L/12 - 1.

Note: When the idler gear assembly is removed. DO NOT TURN the camshaft and crankshaft gears.

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Issue 1

Section L

Engine

14 - 1

Section L 14 - 1

Camshaft Assembly and Techometer Drive Removing, Inspecting and Fitting Removing 1 Remove the timing gear case, see page L/12 - 1. 2

Remove bolt A and then remove keeper plate B.

Slide the camshaft assembly C together with the flyweight retainer out of the camshaft bore.

4 Pull the tachometer drive shaft D from its bore. Inspecting 1 Check the journals and cams for wear and damage. Correct uneven wear and small scratches on the cam surface with an oil stone. 2

Measure the height of the inlet and exhaust cams at position E.

Measure the height of the injection pump cams at position F.

Measure the height of the fuel feed pump cam at position H.

If any of these cam heights is less than the specified value (see Technical Data), replace the camshaft.

Examine the tachometer drive shaft gear, crankshaft gears J, camshaft gear K and idler gear L for damage and wear on the contact area. Replace as necessary.

Measure the backlash of the gears. If the backlash is excessive (see Technical Data) replace ALL timing gears.

Fitting 1 Install the tachometer shaft. 2

Make sure that the set marks on the crankshaft gear J and the idler gear L are aligned as at position M.

Make sure that the set marks on the idler gear L and the camshaft gear K are aligned as at position N and install the camshaft assembly in its bore.

Fit the keeper plate B with the bolt A. Torque the bolt A to 9-14 Nm (0.9-1.3 kgf m, 6.5-10 lbf ft).

Fit the timing gear case, see page L/12 - 1.

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Issue 1

Section L

Engine

15 - 1

Section L 15 - 1

Crankshaft Removing 1 Remove the engine, see page L/9 - 2. 2

Remove the starter, see page C/4 - 1

Remove the engine oil sump, suction pipe and strainer, see page L/4 - 1.

Remove the oil pump assembly, see page L/13 - 1.

Remove the cylinder head, see page L/10 - 1.

Remove the push rods and followers.

Remove the fuel lift pump, see page L/5 - 2.

Remove the fuel injection pump assembly, see page L/5 - 4.

Remove the timing gear case, see page L/12 - 1.

10 Remove the camshaft assembly see page L/14 - 1. 11 Remove the bolts A and lift the front plate B off the locating dowels C. Remove the gasket D and discard, 12 Remove the bolts E and extract the flywheel F. 13 Remove the bolts and remove the backplate. 14 Remove the oil seal G. 15 Remove the pistons and connecting rods, refer to page L/11 - 1. 16 Remove the bolts H fitted through the crankcase cross members and the two recessed bolts at the flywheel end. 17 Slide the crankshaft and main bearing assemblies out of the cylinder block.

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Issue 1

Section L

Engine

Section L

15 - 2

Crankshaft (cont'd) Dismantling and Inspecting 1

Main bearings, No.l, No.2 and No.3.

Crankshaft Bush

a Remove the bearing holder and check it for peeling, melting, stepped wear and other damage. If it is excessively damaged, renew it.

a Check the bearing (bush) for peeling, melting, seizure or poor contact. If found to be defective, renew.

b Using the plastigauge, measure the oil clearance between the crankshaft journal and the bearing. If the oil clearance is more than the allowable limit, renew the bearing. Or, grind the crankshaft journal and use undersize bearing (see Microfiche for part numbers).

b Using cylinder gauge and micrometer, measure the oil clearance between the bearing (bush) and the crankshaft journal. c Measure the inside diameters at positions 1 and 2. At each position, measure in both directions A and B as shown. The oil clearance can be obtained by subtracting the maximum crankshaft journal diameter from this value. Crankshaft journal/bush clearance Standard oil clearance 0.044 - 0.116 mm (0.0017 -0.0046 in)

Standard oil clearance 0.035 - 0.085 mm (0.001 - 0.003 in)

Allowable limit 0.200 mm (0.0078 in)

Bearing size

Crankshaft journal diameter 67.957 - 67.970 mm (2.6755 - 2.6760 in)

Standard 0.25 mm u/size (0.0098 in)

67.707 - 67.720mm (2.6656 - 2.6661 in)

0.50 mm u/size (0.0196 in)

67.457 - 67.470 mm (2.6558 - 2.6563 in)

Thrust washers a Check the thrust washers for wear, poor contact, burning or other defects. Defective washers must be renewed.

Standard Thickness 2.95 - 3.0mm (0. 116 - 0.118in)

9803/3145

Allowable limit 2.8 mm (0.11 in)

Allowable limit 0.2 mm (0.0078 in)

d If the oil clearance exceeds the allowable limit, renew the bearing (bush). Or, grind the crankshaft journal. In this case, use undersize bearing (bush). Âˇ

After grinding the crankshaft journal, check the oil clearance.

Crankshaft Journal Sizes Size Outside diameter Standard 67.957 - 67.970mm (2.6755 - 2.6760 in) 0.25 mm u/size (0.0098 in)

67.707 - 67.720mm (2.6656 - 2.6661 in)

0.50 mm u/size (0.0196 in)

67.457 - 67.470 mm (2.6558 - 2.6563 in) Issue 1

Section L

Engine

Section L

15 - 3

Crankshaft (cont'd) Dismantling and Inspecting 4

Crankshaft deflection a Support the crankshaft with V-blocks. Position a dial gauge on the crankshaft journal and turn the crankshaft gradually by one full turn. If the gauge reading is more than allowable limit, correction or replacement of the crankshaft is needed.

When the measured diameter is less than the allowable limit, correct by grinding and use undersize bearings and bush. Shaft diameter of crankshaft journal

Standard 0.25 mm u/size 0.50 mm u/size

Standard deflection Allowable limit 0.030 mm or less 0.060 mm (0.001 1 in) (0.0023 in)

Standard diameter 67.957 - 67.970 mm (2.6755 - 2.6760 in) 67.707 - 67.720 mm (2.6656 - 2.6661 in) 67.457 - 67.470 mm (2.6558 - 2.6563 in†)

Allowable limit 67.90 mm (2.6732in) 67.65 mm (2.6634 in) 67.4 mm† (2.6535 in†)

Shaft diameter of crankshaft pin

Standard 0.25 mm u/size 0.50 mm u/size † b Oil seal contact face and oiI hole. Check the oil seal contact face for damage or wear. Check oil holes for clogging. c Crankshaft journal and pin for stepped wear. Take four measurements (AA and BB diameters at positions 1 and 2). If the maximum difference between the measurements is more than allowable limit, correction is required. Allowable difference (stepped wear) 0.05 mm (0.0019 in)

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Standard diameter 51.964 - 51.975 mm (2.0458 - 2.0463 in) 51.714 - 51.725 mm (2.0360 - 2.0364 in) 51.464 - 51.475 mm (2.0261 - 2.0266 in)

Allowable limit 51.90 mm (2.0433 in) 51.65 mm (2.0335 in) 51.40 mm† (2.0236 in†)

If the diameter is less than this value, the crankshaft must be replaced

Note: When grinding the crankshaft, work with the following specifications: A Radius at pin/journal B Finish precision C Radius around oil hole:

3mm ± 0.2 mm (0.12 ± 0.008 in) 1.6Z (VVV) 2 mm (0.08 in) max 5 mm (0.20 in) min

Use No. 400 emery cloth for final polishing.

Issue 1

Section L

Engine

15 - 4

Section L 15 - 4

Crankshaft (cont'd) Assembling 1 Replace the crankshaft bush if the crankshaft journal has been ground underside, see page L/153.

a Removal of bush

b Apply new oil to sliding and rotating surfaces of cylinder bores, pistons and bearings, etc.

1 Remove the bush from the cylinder block using Bush Driving Tool to prevent damage.

c Replace gasket, packing etc. Use liquid gasket to prevent oil leakage where necessary.

2 Press fitting the bush Note: Prior to installing the bush inspect the bush housing for marks, scratches etc. The bush should be smoothly pressed in to correct depth by using Bush Driving Tool, adjusting the oil hole and direction of bush as shown and following sequence.

Precautions Before Assembling a Wash parts before assembling. (Especially, oil gallery, bearings, pistons and cylinder bores should be washed thoroughly.)

d Never over tighten bolts and nuts used on aluminium alloy: tighten to specified tightening torques. 3

Assemble the bearing holders, main bearings and thrust washer. a Face the chamfered part of the bearing holder toward front. Install the bearing holder which has reference bit at the centre. Then install the bearing holder on which the thrust washer is to be mounted at the flywheel side.

Press the bush into the cylinder block from the engine front side.

Note: Do not press the bush into the cylinder block from the opposite side. The correct pressing side is chamfered etc. to allow smooth operation. -

Align oil hole of the block and bush.

Lubricate the outer surface of the bush.

Press in the bushing to the block, until correct depth, by using Bush Driving Tool.

Confirm the alignment of oil hole of the block and the bushing, also check inner diameter is within tolerance.

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b Install the thrust washer. Face its oil groove toward thrust face of the crankshaft. c Torque the bearing holder bolts to 49-54 Nm (5.0-5.5 kgf m, 36-40 lbf ft). d Set the bearing with oil groove to upper part, while setting the bearing without the groove to lower part.

Issue 1

Section L

Engine

Section L

15 - 5

Crankshaft (cont'd) Assembling 4 With the bearing holders and thrust washers assembled, insert the crankshaft in the bush at the front end of the cylinder block. 5

Align the bolt holes in the cylinder block with the bearing holders on the crankshaft.

Install the bolts H, including the two recessed bolts at the flywheel end.

Torque the bolts H to 49-54 Nm (5.0-5.5 kgf m, 3640 lbf ft), torque the two recessed bolts to 25-30 Nm (2.5-3.0 kgf m, 18-22 lbf ft).

Measure the crankshaft end float. Standard play Allowable limit 0.1 - 0.4mm 0.5 mm (0.004 - 0.016in) (0.02 in)

Install the press-fit rear oil seal G in the rear of the cylinder block.

19 Install the oil pump, see page L/13 - 1. 20 Install the suction pipe and strainer and the oil sump, see page L/4 - 1. 21 Install the starter and then install the engine.

10 Install the back plate on the rear of the cylinder block. a Coat the area around the M8 threaded holes with liquid packing (solvent based sealant) and fix the back plate with bolts. b Torque the bolts to 14-17 Nm (1.3-1.7 kgf m, 10 -13 lbf ft). 11 Install the flywheel F noting the location of the locating spring pin and retain with the bolts E. Torque the bolts to 58-68 Nm (6.0-7.0 kgf m, 43-50 lbf ft). 12 Install the flywheel housing on the backplate with the bolts. Torque the bolts to 24-28 Nm (2.4-2.9 kgf m, 18-21 lbf ft) 13 Locate the front plate B with gasket D on the dowels C and install the bolts A. Torque the bolts to 9-14 Nm (0.9-1.3 kgf m, 6.5-10 lbf ft). 14 Install the camshaft assembly and tachometer assembly, see page L/14 - 1. 15 Install the timing gear case, see page L/12 - 1. 16 Install the fuel injection pump, see page L/5 - 4. 17 Install the fuel lift pump, see page L/5 - 3. 18 Install the pushrods with followers and the cylinder head, see page L/10 - 4.

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Issue 1