JCB JS200LC, JS220LC, JS230LC, JS210LC, JS370LC Excavator Service Manual – PDF Download

Page 1

Service Manual JS 200 Series Tracked Excavators Section 1 - General Information Section 2 - Operator’s Manual Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track & Running Gear Section K - Engine

Publication No.

9813/5550-01

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


Section 1 General Information Service Manual - JS 200 Series Tracked Excavators Section 1 - General Information Section 2 - Operator’s Manual Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track & Running Gear Section K - Engine

Publication No.

9813/5550-1

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


Section 1 - General Information

Notes:

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Section 1 - General Information Contents

Contents Page No. Introduction Identifying Your Machine ........................................................................... 1-1 Safety Introduction ................................................................................................ 1-3 Use Introduction ................................................................................................ 1-5 Scope ........................................................................................................ 1-6 Personnel ..............................................................................................1-6 Applications ...........................................................................................1-6 Newest Data ..........................................................................................1-6 Format ....................................................................................................... 1-7 Left Side, Right Side .................................................................................. 1-8 Hydraulic Schematic Codes ...................................................................... 1-9 Colour Codes ........................................................................................1-9 General Procedures Introduction .............................................................................................. 1-11 Parking the Machine and Making it Safe ................................................. 1-12 Venting the Hydraulic Pressure ............................................................... 1-13 Connecting/Disconnecting Hydraulic Hoses ............................................ 1-14 Battery Disconnection/Connection .......................................................... 1-15 Removing and Replacing Components ................................................... 1-16 Preparation ..........................................................................................1-16 Original Components ...........................................................................1-16 New Components ................................................................................1-16 Torques and Fixings ............................................................................1-16 Battery Charging System Precautions ..................................................... 1-17 Gas Hydraulic Bladder Accumulators ...................................................... 1-18 Replacement .......................................................................................1-18 Charging ..............................................................................................1-18 Service Consumables Introduction ........................................................................................... 1-6-21 Sealing and Retaining Compounds ...................................................... 1-6-22 Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ..................................... 1-23 Introduction ..........................................................................................1-23 Bolts and Screws .................................................................................1-23 Condition 1 ....................................................................................... 1-23 Condition 2 ....................................................................................... 1-23 Verbus Ripp Bolts ............................................................................ 1-23 Hydraulic Connections ............................................................................. 1-27 'O' Ring Face Seal System ..................................................................1-27 Adaptors Screwed into Valve Blocks ............................................... 1-27 Hoses Screwed into Adaptors ......................................................... 1-28 Adaptors into Component Connections with Bonded Washers ....... 1-29 'Torque Stop' Hose System .................................................................1-30 JCB Standard Torque Settings ................................................................ 1-31 B.S.P. Port Connection (Colour Coded) ..............................................1-31 Hose Ends and Flanged Fittings (Colour Coded) ................................1-32

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Section 1 - General Information Contents

Contents Page No. Service Tools Numerical List .......................................................................................... 1-33 Tool Detail Reference .............................................................................. 1-36 Section B - Body and Framework ........................................................1-36 Section C - Electrics ............................................................................1-40 Section E - Hydraulics .........................................................................1-41 Ram Jigs .......................................................................................... 1-54

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Section 1 - General Information

Introduction Identifying Your Machine For information about identifying your machine and its main components, refer to Section 2, About the Machine, Machine and Component Identification.

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Section 1 - General Information Introduction Identifying Your Machine

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Section 1 - General Information

Safety Introduction In this manual and on the machine there are safety notices. The safety notices have different signal words as follows: – DANGER – WARNING – CAUTION – Notice For an explanation of the safety notice signal words, refer to Section 2, Introduction, Safety. For general safety notices, Introduction, Safety.

refer

to

Section

2,

For maintenance safety notices, refer to Section 2, Maintenance, Maintenance Safety. For safety notices specific to maintenance procedures, refer to the relevant procedure. If you do not fully understand a safety notice ask your employer to explain it.

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Section 1 - General Information Safety Introduction

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Section 1 - General Information

Use Introduction This topic contains information about the structure of the manual and how to use the manual.

K Scope ( T 1-6) K Personnel ( T 1-6) K Applications ( T 1-6) K Newest Data ( T 1-6) K Format ( T 1-7) K Left Side, Right Side ( T 1-8) K Hydraulic Schematic Codes ( T 1-9) K Colour Codes ( T 1-9)

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Section 1 - General Information Use Scope

Scope Personnel This manual is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Finally, please remember above all else SAFETY MUST COME FIRST!

Applications This manual contains data relevant to a range of machines. Make sure you reference the data for the correct machine.

Newest Data From time to time new machines, systems or devices require the manual to be re-issued. Make sure you have the newest issue. Always check the on-line JCB data system for relevant technical information.

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Section 1 - General Information Use Format

Format The manual is compiled in sections, the first two are numbered and contain information as follows: 1

General Information - The section includes general information such as torque settings and service tools.

2

Operator Manual - The section contains a copy of the applicable machine Operator Manual. Refer to this section when necessary for information about the main machine components and controls. Refer also to the safety and daily / weekly maintenance information.

The remaining sections are alphabetically coded and deal with dismantling, overhaul etc. of specific components, for example: A

Attachments

B

Body and Framework...etc.

Each section contains data such as technical data, descriptions, fault finding and test procedures. Some sections contain procedures and specifications for different variants. This happens because of market requirements, or when the machine specification changes after a period of time. Where applicable, a table contains information to help you identify the correct data and procedures.

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Section 1 - General Information Use Left Side, Right Side

Left Side, Right Side In this manual, 'left' A and 'right' B mean your left and right when you are seated correctly in the machine.

B

A C017280

Fig 1.

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Section 1 - General Information Use Hydraulic Schematic Codes

Hydraulic Schematic Codes Colour Codes The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications.

Red

Full Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and LSRV operating pressure.

Pink

Pressure: Pressure that is above neutral circuit pressure but lower than that denoted by Red.

Orange

Blue

Green

Light Green

Yellow

1-9

Pilot: Oil pressure used in controlling a device (Pilot).

Neural: Neutral circuit pressure.

Exhaust:

Cavitation: Oil subjected to a partial vacuum due to a drop in pressure (cavitation).

Lock Up: Oil trapped within a chamber or line, preventing movement of components (lock up).

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Section 1 - General Information Use Hydraulic Schematic Codes

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Section 1 - General Information

General Procedures Introduction When work is done on the machine it is important that the correct care is taken. This will help to prevent personal injury and reduce the risk of component failure. As part of the procedures in this manual you will need to do some general procedures. Two examples of these general procedures are; parking the machine and making it safe, and venting hydraulic pressure. These procedures are given here as an alternative to again and again in the manual. Where applicable you will see a cross reference to this section so that you can refer to the detailed procedures.

K Parking the Machine and Making it Safe ( T 1-12) K Venting the Hydraulic Pressure ( T 1-13) K Connecting/Disconnecting Hydraulic Hoses ( T 1-14) K Battery Disconnection/Connection ( T 1-15) K Removing and Replacing Components ( T 1-16) K Battery Charging System Precautions ( T 1-17) K Gas Hydraulic Bladder Accumulators ( T 1-18)

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Section 1 - General Information General Procedures Parking the Machine and Making it Safe

Parking the Machine and Making it Safe For the correct procedures to park and make the machine safe, refer to Section 2, Maintenance, Maintenance Positions.

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Section 1 - General Information General Procedures Venting the Hydraulic Pressure

Venting the Hydraulic Pressure

!MWARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication. HYD-1-5

For the correct procedures to vent the hydraulic pressure, refer to Section 2, Maintenance, Hydraulic System, General, Discharge.

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Section 1 - General Information General Procedures Connecting/Disconnecting Hydraulic Hoses

Connecting/Disconnecting Hydraulic Hoses

!MWARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication. HYD-1-5

For the correct procedures to connect/disconnect hydraulic hoses, refer to Section 2, Attachments, Connecting/Disconnecting Hydraulic Hoses.

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Section 1 - General Information General Procedures Battery Disconnection/Connection

Battery Disconnection/Connection For the correct procedures to disconnect/connect the battery, refer to Section 2, Maintenance, Electrical System, Battery.

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Section 1 - General Information General Procedures Removing and Replacing Components

Removing and Replacing Components Preparation

– Make sure that all the applicable component assemblies are correct.

Before removing and replacing components do the following:

– Make sure that the applicable fixings are to the correct specification. If necessary discard the original fixings and replace them with new ones. The relevant procedures indicate when this is necessary.

– To prevent contamination of the machine systems, clean the machines in the area of the applicable components. Refer to Section 2, Preservation and Storage, Cleaning the Machine. – Make sure that the correct maintenance procedures are available. – Make sure that the correct tools and equipment are available. – Make sure that the correct replacement parts, consumables, fluids and lubricants are available.

Original Components Always Install new oil seals, gaskets, etc. Components showing obvious signs of wear or damage should be replaced with new ones.

– Make sure that the applicable fixings and threaded holes are free from contamination. This includes; dirt, debris, old sealants and compounds, fluids and lubricants. This manual provides reference to the correct torque settings as follows: – Where no torque setting is given in the applicable procedure, use the standard torque setting. To obtain the correct standard torque setting refer to Torque Settings in this section. – Where torque settings are given in the applicable procedure use the settings given. These settings may be different to the standard torque settings in the case of special fixings for example.

Before re-installing original components do the following: – Clean components using the applicable cleaning materials. – Inspect components for signs of excessive wear or defects. – Check the component specifications such as wear limits where applicable.

New Components Make sure that the correct new components are installed. Do not substitute components from another machine. Components may look the same but may not be interchangeable. Refer to the JCB parts systems.

Torques and Fixings When replacing components always tighten the applicable fixings to the correct torque. For the torque setting to be effective do the following before installing the fixings:

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Section 1 - General Information General Procedures Battery Charging System Precautions

Battery Charging System Precautions Obey the procedures below to prevent damage to the alternator and battery. – Ensure that the battery negative terminal is connected to the earthing cable. – Never make or break connections to the battery or alternator, or any part of the charging circuit whilst the engine is running. Disregarding this instruction will result in damage to the regulator or rectifying diodes. – Main output cables are 'live' even when the engine is not running. Take care not to earth connectors in the moulded plug if it is removed from the alternator. – When arc welding on the machine, protect the alternator by removing the moulded plug (or if separate output cables fitted, remove the cables). – Follow the correct procedures when jump starting the engine. Refer to Section 2, Operation, Moving a Disabled Machine.

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Section 1 - General Information General Procedures Gas Hydraulic Bladder Accumulators

Gas Hydraulic Bladder Accumulators

!MWARNING

Some hydraulic circuits and valve blocks are fitted with gas hydraulic bladder type accumulators. Before removing accumulators make sure hydraulic pressure is vented. K Venting the Hydraulic Pressure ( T 1-13) Even when the hydraulic pressure is vented the accumulator still contains pressurised nitrogen gas. DO NOT attempt to discharge the gas pressure.

Use only nitrogen gas to charge accumulators. The use of any other gas can cause the accumulators to explode. Remember that although nitrogen is not poisonous you can be killed by suffocation if it displaces the air in your workplace. Do not allow excessive quantities of nitrogen to be discharged into the atmosphere. B-3-1-6

DO NOT transport accumulators charged with pressurised gas by air freight.

Replacement

2

Replacement accumulators are generally supplied in a discharged state with no nitrogen gas. A label attached to the accumulator indicates the gas charge state.

8

1

Charging

3

K Fig 1. ( T 1-18)

4 7

Important: The following charging procedure is only applicable to accumulators supplied in a discharged state.

6

5

To carry out the charging procedure the following is required: – Pressurised bottle of nitrogen gas with a suitable pressure reducing valve (3). – Correct gas bottle adaptor depending on territory. – Charging kit 892/00239. Refer to Section 1. C110540-C2

Fig 1.

Operating charge pressures; accumulators are charged to different operating pressures depending on the application. For the correct charge pressure refer to the applicable system specifications.

1

Before fitting a replacement accumulator charge it with nitrogen gas as follows:

Note: Some accumulators are supplied with a measured quantity of oil inside the gas chamber. Take care to prevent oil loss. 2

Hold the accumulator upright and remove the plastic cap from the top of the accumulator.

Using a suitable allen key, slowly remove the filler plug 2. Lightly oil the sealing washer beneath. Replace the washer and plug. Loosen the plug by 1/8 of a turn.

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Section 1 - General Information General Procedures Gas Hydraulic Bladder Accumulators 3

Connect the accumulator adaptor 1 (from kit 892/ 00239) to the accumulator. Connect the charging unit 6 to the accumulator adaptor. Connect the charging hose to the pressure regulator 3 using the correct adaptor. Set the pressure regulator 3 to the minimum pressure.

4

Via the charging tool knob 7, open the filler plug 2 by three turns.

5

Open the discharge valve 5 on the charging unit.

1 3

Carefully open the nitrogen gas bottle valve 4 and confirm that the nitrogen gas flows freely.

2

Shut the gas bottle valve and the discharge valve 5. 6

Carefully open the gas bottle valve. Slowly increase the pressure using the gas bottle pressure regulator and watching the gauge 8 on the charging unit, allow nitrogen to flow until the pressure reading reaches 4 bar (72.5 psi) ABOVE the operating charge pressure.

C110550

Fig 2. 12

Important: DO NOT exceed the maximum working pressure of the accumulator. The maximum working pressure is marked on the accumulator body. Close the gas bottle valve. 7

Wait 10 minutes to dissipate the heat generated during charging.

8

Reduce the pressure in the accumulator to the specified operating charge pressure by carefully opening and closing the discharge valve 5. Turn the knob 7 to shut the filler plug 2 and tighten to a torque of 20 Nm (15 lb ft).

9

Release the pressure from the charging hose by opening the discharge valve 5.

K Fig 2. ( T 1-19) Remove the discharged state label 3 and attach the pressurised warning label 2 at position 1 on the accumulator. Install the accumulator and make sure pressurised warning label is clearly visible.

the

Disconnect the charging unit and adaptor from the accumulator. 10

Check the gas-tightness of filler plug 2 by pouring some oil around it.

11

Replace the plastic cap.

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Section 1 - General Information General Procedures Gas Hydraulic Bladder Accumulators

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Section 1-6 - General Information

Service Consumables Introduction Consumables such as sealing and retaining compounds are necessary to complete some procedures. Before you start work make sure that the consumables show in the tables are available.

K Sealing and Retaining Compounds ( T 1-6-22)

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Section 1-6 - General Information Service Consumables Sealing and Retaining Compounds

Sealing and Retaining Compounds T11-001_4

Table 1. Type

Description

JCB Multi-Gasket

A medium strength sealant suitable for all sizes of 4102/1212 gasket flanges, and for hydraulic fittings of 25-65 mm diameter.

50 ml

JCB High Strength Threadlocker

A high strength locking fluid for use with threaded 4102/0551 components. Gasketing for all sizes of flange where the strength of the joint is important.

50 ml

JCB Retainer (High Strength)

For all retaining parts which are unlikely to be dismantled.

4101/0601

10 ml

4101/0651

50 ml

A medium strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter.

4101/0250

10 ml

4101/0251

50 ml

JCB Threadlocker and Sealer (High Strength)

A high strength locking fluid for sealing and retaining 4101/0550 nuts, bolts, and screws up to 50 mm diameter, and 4101/0552 for hydraulic fittings up to 25 mm diameter.

10 ml 200 ml

JCB Threadseal

A medium strength thread sealing compound.

4102/1951

50 ml

JCB Activator

A cleaning primer which speeds the curing rate of anaerobic products.

4104/0251

200 ml (Aerosol)

4104/0253

1 ltr (Bottle)

JCB Cleaner/Degreaser

For degreasing components prior to use of anaerobic adhesives and sealants.

4104/1557

400 ml (Aerosol)

Direct Glazing Kit

For one pane of glass; comprises of:

993/55700

JCB Threadlocker and Sealer

Part No.

Quantity

– 1 x Ultra Fast Adhesive (310 ml) – 1 x Active Wipe 205 (30 ml) – 1 x Black Primer 206J (30 ml) – plus applicator nozzle etc. Ultra Fast Adhesive

For direct glazing.

4103/2109

310 ml

Active Wipe 205

For direct glazing.

4104/1203

250 ml

Black Primer 206J

For direct glazing.

4201/4906

30 ml

Clear Silicone Sealant

To seal butt jointed glass.

4102/0901

Plastic to Metal Bonder

To seal plastic to metal joints.

4103/0956

50 g

Black Polyurethane Sealant

To finish exposed edges of laminated glass.

4102/2309

310 ml

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Section 1 - General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners

Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners T11-002

Introduction

Bolts and Screws

Some external fasteners on JCB machines are manufactured using an improved type of corrosion resistant finish. This type of finish is called Dacromet and replaces the original Zinc and Yellow Plating used on earlier machines.

Use the following torque setting tables only where no torque setting is specified in the text.

The two types of fasteners can be readily identified by colour and part number suffix. K Table 1. Fastener Types ( T 1-23).

Torque settings are given for the following conditions:

Fastener Type

Table 1. Fastener Types Colour Part No. Suffix

Note: Dacromet fasteners are lubricated as part of the plating process, do not lubricate.

Condition 1 – Un-lubricated fasteners – Zinc fasteners – Yellow plated fasteners

Zinc and Yellow

Golden finish

'Z' (e.g. 1315/3712Z)

Dacromet

Mottled silver finish 'D' (e.g. 1315/3712D)

Condition 2 – Zinc flake (Dacromet) fasteners

Note: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, the torque figures used must be relevant to the type of fastener. Note: A Dacromet bolt should not be used in conjunction with a Zinc or Yellow plated nut, as this could change the torque characteristics of the torque setting further. For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt.

– Lubricated zinc and yellow plated fasteners – Where there is a natural lubrication. For example, cast iron components

Verbus Ripp Bolts

Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification. Note: Dacromet bolts, due to their high corrosion resistance are used in areas where rust could occur. Dacromet bolts are only used for external applications. They are not used in applications such as gearbox or engine joint seams or internal applications.

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Fig 1. Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.

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Section 1 - General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' Fasteners Hexagon (A/F) Condition 1

Bolt Size in.

mm

in.

Nm

kgf m

lbf ft

Nm

kgf m

lbf ft

1/4

6.3

7/16

11.2

1.1

8.3

10.0

1.0

7.4

5/16

7.9

1/2

22.3

2.3

16.4

20.0

2.0

14.7

3/8

9.5

9/16

40.0

4.1

29.5

36.0

3.7

26.5

7/16

11.1

5/8

64.0

6.5

47.2

57.0

5.8

42.0

1/2

12.7

3/4

98.00

10.0

72.3

88.0

9.0

64.9

9/16

14.3

13/16

140.0

14.3

103.2

126.0

12.8

92.9

5/8

15.9

15/16

196.0

20.0

144.6

177.0

18.0

130.5

3/4

19.0

1 1/8

343.0

35.0

253.0

309.0

31.5

227.9

7/8

22.2

1 15/16

547.0

55.8

403.4

492.0

50.2

362.9

1

25.4

1 1/2

814.0

83.0

600.4

732.0

74.6

539.9

1 1/8

31.7

1 7/8

1181.0

120.4

871.1

1063.0

108.4

784.0

1 1/4

38.1

2 1/4

1646.0

167.8

1214.0

1481.0

151.0

1092.3

Table 3. Torque Settings - Metric Grade 8.8 Fasteners Hexagon (A/F) Condition 1

Bolt Size ISO Metric Thread

mm

M5

5

8

5.8

M6

6

10

9.9

M8

8

13

24.0

M10

10

17

47.0

1-24

Condition 2

mm

Nm

kgf m

Condition 2

lbf ft

Nm

kgf m

lbf ft

0.6

4.3

5.2

0.5

3.8

1.0

7.3

9.0

0.9

6.6

2.4

17.7

22.0

2.2

16.2

4.8

34.7

43.0

4.4

31.7

M12

12

19

83.0

8.5

61.2

74.0

7.5

54.6

M16

16

24

205.0

20.9

151.2

184.0

18.8

135.7

M20

20

30

400.0

40.8

295.0

360.0

36.7

265.5

M24

24

36

690.0

70.4

508.9

621.0

63.3

458.0

M30

30

46

1372.0

139.9

1011.9

1235.0

125.9

910.9

M36

36

55

2399.0

244.6

1769.4

2159.0

220.0

1592.4

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Section 1 - General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. Metric Grade 10.9 Fasteners Hexagon (A/F) Condition 1

Bolt Size ISO Metric Thread

mm

mm

Nm

kgf m

Condition 2 lbf ft

Nm

kgf m

lbf ft

M5

5

8

8.1

0.8

6.0

7.3

0.7

5.4

M6

6

10

13.9

1.4

10.2

12.5

1.3

9.2

M8

8

13

34.0

3.5

25.0

30.0

3.0

22.1

M10

10

17

67.0

6.8

49.4

60.0

6.1

44.2

M12

12

19

116.0

11.8

85.5

104.0

10.6

76.7

M16

16

24

288.0

29.4

212.4

259.0

26.4

191.0

M20

20

30

562.0

57.3

414.5

506.0

51.6

373.2

M24

24

36

971.0

99.0

716.9

874.0

89.1

644.6

M30

30

46

1930.0

196.8

1423.5

1737.0

177.1

1281.1

M36

36

55

3374.0

344.0

2488.5

3036.0

309.6

2239.2

Table 5. Metric Grade 12.9 Fasteners Hexagon (A/F) Condition 1

Bolt Size

Condition 2

ISO Metric Thread

mm

mm

Nm

kgf m

lbf ft

Nm

kgf m

lbf ft

M5

5

8

9.8

1.0

7.2

8.8

0.9

6.5

M6

6

10

16.6

1.7

12.2

15.0

1.5

11.1

M8

8

13

40.0

4.1

29.5

36.0

3.7

26.5

M10

10

17

80.0

8.1

59.0

72.0

7.3

53.1

M12

12

19

139.0

14.2

102.5

125.0

12.7

92.2

M16

16

24

345.0

35.2

254.4

311.0

31.7

229.4

M20

20

30

674.0

68.7

497.1

607.0

61.9

447.7

M24

24

36

1165.0

118.8

859.2

1048.0

106.9

773.0

M30

30

46

2316.0

236.2

1708.2

2084.0

212.5

1537.1

M36

36

55

4049.0

412.9

2986.4

3644.0

371.6

2687.7

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Section 1 - General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. Torque Settings - Rivet Nut Bolts/Screws Bolt Size ISO Metric Thread

mm

Nm

kgf m

lbf ft

M3

3

1.2

0.1

0.9

M4

4

3.0

0.3

2.0

M5

5

6.0

0.6

4.5

M6

6

10.0

1.0

7.5

M8

8

24.0

2.5

18.0

M10

10

48.0

4.9

35.5

M12

12

82.0

8.4

60.5

Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc) Bolt Size

1-26

ISO Metric Thread

Nm

kgf m

lbf ft

M3

2.0

0.2

1.5

M4

6.0

0.6

4.5

M5

11.0

1.1

8.0

M6

19.0

1.9

14.0

M8

46.0

4.7

34.0

M10

91.0

9.3

67.0

M12

159.0

16.2

117.0

M16

395.0

40.0

292.0

M18

550.0

56.0

406.0

M20

770.0

79.0

568.0

M24

1332.0

136.0

983.0

9813/5550-1

1-26


Section 1 - General Information Standard Torque Settings Hydraulic Connections

Hydraulic Connections T11-003

'O' Ring Face Seal System Adaptors Screwed into Valve Blocks Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45° seat machined into the face of the tapped port. Table 8. Torque Settings - BSP Adaptors BSP Adaptor Hexagon (A/F) Size

1-27

in.

mm

Nm

kgf m

lbf ft

1/4

19.0

18.0

1.8

13.0

3/8

22.0

31.0

3.2

23.0

1/2

27.0

49.0

5.0

36.0

5/8

30.0

60.0

6.1

44.0

3/4

32.0

81.0

8.2

60.0

1

38.0

129.0

13.1

95.0

1 1/4

50.0

206.0

21.0

152.0

Table 9. Torque Settings - SAE Connections SAE Port Hexagon (A/F)

SAE Tube Size

Thread Size

mm

Nm

kgf m

lbf ft

4

7/16 - 20

15.9

20.0 - 28.0

2.0 - 2.8

16.5 - 18.5

6

9/16 - 18

19.1

46.0 - 54.0

4.7 - 5.5

34.0 - 40.0

8

3/4 - 16

22.2

95.0 - 105.0

9.7 - 10.7

69.0 - 77.0

10

7/8 - 14

27.0

130.0 - 140.0

13.2 - 14.3

96.0 - 104.0

12

1 1/16 - 12

31.8

190.0 - 210.0

19.4 - 21.4

141.0 - 155.0

16

1 5/16 - 12

38.1

290.0 - 310.0

29.6 - 31.6

216.0 - 230.0

20

1 5/8

47.6

280.0 - 380.0

28.5 - 38.7

210.0 - 280.0

9813/5550-1

1-27


Section 1 - General Information Standard Torque Settings Hydraulic Connections Hoses Screwed into Adaptors

Fig 2. Hoses 2-B screwed into adaptors 2-A seal onto an `O' ring 2-C which is compressed into a 45° seat machined into the face of the adaptor port.

BSP Hose Size in.

1-28

Note: Dimension 2-D will vary depending upon the torque applied.

Table 10. BSP Hose - Torque Settings Hexagon (A/F) mm

Nm

1/8

14.0

14.0 - 16.00

1.4 - 1.6

10.3 - 11.8

1/4

19.0

24.0 - 27.0

2.4 - 2.7

17.7 - 19.9

3/8

22.0

33.0 - 40.0

3.4 - 4.1

24.3 - 29.5

1/2

27.0

44.0 - 50.0

4.5 - 5.1

32.4 - 36.9

5/8

30.0

58.0 - 65.0

5.9 - 6.6

42.8 - 47.9

3/4

32.0

84.0 - 92.0

8.6 - 9.4

61.9 - 67.8

1

38.0

115.0 - 126.0

11.7 - 12.8

84.8 - 92.9

1 1/4

50.0

189.0 - 200.0

19.3 - 20.4

139.4 - 147.5

1 1/2

55.0

244.0 - 260.0

24.9 - 26.5

180.0 - 191.8

9813/5550-1

kgf m

lbf ft

1-28


Section 1 - General Information Standard Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 11. BSP Adaptors with Bonded Washers - Torque Settings BSP Size

1-29

in.

Nm

kgf m

lbf ft

1/8

20.0

2.1

15.0

1/4

34.0

3.4

25.0

3/8

75.0

7.6

55.0

1/2

102.0

10.3

75.0

5/8

122.0

12.4

90.0

3/4

183.0

18.7

135.0

1

203.0

20.7

150.0

1 1/4

305.0

31.0

225.0

1 1/2

305.0

31.0

225.0

9813/5550-1

1-29


Section 1 - General Information Standard Torque Settings Hydraulic Connections

'Torque Stop' Hose System

Fig 3. `Torque Stop' Hoses 3-B screwed into adaptors 3-A seal onto an 'O' ring 3-C which is compressed into a 45° seat machined in the face of the adaptor port. To prevent the 'O' ring being damages as a result of over tightening, 'Torque

Stop' Hoses have an additional shoulder 3-D, which acts as a physical stop. Note: Minimum dimension 3-E fixed by shoulder 3-D.

Table 12. BSP `Torque Stop' Hose - Torque Settings BSP Hose Size Hexagon (A/F)

1-30

in.

mm

Nm

kgf m

lbf ft

1/8

14.0

14.0

1.4

10.0

1/4

19.0

27.0

2.7

20.0

3/8

22.0

40.0

4.1

30.0

1/2

27.0

55.0

5.6

40.0

5/8

30.0

65.0

6.6

48.0

3/4

32.0

95.0

9.7

70.0

1

38.0

120.0

12.2

89.0

1 1/4

50.0

189.0

19.3

140.0

1 1/2

55.0

244.0

24.9

180.0

9813/5550-1

1-30


Section 1 - General Information Standard Torque Settings JCB Standard Torque Settings

JCB Standard Torque Settings B.S.P. Port Connection (Colour Coded) Note: All adapters, elbows and hoses should be tightened to JCB standard torque settings unless stated otherwise.

Fig 4.

1-31

9813/5550-1

1-31


Section 1 - General Information Standard Torque Settings JCB Standard Torque Settings

Hose Ends and Flanged Fittings (Colour Coded) Note: All adapters, elbows and hoses should be tightened to JCB standard torque settings unless stated otherwise.

Fig 5.

1-32

9813/5550-1

1-32


Section 1 - General Information

Service Tools Numerical List The tools listed in the table are special tools required for carrying out the procedures described in this manual. These tools are available from JCB Service. Some tools are available as kits or sets, the part numbers for parts within such kits or sets are not listed here. For full

Part Number

details of all tools, including the content of kits and sets, refer to Tool Detail Reference, Section 1. Note: Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier.

Description

See Section

993/68100

Slide Hammer Kit. K 993/68100 Slide Hammer Kit ( T 1-36)

B

-

Rivet Nut Tool. K Rivet Nut Tool ( T 1-36)

B

892/00842

Glass Lifter

B

892/00843

Folding Stand for Holding Glass

B

892/00845

Cartridge Gun

B

892/00846

Glass Extractor (Handles)

B

892/00847

Nylon Spatula

B

892/00848

Wire Starter

B

892/00849

Braided Cutting Wire

B

926/15500

Rubber Spacer Blocks

B

992/12300

12V Mobile Oven

B

992/12400

240V Static Oven (2 Cartridge)

B

992/12800

Cut-Out Knife

B

992/12801

'L' Blades

B

4104/1310

Hand Cleaner

B

892/00281

AVO Meter (not illustrated)

C

892/00298

Fluke Meter

C

892/00285

Hyd. Oil Temperature Probe

C

892/00284

Digital Tachometer

C

892/01174

DLA Kit

C

331/22966

Pump Drive Alignment Tool (not illustrated)

E

-

Male Adaptors - BSP x BSP. K Male Adaptors ( T 1-41)

E

-

Male Adaptors - BSP x NPT (USA only). K Male Adaptors ( T 1-41)

E

-

Pressure Test Points - Adaptors. K Pressure Test Adapters ( T 1-41)

E

-

Pressure Test Points - 'T' Adaptors. K Pressure Test 'T' Adapters ( T 1-41)

E

-

'T' Adaptors. K 'T' Adapters ( T 1-42)

E

1-33

9813/5550-1

1-33


Section 1 - General Information Service Tools Numerical List Part Number

Description

See Section

-

Female Blanking Caps

E

-

Male Cone Blanking Caps. K Male Cone Blanking Caps ( T 1-42)

E

-

Female Connectors. K Female Connectors ( T 1-42)

E

-

Bonded Washers. K Bonded Washers ( T 1-42)

E

-

Ram Protection Sleeves. K Ram Protection Sleeves ( T 1-43)

E

892/00239

Nitrogen Charging Tool Kit (Hydac bladder accumulators). K 892/00239 Accumulator Gas Charge Kit ( T 1-53)

E

892/00334

Ram Seal Fitting Tool

E

Hexagon Spanners. K Hexagon Spanners for Ram Pistons and End Caps ( T 1-43)

E

892/01027

Piston Seal Assembly Tool

E

-

Hydraulic Flow Test Equipment. K Flow Test Equipment ( T 1-44)

E

-

Hydraulic Circuit Pressure Test Kit. K 892/ 00253 Hydraulic Circuit Pressure Test Kit ( T 1-45)

E

-

Hydraulic Hand Pump Equipment. K Hand Pump Equipment ( T 1-46)

E

992/10100

Spool Clamp

E

892/00039

Spool Clamp

E

992/02800

ARV Extractor

E

331/31069

Test Block for A.R.V.

E

892/00891

Valve Spool Seal Fitting Tool

E

892/00346

Gauge

E

892/00279

Gauge

E

892/00280

Gauge

E

892/00347

Connector

E

892/00254

Hose

E

-

Ram Jigs. K Ram Jigs ( T 1-54)

E

-

Ram Piston Nut Spanners. K Ram Piston Nut Removal/Fitting Spanner ( T 1-47)

E

-

Socket Box Wrench

E

-

Nut Adaptor

E

-

Seal Ring Tool

E

-

Stopper

E

-

Bearing Rig

E

-

Inserting Seal Ring and Correction Jig. K Inserting Seal Ring and Correction Jig ( T 1-54)

E

-

Jig for Pulling Out, Press-fitting Bushing. K Jig for Pulling Out, Press-fitting Bushing ( T 1-54)

E

-

Jig for Press-fitting Wiper Ring. K Jig for Press-fitting Wiper Ring ( T 1-54)

E

-

Jig for Inserting Cylinder Head. K Jig for Inserting Cylinder Head ( T 1-54)

E

-

Seal Ring and Connector Jig. K Seal Ring and Connector Jig ( T 1-54)

E

1-34

9813/5550-1

1-34


Section 1 - General Information Service Tools Numerical List Part Number

Description

See Section

-

Bush Removal Jig. K Bush Removal Jig ( T 1-55)

E

-

Bush Fitting Jig. K Bush Fitting Jig ( T 1-55)

E

-

Wiper Ring Fitting Jig. K Wiper Ring Fitting Jig ( T 1-55)

E

-

Wiper Ring Fitting Jig. K Wiper Ring Fitting Jig ( T 1-55)

E

1-35

9813/5550-1

1-35


Section 1 - General Information Service Tools Tool Detail Reference

Tool Detail Reference Section B - Body and Framework Note: Not all service tools are illustrated.

Fig 6. 993/68100 Slide Hammer Kit 1

993/68101

Slide Hammer

7

993/68107

Bar - M20 x M20 X 800 mm

2

993/68102

End Stops

8

993/68108

Adaptor - M20 x 7/8" UNF

3

993/68103

Adaptor - M20 x 5/8" UNF

9

993/68109

Adaptor - M20 x M12

4

993/68104

Adaptor - M20 x 1" UNF

10

993/68110

Adaptor - M20 x 5/8" UNF (Shoulder)

5

993/68105

Adaptor - M20 x M20

11

993/68111

Adaptor - M20 x 1/2" UNF

6

993/68106

Adaptor - M20 x M24 1

826/01099

M6 x 16 mm Rivet Nut

826/01101

M6 x 19 mm Rivet Nut

826/01102

M8 x 18 mm Rivet Nut

826/01103

M8 x 21 mm Rivet Nut

826/01104

M10 x 23 mm Rivet Nut

826/01105A M10 x 26 mm Rivet Nut 2

-

Installation Tool available from: Bollhoff Fastenings Ltd (www.bollhof.com)

Fig 7. Rivet Nut Tool Minimum 2 off - Essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage.

Fig 8. 892/00842 Glass Lifter

1-36

9813/5550-1

1-36


Section 1 - General Information Service Tools Tool Detail Reference

Fig 12. 892/00847 Nylon Spatula General tool used for smoothing sealants - also used to re-install glass in rubber glazing because metal tools will chip the glass edge.

Fig 9. 892/00843 Folding Stand Essential for preparing new glass prior to installation.

Fig 13. 892/00848 Wire Starter Used to access braided cutting wire through original polyurethane seal.

Fig 10. 892/00845 Cartridge Gun Hand operated. Essential for the application of sealants, polyurethane materials etc.

Fig 11. 892/00846 Glass Extractor (Handles) Used with braided cutting wire to cut out broken glass.

1-37

9813/5550-1

1-37


Section 1 - General Information Service Tools Tool Detail Reference

Fig 14. 892/00849 Braided Cutting Wire

Fig 17. 992/12400 Static Oven 240V

Consumable heavy duty cut-out wire used with the glass extraction tool. Approx 25 m length.

Required to pre-heat adhesive prior to use. No plug supplied. Note: 110V models available upon request - contact JCB Technical Service.

Fig 15. 926/15500 Rubber Spacer Blocks Used to provide the correct set clearance between glass edge and cab frame. Unit quantity = 500 off.

Fig 18. 992/12800 Cut-Out Knife Used to remove broken glass.

Fig 16. 992/12300 Mobile Oven 12V 1 cartridge capacity. Required to pre-heat adhesive prior to use. It is fitted with a male plug (703/23201) which fits into a female socket (715/04300).

1-38

Fig 19. 992/12801 'L' Blades 25 mm (1 in.) cut. Replacement blades for cut-out knife. Unit quantity = 5 off.

9813/5550-1

1-38


Section 1 - General Information Service Tools Tool Detail Reference

Fig 20. 4104/1310 Hand Cleaner Special blend for the removal of polyurethane adhesives (454g; 1 lb tub).

1-39

9813/5550-1

1-39


Section 1 - General Information Service Tools Tool Detail Reference

Section C - Electrics Note: Not all service tools are illustrated.

1

2 D

C

B

A

J

E F

H

G

3

5 4 Fig 21. 892/00298 Fluke Meter

6 Fig 24. 892/01174

Fig 22. 892/00285 Hydraulic Temperature Probe

1

Interconnecting cable, DLA to machine ECU diagnostics socket.

2

Interconnecting cable, DLA to machine ECU diagnostics socket.

3

Kit carrying case.

4

Interconnecting cable, DLA to laptop PC.

5

Data Link Adaptor (DLA), enables data exchange between the machine ECU (Electronic Control Unit) and a laptop PC loaded with the applicable diagnostics software.

6

Interconnecting cable, DLA to laptop PC.

Fig 23. 892/00284 Venture Microtach Digital Tachometer

1-40

9813/5550-1

1-40


Section 1 - General Information Service Tools Tool Detail Reference

Section E - Hydraulics Note: Not all service tools are illustrated. Male Adapters - BSP x BSP 1606/2052

3/8 in. x 1/4 in.

1604/0003A 3/8 in. x 3/8 in. 892/00071

3/8 in. x 3/8 in. taper

1606/0004

1/2 in. x 1/4 in.

1606/0007A 1/2 in. x 3/8 in. Fig 25. Male Adaptors

1604/0004A 1/2 in. x 1/2 in. 1606/0017

5/8 in. x 1/2 in.

1606/0008

3/4 in. x 3/8 in.

Male Adapters - BSP x NPT (USA only)

1606/0009

3/4 in. x 1/2 in.

816/00439

3/8 in. x 1/4 in.

1604/2055

3/4 in. x 3/4 in.

816/00440

1/2 in. x 1/4 in.

1606/0012

3/4 in. x 1 in.

816/15007A 3/8 in. x 3/8 in.

1606/0014

3/4 in. x 1.1/4 in.

816/15008

1606/0015

1 in. x 1.1/4 in.

892/00255

1/4 in. BSP x Test Point

892/00256

3/8 in. BSP x Test Point

892/00257

1/2 in. BSP x Test Point

1/2 in. x 3/8 in.

Fig 26. Pressure Test Adapters

892/00258

5/8 in. BSP x Test Point

816/15118

3/4 in. BSP x Test Point

892/00259

1 in BSP x Test Point

892/00260

1.1/4 in. BSP x Test Point

892/00261

5/8 in. UNF x Test Point

816/55045

1/4 in. M BSP x 1/4 in. F BSP x Test Point

816/55038

3/8 in. M BSP x 3/8 in. F BSP x Test Point

816/55040

1/2 in. M BSP x 1/2 in. F BSP x Test Point

892/00263

5/8 in. M BSP x 5/8 in. F BSP x Test Point

892/00264

3/4 in. M BSP x 3/4 in. F BSP x Test Point

892/00265

1 in. M BSP x 1 in. F BSP x Test Point

892/00266

1.1/4 in. M BSP x 1.1/4 in. F BSP x Test Point

892/00267

1.1/4 in. M BSP x 1.1/2 in. F BSP x Test Point

Fig 27. Pressure Test 'T' Adapters

1-41

9813/5550-1

1-41


Section 1 - General Information Service Tools Tool Detail Reference

Fig 28. 'T' Adapters

892/00047

3/8 in. BSP (A) x 1/4 in. BSP (B)

892/00048

1/2 in. BSP (A) x 1/4 in. BSP (B)

892/00049

5/8 in. BSP (A) x 1/4 in. BSP (B)

816/50043

3/4 in. BSP (A) x 1/4 in. BSP (B)

892/00051

1 in. BSP (A) x 1/4 in. BSP (B)

816/50005

1/2 in. BSP (A) x 1/2 in. BSP (B)

816/60096

3/4 in. BSP (A) x 3/4 in. BSP (B)

816/00017

1 in. BSP (A) x 1 in. BSP (B)

892/00055A 1/4 in. BSP 892/00056A 3/8 in. BSP 892/00057

1/2 in. BSP

892/00058A 5/8 in. BSP 892/00059A 3/4 in. BSP Fig 29. Female Blanking Caps

892/00060

1 in. BSP

816/90045

1/4 in. BSP

816/00189A 3/8 in. BSP 816/00190A 1/2 in. BSP

Fig 30. Male Cone Blanking Caps

816/90022

5/8 in. BSP

816/90274

3/4 in. BSP

816/90205

1 in. BSP

892/00074

3/8 in. BSP x 3/8 in. BSP

892/00075

1/2 in. BSP x 1/2 in. BSP

892/00076

5/8 in. BSP x 5/8 in. BSP

892/00077

3/4 in. BSP x 3/4 in. BSP

1406/0011

1/4 in. BSP

1406/0018

1/2 in. BSP

1406/0014

5/8 in. BSP

Fig 31. Female Connectors

Fig 32. Bonded Washers

1-42

1406/0021

3/4 in. BSP

1406/0029

1.1/4 in. BSP

9813/5550-1

1-42


Section 1 - General Information Service Tools Tool Detail Reference

Fig 33. Ram Protection Sleeves

892/01016

For 25 mm Rod Diameter

892/01017

For 30 mm Rod Diameter

892/01018

For 40 mm Rod Diameter

892/01019

For 50 mm Rod Diameter

892/01020

For 50 mm Rod Diameter (slew ram)

892/01021

For 60 mm Rod Diameter

892/01022

For 60 mm Rod Diameter (slew ram)

892/01023

For 65 mm Rod Diameter

892/01024

For 70 mm Rod Diameter

892/01025

For 75 mm Rod Diameter

892/01026

For 80 mm Rod Diameter

892/00167

For 90 mm Rod Diameter

7mm 11o 20mm

10mm

Fig 34. 892/00334 Ram Seal Fitting Tool 5mm

R

m 3m

110mm 175mm 3o

Fig 35. Hexagon Spanners for Ram Pistons and End Caps 992/09300

55mm A/F

992/09400

65mm A/F

992/09500

75mm A/F

992/09600

85mm A/F

992/09700

95mm A/F

992/09900

115mm A/F

992/10000

125mm A/F

1-43

R

1.4

mm

Fig 36. 892/01027 Piston Seal Assembly Tool

9813/5550-1

1-43


Section 1 - General Information Service Tools Tool Detail Reference Note: No longer available, refer to 998/11046 JCB ServiceMaster Flow Test Kit. K Fig 38. ( T 1-44).

892/00268

Flow Monitoring Unit

892/00269

Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)

892/00273

Sensor Head 0 - 380 l/min (0 - 85.5 UK gal/min)

892/00293

Connector Pipe

892/00270

Load Valve

1406/0021

Bonded Washer

1604/0006A Adapter 3/4 in M x 3/4 in M BSP

Fig 37. Flow Test Equipment

1612/2054

Adapter 3/4 in F x 3/4 in M BSP

892/00271

Adapter 3/4 in F x 5/8 in M BSP

892/00272

Adapter 5/8 in F x 3/4 in M BSP

816/20008

Adapter 3/4 in F x 1/2 in M BSP

892/00275

Adapter 1/2 in F x 3/4 in M BSP

892/00276

Adapter 3/4 in F x 3/8 in M BSP

892/00277

Adapter 3/8 in F x 3/4 in M BSP

1606/0015

Adapter 1.1/4 in M BSP x 1 in M BSP

892/00078

Connector 1 in F x 1 in F BSP

1604/0008

Adapter 1 in M x 1 in M BSP

1606/0012

Adapter 1 in M x 3/4 in M BSP

816/20013

Adapter 3/4 in F x 1 in M BSP

998/11047

600 LPM Flow Turbine with Loading Valve

998/11048

1-7/8" UNF x1 - 1/4" BSP Flow Block Adaptors x2

998/11049

Carrying Case for Flow Test Kit

998/11050

Temperature Sensor (125°C Max)

Fig 38. 998/11046 JCB ServiceMaster Flow Test Kit

1-44

9813/5550-1

1-44


Section 1 - General Information Service Tools Tool Detail Reference Note: No longer available, refer to 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit. K Fig 40. ( T 1-45).

1

2

3

892/00201

Replacement Gauge 0-20 bar (0-300 lbf/in2)

892/00202

Replacement Gauge 0-40 bar (0-600 lbf/in2)

892/00203

Replacement Gauge 0-400 bar (0-6000 lbf/in2)

892/00254

Replacement Hose

993/69800

Seal Kit for 892/00254 (can also be used with probe 892/00706)

892/00706

Test Probe

892/00347

Connector - Hose to gauge

998/11052

Hand Held 4-Channel ServiceMaster Unit

998/11053

SensoWin Software Kit and PC Cable

998/11054

Equiment Case SCC-750

998/11055

0-600 Bar Pressure Transduce x2

998/11056

0-100 Bar pressureTransducer x2

998/11057

RPM Tachometer (includes fixed cable, 2 meters)

998/11058

5 Meter Connecting Cable

998/11059

M16 Metric Adaptors for Test Points x4

998/11060

400mm Test Hose 90° HSP to M16 x2

998/11061

400mm Test Hose Straight HSP to M16 x2

Fig 39. 892/ 00253 Hydraulic Circuit Pressure Test Kit

Fig 40. 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit

1-45

9813/5550-1

1-45


Section 1 - General Information Service Tools Tool Detail Reference 892/00223

Hand Pump

892/00137

Micro-bore Hose 1/4 in BSP x 3 metres

892/00274

Adapter 1/4 in M BSP x 3/8 in M BSP Taper

892/00262

1/4 in M BSP x 1/4 in F BSP x Test Point

892/00706

Test Probe

892/00278

Gauge 0 - 40 bar (0 - 600 lbf/in2)

892/00279

Gauge 0 - 400 bar (0 - 6000 lbf/in2)

Fig 41. Hand Pump Equipment

Fig 42. Spool Clamps 892/00039

Spool Clamp

992/10100

Spool Clamp - Diameter 19mm (3/4 in)

992/02800

ARV Extractor

Fig 43. 331/31069 - Test Block for A.R.V.

Fig 44. 892/00881 Valve Spool Seal Fitting Tool 892/00280

Pressure Gauge 0-600 bar (0-9000 lbf/in2)

892/00279

Pressure Gauge 0-400 bar (0-6000 lbf/in2)

892/00346

Pressure Gauge 0-70 bar (0-1000 lbf/in2)

892/00347

Connector

892/00254

Hose

Fig 45. Hydraulic Circuit Test Gauges and Connections

1-46

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1-46


Section 1 - General Information Service Tools Tool Detail Reference

JS07050

Fig 46. Ram Piston Nut Removal/Fitting Spanner

1-47

993/99512

Spanner 55 mm A/F

993/99513

Spanner 60 mm A/F

993/99514

Spanner 65 mm A/F

993/99515

Spanner 70 mm A/F

993/99516

Spanner 75 mm A/F

993/99517

Spanner 85 mm A/F

993/99518

Spanner 90 mm A/F

993/99519

Spanner 100 mm A/F

993/99520

Spanner 110 mm A/F

993/99521

Spanner 115 mm A/F

SSP0046

Spanner 80 mm A/F

SSP0047

Spanner 95 mm A/F

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1-47


Section 1 - General Information Service Tools Tool Detail Reference

A408900

Fig 47. Socket Box Wrench Note: For disassembly and assembly of slew motor gearbox. This tool can not be ordered from JCB.

1-48

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Section 1 - General Information Service Tools Tool Detail Reference

A408860

Fig 48. Nut Adaptor Note: For disassembly and assembly of slew motor gearbox. This tool can not be ordered from JCB.

1-49

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Section 1 - General Information Service Tools Tool Detail Reference

A408880-C1

Fig 49. Seal Ring Tool Note: For assembly and disassembly of slew motor gearbox seal. This tool can not be ordered from JCB.

1-50

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Section 1 - General Information Service Tools Tool Detail Reference

A408890

Fig 50. Stopper Note: For assembly of slew motor gearbox. This tool can not be ordered from JCB.

1-51

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Section 1 - General Information Service Tools Tool Detail Reference

A408870-C1

Fig 51. Bearing Rig Note: For removal of slew motor bearing. This tool can not be ordered from JCB.

1-52

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Section 1 - General Information Service Tools Tool Detail Reference

C118440

Fig 52. 892/00239 Accumulator Gas Charge Kit Use with Hydac bladder type accumulators Kit comprises the following: 1

Pressure gauge

2

Connection hose

3

Mounting bracket (pressure gauge)

4

Gas bottle adaptor (G2)(1)

5

Hydac bladder accumulator adaptor

6

Testing and charging unit

7

Spare seal (accumulator plug)

(1) Some territories require a different adaptor.

1-53

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Section 1 - General Information Service Tools Tool Detail Reference Ram Jigs Inserting Seal Ring and Correction Jig WDB 2052

Bucket

120mm Cylinder inner diameter

WDB 2054

Boom

125mm Cylinder inner diameter

WDB 2164

Boom

130mm Cylinder inner diameter

WDB 2056

Arm

150mm Cylinder inner diameter

Jig for Pulling Out, Press-fitting Bushing WDB 2166

Bucket

80mm Piston Rod diameter

WDB 2167

Boom

85mm Piston Rod diameter

WDB 2170

Arm

100mm Piston Rod diameter

WDB 2168

Bucket

90mm Piston Rod diameter

WDB 2168

Boom

90mm Piston Rod diameter

WDB 2171

Arm

105mm Piston Rod diameter

WDB 2166-1

Bucket

80mm Piston Rod diameter

WDB 2167-1

Boom

85mm Piston Rod diameter

WDB 2170-1

Arm

100mm Piston Rod diameter

WDB 2168-1

Bucket

90mm Piston Rod diameter

WDB 2168-1

Boom

90mm Piston Rod diameter

WDB 2171-1

Arm

105mm Piston Rod diameter

WDB 2174

Bucket

80mm Piston Rod inner diameter

WDB 2175

Boom

85mm Piston Rod inner diameter

WDB 2178

Arm

100mm Piston Rod inner diameter

WDB 2176

Bucket

90mm Piston Rod inner diameter

WDB 2176

Boom

90mm Piston Rod inner diameter

WDB 2179

Arm

105mm Piston Rod inner diameter

Jig for Press-fitting Wiper Ring

Jig for Inserting Cylinder Head

Seal Ring and Connector Jig WDB 2052

Seal Ring insert and connection jig set

Note: The above Part no. is applicable to a tube diameter of 120mm

1-54

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Section 1 - General Information Service Tools Tool Detail Reference Bush Removal Jig WDB 2166 WDB 2166-1

Bush removal jig Retainer

Note: The above Part no. is applicable to a rod diameter of 80mm Bush Fitting Jig WDB 2166 WDB 2166-1

Bush press fitting jig Retainer

Note: The above Part no. is applicable to a rod diameter of 80mm Wiper Ring Fitting Jig WDB 2166-1

Wiper Ring fitting

Note: The above Part no. is applicable to a rod diameter of 80mm Wiper Ring Fitting Jig WDB 2174

Cylinder Head insertion guide jig

Note: The above Part no. is applicable to a rod diameter of 80mm

1-55

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Section 1 - General Information Service Tools Tool Detail Reference

Page left intentionally blank

1-56

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Section 2 Operator’s Manual Service Manual - JS 200 Series Tracked Excavators Section 1 - General Information Section 2 - Operator’s Manual Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track & Running Gear Section K - Engine

Publication No.

9813/5550-1

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


Section 2 - Operator’s Manual

Notes:

2-0

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Foreword The Operator's Manual

OPERATOR'S MANUAL JS200., JS210., JS220., JS230., JS370

EN - 9821/3250 - ISSUE 3 - 03/2015

WARNING You and others can be killed or seriously injured if you operate or maintain the machine without first studying the Operator's Manual. You must understand and follow the instructions in the Operator's Manual. If you do not understand anything, ask your employer or JCB dealer to explain it. Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand. Treat the Operator's Manual as part of the machine. Keep it clean and in good condition. Replace the Operator's Manual immediately if it is lost, damaged or becomes unreadable.

Machine Delivery and Installation Even if you have operated this type of equipment before, it is very important that your new machines operations and functions are explained to you by a JCB Dealer Representative following delivery of your new machine. Following the installation you will know how to gain maximum productivity and performance from your new product. Please contact your local JCB dealer if the Installation Form (included in this manual) has not yet been completed with you. Your local JCB Dealer is

This manual contains original instructions, verified by the manufacturer (or their authorized representative).

Copyright 2014 Š JCB SERVICE All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

www.jcb.com


Notes:

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Table of Contents

Contents

Page No.

Acronyms Glossary ........................................................................................................................................ vii Introduction About this Manual Model and Serial Number ..................................................................................................................... Using the Manual .................................................................................................................................. Left-Hand Side, Right-Hand Side ......................................................................................................... Cross References ................................................................................................................................. Safety Safety - Yours and Others .................................................................................................................... Safety Warnings .................................................................................................................................... General Safety ...................................................................................................................................... Clothing and Personal Protective Equipment (PPE) ............................................................................

1 1 1 2 3 3 4 5

About the Product Introduction General .................................................................................................................................................. 7 Name and Address of the Manufacturer .............................................................................................. 7 Product Compliance .............................................................................................................................. 7 Description General .................................................................................................................................................. 8 Intended Use ......................................................................................................................................... 8 Log Moving/Object Handling ................................................................................................................. 8 Optional Equipment and Attachments .................................................................................................. 8 Danger Zone ......................................................................................................................................... 8 Main Component Locations .................................................................................................................. 9 Product and Component Identification Machine ............................................................................................................................................... 10 Engine ................................................................................................................................................. 11 Operator Protective Structure ............................................................................................................. 13 Safety Labels General ................................................................................................................................................ 16 Safety Label Identification ................................................................................................................... 16 Operator Station Component Locations ......................................................................................................................... 19 Console Switches General ................................................................................................................................................ 20 Work Lights ......................................................................................................................................... 20 Beacon ................................................................................................................................................ 20 Seat Heater ......................................................................................................................................... 20 Seat Ventilation ................................................................................................................................... 21 Control Locks ...................................................................................................................................... 21 Excavator Arm Quickhitch .................................................................................................................. 21 Radio Mute .......................................................................................................................................... 21 Engine Stop Switch ............................................................................................................................ 21 Slew Lock ........................................................................................................................................... 21 Cushion ............................................................................................................................................... 21 Window Washer .................................................................................................................................. 22 Window Wipers ................................................................................................................................... 22 Front Lower Window Wiper ................................................................................................................ 22 i

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Table of Contents

Cab Raise/Lower ................................................................................................................................ 22 Interior Switches Ignition Switch ..................................................................................................................................... 23 Cab Interior Light ................................................................................................................................ 23 Operation Introduction General ................................................................................................................................................ Operating Safety General ................................................................................................................................................ Worksite Safety ................................................................................................................................... Risk Assessment ................................................................................................................................ Walk-Around Inspection General ................................................................................................................................................ Entering and Leaving the Operator Station General ................................................................................................................................................ Emergency Exit ................................................................................................................................... Doors Operator Door ..................................................................................................................................... Windows Front Window ...................................................................................................................................... Side Window ....................................................................................................................................... Sun Visor/Sunblind Sunblind .............................................................................................................................................. Before Starting the Engine General ................................................................................................................................................ Operator Seat General ................................................................................................................................................ Suspension Seat ................................................................................................................................. Seat Belt General ................................................................................................................................................ Inertia Reel Seat Belt ......................................................................................................................... Static Seat Belt ................................................................................................................................... Mirrors General ................................................................................................................................................ Starting the Engine General ................................................................................................................................................ Immobiliser .......................................................................................................................................... Warming Up ........................................................................................................................................ Stopping and Parking General ................................................................................................................................................ Preparing for Travel General ................................................................................................................................................ Preparing for Worksite Travel ............................................................................................................. Beacon ................................................................................................................................................ Locks General ................................................................................................................................................ Control Lock ........................................................................................................................................ Drive Controls Track Controls ..................................................................................................................................... Travel Speed Selector ........................................................................................................................

ii

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ii


Table of Contents

Instruments General ................................................................................................................................................ 69 Instrument Panel ................................................................................................................................. 70 Getting the Machine Moving General ................................................................................................................................................ 92 Driving the Machine General ................................................................................................................................................ 95 Towing Other Equipment .................................................................................................................... 96 Operating Levers/Pedals General ................................................................................................................................................ 97 Control Layouts ................................................................................................................................... 97 Excavator Arm Controls ...................................................................................................................... 97 Dozer Blade Controls ....................................................................................................................... 108 Auxiliary Circuit Controls ................................................................................................................... 108 Lifting and Loading General .............................................................................................................................................. 112 Load Charts ...................................................................................................................................... 112 Overload Warning System ................................................................................................................ 113 Working with the Excavator Arm General .............................................................................................................................................. 115 Preparing to Use the Excavator Arm ............................................................................................... 115 Lifting With the Excavator Arm ......................................................................................................... 115 Digging .............................................................................................................................................. 116 Changing the Bucket Linkage .......................................................................................................... 121 Dipper Stroke Limiter ........................................................................................................................ 122 Working with the Dozer Blade General .............................................................................................................................................. 125 Dozing and Grading .......................................................................................................................... 125 Scraping and Cutting ........................................................................................................................ 125 Backfilling .......................................................................................................................................... 125 Slopes General .............................................................................................................................................. 127 Driving on Slopes ............................................................................................................................. 127 Working on Slopes ........................................................................................................................... 129 Heating, Ventilating and Air-Conditioning (HVAC) General .............................................................................................................................................. 131 Air-Conditioning Controls .................................................................................................................. 131 Power Sockets Auxiliary Power Socket ..................................................................................................................... 134 Battery Isolator General .............................................................................................................................................. 135 Fire Extinguisher General .............................................................................................................................................. 136 Moving a Disabled Machine General .............................................................................................................................................. 138 Getting the Machine Unstuck ........................................................................................................... 138 Jump-Starting the Engine ................................................................................................................. 139 Retrieval ............................................................................................................................................ 140 Excavator Arm (Emergency Operation) ............................................................................................ 140 Lifting the Machine General .............................................................................................................................................. 142 iii

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Table of Contents

Transporting the Machine General .............................................................................................................................................. Loading the Machine onto the Transporting Vehicle/Trailer ............................................................. Unloading the Machine from the Transporting Vehicle/Trailer .......................................................... Operating Environment General .............................................................................................................................................. Operating in Low Temperatures ....................................................................................................... Operating in High Temperatures ....................................................................................................... Cab Filters ......................................................................................................................................... Refuelling General .............................................................................................................................................. Low Fuel Levels ................................................................................................................................ Filling the Tank .................................................................................................................................. Attachments Working with Attachments Introduction ........................................................................................................................................ Attachments for your Machine .......................................................................................................... Connecting/Disconnecting Hydraulic Hoses ..................................................................................... Impact Protection .............................................................................................................................. Direct-Mounted Attachments General .............................................................................................................................................. Quickhitch Excavator Arm Quickhitch ................................................................................................................ Buckets General .............................................................................................................................................. Bucket Teeth ..................................................................................................................................... Preservation and Storage Cleaning General .............................................................................................................................................. Preparation ........................................................................................................................................ Checking For Damage General .............................................................................................................................................. Storage General .............................................................................................................................................. Put into Storage ................................................................................................................................ During Storage .................................................................................................................................. Take out of Storage .......................................................................................................................... Security General .............................................................................................................................................. JCB Plantguard ................................................................................................................................. LiveLink ............................................................................................................................................. Anti-Vandal Guards ........................................................................................................................... Maintenance Introduction General .............................................................................................................................................. Owner/Operator Support ................................................................................................................... Service/Maintenance Agreements .................................................................................................... Obtaining Spare Parts ...................................................................................................................... Maintenance Safety General .............................................................................................................................................. iv

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155 155 156 159 160 163 166 166

169 169 171 172 172 172 173 174 174 174 174

177 177 177 178 179 iv


Table of Contents

Fluids and Lubricants ....................................................................................................................... Maintenance Schedules General .............................................................................................................................................. How to Use the Maintenance Schedules ......................................................................................... Maintenance Intervals ....................................................................................................................... Pre-start Cold Checks, Service Points and Fluid Levels .................................................................. Functional Tests and Final Inspection .............................................................................................. Maintenance Positions General .............................................................................................................................................. Maintenance Position (Excavator Arm Lowered) ............................................................................. Service Points General .............................................................................................................................................. Access Apertures General .............................................................................................................................................. Battery Cover .................................................................................................................................... Engine Compartment Cover ............................................................................................................. Hydraulic Compartment Cover ......................................................................................................... Radiator Cover .................................................................................................................................. Tools General .............................................................................................................................................. Toolbox .............................................................................................................................................. Lubrication General .............................................................................................................................................. Preparation ........................................................................................................................................ Attachments General ............................................................................................................................................. Body and Framework General ............................................................................................................................................. Slew Ring Bearings .......................................................................................................................... Pivot Pins .......................................................................................................................................... Operator Station General ............................................................................................................................................. Operator Protective Structure ........................................................................................................... Seat ................................................................................................................................................... Seat Belt ........................................................................................................................................... Controls ............................................................................................................................................. Engine General ............................................................................................................................................. Oil ...................................................................................................................................................... Drive Belt .......................................................................................................................................... Air Filter General ............................................................................................................................................. Pre-Cleaner ....................................................................................................................................... Dust Valve ........................................................................................................................................ Fuel System General ............................................................................................................................................. Tank .................................................................................................................................................. Fuel Filter .......................................................................................................................................... Water Separator ............................................................................................................................... Cooling System General ............................................................................................................................................. v

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Table of Contents

Coolant .............................................................................................................................................. Cooling Pack .................................................................................................................................... Tracks General ............................................................................................................................................. Steel .................................................................................................................................................. Idler Wheels ...................................................................................................................................... Rollers ............................................................................................................................................... Track Gearbox Oil ...................................................................................................................................................... Hydraulic System General ............................................................................................................................................. Services ............................................................................................................................................ Oil ...................................................................................................................................................... Cylinder Rams .................................................................................................................................. Electrical System General ............................................................................................................................................. Battery ............................................................................................................................................... Battery Isolator ................................................................................................................................. Fuses ................................................................................................................................................ Relays ............................................................................................................................................... Window Washer ................................................................................................................................ Miscellaneous Fire Extinguisher ............................................................................................................................... Technical Data Static Dimensions General .............................................................................................................................................. Dimensions ........................................................................................................................................ Weights ............................................................................................................................................. Performance Dimensions Excavator Arm Dimensions and Performance .................................................................................. Driving Performance ......................................................................................................................... Noise Emissions General .............................................................................................................................................. Noise Data ........................................................................................................................................ Vibration Emissions General .............................................................................................................................................. Vibration Data ................................................................................................................................... Fluids, Lubricants and Capacities General .............................................................................................................................................. Fuel ................................................................................................................................................... Coolant .............................................................................................................................................. Torque Values General .............................................................................................................................................. Electrical System General .............................................................................................................................................. Fuses ................................................................................................................................................. Relays ............................................................................................................................................... Tracks General .............................................................................................................................................. Warranty Information Service Record Sheet ....................................................................................................................... vi

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247 248 251 252 257 258 258 259 260 263 264 265 267 274 274 279 283 284 vi


Table of Contents

Acronyms Glossary ARV

Auxiliary Relief Valve

DECU

Display Electronic Control Unit

ECM

Engine Control Module

ECU

Electronic Control Unit

EGR

Exhaust Gas Recirculation

FOGS

Falling Object Guard System

FOPS

Falling Object Protective Structure

HVAC

Heating Ventilation Air Conditioning

LED

Light Emitting Diode

PIN

Product Identification Number

PPE

Personal Protective Equipment

RMS

Root Mean Square

ROPS

Roll-Over Protective Structure

SWL

Safe Working Load

TOPS

Tip-Over Protective Structure

VGT

Variable Geometry Turbocharger

vii

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Notes:

viii

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viii


Introduction About this Manual

Introduction

About this Manual Model and Serial Number This manual provides information for the following model(s) in the JCB machine range: Model From: To: JS200. 02412201 JS210. 02412401 JS220. 02412801 JS230. 02413001 JS370 02413401 02413600

Using the Manual This operator's manual is arranged to give you a good understanding of the product and its safe operation. It also contains maintenance and technical data. Read this manual from the front to the back before you use the product for the first time, even if you have used machines of a similar/same type before as the technical specification, systems and controls of the machine may have changed. Particular attention must be given to all the safety aspects of operating and maintaining the product. If there is anything you are not sure about, ask your JCB dealer or employer. Do not guess, you or others could be killed or seriously injured. The general and specific warnings in this section are repeated throughout the manual. Read all the safety statements regularly, so you do not forget them. Remember that the best operators are the safest operators. The illustrations in this manual are for guidance only. Where the machines are different, the text and or the illustration will specify. The manufacturer's policy is one of continuous improvement. The right to change the specification of the product without notice is reserved. No responsibility will be accepted for discrepancies which may occur between specifications of the product and the descriptions contained in this manual. All of the optional equipment included in this manual may not be available in all territories

Left-Hand Side, Right-Hand Side In this manual, 'left' and 'right' mean your left and right when you are seated correctly in the machine. Figure 1.

B

A A B

1

Left Right

9821/3250-3

1


Introduction About this Manual

Cross References In this manual, cross references are made by presenting the subject title in blue (electronic copy only). The number of the page upon which the subject begins is indicated within the brackets. For example: Refer to: Introduction > About this Manual > Cross References (Page 2).

2

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Introduction Safety

Safety Safety - Yours and Others All machinery can be hazardous. When a product is correctly operated and maintained, it is a safe product to work with. When it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others. In this manual and on the product you will find warning messages, read and understand them. They inform you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB dealer to explain them. Safety is not just a matter of responding to the warnings. All the time you are working on or with the product you must be thinking of what hazards there might be and how to avoid them. Do not work with the product until you are sure that you can control it. Do not start any work until you are sure that you and those around you will be safe. If you are not sure of anything, about the product or the work, ask someone who knows. Do not assume anything. Remember: • • •

Be careful Be alert Be safe.

Safety Warnings In this manual and on the product, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. The signal word 'DANGER' indicates a hazardous situation which, if not avoided, will result in death or serious injury. The signal word 'WARNING' indicates a hazardous situation which, if not avoided, could result in death or serious injury. The signal word 'CAUTION' indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. The signal word 'Notice' indicates a hazardous situation which, if not avoided, could result in product damage. The safety alert system (shown) also helps to identify important safety messages in this manual and on the product. When you see this symbol, be alert, your safety is involved, carefully read the message that follows, and inform other operators. Figure 2. The safety alert system

3

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Introduction Safety

General Safety Training To operate the machine safely you must know the machine and have the skill to use it. You must abide by all relevant laws, health and safety regulations that apply to the country you are operating in. The operator's manual instructs you on the machine, its controls and its safe operation; it is not a training manual. If you are a new operator, get yourself trained in the skills of using a machine before trying to work with it. If you don't, you will not do your job well, and you will be a danger to yourself and others. In some markets and for work on certain jobsites you may be required to have been trained and assessed in accordance with an operator competence scheme. Make sure that you and your machine complies relevant local laws and jobsite requirements - it is your responsibility. Care and Alertness All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be alert for hazards. Clothing You can be injured if you do not wear the correct clothing. Loose clothing can get caught in the machinery. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. Remove rings, watches and personal jewellery. Alcohol and Drugs It is extremely dangerous to operate machinery when under the influence of alcohol or drugs. Do not consume alcoholic drinks or take drugs before or while operating the machine or attachments. Be aware of medicines which can cause drowsiness. Feeling Unwell Do not attempt to operate the machine if you are feeling unwell. By doing so you could be a danger to yourself and those you work with. Mobile Phones Switch off your mobile phone before entering an area with a potentially explosive atmosphere. Sparks in such an area could cause an explosion or fire resulting in death or serious injury. Switch off and do not use your mobile phone when refuelling the machine. Lifting Equipment You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting equipment is in good condition and complies with all local regulations. Raised Equipment Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which is supported only by a hydraulic device can drop and injure you if the hydraulic system fails or if the control is operated (even with the engine stopped). Make sure that no-one goes near the machine while you install or remove the mechanical device. Raised Machine Never position yourself or any part of your body under a raised machine which is not correctly supported. If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed. Lightning Lightning can kill you. Do not use the machine if there is lightning in your area. Machine Modifications This machine is manufactured in compliance with prevailing legislative requirements. It must not be altered in any way which could affect or invalidate its compliance. For advice consult your JCB dealer.

4

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Introduction Safety

Clothing and Personal Protective Equipment (PPE) Do not wear loose clothing or jewellery that can get caught on controls or moving parts. Wear protective clothing and personal safety equipment issued or called for by the job conditions, local regulations or as specified by your employer.

5

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Notes:

6

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About the Product Introduction

About the Product Introduction

General Before you start using the product, you must know how the product operates. Use this part of the manual to identify each control lever, switch, gauge, button and pedal. Do not guess, if there is anything you do not understand, ask your JCB dealer.

Name and Address of the Manufacturer JCB Construction Equipment (Shanghai)Co., LTD. No 3698 Xiu Yan Road, Kang Qiao Industrial Zone, Nanhui, Shanghai 201319. P.R.China.

Product Compliance Your JCB product was designed to comply with the laws and regulations applicable at the time of its manufacture for the market in which it was first sold. In many markets, laws and regulations exist that require the owner to maintain the product at a level of compliance relevant to the product when first produced. Even in the absence of defined requirements for the product owner, JCB recommend that the product compliance be maintained to ensure safety of the operator and exposed persons and to ensure the correct environmental performance. Your product must not be altered in any way which could affect or invalidate any of these requirements. For advice consult your JCB dealer. For its compliance as a new product, your JCB and some of its components may bear approval numbers and marking's, and may have been supplied with a Declaration/Certificate of Conformity. These marking's and documents are relevant only for the country/region in which the product was first sold to the extent that the laws and regulations required them. Re-sales and import/export of products across territories with different laws and regulations can cause new requirements to become relevant for which the product was not originally designed or specified. In some cases, pre owned products irrespective of their age are considered new for the purposes of compliance and may be required to meet the latest requirements which could present an insurmountable barrier to their sale/use. Despite the presence of any compliance related marking's on the product and components, you should not assume that compliance in a new market will be possible. In many cases it is the person responsible for import of a pre owned product into a market that becomes responsible for compliance and who is also considered the manufacturer. JCB may be unable to support any product compliance related enquiry for a product which has been moved out of the legislative country/region where it was first sold, and in particular where a product specification change or additional certification would have been required in order for the product to be in compliance.

7

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About the Product Description

Description General The JCB Tracked Excavator is a self propelled machine with a tracked undercarriage and a revolving upper structure which has a boom, dipper, bucket and swing mechanism. The excavator is mainly used to dig below ground level with bucket motions towards the machine. The upper structure can slew 360° and discharge material when the tracked undercarriage is stationary.

Intended Use The machine is intended to be used in normal conditions for the applications and in the environmental conditions as described in this manual. When used normally with a bucket fitted the machine the work cycle consists of, digging, elevating, slewing and the discharging of material without movement of the undercarriage. Applications include earthmoving, road construction, building and construction, landscaping and similar applications. An excavator can also be used for object handling if it is suitably equipped with relevant parts and systems. Refer to: Operation > Lifting and Loading (Page 112). The machine is not intended for use in mining and quarrying applications, in demolition activities, forestry, any use underground or in any kind of explosive atmosphere. If the machine is to be used in applications where there is a high silica concentration, risk due to materials containing asbestos or similar hazards, additional protective measures such as the use of PPE (Personal Protective Equipment) may be required. The machine should not be operated by any person who does not have an appropriate level of qualification, training or experience of use of this type of machine. Prior to use of the machine, its suitability (size, performance, specification etc.) should be considered with regards to the intended application and any relevant hazards that may exist. Contact your JCB dealer for support in determining the appropriate JCB machine, attachment and any optional equipment that is suitable for the application and environment.

Log Moving/Object Handling Do not use the machine to move or handle logs unless sufficient log protection is installed. You could cause serious injury to yourself and damage to the machine. For more information, contact your JCB dealer.

Optional Equipment and Attachments A wide range of optional attachments are available to increase the versatility of your machine. Only the JCB approved attachments are recommended for use with your machine. Contact your JCB dealer for the full list of approved attachments available.

Danger Zone The danger zone is any zone within and/or around the machinery in which a person is subject to a risk to their health or safety. The danger zone includes the area in immediate proximity to any hazardous moving parts, areas into which working equipment and attachments can be moved to quickly, the machine normal stopping distances and also areas into which the machine can quickly turn under normal conditions of use. Depending on the application at the time, the danger zone could also include the area into which debris, from use of an attachment or working tool, could be projected and any area into which debris could fall from the machine. During the operation of the machine, keep all persons out of the danger zone. Persons in the danger zone could be injured. Refer to: Technical Data (Page 247).

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About the Product Description

Before you do a maintenance task, make the product safe. Refer to: Maintenance > Maintenance Positions (Page 190).

Main Component Locations Figure 3. H J

G F

K

A

D A B C D E F G H J K L

C

E

B

L

Bucket Bucket link Bucket ram Dipper Dipper link Dipper ram Boom Boom ram Operators cab Counterweight Undercarriage

The boom dipper and bucket are collectively referred to as the excavator end, or dig end.

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About the Product Product and Component Identification

Product and Component Identification Machine Your machine has an identification plate. The PIN (Product Identification Number), weight, engine power, year of manufacture and serial number of the machine are shown on the identification plate. The machine serial number is also inscribed at the baseplate of the rear frame. Figure 4.

B A

A B

Identification plate (location) Serial number (inscribed)

The machine model and build specification are indicated by the PIN. The PIN has 17 digits and must be read from left to right. Table 1. Typical PIN JCB

8085

L

01536000

Table 2. Explanation of the PIN Digit 1 to 3 4 to 8 9 10 to 17

10

Description World manufacturer identification. For example, JCB = UK Build. Machine type and model. For example, 8025 = 8025. Random check letter. The check letter is used to verify the authenticity of a machine's PIN. Machine serial number.

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About the Product Product and Component Identification

Figure 5.

A

Identification plate

Engine For: DE Engine, JS200., JS210., JS220., JS230. .................................................................... Page 11 For: EK Engine, JS370 ............................................................................................................ Page 12

(For: DE Engine, JS200., JS210., JS220., JS230.) The engine data labels are attached to the cylinder block as shown. Figure 6.

A

C

D

B B D A B C D

Engine data label - rocker cover Engine data label - tread plate Engine identification number Stamp

The data label includes the engine identification number. Table 3. Example of the engine identification number Digit

11

SD 1-2

320/40001 3-10

U 11

9821/3250-3

00001 12-16

04 17-18

11


About the Product Product and Component Identification

Table 4. Explanation of the engine identification number Digit 1-2 3-10 11 12-16 17-18

Explanation Engine type. SH = 4.4L electronic common rail fuel injection tier 4i. SD = 4.4L mechanical fuel injection tier 3. SE = 4.4L electronic common rail fuel injection tier 3. DE = 4.8L electronic common rail fuel injection tier 2 Engine part number Country of manufacture. U = United Kingdom Engine serial number Year of manufacture

The country of manufacturer, engine serial number and year of manufacture of the engine are also stamped on the cylinder block. Refer to Figure 6.

(For: EK Engine, JS370) The engine data labels are attached to the cylinder block as shown. Figure 7. C

A

C

B

D A B C D

12

Engine data label - rocker cover Engine data label - flywheel housing Engine identification number Stamp

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About the Product Product and Component Identification

Figure 8. E

E

Engine data label - tread plate

The data label includes the engine identification number. Table 5. Example of the engine identification number Digit

SD 1-2

320/40001 U 3-10 11

00001 04 12-16 17-18

Table 6. Explanation of the engine identification number Digit 1-2

3-10 11 12-16 17-18

Explanation Engine type. SH = 4.4L electronic common rail fuel injection tier 4i. SD = 4.4L mechanical fuel injection tier 3. SE = 4.4L electronic common rail fuel injection tier 3. DE = 4.8L electronic common rail fuel injection tier 2. EK = 7.2L electronic common rail fuel injection tier 2 Engine part number Country of manufacture. U = United Kingdom Engine serial number Year of manufacture

The country of manufacturer, engine serial number and year of manufacture of the engine are also stamped on the cylinder block. Refer to Figure 7.

Operator Protective Structure WARNING Machines with a ROPS, FOPS,FOGS or TOPS are equipped with a seat belt. The ROPS, FOPS,FOGS or TOPS is designed to give you protection in an accident. If you do not wear the seat belt you could be thrown off the machine and crushed. You must wear a seat belt when using the machine. Fasten the seat belt before starting the engine. WARNING Modified and wrongly repaired ROPS, TOPS and FOGS are dangerous. Do not modify the TOPS. Do not attempt to repair the ROPS, TOPS and FOGS. If the ROPS, TOPS and FOGS has been in an accident, do not use the machine until the structure has been examined and repaired. This must be done by a qualified person. For assistance, contact your JCB dealer. Failure to take precautions could result in death or injury to the operator.

FOPS Data Plate WARNING Do not use the machine if the falling objects protection level provided by the structure is not sufficient for the application. Falling objects can cause serious injury. If the machine is used in any application where there is a risk of falling objects then a FOPS (Falling Object Protective Structure) must be installed. For further information, contact your JCB dealer. 13

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About the Product Product and Component Identification

The FOPS has a data plate attached. The data plate indicates what level of protection the structure provides. There are two levels of FOPS: • •

Level I Impact Protection - impact strength for protection from small falling objects (e.g. bricks, small concrete blocks, hand tools) encountered in operations such as highway maintenance, landscaping and other construction site services. Level II Impact Protection - impact strength for protection from heavy falling objects (e.g. trees, rocks) for machines involved in site clearing, overhead demolition or forestry. Figure 9.

The cab mounted FOPS available for the JS excavator range are tested to ISO 10262 level 2 and comply with EN 13627:2000. The frame mounted FOPS available for the JS excavator range are tested to ISO 3449 level 2 and comply with EN 13627:2000.

ROPS Data Plate WARNING Your machine may be fitted with a Roll-Over Protective Structure (ROPS) indicating that the purchaser specified the machine for use in applications where there is risk of roll-over. ROPS is a device to protect the operator in the event of roll-over. Any damage or modification to the structure may invalidate the ROPS certification. If damage has occurred then an authorised JCB dealer should be consulted. An excavator with a ROPS (Roll-Over Protective Structure) can be identified by referring to the cab identification plate. Work place (work site, job site) risk assessment should facilitate the machine selection and the need for an excavator with a ROPS. Figure 10.

TOPS Data Plate An excavator with a TOPS (Tip-Over Protective Structure) can be identified by referring to the cab identification plate. Work place (work site, job site) risk assessment should facilitate the machine selection and the need for an excavator with a TOPS.

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About the Product Product and Component Identification

Figure 11. XXXX XXXX XXXX XXXX XXXX

Figure 12.

XXXX

XXXX XXXX

XXXX

15

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About the Product Safety Labels

Safety Labels General WARNING Safety labels on the machine warn you of particular hazards. You can be injured if you do not obey the safety instructions shown. The safety labels are strategically placed around the product to remind you of possible hazards. If you need eye-glasses for reading, make sure you wear them when reading the safety labels. Do not overstretch or put yourself in dangerous positions to read the safety labels. If you do not understand the hazard shown on the safety label, then refer to Safety Label Identification. Refer to: About the Product > Safety Labels > Safety Label Identification (Page 16). Keep all of the safety labels clean and readable. Replace a lost or damaged safety label. Make sure the replacement parts include the safety labels where necessary. Each safety label has a part number printed on it, use this number to order a new safety label from your JCB dealer.

Safety Label Identification Figure 13. A

B

C

D

G

F

H 16

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E

N 16


About the Product Safety Labels

Figure 14.

J

O

M

P

L

K

Table 7. Safety Labels Item A

Part No. 332/J2896

B C

817/70005 332/P4679

D E F

817/70024 817/70003 817/70116

G H J

817/18541 817/19470 332/J9693

17

Description (Combination label) The coolant is under pressure. Risk of severing of hands/fingers in the rotating parts. Hot surfaces. Remove the ignition key and refer to the operator's manual and the service manual. Hot fluid under pressure. Do not touch, consult operator's manual. Severing of hands and fingers. Keep clear of/do not reach into rotating parts. Read the Service Manual. Warning. Do not use as a step. Crushing/shearing of hands. Do not touch. Fall. Unexpected machine movement due to accidental contact with the controls when the hydraulics are not isolated. Read the operator's manual before you operate the machine. The arm or bucket may move, keep clear. (Combination label) The bucket can foul the boom when dipper is swinging inwards. Maintain the clearance between the bucket and boom. Danger of collision, maintain the clearance between the bucket and cab. Risk of tripping, raise the control lock lever before you exit the machine. Risk of injury by crushing, do not lean out of the window. Risk of electrocution, maintain the minimum clearance recommended by your local electricity supplier. 9821/3250-3

Qty. 1 1 1 1 1 1 1 1 1

17


About the Product Safety Labels

Item K L M

Part No. 817/70027 817/70001 333/J2439

N O

332/F5860 817/18532

P

335/E7623

18

Description Crushing of whole body. Keep a safe distance. Falling hazard. Keep a safe distance from the edge. Strike to the whole body (machine swing). Keep a safe distance from the machine. Hot fluid under pressure. Read the Operator's Manual. Pressure hazard. Stop the engine, remove the ignition key and release the hydraulic pressure before you start maintenance work. Refer to Maintenance Section in the operator's manual. Burns to fingers and hands. Keep a safe distance from machine.

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Qty. 1 1 1 1 1 1

18


About the Product Operator Station

Operator Station Component Locations Figure 15. B

A C

D

Q P N

E

F G

M

H J

L

J

K A B

K

L M N P Q

Left hand track control, Refer to: Operation > Drive Controls > Track Controls (Page 66). DECU (Display Electronic Control Unit), Refer to: Operation > Instruments > Instrument Panel (Page 70). Right hand track control, Refer to: Operation > Drive Controls > Track Controls (Page 66). Optional circuit pedal, Refer to: Operation > Operating Levers/Pedals > Auxiliary Circuit Controls (Page 108). Right joystick, Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 97). Machine power band controller, Refer to: Operation > Instruments > General (Page 69). Ignition switch, Refer to: About the Product > Interior Switches > Ignition Switch (Page 23). Dozer lever, Right switch console, Refer to: About the Product > Console Switches (Page 20). 12V auxiliary power socket, Refer to: Operation > Power Sockets > Auxiliary Power Socket (Page 134). Door lever, Refer to: Operation > Doors > Operator Door (Page 37). Left switch console, Refer to: About the Product > Console Switches (Page 20). Controls isolation lever,Refer to: Operation > Locks > Control Lock (Page 64). Seat, Refer to: Operation > Operator Seat (Page 46). Left joystick, Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 97).

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C D E F G H J K

19


About the Product Console Switches

Console Switches General The installed switches and their positions can change according to the specification of the machine. Each switch has a graphic symbol to show the function of the switch. Before you operate a switch, make sure that you understand its function. The rocker switches have two or three positions (as shown). If the switch has a backlight, then the graphic symbol illuminates when the ignition switch or side lights are in the on position. The light bar illuminates to show that the switch function is active. Figure 16. 1

A

2

B

A B

3

Graphic symbol Light bar

Work Lights Three position rocker switch. The switch functions operate when the ignition switch is in the on and off positions. Position : 1 = Off Position : 2 = Boom and toolbox work lights on Position : 3 = Boom, toolbox and counterweight work lights on.

Beacon Two or three position rocker switch. The switch functions operate when the ignition switch is in the on and off positions. Position : 1 = Off Position : 2 = Cab beacon on Position : 3 = Cab and two rear beacons on (option). Refer to: Operation > Preparing for Travel > Beacon (Page 62).

Seat Heater Two position rocker switch. The switch functions operate when the ignition switch is in the on position. Position : 1 = Heater off, suspension adjustment on Position : 2 = Heater on, suspension adjustment off.

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About the Product Console Switches

Seat Ventilation Two position rocker switch. The switch functions operate when the ignition is in the on position. Position : 1 = Seat ventilation off Position : 2 = Seat ventilation on

Control Locks Controls isolation switch. Two position momentary rocker switch. The switch functions when the engine is running, and the controls isolation lever is lowered. Press momentarily to isolate the controls, the switch light illuminates. Press momentarily again to enable the controls, the switch light extinguishes. Position : 1 = Rest position. Switch light illuminates when the controls are isolated Position : 2 = Momentary position.

Excavator Arm Quickhitch Three position rocker switch. The switch functions operate when the ignition switch is in the on position and the controls are active. Position : 1 = Quickhitch deactivate Position : 2 = Off Position : 3 = Quickhitch activate.

Radio Mute Two position rocker switch. The switch functions operate when the ignition switch is in the on position. Position : 1 = Radio is on Position : 2 = Radio is muted.

Engine Stop Switch Two position rocker switch. The switch functions operate when the ignition switch is in the on position. Position : 1 = Engine run Position : 2 = Engine stop. Engine cannot be cranked.

Slew Lock Two position rocker switch. The switch functions operate when the ignition switch is in the on position. Position : 1 = Slew available. Position : 2 = Slew locked.

Cushion Two position rocker switch. The switch functions operate when the ignition switch is in the on position. Position : 1 = Off Position : 2 = On.

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About the Product Console Switches

Window Washer Two position momentary rocker switch. The switch functions when the ignition switch is in the on position. The window washers will operate as long as the switch is held in the momentary position. The upper wiper will operate automatically as the window is washed. Position : 1 = Off. Window washers are off. Position : 2 = Momentary position. Window washers are on.

Window Wipers Three position rocker switch. The switch functions operate when the ignition switch is in the on position. Position : 1 = Off Position : 2 = Upper wiper intermittent on Position : 3 = Upper wiper continuous on.

Front Lower Window Wiper Three position rocker switch. The switch functions operate when the ignition switch is in the on position. Position : 1 = Off Position : 2 = Upper wiper continuous on Position : 3 = Momentary position. Window washers upper and lower are on.

Cab Raise/Lower Three position rocker switch (spring loaded). The switch functions operate when the ignition switch is in the on position and the engine is running. Position : 1 = Cab raise (Push and hold) Position : 2 = Neutral Position : 3 = Cab lower (Push and hold).

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About the Product Interior Switches

Interior Switches Ignition Switch The ignition key operates the four-position ignition switch. The ignition key can only be inserted or removed in position 0. If the engine fails to start, the ignition key must be returned to position 0 before the starter motor is re-engaged. Do not operate the starter motor for more than 20s without the engine firing. If the engine fires but does not fully start, let the starter motor cool for at least 2min between starts. Figure 17. A

B A B

Ignition switch Ignition key Table 8. Switch Positions

Position 0 I II III

Function Off/Stop the Engine: Turn the ignition key to this position to stop the engine. Make sure the controls are in neutral and the excavator and dozer are lowered before you stop the engine. On: Turn the ignition key to this position to connect the battery to all of the electrical circuits. The ignition key will return to this position when it is released from position II or position III. This position is not used. Start: Turn the ignition key to this position to operate the starter motor and turn the engine. The ignition switch has an inhibitor to stop the ignition switch being turned on when the engine is running. There may be a delay of up to 1s between switch operation and engine cranking.

Cab Interior Light Press either end of the light unit to turn on the cab interior light. Press the other end of the light unit to turn off the cab interior light. When the cab interior light is in the centre position, it will turn on automatically when the cab door is opened and turn off when the door is closed. A timer will switch off the cab interior light if the cab door is left open for prolonged periods. Make sure the cab interior light is turned off when you intend to leave the machine for a long period of time.

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About the Product Interior Switches

Figure 18.

A

A

24

Cab interior light

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24


Operation Introduction

Operation

Introduction General The aim of this part of the manual is to guide the operator step-by-step through the task of learning how to operate the machine efficiently and safely. Read the Operation section through from beginning to end. The operator must always be aware of events happening in or around the machine. Safety must always be the most important factor when you operate the machine. When you understand the operating controls, gauges and switches, practice using them. Drive the machine in an open space, clear of people. Get to know the 'feel' of the machine and its driving controls. Do not rush the job of learning, make sure you fully understand everything in the Operation section. Take your time and work efficiently and safely. Remember: • • •

25

Be careful. Be alert. Be safe.

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Operation Operating Safety

Operating Safety General Training Make sure that you have had adequate training and that you are confident in your ability to operate the machine safely before you use it. Practice using the machine and its attachments until you are completely familiar with the controls and what they do. With a careful, well trained and experienced operator, your machine is a safe and efficient machine. With an inexperienced or careless operator, it can be dangerous. Do not put your life, or the lives of others, at risk by using the machine irresponsibly. Before you start to work, tell your work mates what you will be doing and where you will be working. On a busy site, use a signalman. Before doing any job not covered in this manual, find out the correct procedure. Your local JCB distributor will be glad to advise you. Fuel Fuel is flammable, keep naked flames away from the fuel system. Stop the engine immediately if a fuel leak is suspected. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. Completely wipe off any spilt fuel which could cause a fire. There could be a fire and injury if you do not follow these precautions. Machine Condition A defective machine can injure you or others. Do not operate a machine which is defective or has missing parts. Make sure the maintenance procedures in this manual are completed before using the machine. Machine Limits Operating the machine beyond its design limits can damage the machine, it can also be dangerous. Do not operate the machine outside its limits. Do not try to upgrade the machine performance with unapproved modifications. Engine/Steering Failure If the engine or steering fails, stop the machine as quickly as possible. Do not operate the machine until the fault has been corrected. Exhaust Gases Breathing the machine exhaust gases can harm and possibly kill you. Do not operate the machine in closed spaces without making sure there is good ventilation. If possible, install an exhaust extension. If you begin to feel drowsy, stop the machine at once and get into fresh air. Worksites Worksites can be hazardous. Examine the site before working on it. 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. Check for utilities such as electric cables (overhead and underground), gas and water pipes etc. Mark the positions of the underground cables and pipes. Make sure that you have enough clearance beneath overhead cables and structures. Communications Bad communications can cause accidents. Keep people around you informed of what you will be doing. If you will be working with other people, make sure any hand signals that may be used are understood by everybody. Worksites can be noisy, do not rely on spoken commands. Parking An incorrectly parked machine can move without an operator. Follow the instructions in the Operator's Manual to park the machine correctly. Banks and Trenches Banked material and trenches can collapse. Do not work or drive too close to banks and trenches where there is danger of collapse. Safety Barriers Unguarded machines in public places can be dangerous. In public places, or where your visibility is reduced, place barriers around the work area to keep people away.

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Operation Operating Safety

Sparks Explosions and fire can be caused by sparks from the exhaust or the electrical system. Do not use the machine in closed areas where there is flammable material, vapour or dust. Hazardous Atmospheres This machine is designed for use in normal out door atmospheric conditions. It must not be used in an enclosed area without adequate ventilation. Do not use the machine in a potentially explosive atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB dealer. Regulations Obey all laws, worksite and local regulations which affect you and your machine. Electrical Power Cables You could be electrocuted or badly burned if you get the machine or its attachments too 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. Before you start using the machine, check with your electricity supplier if there are any buried power cables on the site. There is a minimum clearance required for working beneath overhead power cables. You must obtain details from your local electricity supplier. Working Platform Using the machine as a working platform is hazardous. You can fall off and be killed or injured. Never use the machine as a working platform unless with approved man-basket or man-crate (if applicable). Machine Safety Stop work at once if a fault develops. Abnormal sounds and smells can be signs of trouble. Examine and repair before resuming work. Hot Components Touching hot surfaces can burn skin. The engine and machine components will be hot after the unit has been running. Allow the engine and components to cool before servicing the unit. Travelling at High Speeds Travelling at high speeds can cause accidents. Do not reverse in a high gear with full throttle. Always travel at a safe speed to suit working conditions. Hillsides Operating the machine on hillsides can be dangerous if the correct precautions are not taken. Ground conditions can be changed by rain, snow, ice etc. Check the site carefully. When applicable, keep all attachments low to the ground. Visibility Accidents can be caused by working in poor visibility. Use your lights to improve visibility. Keep the road lights, windows and mirrors clean. Do not operate the machine if you cannot see clearly. Modification of the machine's configuration by the user (e.g. the fitting of large and non-approved attachments) may result in a restriction of the machine visibility. Hands and Feet Keep your hands and feet inside the machine. When using the machine, keep your hands and feet clear of moving parts. Keep your hands and feet within the operator compartment while the vehicle is in motion. Controls You or others can be killed or seriously injured if you operate the control levers from outside the machine. Operate the control levers only when you are correctly seated.

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Operation Operating Safety

Passengers Passengers in or on the machine can cause accidents. Do not carry passengers. Fires If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the correct machine location until you need to use it. Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical fire. Use carbon dioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as possible. Firefighters must use self-contained breathing apparatus. Roll Over Protection If the machine starts to roll over, you can be crushed if you try to leave the cab. If the machine starts to roll over, do not try and jump from the cab. Stay in the cab, with your seat belt fastened. Safe Working Loads Overloading the machine can damage it and make it unstable. Study the specifications in the Operator's Manual before using the machine.

Worksite Safety WARNING You or others can be killed or seriously injured if you do unfamiliar operations without first practising them. Practise away from the worksite on a clear area. Keep other people away. Do not perform new operations until you are sure you can do them safely. WARNING There could be dangerous materials such as asbestos, poisonous chemicals or other harmful substances buried on the site. If you uncover any containers or you see any signs of toxic waste, stop the machine and advise the site manager immediately. WARNING Before you start using the machine, check with your local gas company if there are any buried gas pipes on the site. If there are buried gas pipes we recommend that you ask the gas company for any specific advice regarding the way you must work on the site. Some modern gas pipes cannot be detected by metal detectors, so it is essential that an accurate map of buried gas pipes is obtained before any excavation work commences. Hand dig trial holes to obtain precise pipe locations. Any cast iron pipes found must be assumed to be gas pipes until contrary evidence is obtained. Older gas pipes can be damaged by heavy vehicles driving over the ground above them. Leaking gas is highly explosive. If a gas leak is suspected, contact the local gas company immediately and warn all personnel on the site. Ban smoking, make sure 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. CAUTION Before you start using the machine, check with your local public water supplier 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 pipes and drains. CAUTION If you cut through a fibre optic cable, Do not look into the end of it, your eyes could be permanently damaged. An applicable worksite organisation is required in order to minimise hazards that are caused by restricted visibility. The worksite organisation is a collection of rules and procedures that coordinates the machines and people that work together in the same area. Examples of worksite organisation include: • • 28

Restricted areas Controlled patterns of machine movement 9821/3250-3

28


Operation Operating Safety

A system of communication.

You and/or your company could be legally liable for any damage you may cause to public utilities. It is your responsibility to make sure that you know the locations of any public utility cables or pipes on the worksite which could be damaged by your machine.

Risk Assessment It is the responsibility of the competent people that plan the work and operate the machine to make a judgement about the safe use of the machine, they must take into account the specific application and conditions of use at the time. It is essential that a risk assessment of the work to be done is completed and that the operator obeys any safety precautions that the assessment identifies. If you are unsure of the suitability of the machine for a specific task, contact your JCB dealer who will be pleased to advise you. The following considerations are intended as suggestions of some of the factors to be taken into account when a risk assessment is made. Other factors may need to be considered. A good risk assessment depends on the training and experience of the operator. Do not put your life or the lives of others at risk.

Personnel • • •

Are all persons who will take part in the operation sufficiently trained, experienced and competent? Are they fit and sufficiently rested? A sick or tired operator is a dangerous operator. Is supervision needed? Is the supervisor sufficiently trained and experienced? As well as the machine operator, are any assistants or lookouts needed?

The Machine • • • •

Is it in good working order? Have any reported defects been corrected? Have the daily checks been carried out? Are the tyres still at the correct pressure and in good condition and is there sufficient fuel to complete the job (if applicable)?

The Load • • • •

How heavy is it? Is it within the capabilities of the machine? How bulky is it? The greater the surface area, the more affected it will be by wind speeds. Is it an awkward shape? How is the weight distributed? Uneven loads are more difficult to handle. Is there a possibility of the load shifting while being moved?

Loading/Unloading Area • • • • • • •

Is it level? Any slope of more than 2.5% (1 in 40) must be carefully considered. Is more than one direction of approach to the load possible? Approaching across the slope must be avoided, if possible. Is the ground solid? Will it support the weight of the machine when loaded? How rough is the ground? Are there any sharp projections which could cause damage, particularly to the tyres? Are there any obstacles or hazards in the area, for example, debris, excavations, manhole covers, power lines? Is the space sufficient for safe manoeuvring? Are any other machines or persons likely to be in or to enter the area while operations are in progress?

The Route to be Travelled • 29

How solid is the ground, will it provide sufficient traction and braking? 9821/3250-3

29


Operation Operating Safety

How steep are any slopes, up/down/across? A cross slope is particularly hazardous, is it possible to detour to avoid them?

Weather • •

30

How windy is it? High wind will adversely affect the stability of a loaded machine, particularly if the load is bulky. Is it raining or is rain likely? The ground that was solid and smooth when dry will become uneven and slippery when wet, and it will not give the same conditions for traction, steering or braking.

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Operation Walk-Around Inspection

Walk-Around Inspection General WARNING Walking or working under a raised boom and dipper is hazardous. You could be crushed by the boom and dipper or get caught in the linkages. Lower the boom and dipper before doing these checks. The following checks must 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. 1. Check for cleanliness. 1.1. Clean the windows, light lenses and the rear view mirrors (where applicable). 1.2. Remove dirt and debris, especially from around the linkages, rams, pivot points and radiator. 1.3. Make sure the cab step and handrails are clean and dry. 1.4. Clean all of the safety and instructional labels. Replace any label that is missing or cannot be read. 2. Check for damage. 2.1. Examine the machine generally for damaged and missing parts. 2.2. Make sure that the attachment is correctly attached and in good condition. 2.3. Make sure that all of the pivot pins are correctly installed. 2.4. Examine the windows for cracks and damage. Glass splinters can blind. 2.5. Check for oil, fuel and coolant leakages below the machine. WARNING! You could be killed or injured with damaged tracks. Do not use the machine with damaged or excessively worn tracks. 3. Check the tracks. Refer to: Maintenance > Tracks (Page 230). 4. Make sure that all of the filler caps are installed correctly. 5. Make sure that all of the access panels are closed correctly. Refer to: Maintenance > Access Apertures (Page 202). 6. If the filler caps and access panels are installed with locks, we recommend that you lock them to prevent theft or tampering.

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31


Operation Entering and Leaving the Operator Station

Entering and Leaving the Operator Station General General WARNING For safety reasons, machines installed with single access canopies from new must not have the barrier removed. The machine must always be entered/exited with the left hand isolator raised via the left hand side. WARNING Do not enter or exit the cab unless the controls isolation lever is in the fully raised position. CAUTION Entering or leaving the operator station must only be made where steps and handrails are provided. Always face the machine when entering and leaving. 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 as handholds, use the handrails.

Standard Cab Machines Entering the Cab 1. Open the cab door and if necessary, latch it in the open position. Refer to: Operation > Doors > Operator Door (Page 37). 2. Make sure that the controls lock lever is in the raised position. Refer to: Operation > Locks > Control Lock (Page 64). 3. Hold the two handrails (one each side of the cab entrance), then use the step between the top and bottom tracks to climb onto the top of the track. Refer to Figure 19. Figure 19. A

C

C B B

A B C

Handrails Step Track

4. Keep hold of the left handrail, then climb into the cab and swing yourself into the operators seat. 5. Close the cab door.

Leaving the Cab 1. Park the machine on solid, level ground with the upper structure parallel to the undercarriage. 2. Lower the attachment. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 97). 32

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Operation Entering and Leaving the Operator Station

3. Stop the engine. 4. Turn the ignition key to the on position. 5. Operate the hydraulic controls several times to release any residual hydraulic pressure in the system. Refer to: Operation > Moving a Disabled Machine > Excavator Arm (Emergency Operation) (Page 140). 6. Turn the ignition key to the off position. 7. Raise the controls lock lever. 8. Open the cab door and latch it in the open position. 9. Hold the left handrail and turn your back towards the step. Refer to Figure 20. Figure 20. A

C

C B B

A B C

Handrails Step Track

10. Hold both of the handrails and use the track and step to climb down backwards from the cab onto the ground. 11. Close the cab door.

Hydraulically Raised Cab Introduction Read and understand this section before you start working with the machine. The hydraulically raised cab is raised and lowered through a pantograph linkage operated by a pair of hydraulic cylinders. The cab raise/lower switch installed in the cab controls the hydraulic cylinders. Refer to: About the Product > Console Switches > Cab Raise/Lower (Page 22). WARNING! Keep yourself and all others away from the lifting mechanism. Never allow persons to walk below a raised cab at any time. Do not carry passengers. WARNING! Only raise/lower the cab if the environment is safe. Do not lower the cab if persons are within a radius of 5m WARNING! Do not work below a raised cab unless the cab is secured in position and safely supported.

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Operation Entering and Leaving the Operator Station

Entering the Cab 1. Open the cab door and if necessary latch it in the open position. 2. Make sure that the controls lock lever is in the raised position. 3. Hold the two handrails (one each side of the cab entrance), then use the step between the top and bottom tracks to climb onto the top of the track. Refer to Figure 21. Figure 21.

A

B C

A B C

Handrail Handrail Step

4. Use the handrails to side-step to the cab entrance. Refer to Figure 22. Figure 22.

B

D

B D

Handrail Handrail

5. Keep hold of the left handrail, then climb into the cab and swing yourself into the operators seat. 6. Close the door.

Raising the Cab 1. Get access to the cab, refer to Entering the Cab. WARNING! If you do not wear your seat belt you could be thrown about inside the machine, or thrown out of the machine and crushed. You must wear a seat belt when using the machine. Fasten the seat belt before starting the engine.

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Operation Entering and Leaving the Operator Station

2. Fasten the seat belt. Refer to: Operation > Seat Belt (Page 48). 3. Start the engine. Refer to: Operation > Starting the Engine (Page 57). 3.1. An alarm will sound if the door is open. 4. Operate the horn. 5. Push and hold the cab raise/lower switch until you get to the required or maximum position of the cab. Release the switch to stop the movement. Refer to: About the Product > Console Switches > Cab Raise/Lower (Page 22). When the cab is fully raised, the position of the cab is 590mm forward and 2,140mm higher than when it is fully lowered.

Lowering the Cab 1. Park the machine on solid, level ground with the upper structure parallel to the undercarriage. 2. Operate the horn. 3. Push and hold the cab raise/lower switch until you get to the required or lowest position of the cab. Release the switch to stop the movement. 4. Stop the engine and remove the ignition key. 5. Make sure the cab is at its lowest position before you leave the cab, refer to Leaving the Cab.

Leaving the Cab 1. Park the machine on solid, level ground with the upper structure parallel to the undercarriage. 2. Stop the engine. 3. Turn the ignition key to the on position. 4. Operate the hydraulic controls several times to release any residual hydraulic pressure in the system. 5. Turn the ignition key to the off position. 6. Open the cab door and secure it in the open position. 7. Raise the controls lock lever. 8. Leave the cab. (Reverse the instructions of Entering the Cab).

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Operation Entering and Leaving the Operator Station

Emergency Exit Standard Cab Figure 23.

A A

Glazing breaker

In an emergency, if the door cannot be used: 1. Turn the backrest of the seat fully forward/down. 2. Use the glazing breaker to hit the rear window near the corner to shatter the window.

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Operation Doors

Doors Operator Door To open the door from the outside, unlock it with the key provided and pull the handle towards you to release the latch. To open the door from inside, pull the lever towards you. Figure 24. A

A

Lever

Close the door from the inside by pulling it towards you, it will latch itself.

Latch the Door in the Open Position To latch the door in the open position open the door until it latches correctly on the side of the cab. To release the door from the stowed position pull the lever in the cab up.

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Operation Doors

Figure 25.

A

A

38

Lever

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Operation Windows

Windows Front Window Depending on machine specification, windows are provided to function as guards. Damaged windows must be replaced with those of equivalent specification before the machine is used again. Is is the responsibility of the operator to assess whether the attachment they are using and/or the operation they are performing requires the protection offered by a screen. Keep the windows closed when there is a risk of flying debris.

Opening and Closing the Front Upper Window CAUTION Take care when raising and lowering the window. Lower your head as you pull the window back. Isolate the hydraulic controls before opening and closing the window. To open the window: 1. Hold the handles, press and hold down the buttons. 2. Use the handles to lift the window into a position parallel with the roof. 3. Release the buttons to hold the window in position. Make sure the window locates on the latches in the cab roof. Figure 26. C

C

A B C

B

B

A

A

Handles Buttons Latches

To close the window: 1. Hold the handles, press and hold down the buttons. 2. Use the handles to pull the window into a vertical position. 3. Release the buttons to hold the window in position. Make sure the window locates on the latches in the cab front.

Removing and Installing the Front Window Lower Panel When the lower window is removed it must be securely stowed behind the operator seat in its correct stowage position. Before the lower window is removed, turn the ignition off and isolate the machine hydraulics. Refer to: Operation > Locks > Control Lock (Page 64). 39

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Operation Windows

To open the front lower window: 1. For a small amount of ventilation pinch the locks between finger and thumb and move the window down until the locks locate in the lower latch positions. 2. For a larger amount of ventilation the window can be removed. Pinch the locks between finger and thumb and pull the window out of the brackets at the bottom of the frame. Figure 27.

D E F

D

D

E

E

F

F

Locks Lower latch positions Brackets

To stow the front lower window: 1. Locate the bottom edge of the window into the lower latches. 2. Pinch the locks between finger and thumb and locate the locks into the upper latches. Figure 28.

J

G

G

H

G H J

J

H

Locks Lower latches Upper latches

To close the front lower window: 1. Pinch the locks between finger and thumb and return the window to the closed position at the front of the cab.

Side Window The side window is held closed by a latch operated from inside the cab.

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Operation Windows

To open the window, operate the latch and slide the window to the required position. To close the window, slide the window fully shut and check that the latch has located into position at one of the slots. Figure 29. A B

A B

41

Latch Slot

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Operation Sun Visor/Sunblind

Sun Visor/Sunblind Sunblind Standard Sunblind The sunblind is installed in the cab roof and can be secured in three positions: 1. Use the handle in the centre of the sunblind lower edge to pull the sunblind forward. Figure 30.

A

A

Handle

2. Attach both sides of the sunblind edge on to the front hooks or upper hooks. Figure 31.

C

B

B C

Front hooks Upper hooks

3. To release the sunblind, hold the handle, release the bottom edge of the sunblind from the hooks and let the sunblind slowly rewind back into the stowed position.

Optional Sunblind - Full Length The sunblind is installed at the top of the cab front window and can be secured in three positions on the front window or alternatively secured in position on the ceiling: 1. Use the handle in the centre of the sunblind lower edge to pull the sunblind downwards or backwards. 2. Attach both sides of the sunblind edge on to the front hooks or upper hooks. 42

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Operation Sun Visor/Sunblind

3. To release the sunblind, hold the handle, release the bottom edge of the sunblind from the hooks and let the sunblind slowly rewind back into the stowed position. Figure 32. C

C

A

B

B

A B C

B

Handle Front hooks Upper hooks

Optional Sunblind - Half Length The sunblind is installed at the top of the cab front window and can be secured in a position to suit the operator: 1. Use the handle in the centre of the sunblind lower edge to pull the sunblind down to the required position. The sunblind will hold itself in position. 2. To release the sunblind, gently pull the hoop, while holding the handle and let the sunblind slowly rewind back into the stowed position. Figure 33.

B A B 43

A

Handle Hoop

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Operation Before Starting the Engine

Before Starting the Engine General DANGER 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. WARNING Secure all loose articles. 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 could lose control of the machine. CAUTION Machines installed with hose burst protection valves cannot have their attachments lowered with the engine stopped. Start the engine and lower the attachments before doing the walk-around inspection. 1. Read the Operating in Low Temperatures or Operating in High Temperatures procedures in the Operation section if you will be using the machine in very cold or very hot climates. Refer to: Operation > Operating Environment (Page 149). 2. If the fuel tank was empty or if any part of the fuel system has been drained or disconnected, the fuel system must be primed before you try to start the engine. Refer to: Maintenance > Fuel System > General > Bleed (Page 223). 3. 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. Refer to: Operation > Operating Levers/Pedals (Page 97). 4. For your own safety (and others) and for the maximum service life of your machine, do a pre-start inspection before you start the engine. 4.1. If you have not done it, do a walk-around inspection of the outside of the machine. Refer to: Operation > Walk-Around Inspection (Page 31). 4.2. Remove any dirt and rubbish from the cab interior, specially around the pedals and control levers. 4.3. Remove any oil, grease and mud from the pedals and control levers. 4.4. Make sure that your hands and shoes are clean and dry. 4.5. Remove or stow all loose articles in the cab, for example tools. 4.6. Examine the ROPS (Roll-Over Protective Structure), FOPS (Falling Object Protective Structure) and FOGS (Falling Object Guard System) for damage. Get your JCB dealer to repair any damage. Make sure all securing bolts are installed and correctly tightened. Refer to: Maintenance > Operator Station > Operator Protective Structure > Check (Condition) (Page 215). 4.7. Check around the cab for loose or missing bolts, screws etc. Replace or tighten where necessary. 4.8. Check the excavator lever gaiters are not damaged or loose, replace or attach as required with new fasteners. 4.9. Examine the seat belt and its mountings for damage and excessive wear. Refer to: Maintenance > Operator Station > Seat Belt > Check (Condition) (Page 217). 4.10.Make sure that the following operate correctly: lights, horn, all switches, front window washer and wipers (if installed). Refer to: Maintenance > Electrical System (Page 237). 5. Adjust the seat so that you can comfortably reach all the driving controls. You must be able to operate the control pedal with your back against the seat back. Make sure the seat locking lever has fully engaged. Refer to: Operation > Operator Seat (Page 46). 6. Adjust the rear view mirrors (where applicable) to give you a good view close behind the machine, when you are correctly seated. 44

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Operation Before Starting the Engine

7. Fasten the seat belt.

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Operation Operator Seat

Operator Seat General CAUTION Position the seat so that you can comfortably reach the machine controls. Do not adjust the seat while the machine is moving. You could have an accident if you operate the machine with the seat in the wrong position. The operator's seat can be adjusted for your comfort. A correctly adjusted seat will decrease the operator fatigue. Adjust the seat so that you can comfortably reach the machine controls. For driving the machine, adjust the seat so that you can push the pedals fully down when your back is against the seat back. Stop using the machine if the operators seat becomes defective. Repair or replace the seat before using the machine again.

Suspension Seat Seat Adjustments Console Fore/Aft Lift the console fore/aft lever and slide the console into the required position. Release the lever. Make sure the console is locked in position.

Seat Fore/Aft Lift the seat fore/aft lever and slide the seat into the required position. Release the lever. Make sure the seat is locked in position.

Weight Turn the suspension adjuster or the push/pull lever to increase or decrease the suspension of the seat to match the operator weight. Check the indicator.

Backrest Lift the backrest lever and move the backrest to the required angle. Release the lever.

Cushion Tilt - Forward Lift the cushion tilt lever and use your weight to adjust the height of the front of the cushion as required. Release the lever.

Cushion Tilt - Backward Lift the cushion tilt lever and use your weight to adjust the height of the back of the cushion as required. Release the lever.

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Operation Operator Seat

Figure 34.

D

E F

C A

A B C D E F

47

B

Console fore/aft lever Seat fore/aft lever Weight adjuster Back angle adjustment lever Cushion tilt lever - backward Cushion tilt lever - forward

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Operation Seat Belt

Seat Belt General WARNING Operating the machine without a seat belt can be dangerous. Before starting the engine, make sure your seat belt is fastened. Check the tightness and condition of the seat belt securing bolts regularly. WARNING When a seat belt is installed on your machine replace it with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident. Install a new seat belt every three years.

Inertia Reel Seat Belt Fasten the Seat Belt WARNING If you do not wear your seat belt you could be thrown about inside the machine, or thrown out of the machine and crushed. You must wear a seat belt when using the machine. Fasten the seat belt before starting the engine. 1. Sit correctly in the seat. 2. Pull the seat belt and the tongue from the inertia reel holder in one continuous movement. 3. Push the tongue into the latch. Make sure the seat belt is not twisted and that it is over your hips not your stomach. 3.1. If the seat belt 'locks' before the tongue is engaged, let the seat belt retract into the inertia reel holder then try again. The inertia mechanism can lock if you pull the seat belt too quickly or if the machine is parked on an slope. Figure 35.

A

B

A B

Tongue Latch

WARNING! If the seat belt does not 'lock' when you check if the seat belt is operating correctly, do not drive the machine. Get the seat belt repaired or replaced immediately. 4. To make sure the seat belt operates correctly, hold the middle of the seat belt and pull. The seat belt should 'lock'. Refer to Figure 36.

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Operation Seat Belt

Figure 36.

C

D

C D

Seat belt Button

Release the Seat Belt WARNING Release the seat belt only after safely stopping the machine, switching off the engine and engaging the park brake (if applicable). 1. Push the button and pull the tongue from the latch. 2. Carefully let the seat belt retract into the inertia reel holder.

Static Seat Belt Fasten the Seat Belt WARNING If you do not wear your seat belt you could be thrown about inside the machine, or thrown out of the machine and crushed. You must wear a seat belt when using the machine. Fasten the seat belt before starting the engine. 1. Sit correctly in the seat. 2. Push the tongue into the latch. Make sure the seat belt is not twisted and that it is over your hips not your stomach.

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Operation Seat Belt

Figure 37. B

A A B

Tongue Latch

Adjust 1. Move the toggle the required distance down the strap. 2. To make the strap longer, pull the end as far as it will go. 3. To make the strap shorter, pull the end as far as it will go. Figure 38. D A

A B C D

B

C

Tongue Toggle Strap (pull here to lengthen) Strap (pull here to shorten)

Release the Seat Belt WARNING Release the seat belt only after safely stopping the machine, switching off the engine and engaging the park brake (if applicable). 1. Push the button and pull the tongue from the latch.

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Operation Seat Belt

Figure 39. B C

A

A B C

51

Tongue Latch Button

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51


Operation Mirrors

Mirrors General Installation Introduction When they operate the machine, the operator must continually survey their field of vision. It is important that the mirrors are securely installed and give maximum vision around the machine. When a mirror is provided to supplement the operators direct field of vision, it must be adjusted to serve as an aid to the operator in seeing people or obstacles around the machine. The mirror provides indirect vision to hidden areas and improves the effectiveness of the machines usage. A

A B C

52

B

Figure 40.

B

C

Mirror position Mirror position Mirror position

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Operation Mirrors

Cab Mirrors - Position A and B Secure the mirror to the handrail: 1. Secure the mirror support to the handrail with the cap-screws and nuts. 2. Remove the protective cap from the back of the mirror and tighten the nut to secure the mirror to the support. 3. Replace the protective cap after the adjustment. Do not fully tighten the fittings until the mirrors are adjusted correctly. Figure 41.

D,E F

D E F

Cap-screw Nut Protective cap

Rear Mirror - Position C Secure the mirror to the counterweight: 1. Remove the bolt from the mounting lug on the counterweight. 2. Use the bolt, spring washer and washer to secure the mirror support to the counterweight. 3. Remove the protective cap from the back of the mirror and tighten the nut to secure the mirror to the support. 4. Replace the protective cap after the adjustment. Do not fully tighten the fittings until the mirror is adjusted correctly.

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Operation Mirrors

Figure 42.

F

G H

L M F G H L M

Protective cap Bolt Spring washer Washer Mirror support

Hydraulically Raised Cab Mirror Secure the mirror to the screen guard: 1. Use the bolts provided with the mirror support in place of the bolts in the screen guard. 2. Secure the flexible portion of the mirror support with the nuts and bolts. 3. Remove the protective cap from the back of the mirror and tighten the nut to secure the mirror to the support. 4. Replace the protective cap after the adjustment. Do not fully tighten the fittings until the mirror is adjusted correctly. Figure 43. G D,E

F D E F G

Cap-screw Nut Protective cap Bolt

Adjusting the Mirrors 1. Adjust the seat to suit the operator. 2. Adjust the mirror(s) to suit your specific working requirements before you drive or operate the machine. 3. Check the field of vision. 54

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Operation Mirrors

Checking the Field of Vision Cab Mirrors 1. Adjust the seat to suit the operator. 2. Adjust the mirrors. The field of vision shall be such that the operator can see, using the mirrors, at least a flat portion bounded on the left and right of the machine, starting at the rear end of the machine at a height of 1m above ground level and a width of 0.75m, continuing to a width of 3.5m at ground level, 30m behind the rear end of the machine. Figure 44. Side Mirror Y A

V B

X

Z

D

X C

A

A B C D T V X Y Z

55

T Field of vision Filament position centre point Outer borderline Inner borderline Measurement at ground level Measurement at 1m above ground level 3.5m 30m 750mm

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Operation Mirrors

Rear Mirror 1. Adjust the seat to suit the operator. 2. Adjust the mirror. The field of vision shall be such that the operator can see, using the mirror the area of ground directly behind the machine.

Hydraulically Raised Cab Mirror 1. Adjust the seat to suit the operator. 2. Adjust the mirror. The field of vision shall be such that the operator can see, using the mirror the hazardous zone below the cab during raising and lowering and a 1m zone along the side of the machine and front.

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Operation Starting the Engine

Starting the Engine General WARNING Thoroughly warm the hydraulic oil before operating the excavator services. Before selecting boom up, check there are no overhead obstructions or electric power cables. CAUTION Do not use ether or other starting fluids to assist cold starting. Using these fluids may result in an explosion causing possible injury and/or damage to the engine. The engine noise and or tone may be louder than usual when cold. The engine will become quieter when the engine reaches normal operating temperature. 1. Make sure that the machine is ready to start. Refer to: Operation > Before Starting the Engine (Page 44). 2. Make sure the controls isolation lever is raised. 3. If the machine has an immobiliser then you must disarm the immobiliser before you can start the engine. 4. Turn the ignition key to the on position. Figure 45. 0

1 2

3

0 1 2 3

Ignition off/engine stop position Ignition on position Not used Start position

5. Check the DECU (Display Electronic Control Unit) for error messages. Correct any critical faults before starting the engine. 6. Sound the horn as a warning. 7. Turn the ignition key to the start position and hold it there until the engine starts. Do not operate the starter motor for more than: Duration: 15s 8. If the engine does not start, turn the ignition key to the off position. 9. Let the starter motor cool for a few minutes before you repeat the steps 7 and 8. 10. When the engine has started, check the DECU for critical faults. If any critical faults are displayed, stop the engine as soon as it is safe to do so. 11. Warm the engine and hydraulics. Refer to: Operation > Starting the Engine > Warming Up (Page 59).

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Operation Starting the Engine

Immobiliser Introduction If your machine has an immobiliser system installed, then your JCB dealer must enable the system as part of the standard machine installation.

Coded Immobiliser System Introduction Before you try to disarm the immobiliser, make sure that the machine is ready to start and that you have your four digit security code available. If you are unsure of the security code, then do not start this procedure. If the security code is incorrectly entered five times the immobiliser will lock. 15min. If this occurs, it is recommended that you contact the machine owner for confirmation of the security code. The security code must be entered every time that the ignition key is in the off position for more than the time specified. 2min.

Disarm the Immobiliser 1. Put the ignition key in the ignition switch. 2. Turn the ignition key to the on position. 3. Push the rotary control. Refer to: Operation > Instruments > General (Page 69). 4. Turn the rotary control left or right to display the first digit. Figure 46.

5. Repeat for digits 2 to 4. 6. Push rotary control button to finalize the security code entry. 7. If the correct security code is entered, a grey unlocked padlock is displayed momentarily and the machine can be started.

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Operation Starting the Engine

Figure 47.

8. If an incorrect security code is entered a red locked padlock is displayed. Turn the ignition key to the off position and repeat steps 2 to 5. A divided bar under the PIN numbers shows the number of tries left. 8.1. After five failed tries the system will lock. Duration: 15min 8.2. A red locked padlock is displayed with a minute timer. For the time to expire the ignition must be left on. Figure 48.

Arm the Immobiliser 1. Stop the engine. 2. Remove the ignition key. The immobiliser arms automatically after the time specified. Duration: 2min 3. If you restart the engine within the time, the system disarms automatically.

Add/Change/Delete a Security Code Immobiliser codes can only be added, changed or deleted using JCB Servicemaster software. Contact your local JCB dealer.

Warming Up Before starting work in temperatures below -15°C, the hydraulic fluid must be warmed. 1. Warm up the engine. 1.1. Start the engine. 1.2. Do not operate any services. 2. After the warm up period make sure that everyone is clear of the machine. 3. Warm up the hydraulic oil. 3.1. Increase the machine power to maximum. 59

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Operation Starting the Engine

3.2. Warm up the hydraulic oil by repeatedly selecting bucket crowd by moving the right hand lever to the left for: Duration: 5s 3.3. Repeat for several minutes. 3.4. Select dozer up (if installed) by moving the dozer control lever backwards, keep it selected for: Duration: 1min 4. Warm up the hydraulic circuit. 4.1. Decrease the machine power to medium. 4.2. Raise and lower the boom from ground level to full height, five times. 4.3. Move the dipper fully in both directions, five times. 4.4. Rotate the bucket in both directions fully five times. 4.5. Slew the upper structure clockwise for one revolution and stop. 4.6. Slew the upper structure counterclockwise for one revolution and stop. 4.7. Repeat step 4.3 three times. 5. If the operation still appears slow, then repeat the steps 4.2 and 4.3.

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Operation Stopping and Parking

Stopping and Parking General Stopping and Parking DANGER 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. CAUTION Entering or leaving the operator station must only be made where steps and handrails are provided. Always face the machine when entering and leaving. 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 as handholds, use the handrails. 1. Stop the machine. Refer to: Operation > Drive Controls > Track Controls (Page 66). 2. Align the upper structure and undercarriage to allow you to use the handrails and steps. 3. Lower the attachment. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 97). 4. If applicable, lower the dozer blade. Before you stop the engine, run it at idle speed for 30s, to let the turbocharger cool down. 1. Stop the engine. 1.1. Press the controls isolation switch. Refer to: Operation > Locks > Control Lock (Page 64). 1.2. Turn the ignition key to the 0 position. Figure 49. 0 1 2

3

0 1 2 3

Ignition off/engine stop position Ignition on position Not used Start position

2. If you are going to leave the machine, remove the ignition key and make sure that all unnecessary switches are set to off. 3. Leave and secure the machine: 3.1. Lift the controls isolation lever. Refer to: Operation > Locks > Control Lock (Page 64). 3.2. If you are leaving the machine for a long period, close and latch the window(s) and lock the door. 3.3. Use the handrails and steps to leave the cab. Refer to: Operation > Entering and Leaving the Operator Station > General (Page 32). 3.4. Make sure that the fuel filler cap is locked (if a lock is installed). 61

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Operation Preparing for Travel

Preparing for Travel General When you travel on the road or on site there are usually local rules and safety regulations for the machine travel position. This publication contains recommendations that may help you meet the requirements of these regulations, they are not necessarily the applied law. Make sure that before you travel on site, you and your machine comply with all the relevant local laws - it is your responsibility.

Preparing for Worksite Travel 1. Start the beacon, if installed. 2. Move the cab so that it faces forward over the dozer blade. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 97). 3. If applicable, lift the dozer blade. Refer to: Operation > Operating Levers/Pedals > Dozer Blade Controls (Page 108). 4. Uneven worksite conditions: Lower the boom so that the bucket or attachment is clear of the ground. Figure 50.

A

B A B

Beacon 150mm

5. Level worksite conditions: 5.1. Fold the attachment as shown, so that the attachment is a sufficient distance from the ground. Distance: 500mm Figure 51.

Beacon In certain territories you will break the law if you do not install a beacon before you travel on site/public highways, make sure you comply with the local laws. 62

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Operation Preparing for Travel

Be careful when you operate the machine with a beacon. The total height of the machine is increased when the beacon is in the operating position. 1. Put the beacon on the cab roof. A magnetic base keeps the beacon in position. Figure 52. A

C

A B C

B

Beacon Plug Socket

2. Put the plug into the socket. 3. Use the beacon switch in the cab to operate the beacon. The indicator light in the switch illuminates when the beacon is operating. Refer to: About the Product > Console Switches (Page 20).

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Operation Locks

Locks General WARNING The slew lock must be engaged when travelling on road or trailer, otherwise the boom could slew to one side and cause injury or death. The requirement for controls isolation varies according to local legislation. You must comply with local legislation at all times. The controls lock is designed to isolate the control(s) in the neutral position. You must isolate the controls before you travel on public roads.

Control Lock Isolate the Hydraulic Controls There are two methods of isolating the machines hydraulic controls: 1. Raise the controls isolation lever. Refer to: Operation > Locks > Control Lock (Page 64). 2. Push the controls isolation switch. Refer to: About the Product > Console Switches > Control Locks (Page 21). If either of the two methods of isolating the hydraulic controls is used, the other method cannot be used to reactivate the controls. WARNING! Activate the drive and lift arm isolation switches when you are not operating the machine, to avoid accidentally operating the controls and causing a dangerous movement of the machine. Before adjusting the cab environment, e.g. opening the windows or adjusting the seat, you must always isolate the controls by activating drive and lift arm isolate switches.

Enable the Controls To enable the machines hydraulic controls: 1. If the controls isolation lever is raised to isolate the controls, lower it to enable the controls. 2. Push the controls isolation switch after lowering the controls isolation lever to enable the controls. If the controls isolation switch was pushed to isolate the controls, push it a second time to enable the controls.

Controls Isolation Lever Raise the controls isolation lever to isolate the hydraulic controls. The isolation of the controls is an integral part of the safety procedure for leaving the cab. Lower the controls isolation lever to enable the hydraulic controls.

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Operation Locks

Figure 53. A

A

65

Controls isolation lever

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Operation Drive Controls

Drive Controls Track Controls WARNING When the cab is swung around so that it is facing the track motor end of the undercarriage, the action of the track controls is reversed. Take extra care! The two levers/foot pedals at the front of the cab control the travel. The left travel lever and pedal are connected, so are the right travel lever and pedal. To control the travel either can be used. Each travel lever/pedal controls the track on the same side. For example the left travel lever controls the left track when the cab faces forwards, (towards the recoil units). Before a travel lever/pedal is moved, check if the undercarriage faces forwards or backwards. Figure 54. B A

D

A B C D

C

Left travel lever Right travel lever Right travel pedal Left travel pedal

Do not travel with the track motors in front, particularly on hard or rocky ground. The recoil units will not be able to absorb the shocks and damage can be caused to the track running gear. When the machine is not travelling, do not put your feet on the travel pedals. Push the left and right travel levers slowly forwards, to travel forwards or pull them towards you, to travel backwards.

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Operation Drive Controls

Figure 55.

To turn the machine to the right, push the left travel lever forwards. To turn the machine to the left, push the right travel lever forwards. If the travel speed selector is set to fast speed and the travel levers are operated quickly, the machine will start quickly. Refer to: Operation > Drive Controls > Travel Speed Selector (Page 67). The simultaneous movement of the left and right travel levers, moved in the opposite directions will cause the machine to turn around its centre. To move the machine backwards in a straight line pull both levers in a backwards motion equally. Both tracks will operate in a reverse direction.

Travel Speed Selector Figure 56.

AUTO

n/min n/min

H+

A

A

Travel speed change button

The travel speed of the machine can be changed between fast, creep and slow. (The travel speed is recorded when the engine is shut-down and the travel speed is re-applied at the next engine start-up). Each press of the travel speed change button selects as follows: Fast, Slow, Creep, Slow, Fast, Slow, Creep etc. Dependant on the machine software installed it may be necessary to press and hold the travel speed change button for 1.5s to select creep speed. 67

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Operation Drive Controls

The travel speed selected is shown in the top left corner of the DECU (Display Electronic Control Unit): Figure 57. B

B C D

68

C

D

Fast (hare) Slow (tortoise) Creep (snail)

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Operation Instruments

Instruments General Machine Power Band Controller The machine power band controller matches engine speed and hydraulic pump output dependant on the machine power selected by the operator. Machine power can be varied from Light (L), General (G), Heavy (H) and Heavy Plus (H+) using the rotary control. The machine power selected is displayed on the DECU (Display Electronic Control Unit) with bars. Refer to: Operation > Instruments > Instrument Panel (Page 70). Small, slow rotation of the rotary control offers precise control of machine power. Large, fast rotation of the rotary control gives a large jump up or down the power band. Figure 58.

L

G

H

H+

Table 9. Display Bars 0 1 2 3 4 5 6 7 8

Machine Power Idle L1 L2 L3 G1 G2 G3 H H+

At idle and low power there will be no bars on the DECU. Powers L1,L2 and L3 are for precision and lifting operations. These powers give you low hydraulic pump flow but permanent high pressure (two stage relief activated). This allows a precise control of the services for accuracy. The auto idle function is not active, only one touch idle can be used. Overload caution is on Powers G1,G2 and G3 are for general operations. These powers have increased engine speed, increased hydraulic pump flow without permanent power boost. These powers are for general digging and loading work with good fuel efficiency. Power boost is selectable. The DECU will not give any indication if you use the power boost button. Each power boost will give you 3s of higher hydraulic power for extra tearout. Once the 3s has elapsed the system will automatically deactivate for 9s. The DECU will not give any indication of this occurring. Power H is for heavy duty operations. Fuel economy is reduced. High speed operation of all hydraulic functions/ services is enabled. Selectable power boost is also available as per general mode. H+ is for very heavy digging or increased work output. To select H+ first select power H using the rotary control. Then press the H+ button on the power band controller to select H+ power. If the machine power does not change even after turning the control it is because the auto idle button or one touch idle is selected. Refer to Figure 59. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 97). When the engine is started in ambient temperatures between -19°C and 2°C the machine will default to engine idle for between 2s and 30s Press the automatic idle button to activate the automatic engine idle system. The engine speed will drop to idle when the machine has been idle for 5 seconds. The time delay can be adjusted by the DECU. 69

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Operation Instruments

A

Figure 59.

B

AUTO

n/min n/min

C

H+

A B C

Rotary control Automatic idle button H+ button

Instrument Panel The DECU (Display Electronic Control Unit) is located at the front of the cab in the line of sight from the operator's seat. It provides the interface with the machines electronic system.

4 Inch Colour Display The display has mechanical gauges for fuel level and engine coolant temperature as well as a digital display. Figure 60.

7 Inch Colour Display The display is digital. The display can incorporate images from multiple cameras (option). When the operator switches of the ignition and leaves the cab (closing the door) the display will remain in a sleep state for 90min. After this time the display will automatically shut-down. 70

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Operation Instruments

To wake the display from sleep state open the cab door. The display will become active within 12s. During this time it is still possible to start the engine. Figure 61.

Camera System WARNING The camera system is a supplementary vision device that requires the operator to use it in conjunction with the rear view mirror and side mirrors for maximum coverage. WARNING If the camera image is not clear or seems distorted, it may be covered with water droplets, snow, mud or any other substance. If this occurs, clean the camera lens before using the camera system. Clean the lens with a soft, lint-free cloth and non-abrasive cleaner. The camera(s) contain automatic heaters that de-mist/de-frost the lens automatically. Do not rely on the rear view camera system when operating from cold until the heaters have cleared the lens. If the image is still not clear after cleaning/heating, have the system inspected by your JCB dealer. WARNING Objects displayed may be closer than they appear WARNING At night or in dark areas, the camera system relies on the counterweight lamp for light, therefore it is important that the counterweight lamp is operating correctly to obtain a clear image on the display. If the lamp is not operating correctly stop using the camera system, at least in the dark, until the lamp repaired. WARNING Objects that are close to the corners of the counterweight or under the bodywork may not be visible on the display due to the limited coverage of the camera system. NOTICE Reverse as slowly as possible since higher speeds may limit your reaction time to stop the machine. If the rear of the machine is hit or damaged, ask your JCB dealer to check the camera system for correct coverage and operation. When a 7inch display is installed the machine can also be installed with one or two cameras. Camera one is a rear view camera. Camera two is a side camera. Camera one can be displayed in the bottom half of the display only. Camera two can be displayed in the top or bottom half of the display. The rear view camera can be shown normal or mirrored for operator preference. To view a camera on the display: 1. Press the home button twice. 2. Select either the top left or bottom of the screen with the rotary control and select button. Select a camera with the rotary control and select button. When selecting camera one it can be selected as a normal image or a mirrored image 71

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Operation Instruments

3. Press the home button. Figure 62.

2

1 1 2

1

Camera one bottom of screen, normal. Camera two, top of screen. Figure 63.

2

1

1 1 2

Camera one bottom of screen, mirrored Camera two, top of screen.

If the back button is pressed whilst cameras one and two are displayed on the screen the home screen is shown for 3s.

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Operation Instruments

Controls Figure 64. A

B

C

G A B C D E F G

E

D

F

Back button Minus button Home button Plus button Enter button Rotary control and select button Fault indicator

Press the home button to return to the home screen. Press the back button to return to the previous screen. Press the minus key to decrease a numerical entry. When at the home screen, press the minus key to decrease the display brightness. Press the plus key to increase a numerical entry. When at the home screen, press the plus key to increase the display brightness. Press the enter key to enter a numerical entry or command into the display. Use the control wheel to navigate through the various screens. Press the button to select an item. The fault indicator is wired direct to the machine ECU (Electronic Control Unit) and will function even if the display fails. If the indicator illuminates red, stop the machine and turn off the engine as soon as it is safe to do so. If the indicator illuminates amber, proceed with caution, stop the machine and turn off the engine as soon as it is safe to do so.

Display Screens Start-Up Screen When the cab door is opened the JCB logo is displayed followed by a machine hours, hours to service and fuel level screen. The 7 Inch display shows a egg timer next to the JCB logo to indicate it is loading.

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Operation Instruments

Figure 65.

Figure 66.

The work lights screen is displayed to warn that the work lights are left on and the ignition is off. The buzzer will sound in this state after 15s. Figure 67.

Immobilizer Screen If the JCB immobilizer option is enabled the operator must enter the 4 digit immobilizer code before the engine will start. Refer to: Operation > Starting the Engine > Immobiliser (Page 58). Figure 68.

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Operation Instruments

Main Display Screens After the engine has been started the operator can select one of three main display screens using the control wheel. Turn the rotary control right or left to navigate the screens. Default Operating Screen (Home Screen) Displays the engine speed, inside and outside air temperature, selected travel speed, time, isolator status. Figure 69. F B

A

E

D A B C D E F

C

Travel speed Auto idle/Controls isolation Clock Inside/outside temperature, Fan speed, A/C Engine speed Power band

Customisation of the Home Screen To personalise the split screen home screen: 1. Press the home button to display the home screen. 2. Press the home button again. A split screen with the right side highlighted is displayed. 3. Use the rotary controller to choose the right side split screen. 4. Press select to confirm. A split screen with the left side highlighted is displayed. 5. Use the rotary controller to choose the left side split screen. 6. Press select to confirm. If either side of the screen is left blank then the home screen shall revert to a single screen.

Second Level Display Screens Pressing the control wheel on any one of the three main display screens will take the operator to the second level display screens. Turn the rotary control right or left to navigate the screens.

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Operation Instruments

Machine Status Figure 70.

Press the rotary control again to display machine status information. Turn the rotary control to switch between screen 1 and 2. Press the back button to return. Figure 71. A B C D A B C D

Battery voltage Alternator voltage Coolant temperature Hydraulic temperature Figure 72. E F G

E F G

Barometric pressure Hydraulic pump current Engine speed

Service Information Figure 73.

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Operation Instruments

Press the rotary control again to display service information. Turn the rotary control to switch between screen 1 and 2. Press the back button to return. Figure 74. A B C D A B C D

Engine hours Machine type Vehicle identification number Time to next service Figure 75. E F G H J

E F G H J

Display ECU software version Machine ECU software version Hydraulic ECU software version Wheeled ECU software version LiveLink software version

User/Machine Information Figure 76.

Press the rotary control again to display user/machine information. Turn the rotary control to switch between screens 1, 2 and 3. Press the back button to return. Press the rotary control again on screens 1 to 3 to change settings.

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Operation Instruments

Figure 77. A B C D A B C D

Time Date Units Display brightness Figure 78. A B C D

A B C D

Auto refuel maximum level Auto idle time Kerosene Overload warning system Figure 79. A B C

A B C

Slew/boom priority default Dipper arm limiter setup ISO/SAE controls selection

Error Log Figure 80.

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Operation Instruments

Press the rotary control again to display a list of the machine faults recorded. Turn the rotary control to switch between screens 1 and 2. Press the back button to return. Figure 81.

Figure 82.

The fault log screen is used to provide information on the active and previously active faults on the machine. The fault log display screen displays the fault code, time, date, engine hours and number of times that the fault has been active. By default, the fault log display shall only display active faults. It shall be possible to view active and historical faults by going to the diagnostic menu. Faults shall be displayed in the colour of their severity (critical = red, warning = yellow, trivial = gray). GPS Figure 83.

Press the rotary control again to display the GPS position of the machine. Press the back button to return.

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Operation Instruments

Figure 84.

Attachments- Basic Tool Select Figure 85.

Press the rotary control again to change between hammer and auxiliary mode. A tick next to the hammer enables hammer. A cross next to the hammer enables auxiliary. Figure 86.

Press the rotary control to access the auxiliary settings. Press the back button to return to the home screen. Figure 87.

Turn the rotary control clockwise to scroll down the list and counter clockwise to scroll up the list.

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Operation Instruments

Figure 88.

Turn the rotary control until the High flow auxiliary is selected then press the rotary control. Figure 89.

Turn the rotary control to change the setting. Press the back button to return to the auxiliary settings. Machines can be equipped with Hydraulic High Flow Circuits in 3 types. • • •

High Flow Single Direction – The Oil only flows one way through the Boom Pipes (If an Auger were fitter it would only rotate one way). High Flow Two Direction – The Oil can flow two ways through the Boom Pipes (If an Auger were fitted it could rotate both ways). Super High Flow Two Direction Merged – The Oil from the combined output of two pumps can flow two ways through the Boom Pipes (If an Auger were fitted it could rotate both ways). Figure 90. High Flow Auxiliary Off

Figure 91. High Flow Hammer

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Operation Instruments

Figure 92. High Flow Auxiliary Single Direction

Figure 93. High Flow Auxiliary Two Direction

Figure 94. Super High Flow Auxiliary Two Direction

Figure 95.

Turn the rotary control until the flow rate is selected then press the rotary control. Figure 96.

Turn the rotary control to change the flow rate to the desired level. press the back button to return to auxiliary settings. The default pressure for all selectable flow settings is 170bar. 82

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Operation Instruments

Attachment- Advanced Tool Select Figure 97.

From the home screen, Advanced Tool Select is accessed by selecting the attachment icon. Figure 98.

In the attachment overview screen,turn the rotary control to scroll through the available attachments. Press the rotary control to set the highlight attachment as being active or inactive. If the attachment is active, it will shown in green. Figure 99.

Press enter on the display to show the attachment detail screen. The attachment detail screen are presented with the attachment type and can scroll to either the high or low flow settings for this attachment. Press the back button to return to the previous screen. Press the home button to return to the home screen. To edit the attachment setting go back to the attachment overview screen and press and hold the rotary control on your selected attachment for 5s seconds.

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Operation Instruments

Figure 100.

The attachment settings can then be modified by selecting the attachment and entering the attachment detail screen using the rotary control. Figure 101.

The attachment type can be changed from any of the icons as shown above. To edit the High-Flow settings: Figure 102.

High-Flow control type select from: •

Single direction high-flow Figure 103.

84

Two direction high-flow

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Operation Instruments

Figure 104.

Two direction super high-flow Figure 105.

High-Flow operating flow- This is normally set according to the recommended flow rating on the attachment data sheet but can be adjusted lower to optimize attachment performance.

High-Flow operating pressure- This is set normally between 20–50bar below the ARV (Auxiliary Relief Valve) pressure and can be adjusted to optimize attachment performance.

High-Flow ARV pressure- This is set according to the recommended pressure rating on the attachment data sheet.

To edit the Low-Flow settings: Figure 106.

Low-Flow operating flow- This is normally set according to the recommended flow rating on the attachment datasheet but can be adjusted lower to optimize attachment performance.

Low-Flow operating pressure- This is set normally between 10–30bar below the ARV pressure and can be adjusted to optimize attachment performance.

Low-Flow ARV pressure- This is set according to the recommended pressure rating on the attachment data sheet.

Make the attachment active in the attachment overview screen to be begin operation.

Faults If a service fault is recognised by the machines electronic system a fault icon and fault code is displayed on the right side of the home screen. The fault indicator is illuminated amber. The buzzer sounds momentarily when 85

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Operation Instruments

a service fault is active. The code will remain until it is acknowledged by pressing the enter button. The fault indicator remains on if the fault is acknowledged with the enter button. If multiple service faults are active, the fault screen (icon and fault code) shall alternate through the active faults. Figure 107.

When a critical fault is active, the left area of the main screen will show the fault icon and the right area of the main screen will show the 3 or 4 digit fault code. The fault indicator is illuminated red. The buzzer sounds when a critical fault is active. It sounds until the critical fault is no longer active. The active fault screen alternates with the standard main screen but with a colour substitution: Figure 108.

Figure 109.

If multiple critical faults are active, the fault screen (icon and fault code) shall alternate through the active critical faults). Pressing the control wheel will take the operator to the active error log screen. Press enter on this screen to acknowledge all active faults. Critical faults take precedence over service faults. If both service and critical faults are active, only critical faults shall be displayed.

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Operation Instruments

Figure 110.

Notification Symbols Table 10. Quickhitch entry

Quickhitch hose reminder

Quickhitch exit and confirm

Boom and dipper not aligned

Boom aligned, dipper not aligned

Boom not aligned, dipper aligned

Boom and dipper aligned

Boom and dipper aligned, crowd pressed raised

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Operation Instruments

Boom and dipper aligned, crowd pressure raised, joystick unlock button pressed.

Hammer engaged (green)

Hammer overwork alarm (amber)

Hammer overwork alarm (red)

Engine automatic warm-up (blue)

Cold Idle (blue)

Engine pre-heat (amber)

Engine stop (red)

Work lights (amber). Warns that the work lights are on and the ignition is off. The buzzer will sound in this state after 15.

Overload caution alarm (red)

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Operation Instruments

Overload caution enabled (green)

Scrap magnet (amber)

Throttle recalibrate (amber). Informs the operator that they must calibrate the throttle in order to control the engine speed.

Engine shutdown (red)

Service event (amber). When a service is required the service symbol is displayed and the fault indicator is illuminated amber. They remain on even when the operator turns the ignition switch off and on. The service should be performed by your JCB dealer. The symbol and fault indicator can only be cancelled by your JCB dealer. Engine oil change event (amber). When an engine oil change is required the oil change symbol is displayed and the fault indicator is illuminated amber. They remain on even when the operator turns the ignition switch off and on. The operator can perform the oil change and then cancel the symbol and fault indicator by pressing the enter button. When the operator has pressed the enter button, the display will set the time for the next service event from the time when the enter button was pressed. Diesel particulate filter regeneration (red) (if fitted). DPF is in regeneration mode.

Diesel particulate filter regeneration (red) (if fitted). Regeneration mode required.

Seat belt/occupancy (red)

Water in fuel (amber)

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Operation Instruments

Hydraulics oil temperature high (red)

Hydraulic oil temperature high (amber)

Fuel level low (amber)

Coolant temperature high (amber)

Engine (amber)

Engine (red)

Engine oil pressure low (red)

Engine oil level low (amber)

Coolant temp high (red)

CAN lost communications (red)

Coolant level low (amber)

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Operation Instruments

Battery no charge (amber)

Air filter blocked (amber)

Livelink (amber)

Livelink (red)

Buzzer The buzzer is activated to notify the operator of a message or a fault. Some messages/faults are acknowledgeable and will silence the buzzer and some messages/faults are not acknowledgeable and the buzzer will continue until the message/fault clears. If a message/fault is acknowledgeable, it can be silenced by pressing the enter button on the display. The buzzer will come on constantly while the Quickhitch mode is enabled and is not acknowledgeable. The buzzer will change to an intermittent signal while the Quickhitch is unlocked and is not acknowledgeable.

Throttle Motor Calibration (Where applicable) Mechanical Engine Engine speed is controlled by the MECU. The display is used to help calibrate the throttle. The following procedure will calibrate the throttle. 1. Start the engine 2. Navigate to the machine set-up menu 3. Use the rotary control to select the Throttle Calibrate icon. 4. Press the rotary control. The display will show RPM and Throttle % during the calibration process. The calibration screen will show a cross when calibration is required/aborted/failed a timer when calibration is in progress and a tick when the calibration is complete. Once the calibration is complete the display will exit calibration mode and the operator will have full control of the throttle.

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Operation Getting the Machine Moving

Getting the Machine Moving General Moving the Machine 1. Prepare the machine. Refer to: Operation > Preparing for Travel (Page 62). 2. Select a general power band. Refer to: Operation > Instruments > General (Page 69). 3. Check the area around the machine, then sound the horn to warn other personnel of a machine operation. 4. Use the track controls to move the machine in the required direction. Refer to: Operation > Drive Controls > Track Controls (Page 66). 5. Do not change the travel speed when the machine is moving. Stop the machine, then change the travel speed. Refer to: Operation > Drive Controls > Travel Speed Selector (Page 67).

Stability Pull the dig end close when you travel, to improve the stability of the machine.

Decreasing the Machine Wear When you travel on level ground keep the drive sprockets at the rear. If the drive sprockets are at the front, the tracks could wear prematurely. Figure 111.

If you travel with the track raised on one side, it increases the load on the other side of the undercarriage. If possible to decrease the wear, travel on level ground. Figure 112.

If you travel while using the dig end, it increases the load on the undercarriage and increases its wear.

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Operation Getting the Machine Moving

Figure 113.

When a track comes off the ground, the track will loosen and the track rollers may come off their links. On hard surfaces the shock forces are larger and have an adverse effect on the undercarriage. Always keep the correct track tension. Figure 114.

When the machine is operated on muddy ground, the tracks will fill with mud. If the machine travels in this condition it will cause wear to the tracks. To decrease the wear, lift one track off of the ground at a time and turn the track to remove the mud. Figure 115.

If the machine travels over obstacles for example tree stumps and rocks, the track shoes may bend and a high load will be applied to the individual track pins. Figure 116.

If the machine must travel over such obstacles, drive the centre of the track shoes over the obstacles.

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Operation Getting the Machine Moving

Figure 117.

When you travel over a mound, always support the chassis with the dig end to prevent shock loads. Figure 118.

Figure 119.

1

2

3

4

5

When the machine travels for long distances heat is generated in the undercarriage, which causes increased wear. When possible, stop the machine and let it cool down. Figure 120.

If the track comes off the ground, the track will loosen. When you slew the machine, if the track is too loose the track roller can ride up on the link. Always keep the correct track tension. Figure 121.

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Operation Driving the Machine

Driving the Machine General WARNING When the cab is swung around so that it is facing the track motor end of the undercarriage, the action of the track controls is reversed. Take extra care! CAUTION Drive the machine smoothly. Spin turn manoeuvres, zig-zag driving or turning too fast can cause the vehicle to overturn. The track controls operate as described when the excavator is positioned about the dozer. If the excavator is at the opposite end to the dozer, the lever operation will be reversed. Always travel the machine with the excavator positioned at the same end as the dozer, especially on hard and rocky ground. Ensure you have complete field of vision when driving the machine. To move the machine forward, push both levers forward. Release the levers to stop. Track motor braking occurs automatically when the levers are released. To move the machine backward, pull both levers backward. Release the levers to stop. Track motor braking occurs automatically when the levers are released. Figure 122. A

A B

B

Forward travel Backward travel

To turn the machine while you travel, move the lever back towards the central position on the side towards which direction you want to go, for example, 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. Figure 123.

C

D

C D

Turn right Turn left

To spin the machine around through 360°, 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. Figure 124. E

E

E F

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F

F

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Operation Driving the Machine

Towing Other Equipment A light duty tow eye is attached to the undercarriage. The maximum tow capacity of the tow eye is 25% of the machine weight. Do not exceed the maximum tow capacity of the tow eye. Use the minimum force to move the equipment slowly (not greater than 2km/h) smoothly and without shocks. Do not use the tow eye to retrieve the machine, as this will cause damage.

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Operation Operating Levers/Pedals

Operating Levers/Pedals General WARNING Make sure it is clear overhead before raising the boom. Keep an adequate safe distance from all electrical power lines. Contact your local power company for safety procedures. CAUTION Keep the machine controls clean and dry. Your hands and feet could slide off slippery controls. If that happens you could lose control of the machine.

Control Layouts WARNING Control lever/switch action may vary on machines, instructional labels near the levers/switches show by symbols, which levers/switches cause what actions. Before operating control levers/switches check the instructional label to make sure you select the desired action. The control levers and switches may vary on machines.

Excavator Arm Controls For: JS200., JS210., JS220., JS230. ....................................................................................... Page 97 For: JS370 .............................................................................................................................. Page 103

(For: JS200., JS210., JS220., JS230.) Introduction NOTICE Do not excavate on hard or rocky ground with the boom positioned diagonally across the undercarriage. The resulting rocking motion could cause damage to the track gearbox sprockets and tracks. NOTICE When carrying out deep digging it is advisable to have the super structure swung in line with the chassis. It is possible that part of the dig end may contact the machine. Take extra care when digging to avoid damaging the machine. The excavating is controlled mainly by the movements of the left and right excavator joystick controllers. Many of the excavating movements are a combination of two (or more) movements at the same time, which requires practice. Practice the movements singly at first and then in combination, until you are completely familiar with the effects of all the controls. Before you start to excavate, make sure that the controls isolation lever is down and the slew lock and isolator switches are off. Use the label on the front window to remind you of the operating patterns when you move the excavator joystick controllers. When the engine has stopped, there will be sufficient pressure available for a limited time to enable the boom/ dipper to be lowered to a safe position.

ISO/CHINESE Controls This machine's operation conforms to the ISO operating method unless they have the ISO to CHINESE option installed. With this option the machines excavating controls can be set to one of two operating patterns, ISO or CHINESE. These operating patterns are shown on a label on the front window. Use the DECU (Display Electronic Control Unit) to select the different operating patterns. Refer to: Operation > Instruments > Instrument Panel (Page 70).

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Operation Operating Levers/Pedals

ISO Pattern Right Joystick NOTICE In some instances it may be possible to hit the cab with the bucket or attachment. To prevent damage care should be taken when operating with the bucket/attachment close to the cab. The right hand joystick controls the movements of the boom and the bucket. When released, the joystick returns to the neutral position. The boom will move within its limits for as long as you hold the joystick forward or backwards. It will stop automatically when you release the joystick. To raise the boom, pull the joystick backwards (position 1). To lower the boom, push the joystick forwards (position 2). If the engine stops and will not re-start, to lower the attachment the ground: 1. Make sure the ignition is on. 2. Make sure the controls isolation lever is down and the controls isolation switch is off. Refer to: Operation > Locks > Control Lock (Page 64). 3. Push the joystick forwards (position 2). The bucket will move within its limits for as long as you hold the joystick to one side. It will stop automatically when you release the joystick. To fill the bucket, move the joystick to the left (position 3). To empty the bucket, move the joystick to the right (position 4). Press the one touch idle switch to instantly change the engine rpm back and forth between that selected for working and a low idling speed. Figure 125. 1

2 A

3

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4

3

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4 1 98

Backward: Raise the boom 9821/3250-3

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Operation Operating Levers/Pedals

2 3 4 A

99

Forward: Lower the boom Left: Fill the bucket Right: Empty the bucket One touch idle

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Operation Operating Levers/Pedals

Left Joystick The left hand joystick controls the slew of the superstructure and the movements of the dipper. When released, the joystick returns to the neutral position. The superstructure will slew within its limits for as long as you hold the joystick over to one side. It will stop automatically when you release the joystick. When the joystick is returned to neutral, the machine will still not stop moving immediately because of inertia. Remember this when you do a slew operation. The operation of the bucket attachment is reversed when it is installed in the reverse position, be careful. To slew to the left, move the joystick to the left (position 1). To slew to the right, move the joystick to the right (position 2). The dipper will move within its limits as long as you hold the joystick forward or backwards. It will stop automatically when you release the joystick. To move the dipper outwards, move the joystick forwards (position 3). To move the dipper inwards, move the joystick backwards (position 4). Press the horn switch to sound the horn, to give a signal before the machine is started or before you engage travel or slew. Figure 126.

3 A 4

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3

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100

Left: Slew to the left Right: Slew to the right Forward: Move the dipper outwards Backward: Move the dipper inwards Horn

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Operation Operating Levers/Pedals

CHINESE Pattern Right Joystick NOTICE In some instances it may be possible to hit the cab with the bucket or attachment. To prevent damage care should be taken when operating with the bucket/attachment close to the cab. The right hand joystick controls the movements of the dipper and the bucket. When released, the joystick returns to the neutral position. The dipper will move within its limits for as long as you hold the joystick forward or backwards. It will stop automatically when you release the joystick. To move the dipper outwards, move the joystick forwards (position 2). To move the dipper inwards, move the joystick backwards (position 1). The bucket will move within its limits for as long as you hold the joystick to one side. It will stop automatically when you release the joystick. To fill the bucket, move the joystick to the left (position 3). To empty the bucket, move the joystick to the right (position 4). Press the one touch idle switch to instantly changes the engine rpm back and forth between that selected for working and a low idling speed. Figure 127. 1

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4 1 2 3 4 A

101

Backward: Raise the boom Forward: Lower the boom Left: Fill the bucket Right: Empty the bucket One touch idle

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Operation Operating Levers/Pedals

Left Joystick The left hand joystick controls the slew of the superstructure and the movements of the boom. When released, the joystick returns to the neutral position. The superstructure will slew within its limits for as long as you hold the joystick over to one side. It will stop automatically when you release the joystick. When the joystick is returned to neutral, the machine will still not stop moving immediately because of inertia. Remember this when you do a swing operation. The operation of the bucket attachment is reversed when it is fitted in the reverse position, be careful. To move the dipper outwards, move the joystick to the left (position 1). To move the dipper inwards, move the joystick to the right (position 2). The dipper will move within its limits for as long as you hold the joystick left or right. It will stop automatically when you release the joystick. To slew to the right, push the joystick forwards (position 3). To slew to the left, pull the joystick backwards (position 4). If the engine stops and will not re-start, to lower the attachment the ground: 1. Make sure the ignition is on. 2. Make sure the controls isolation lever is down. 3. Make sure the controls isolation switch button is off. 4. Move the joystick to the right (position 2). Press the horn switch to sound the horn. Sound the horn to give a signal before the machine is started or before you engage travel or slew. Figure 128.

3 A 2

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2

1

4

3 4 1 2 102

Left: Move the dipper outwards Right: Move the dipper inwards 9821/3250-3

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Operation Operating Levers/Pedals

3 4 A

Forward: Slew to the right Backward: Slew to the left Horn

(For: JS370) Introduction NOTICE Do not excavate on hard or rocky ground with the boom positioned diagonally across the undercarriage. The resulting rocking motion could cause damage to the track gearbox sprockets and tracks. NOTICE When carrying out deep digging it is advisable to have the super structure swung in line with the chassis. It is possible that part of the dig end may contact the machine. Take extra care when digging to avoid damaging the machine. The excavating is controlled mainly by the movements of the left and right excavator joystick controllers. Many of the excavating movements are a combination of two (or more) movements at the same time, which requires practice. Practice the movements singly at first and then in combination, until you are completely familiar with the effects of all the controls. Before you start to excavate, make sure that the controls isolation lever is down and the slew lock and isolator switches are off. Use the label on the front window to remind you of the operating patterns when you move the excavator joystick controllers. When the engine has stopped, there will be sufficient pressure available for a limited time to enable the boom/ dipper to be lowered to a safe position.

ISO/CHINESE Controls This machine's operation conforms to the ISO operating method unless they have the ISO to CHINESE option installed. With this option the machines excavating controls can be set to one of two operating patterns, ISO or CHINESE. These operating patterns are shown on a label on the front window. Use the DECU to select the different operating patterns. Refer to: Operation > Instruments > Instrument Panel (Page 70).

ISO Pattern Right Joystick NOTICE In some instances it may be possible to hit the cab with the bucket or attachment. To prevent damage care should be taken when operating with the bucket/attachment close to the cab. The right hand joystick controls the movements of the boom and the bucket. When released, the joystick returns to the neutral position. The boom will move within its limits for as long as you hold the joystick forward or backwards. It will stop automatically when you release the joystick. To raise the boom, pull the joystick backwards (position 1). To lower the boom, push the joystick forwards (position 2). If the engine stops and will not re-start, to lower the attachment the ground: 1. Make sure the ignition is on. 2. Make sure the controls isolation lever is down and the controls isolation switch is off. Refer to: Operation > Locks > Control Lock (Page 64). 103

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Operation Operating Levers/Pedals

3. Push the joystick forwards (position 2). The bucket will move within its limits for as long as you hold the joystick to one side. It will stop automatically when you release the joystick. To fill the bucket, move the joystick to the left (position 3). To empty the bucket, move the joystick to the right (position 4). Press the one touch idle switch to instantly change the engine rpm back and forth between that selected for working and a low idling speed. Figure 129. 1

2 A

3

2

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3

1

4 1 2 3 4 A

104

Backward: Raise the boom Forward: Lower the boom Left: Fill the bucket Right: Empty the bucket Power boost

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Operation Operating Levers/Pedals

Left Joystick The left hand joystick controls the slew of the superstructure and the movements of the dipper. When released, the joystick returns to the neutral position. The superstructure will slew within its limits for as long as you hold the joystick over to one side. It will stop automatically when you release the joystick. When the joystick is returned to neutral, the machine will still not stop moving immediately because of inertia. Remember this when you do a slew operation. The operation of the bucket attachment is reversed when it is installed in the reverse position, be careful. To slew to the left, move the joystick to the left (position 1). To slew to the right, move the joystick to the right (position 2). The dipper will move within its limits as long as you hold the joystick forward or backwards. It will stop automatically when you release the joystick. To move the dipper outwards, move the joystick forwards (position 3). To move the dipper inwards, move the joystick backwards (position 4). Press the horn switch to sound the horn, to give a signal before the machine is started or before you engage travel or slew. Figure 130.

3 A 4

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105

Left: Slew to the left Right: Slew to the right Forward: Move the dipper outwards Backward: Move the dipper inwards Horn

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Operation Operating Levers/Pedals

CHINESE Pattern Right Joystick NOTICE In some instances it may be possible to hit the cab with the bucket or attachment. To prevent damage care should be taken when operating with the bucket/attachment close to the cab. The right hand joystick controls the movements of the dipper and the bucket. When released, the joystick returns to the neutral position. The dipper will move within its limits for as long as you hold the joystick forward or backwards. It will stop automatically when you release the joystick. To move the dipper outwards, move the joystick forwards (position 2). To move the dipper inwards, move the joystick backwards (position 1). The bucket will move within its limits for as long as you hold the joystick to one side. It will stop automatically when you release the joystick. To fill the bucket, move the joystick to the left (position 3). To empty the bucket, move the joystick to the right (position 4). Press the one touch idle switch to instantly changes the engine rpm back and forth between that selected for working and a low idling speed. Figure 131. 1

2 A

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1

4 1 2 3 4 A

106

Backward: Raise the boom Forward: Lower the boom Left: Fill the bucket Right: Empty the bucket Power boost

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Operation Operating Levers/Pedals

Left Joystick The left hand joystick controls the slew of the superstructure and the movements of the boom. When released, the joystick returns to the neutral position. The superstructure will slew within its limits for as long as you hold the joystick over to one side. It will stop automatically when you release the joystick. When the joystick is returned to neutral, the machine will still not stop moving immediately because of inertia. Remember this when you do a swing operation. The operation of the bucket attachment is reversed when it is fitted in the reverse position, be careful. To move the dipper outwards, move the joystick to the left (position 1). To move the dipper inwards, move the joystick to the right (position 2). The dipper will move within its limits for as long as you hold the joystick left or right. It will stop automatically when you release the joystick. To slew to the right, push the joystick forwards (position 3). To slew to the left, pull the joystick backwards (position 4). If the engine stops and will not re-start, to lower the attachment the ground: 1. Make sure the ignition is on. 2. Make sure the controls isolation lever is down. 3. Make sure the controls isolation switch button is off. 4. Move the joystick to the right (position 2). Press the horn switch to sound the horn. Sound the horn to give a signal before the machine is started or before you engage travel or slew. Figure 132.

3 A 2

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1

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3 4 1 2 107

Left: Move the dipper outwards Right: Move the dipper inwards 9821/3250-3

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Operation Operating Levers/Pedals

3 4 A

Forward: Slew to the right Backward: Slew to the left Horn

Dozer Blade Controls NOTICE Before operating the dozer blade, make sure that large rocks or other objects will not jam the dozer mechanism. The dozer blade (option) is operated by a single control lever on the right side of the cab. The control lever is spring loaded to the central position. In this position the dozer blade will not move. To lift the dozer blade, pull the control lever backwards. At the required position release the control lever. To lower the dozer blade, push the control lever forward. At the required position release the control lever. Figure 133.

B

A

C A B C

Control lever Forward: Lower the dozer blade Backward: Lift the dozer blade

Auxiliary Circuit Controls WARNING Before operating the auxiliary control system make sure that you are aware of all safety notices that apply to the attachment you are using. Also make sure you have installed the attachment correctly and have read its operator's manual.

General The auxiliary controls are on the excavator arm controls. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 97). There is also an auxiliary control pedal option, push the pedal to operate a full flow auxiliary circuit. For more information, refer to the operator manual supplied with the attachment.

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Operation Operating Levers/Pedals

Figure 134.

A A

Auxiliary control pedal

Attachment Systems Your machine may be equipped with one of four systems, for operating attachments requiring high flow or a system for operating attachments requiring both standard and high flow. An optional low flow two-way circuit is also available in addition to or as an alternative to the above.

Rockbreaker Circuit This system supplies a one-way, regulated hydraulic flow to operate a rockbreaker. The flow to the rockbreaker is controlled by a pedal at the operator's feet. Automatic engine speed reduction is incorporated, to prevent damage to the rockbreaker because of excessive oil flow.

Two-Way Auxiliary Circuit This system supplies a two-way flow, controlled by the pedal. It is suitable for attachments which need a relatively high flow in either direction.

Combined Rockbreaker and Two-Way Auxiliary Circuit This system allows the operation of a rockbreaker and two-way attachments without changing the pipework.

Rockbreaker, Two-Way Auxiliary and Merged Flow System This system allows the operation of a rockbreaker and standard flow two-way attachments. The outputs of both pumps can be merged to give a greater flow for high capacity attachments such as large demolition cutters and crushers.

Low Flow Auxiliary Circuit This system lets the joystick operate a low flow attachment (for example a weedcutter).

Change-Over Valves To change from the bucket to the grab option operate the change-over valve.

109

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Operation Operating Levers/Pedals

Figure 135. A

A

Change-over valve

If you operate the change-over valve with stored pressure in the hydraulic system its seals will be damaged. When the change-over valve is operated, you must follow the procedure below to prevent damage to its seals. Remove the handle from the change-over valve when the machine is in use, to prevent the accidental operation of the change-over valve.

Bucket Mode to Grab Mode 1. Fully retract the bucket ram, extend the arm and lower the boom to the ground. 2. Extend the bucket ram until the bucket sits flat on the ground. 3. Set the engine speed to minimum. 4. Put the isolator bar down. Do not operate the machine services. Let the engine idle for Duration: 10s 5. Stop the engine with the engine shutdown button. 6. Operate the two hand controllers to release the pressure in the hydraulic system. 7. Apply the servo isolator. 8. Turn the ignition key to the off position. 9. Set the change-over valve to the grab position.

Grab to Bucket Mode In grab mode the bucket ram will fully retract and hold this position during operation. To select bucket mode the attachment must be stopped in a position so that no load is applied to the rod side of the ram. Any force exerted by the attachment on the ram must be in a direction that pushes the ram in. How the excavator is positioned to do this will depend on the attachment used. 1. Park the machine as described above. 2. Put the isolator bar down. 3. Stop the engine with the engine shutdown button. 4. Operate the two hand controllers to release the pressure in the hydraulic system. Make sure any force exerted by the attachment on the ram is in a direction that pushes the ram in. 5. Turn the ignition key to the off position. 110

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Operation Operating Levers/Pedals

6. Set the change-over valve to the bucket position.

111

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Operation Lifting and Loading

Lifting and Loading General WARNING A high load can block your view and reduce the machine's stability. Travel with the load low to the ground. Travel slowly and with caution over rough, muddy or loose surfaces. WARNING When transporting a load on a slope, drive slowly and keep the load uphill of the machine. This will increase stability. WARNING Do not use the machine for object handling unless it is equipped for this purpose. Without the relevant devices the machine can become unstable and tip over. You and others could be seriously injured or killed. WARNING Before you lift a load with the machine, you must read and understand this section. Failure to take the precautions shown can result in death or injury. If your machine is not installed with a lifting point (for example a hook or shackle), hose burst check valves, load charts and an overload warning system then it must not be used for object handling. If your machine is not installed with this equipment you must only use the machine for earthmoving purposes.

Lifting (Object Handling) Regulations The owner and/or operator must make sure that they fully understand the laws and regulations concerning the use of the JCB machine as an earthmover and for lifting. Consult your JCB dealer for more information. In certain countries safety regulations in force call for the application of specific safety factors. Consult your JCB dealer for more information. All figures and lift capacities (if applicable) in this publication are based on the machine being on level, solid ground.

Safe Working Loads The maximum load which may be lifted depends on the equipment attached to the machine and the laws and regulations in force at the time and in the country in which the machine is being used. If your machine is equipped to be operated under 'Exemption Certificate' rules, your Exemption Certificate will specify the safe working loads.

Fit for Purpose Tests for Lifting Equipment All lifting equipment (for example forks, lifting hooks and shackles) needs regular inspections and testing by a competent person to make sure they are fit for purpose. These may be needed every six months or at least annually in some countries to meet and comply with legislation and for insurance purposes. Refer to: Maintenance > Maintenance Schedules > Functional Tests and Final Inspection (Page 188). Check with your local JCB dealer for further advice.

Load Charts WARNING Rated operating capacities and lift capacities are based on the criteria of the machine being level on a firm supporting ground. When the machine is operated in conditions that deviate from these criteria (e.g. on soft or uneven ground, on a slope or when subject to slide loads), these conditions shall be taken into account by the operator. CAUTION The load chart shown is only an example. Do not use it to find the loading limits on your machine. Before lifting or placing loads, refer to the load charts in the cab of your machine. The SWL (Safe Working Load) of the machine depends on how far the lift arm is extended and the angle it is raised to.

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Operation Lifting and Loading

All lifting operations must be done using the load charts in the cab. The load charts refer to the lift capacities relevant to the machine specification when equipped with an approved JCB tipping link, shackle and bucket ram. The weights of buckets, slings and auxiliary devices must be deducted from these capacities. Care must be taken to make sure that these loads are not exceeded. If a load chart is not installed in the cab, the machine is not designed for lifting. The load chart is only installed on machines with object handling equipment, it is attached to the right hand window. The load chart shows how far you can raise and extend a load without exceeding the SWL. Each machine model has its own specific load chart. The relevant load chart for your machine has a part number. If the load chart is missing or damaged a new label must be attached, contact your JCB dealer for advice if you are not sure. Figure 136. C G

B

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JSXXXX XX

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XXm

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C

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Bm

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A = 2.4 m

Z1 Z2 Z3

A = 3.0 m

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9 8 7 6 5 4 3 2 1 0 -1 -2 -3 -4 -5 -6 -7 10 9 8 7 6 5 4 3 2 1

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E

Holding circuit pressure Refer to the operators manuals before you try to lift a load Working circuit pressure Complete slew of the upper structure Lift with the bucket cylinder retracted Weight of the counterweight Width of the track

Overload Warning System WARNING When the overload protection system buzzer sounds, you must decrease the machine lift. If you do not decrease the machine lift a stability hazard could occur. When the machine is in a safe position the buzzer stops. When the machine is used for lifting it may become unstable, there is a requirement for an audible and visible warning system. The overload warning system senses the pressure in the boom lift pressure circuit, and gives a visual and audible warning when the pressure exceeds the pre-determined limits and there is a risk that the machine could become unstable. When the machine is used for lifting, the system must be turned on. The overload warning system must be enabled through the DECU (Display Electronic Control Unit). When the system is active the DECU will show the enabled icon in the lower section of the DECU.

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Operation Lifting and Loading

Figure 137.

If the safe operating lift limit is exceeded, the buzzer will sound and the icon in the lower section will turn red. A red hook notification symbol is also displayed in the right section of the DECU. When the buzzer sounds and the icon appears, the operator must take the necessary action to lower the lift. When this is done, the buzzer and icon are cancelled and the system resets automatically. When the machine is not used for object handling the system must be turned off through the DECU, or the buzzer may sound and the icon may appear during a digging operation. All of the lifting operations must be done in accordance with the local lifting regulations.

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Operation Working with the Excavator Arm

Working with the Excavator Arm General WARNING When using the boom and dipper fully extended, take the following precautions, otherwise the machine could get damaged or become unstable and become a danger to you and other people. Make sure you do not exceed the working capacity of the boom at maximum reach. Slew the boom slowly to prevent any chance of the machine becoming unstable. For the same reason avoid dumping downhill if possible. WARNING Care must be taken with machines installed with an extra long dipper as it may affect the stability of the machine. Before you start using the excavator, you must convert the machine into a safe and stable working platform. Refer to: Operation > Working with the Excavator Arm > Preparing to Use the Excavator Arm (Page 115). To use the excavator efficiently and safely you must know the machine and have the skill to use it. This manual instructs you on the machine, its controls and its safe operation. It is not a training manual on the art of excavating. If you are a new operator, get yourself trained in the skills of using the excavator before trying to work with it. If you don't, you will not do your job well, and you will be a danger to yourself and others. If you will be working with a labourer, make sure you both understand what each other will be doing. Learn and use the recognised signalling procedures. Do not rely on shouting - he or she will not hear you. Make sure the correct bucket for the job is installed. Refer to: Attachments > Buckets (Page 166).

Preparing to Use the Excavator Arm When choosing a digging position, avoid digging downhill if possible. When possible, dump the load on the uphill side of the excavation. Both of these precautions will help to keep the machine stable. When the machine is in the required position on the worksite, lower the dozer blade to the ground. Ensure you have complete field of vision before using the excavator arm.

Lifting With the Excavator Arm WARNING You must turn on the overload warning system before you use the excavator for object handling, or a stability hazard could occur. All lifting operations must be done with the overload warning system turned on. Refer to: Operation > Lifting and Loading > Overload Warning System (Page 113). Use a signalman when lifting with the excavator. Make sure you both understand and use the recognised signals. Keep all persons clear of the load and machine when the load is on the excavator. A bucket must be installed when lifting with the excavator to prevent the bucket link from swinging. Make sure that the load is not more than the SWL (Safe Working Load)for the bucket. If a hook is installed a shackle may not be required. Refer to: Technical Data > Static Dimensions (Page 247). If a lug is installed a shackle is required. The lifting shackle must be removed when excavating to prevent the possibility of damage. Refer to: Technical Data > Static Dimensions (Page 247). If your machine is not installed with this equipment there will be a label in the operators cab to indicate this and you must use the machine for earth moving purposes only. 1. Where possible lifting should be carried out with the bucket closed in order to increase visibility, move the sharp objects away from the lifting chains and prevent any obstruction or deflection of the lifting chains away from the vertical position. 2. Attach the lifting chains to the shackle or hook. Keep the chain length as short as possible, to prevent swinging. Always use lifting tackle which is strong enough and in good condition. Check the load weight before choosing the lifting chains. 115

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Operation Working with the Excavator Arm

3. Attach a handline to the load. Make sure the person holding the handline stands clear of the load and machine. 4. Test the load by lifting it: Distance: 25–50mm 5. If the load is to be lifted to a height where it is not possible to prevent the bucket obstructing or deflecting the lifting chains then the lifting chains must only be guided by the back wall of the bucket and not by any other parts of the machine. A

A B

Figure 138.

B

Lifting hook Shackle

6. Slowly manoeuvre the load across the ground with the excavator controls. Lower the load to the ground if you feel any instability of the load or the machine. When you are using the dipper movement to lift, always lift by moving the dipper away from you, as shown, not towards you. This is because hose burst check valves (if installed) are provided only on the 'dipper-in' side.

Digging WARNING Do not use pedals which are not locked in position as foot rests. NOTICE When carrying out deep digging it is advisable to have the super structure swung in line with the chassis. It is possible that part of the dig end may contact the machine. Take extra care when digging to avoid damaging the machine. NOTICE Do not excavate on hard or rocky ground with the boom positioned diagonally across the undercarriage. The resulting rocking motion could cause damage to the track gearbox sprockets and tracks. NOTICE Do not use the side of the excavation to stop the bucket when slewing back into position for the next dig. Similarly, do not use the side of the bucket to push soil into the excavation. Both these practices will damage the machine.

Decreasing the Machine Wear Do not use the weight of the machine to dig. The shock load will cause stress to the dig end and the chassis. Use the machines hydraulic force to dig. Figure 139.

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Operation Working with the Excavator Arm

If impact force is used to do a task, it will cause damage to the dig end. An impact force will also create high pressures inside the cylinders, which will cause the cylinders to swell. Figure 140.

The cylinders are designed with a cushion mechanism which will gradually release any back pressure. If an impact force is applied at the end of the cylinder stroke, the piston will hit the head or bottom end and cause damage. Figure 141.

Stability A machine which is stable during operation, increases productivity, extends the life of the machine and makes sure of operator safety. Figure 142.

The dig point effects stability, if the dig point is too far away the machine can become unstable. Figure 143.

Keep the dig point close to the machine to improve stability and increase the dig force.

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Operation Working with the Excavator Arm

Figure 144.

When the dig end is used, always keep the drive sprockets at the rear. The stability of the machine is improved and wear to the drive is decreased. Figure 145.

Where practical work with the tracks pointing forwards, to improve the stability of the machine. When working with the tracks pointing to the sides exercise caution due to reduced stability. Figure 146.

Digging on a Slope Before you dig a vertical trench on a slope, if possible cut-out a level base to work from. Refer to: Operation > Slopes > Working on Slopes (Page 129). Dump the trench material on the uphill side of the trench, far enough away to prevent it falling back into the trench.

Machine Efficiency When the bucket cylinder and link, and the arm cylinder and dipper are both at 90° to each other, the force of each cylinder is at a maximum and the efficiency of the operation is increased.

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Operation Working with the Excavator Arm

Figure 147.

90

90 90

30

When you dig with the dipper, keep the dipper angle within a range of 45° to the front and 30° to the rear. In this range if the boom and bucket are also used, the efficiency of the operation is increased. Figure 148.

45

30

Backfilling When you backfill on a slope, pile the material on the high side of the trench if possible. 1. Move the bucket level to the ground. 2. Select a bucket height and excavating speed which will give you a maximum depth of cut, without overloading the machine. 3. Work at right angles to the trench and fill a buckets width at a time. Leave any spillage until the trench is filled. 4. Use the spillage to finish the job by driving the length of the trench with bucket low to the ground.

Travelling With a Load (Pick and Carry) WARNING Do not use the machine for object handling unless it is equipped for this purpose. Without the relevant devices the machine can become unstable and tip over. You and others could be seriously injured or killed. If your machine is not fitted with a lift point (for example a hook or shackle), hose burst check valves, load charts and a overload warning system then it must not be used for object handling. 1. Stop the machine on solid, level ground. 2. Align the undercarriage with the upper structure. Refer to: Operation > Operating Levers/Pedals (Page 97). 3. Make sure that the load is within the capacity of the machine. Refer to the lift chart in the machine cab. 4. When possible the load should be attached to the machine frame to prevent the load from swinging and causing instability. 119

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Operation Working with the Excavator Arm

5. Important: All of the lifting equipment, including the hook and/or the shackle and any chains/slings/webs between the machine and the load, will need regular inspections and testing by a competent person to make sure they are fit for purpose. 6. Select power band L1,L2 or L3 dependant on the load being manoeuvred. The machine must be in power band L1,L2 or L3 at all times. Refer to: Operation > Instruments > General (Page 69). 7. Select creep speed travel. Maintain creep travel speed at all times. Refer to: Operation > Drive Controls > Travel Speed Selector (Page 67). 8. Suspend the load as low to the ground as possible. The load must be visible at all times by the operator or an appropriately trained person who is in contact with the operator at all times. 9. When you travel with the load, do not apply sharp adjustments to the controls.

Dumping Into a Truck 1. To prevent unnecessary manoeuvring, put the truck(s) in position, as shown. Refer to Figure 149. Figure 149.

2. Do not dump the material in one sudden movement. Roll the bucket forward in stages until it is empty. Refer to Figure 150. 3. Use the joystick to move the bucket backwards and forwards to loosen any sticky material. 4. Keep the wind on your back. This keeps the dust away from you and your machine. 5. If the truck body is about as long as a buckets width, dump the load into the centre of the truck. If the truck is two bucket widths long or more, fill the front of the truck first. 6. When you lift a large, heavy load: 6.1. Dump the load close to the bed of the truck. 6.2. Do not dump the load from height, this will damage the bed of the truck. 6.3. Put soil into the bed of the truck first to act as a cushion for the loads. 7. Move the truck into a position where it can easily be seen by the operator and lift multiple loads. This will increase the operating efficiency and improve safety.

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Operation Working with the Excavator Arm

Figure 150. 3

2

1 1 2 3

3 1 2

Changing the Bucket Linkage It is possible to compensate for the lateral wear which causes the sideways play of the bucket. The regular use of this compensating procedure leads to less wear on the bucket swivel pin and the dipper bushes. Figure 151.

B

A B C

A

C

Swivel pin Dipper bush Clearance

1. Park the machine on solid, level ground. 2. Set the bucket as shown.Refer to Figure 152. Figure 152.

3. Turn the bucket slightly to the left and adjust it so that the arm end is pressed to the side which is not to be adjusted. 4. Stop the engine and remove the ignition key. 5. Measure the clearance. Refer to Figure 151. 121

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Operation Working with the Excavator Arm

5.1. The distance should be approximately: Distance: 0.8mm 6. If the clearance is incorrect, contact your JCB dealer.

Dipper Stroke Limiter NOTICE In some instances it may be possible to hit the cab with the bucket or attachment. To prevent damage care should be taken when operating with the bucket/attachment close to the cab. NOTICE It is the operator's responsibility that the position of the sensor is correctly adjusted to prevent the attachment striking the cab.

General The dipper stroke limiter allows the inward stroke of the dipper to be restricted and prevent the attachment from accidentally striking the cab. The adjustment of the dipper stroke limiter is governed by a proximity switch installed on the boom. The dipper stroke limiter is factory set to 500mm For the dipper stoke limiter to operate it must be enabled by the JCB Service Master set up tool. When enabled, it is set up by the DECU (Display Electronic Control Unit). The dipper stoke limiter defaults to on, every time the ignition key is turned to the on position, but can be temporarily turned off by the DECU. When the dipper moves to a preset position detected by the proximity switch, the stroke of the dipper-in service is stopped. The dipper-out service will continue to operate and when the dipper moves away from the preset position the dipper-in service is available. The DECU will show an icon when the dipper gets to the preset position.

Adjusting the Clearance 1. Disable the dipper stoke limiter. Refer to: Operation > Instruments > Instrument Panel (Page 70). 2. Adjust the positions of the boom, dipper and attachment until the attachment is the correct clearance from the operators cab. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 97).

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Operation Working with the Excavator Arm

Figure 153.

X

X

Clearance

3. Fully crowd the bucket and lower the boom until the bucket is on the ground. Do not retract or extend the dipper ram. 4. Stop the engine and remove the ignition key. 5. Remove the proximity switch cover, then loosen the proximity switch sensor fixings. Figure 154.

C B A A B C

Proximity switch cover Proximity switch sensor Sensor fixings

6. Put the proximity switch sensor on the slot, so that it is in line with the pick up block on the dipper. 7. Tighten the proximity switch sensor in position, then check that the distance between the sensor and the pick up block is Distance: 4.5 Âą 0.5mm 8. Install the proximity switch cover. 123

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Operation Working with the Excavator Arm

9. Check the clearance.

Check the Clearance WARNING If two people are doing this job make sure that the person working 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. 1. Set the machine as shown with boom ram fully extended. Refer to Figure 153. 2. Move the dipper out and then slowly back in, make sure the dipper stops short of a full stroke on the dipper ram. 3. Make sure the clearance is correct.

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Operation Working with the Dozer Blade

Working with the Dozer Blade General When you work with the dozer blade, remember that you will be driving the machine. Keep alert for bystanders, animals and possible hazards. When you work with the dozer blade, make sure the slew lock is engaged. When possible, do not slew the machine to do a dozer blade task. If you must slew the machine to do a dozer blade task, use a smooth slew action and make sure there are no obstacles. When the machine is slewed to do a dozer blade task, it will create large side loads on the dig end and this will cause twisting and bending. Figure 155.

Dozing and Grading Keep the bottom of the dozer blade parallel to the ground. When grading a site remove the high spots first, then use this soil to fill in troughs. Do not use excessive downward pressure on the dozer blade or machine traction could be lost. When you work with the dozer blade, move the excavator straight with the machine, as for worksite travel. Refer to: Operation > Preparing for Travel > Preparing for Worksite Travel (Page 62). Keep the dozer blade high during travel as this increases the machines ground clearance.

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

Backfilling When you backfill on a slope, pile the material on the high side of the trench when possible. Move the dozer blade level to the ground. Work at right angles to the trench, fill a dozer blades 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 blade low to the ground.

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Operation Working with the Dozer Blade

Figure 156.

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Operation Slopes

Slopes General WARNING Make sure that you have been trained and are familiar with the use of machines on slopes, and understand the adverse affects that slopes and site conditions can have on stability. Never use the machine on a slope if you do not understand the recommended practices for the use of machines in such applications. There are a number of factors which can adversely affect the stability of the machine and the safety of the machine and operator when used on a slope. It is essential that a risk assessment of the work to be done is completed and that the operator complies with any safety precautions that the assessment identifies.

Driving on Slopes Introduction WARNING Operating the machine on hillsides can be dangerous if proper precautions are not taken. Ground conditions can be changed by rain, snow, ice etc. Check the site carefully. Going uphill, reverse when unloaded or travel forwards when loaded. Going downhill, travel forwards when unloaded or reverse when loaded. Take special care when 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. The machine can operate without affecting its systems on slopes of up to 35°. On slopes greater than 10° the operator must use his discretion and continue with extreme caution.

Driving Down a Slope When you drive down a slope, make sure that the bucket is set 250 Âą 50mm above the ground (in the position shown) and drive at a low speed. Refer to Figure 157. Figure 157.

When you drive down a slope always keep the drive sprockets at the front. If the drive sprockets are at the rear, the tracks will be loose and there is a danger the machine could move unexpectedly after it stops. Keep the dig end in a position that makes sure the machine is stable and at the same time where it is possible, to use the dig end to stop the machine in an emergency. The steering speed is quite fast when you drive down a steep slope. If it is necessary to change direction, stop the machine and turn the track backward on the side to which the machine will turn. This will improve safety when you turn on a slope. Refer to Figure 158.

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Operation Slopes

Figure 158.

Driving Up a Slope When you drive up a slope, make sure that the bucket is set 250 Âą 50mm above the ground (in the position shown). Refer to Figure 159. Figure 159.

When you drive up a steep slope, make sure that the bucket is set 250 Âą 50mm above the ground (in the position shown). Refer to Figure 160. Figure 160.

When you drive up a slope, always keep the drive sprockets at the rear. If the drive sprockets are at the front, the tracks will be loose and the drive will be decreased.

Driving Across a Slope Never drive across or turn on a steep slope, always drive to level ground before you do this. Be careful when you open or close the door on a slope, make sure the door is locked in the open or closed position. 128

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Operation Slopes

Working on Slopes The illustrations show a typical model. Your machine may look different to the model shown. It is dangerous to operate the machine on a slope. Where possible, use a platform or a level cut-out to keep the machine horizontal when in use. Refer to Figure 161. Figure 161.

If it is necessary to stop on a slope, dig the bucket into the surface of the ground and put blocks under the tracks. Refer to Figure 162. Figure 162.

When you stop on a steep slope for a long period with the engine running, there is a risk that the oil cannot circulate around the engine correctly. This can cause damage to the engine. If necessary, stop with the machine facing down the slope. Refer to Figure 163. Figure 163.

When you drive over ditches or holes, it is safer if the work equipment is used to help the machine.

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Operation Slopes

Figure 164. 3

2

1

4

When you climb a ramp, it is easier and safer if the work equipment is used to help the machine. Figure 165. 1

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Operation Heating, Ventilating and Air-Conditioning (HVAC)

Heating, Ventilating and Air-Conditioning (HVAC) General The operator must set the controls to obtain the best working environment in the operator station. Poor ventilated air can cause tiredness. Do not operate the machine for long periods without ventilation or with the operator station fully closed and the fan turned off.

Air-Conditioning Controls Heater Only Controls Introduction Figure 166.

C A B C 1 2

B

1

2

A

Recirculation switch Temperature control switch 3-speed fan switch Recirculation switch - position '1' Recirculation switch - position '2'

The heater control panel is installed on the left console. The temperature is adjusted by the recirculation switch, a 3-speed heater fan switch and the temperature control switch. Adjust the air vents to direct the hot air flow to the front window (for demisting) and/or the cab floor.

Air Control Turn the recirculation switch to position '1' to let fresh air enter the cab. Turn the recirculation switch to position '2' to recirculate the air, this should be used when you operate in a dusty working environment. Position '2' can also be used to increase the heater performance during cab warmup and when machine coolant temperatures are below optimum.

Heat Control Turn the temperature control switch clockwise to increase the temperature. Turn the temperature control switch counterclockwise to decrease the temperature.

Heater Fan Turn the 3-speed fan switch to adjust the speed of the heater fan. This functions only when the ignition key is in position I.

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Operation Heating, Ventilating and Air-Conditioning (HVAC)

Heater/Air Conditioning Controls Introduction Figure 167.

A

G A B C D E F G

F

E

D

C

B

Display Fan speed switch Temperature control switch Defrost/Demist switch Recirculation switch Auto mode switch On/Off switch

The heater/air conditioning control panel is installed on the left console. Adjust the air vents to direct the hot air flow to the front window (for demisting) and/or the cab floor. To activate the control panel push the On/Off switch, the switch LED (Light Emitting Diode) and the panel will illuminate.

Auto Mode The heater can be set to a selected temperature. The fan speed and the temperature are then automatically controlled to maintain the set temperature. 1. Push the auto mode switch to start the auto mode. The LED will illuminate and the letter 'A' is shown on the display. 2. Turn the temperature control switch to set the required temperature. This temperature is shown on the display and the fan speed is automatically set to reach and then maintain this set temperature. 3. If the fan speed switch is adjusted, then the auto mode will have to be reset. Push the auto mode switch to reactivate. 4. In hot weather or dusty environments, the recirculation mode should be used. Push the recirculation switch.

Recirculation Mode To start, push the defrost/demist switch, the LED will illuminate and the switch symbol is shown on the display. In hot weather to produce comfortable working conditions: 1. Close the door and windows. 2. Push the recirculation switch. 3. Turn the fan speed switch clockwise and direct the air flow into the body of the cab. 4. Turn the temperature control switch fully counterclockwise for maximum defrost. If the temperature in the cab drops too low turn the switch clockwise.

Defrost/Demist Mode In cold/damp weather, to minimise misting: 132

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Operation Heating, Ventilating and Air-Conditioning (HVAC)

1. Close the door and windows. 2. Push the defrost/demist switch. 3. Turn the fan speed switch clockwise fully clockwise and direct the air flow onto the front window. 4. Turn the temperature control switch fully clockwise to heat the dehumidified conditioned air, demist the screen and generally dehumidify the cab air.

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Operation Power Sockets

Power Sockets Auxiliary Power Socket Your machine may be fitted with one or more 12V auxiliary power sockets, which can be used for mobile phone chargers or other 12V powered devices. Refer to: About the Product > Operator Station > Component Locations (Page 19). Only connect items which are compatible with the power rating of the socket and have the correct plug. Always operate the engine during the prolonged use of the electrical accessories, or the battery can discharge. Make sure that the socket cap is closed when the socket is not in use.

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Operation Battery Isolator

Battery Isolator General NOTICE Before carrying out arc welding on the machine, disconnect the battery and alternator to protect the circuits and components. The battery must still be disconnected even if a battery isolator is installed. NOTICE Do not isolate the machine electrics when the engine is running, this may cause damage to the machine electrics. To allow the engine ECU (Electronic Control Unit) to shutdown correctly, you must wait 30s before you isolate the battery. The 30s period starts when you turn the ignition off. Figure 168.

Disconnect the Machine Electrics: 1. Turn the ignition key to the off position. 2. Wait for the engine ECU to shutdown correctly. Duration: 30s 3. Get access to the battery isolator. Refer to: Maintenance > Service Points > General (Page 191). 4. Turn the battery isolator key in a counter-clockwise direction and remove.

Connect the Machine Electrics: 1. Make sure the ignition is switched off. 2. Insert the battery isolator key and turn in a clockwise direction.

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Operation Fire Extinguisher

Fire Extinguisher General Location The fire extinguisher is stowed in a bracket behind the seat. Keep the fire extinguisher in the bracket until you need to use it. Figure 169.

A

A

Fire extinguisher

Operation WARNING Do not use the fire extinguisher in a confined space. Make sure that the area is well ventilated during and after using the fire extinguisher. WARNING After any use, the extinguisher must be replaced or serviced. Make sure that you understand how to use the fire extinguisher. If necessary, refer to the instructions found on the fire extinguisher. Only try to extinguish a fire if the circumstances permit and your safety is not endangered. If necessary, contact your nearest fire department. Using the fire extinguisher: 1. Remove the fire extinguisher from its bracket. 2. Remove the safety pin. 3. Aim directly at the fire from an upwind position, if possible. 4. Squeeze the trigger to operate the fire extinguisher, release the trigger to stop the flow.

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Operation Fire Extinguisher

Figure 170. B

A

A B

137

Safety pin Trigger

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Operation Moving a Disabled Machine

Moving a Disabled Machine General If the machine becomes disabled, the machine must be made safe, lifted onto a transporter and moved to a location where it can be repaired. You must contact your nearest JCB dealer before you try to tow, winch or push the machine. Towing, winching or pushing the machine without following the correct procedure will damage parts of the hydraulic system. If possible, repair the disabled machine where it stands.

Getting the Machine Unstuck Pulling the Machine Out of Soft Ground If the machine gets bogged down in soft ground, the excavator controls can be used to help get the machine moving again. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 97). To free the machine it is necessary to put something below the track(s) to provide grip. 1. One Track is Bogged Down. Refer to Figure 171. 1.1. Slew the boom towards the side to be freed and stop it at the required angle to the track (the correct angle is shown ): Angle: 90° 1.2. Set the dipper angle (the correct angle is shown) to the boom and crowd the bucket: Angle: 90° 1.3. Lower the boom until the bucket touches the ground. If necessary, put a board or something else with a broad ground contact, under the bucket. 1.4. Lower the boom further and lift the bogged down track off the ground. 1.5. Put a mat, board or log, etc below the track and raise the boom until the track rests on it. 1.6. Drive the machine away. Figure 171.

2. Both of the Tracks are Bogged Down. Refer to Figure 172. Do steps 1.1 to 1.5 of the One Track is Bogged Down procedure for each track, then drive the machine away or do the following procedure: 2.1. Drive a heavy stake into the ground directly in front of the machine. 2.2. Set the boom and dipper as if to dig, then hook the bucket onto the stake. 2.3. Use the excavator controls to draw in the dipper and the track controls to drive the machine forward and drag it out of the soft ground.

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Operation Moving a Disabled Machine

Figure 172.

Jump-Starting the Engine WARNING In temperatures below freezing, the battery electrolyte may freeze if the battery is discharged or poorly charged. Do not use a battery if its electrolyte is frozen. To prevent the battery electrolyte from freezing, keep the battery at full charge. If you try to charge a frozen battery or jump-start and run the engine, the battery could explode. Batteries produce a flammable gas, which is explosive. Do not smoke when checking the electrolyte levels. When jump-starting from another vehicle, make sure that the two vehicles do not touch each other. This prevents any chance of sparks near the battery. Switch off all circuits which are not controlled by the ignition key. Do not connect the booster (slave) supply directly across the starter motor. Use only sound jump leads with securely attached connectors. Connect one jump lead at a time. The machine has a negative earth electrical system. Check which battery terminal is positive (+) before making any connections. Keep metal watch straps and jewellery away from the jump lead connectors and the battery terminals - an accidental short could cause serious burns and damage equipment. Make sure you know the voltage of the machine. The booster (slave) supply must not be higher than that of the machine. Using a higher voltage supply will damage your machine's electrical system. If you do not know the voltage of your booster (slave) supply, then contact your JCB dealer for advice. Do not attempt to jump-start the engine until you are sure of the voltage of the booster (slave) supply. The negative (-) terminal on the battery is connected to frame earth. 1. Lower the excavator bucket and dozer blade 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. Refer to: Operation > Operating Levers/Pedals (Page 97). 2. Set all switches in the cab to their off positions. 3. Get access to the battery. Refer to: Maintenance > Access Apertures (Page 202). 4. Connect the booster cables: 4.1. 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. 4.2. Connect the negative (-) booster cable to a good frame earth on the machine, away from and below the battery. A good frame earth is a part of the machine frame, free from paint and dirt. Do not use a pivot pin for an earth. 4.3. Connect the other end of this cable to the negative (-) terminal on the booster supply. 5. Do the pre-start checks. 6. Start the engine.

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Operation Moving a Disabled Machine

7. Disconnect the booster cables: 7.1. Disconnect the negative booster cable from the machine frame earth. Then disconnect if from the booster supply. 7.2. Disconnect the positive booster cable from the positive (+) terminal on the battery. Then disconnect it from the booster supply.

Retrieval NOTICE It is not recommended to tow a disabled machine. Permanent damage to the track motors of the disabled machine may occur if the machine is towed. If the machine cannot be moved to a safe area, then attach wire ropes or chains which are capable of pulling the machine to the lower frame, as shown. Refer to Figure 173. Notice: Do not use the tow eye or tie down points (if installed) to tow the machine, as this will cause damage to the machine. Figure 173.

A

A

B

A B

B

B

B

Tow eye Tie down points

Use the minimum force necessary to slowly move the machine (not greater than 2km/h) smoothly and without shocks). Tow the machine the minimum distance (not to exceed 20m) to a safe area for recovery by lifting. Refer to: Operation > Lifting the Machine > General (Page 142). Do not use the tow eye or tie down points to tow the machine, as this will potentially cause damage. When the machine is recovered, a qualified person must inspect the track motors for damage.

Excavator Arm (Emergency Operation) The excavator has an accumulator installed. The accumulator stores a limited amount of hydraulic pressure for use in an emergency (engine failure for example). This hydraulic pressure must be used to move the dipper and lower the boom into a safe position. Do not try to operate other machine functions as this will deplete the hydraulic pressure in the accumulator and it may then not be possible to move the dipper and lower the boom. 140

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Operation Moving a Disabled Machine

If an emergency occurs: 1. Turn the ignition key to the on position. 2. Enable the controls. Refer to: Operation > Locks > Control Lock (Page 64). 3. Use the right and left control levers to move the dipper and lower the boom. 4. Vent the hydraulics. Refer to: Maintenance > Hydraulic System > General > Discharge (Page 234). 5. Turn the ignition key to the off position.

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Operation Lifting the Machine

Lifting the Machine General Figure 174.

A

A

A

A C

75 D

B

B A B C D

Spacer bars Lifting platform Lifting-hook height Angle = 75°

DANGER! Do not stand underneath the raised load during the lowering procedure. Stand clear and to one side until the load has been safely lowered. Make sure that the area is clear of other people before lowering the load. If you do not follow these precautions you or others could be killed or seriously injured. 1. Park the machine on a suitable lifting platform with the attachment in the position shown. Refer to Figure 174. Refer to: Operation > Operating Levers/Pedals > General (Page 97). 2. Stop the engine. 3. Push the controls isolation switch. Refer to: Operation > Locks > Control Lock (Page 64). 4. Turn the ignition key to the 'off' position. 5. Make sure there are no loose items in the cab or on the machine. 6. Check the unladen weight and the height of the machine. Refer to: Technical Data > Static Dimensions > Dimensions (Page 248). 7. Make sure the lifting equipment complies with all of the local regulations, is suitable and strong enough for the task. 8. Use spacer bars are of sufficient length and strength to prevent the cables from touching the machine and causing damage. 9. Maintain the correct lifting angle between the engine cover and the sling. Refer to: Technical Data > Static Dimensions > Dimensions (Page 248). 10. Maintain the correct height to the lifting-hook. Refer to: Technical Data > Static Dimensions > Dimensions (Page 248). 142

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Operation Lifting the Machine

11. Lift the machine slightly to check the balance of the machine and the installation of the lifting equipment. If the machine does not lift horizontally, adjust the length of the slings. Proceed slowly and evenly until the lift is complete. 12. Keep the machine horizontal during the lift. The centre of gravity of the machine is approximately above the slew centre.

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Operation Transporting the Machine

Transporting the Machine General WARNING The safe transit of the load is the responsibility of the transport contractor and driver. Any machine, attachments or parts that may move during transit must be adequately secured. WARNING Make sure that the ramp incline does not exceed the machine's operational limits. CAUTION 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. Check the condition of the transport vehicle before the machine is loaded on to its trailer. Make sure that the transport trailer is suitable for the dimensions and weight of your machine. Refer to: Technical Data > Static Dimensions (Page 247). The bed of the trailer should have a wood surface to aid stability. 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.

Loading the Machine onto the Transporting Vehicle/Trailer CAUTION The machine must be securely tied down to the transport vehicle 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. Stop the transport vehicle on solid, level ground. 2. Apply the park brakes. 3. Lower any stability jacks. 4. Put blocks at the front and rear of the wheels on the transport trailer. 5. Make sure the ramps are in their correct positions and angle, then secure them. The ramps should not be at more than the specified angle: Angle: 15° Figure 175.

A A

Angle of the ramp

6. Before the machine is driven on to the transport trailer, make sure that the machine will not catch on the ramp/trailer angle. Refer to Figure 175. 7. Start the machine. Refer to: Operation > Starting the Engine (Page 57). 8. Slew the cab to make sure the excavating equipment is in a position where it will not interfere with your view of the ramp and the transport trailer. Refer to: Operation > Operating Levers/Pedals (Page 97).

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Operation Transporting the Machine

9. Lift the bucket/attachment. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 97). 10. If applicable, lift the dozer blade. Refer to: Operation > Operating Levers/Pedals > Dozer Blade Controls (Page 108). 11. Slowly and carefully drive the machine onto the transport trailer. Be careful when the machine leaves the ramp and goes onto the transport trailer, because its centre of gravity will move suddenly. Refer to: Operation > Drive Controls (Page 66). 12. When the machine is safely in position, slew the cab to face forwards. 13. Engage the slew lock. Refer to: About the Product > Console Switches > Slew Lock (Page 21). 14. On a triple articulating boom machine, put the boom, dipper and bucket in the positions shown. Refer to Figure 176. Figure 176.

B A B

A

A

Undercarriage securing method Dipper arm securing method

15. Put suitable wooden blocks on the transport trailer at the front of the machine. 16. Crowd the bucket/attachment and move in the dipper. 17. Lower the boom until the dipper rests on the wooden blocks. Be careful, if you do not crowd the bucket/ attachment the cab could be damaged when the dipper is moved in. 18. Do not transport the machine with any of the rams fully extended. A fully extended ram could be damaged because of road shocks. 19. Isolate the controls. Refer to: Operation > Locks > Control Lock (Page 64). 20. Check that the overall height of the load is within the regulations. Adjust if necessary. 21. Stop the engine. 22. Secure the cab. 23. Put the cover on the exhaust stack. 24. Attach suitable tying-down accessories to secure the undercarriage to the transport trailer, as shown. Make sure the tying down accessories are strong enough for the purpose and tensioned correctly. Refer to Figure 177. Refer to Table 11.

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Operation Transporting the Machine

Figure 177.

B

B X-X

Y

X

Y-Y

A

A

E A

A

D

Y

X

A B C D E

34–39° 15–25° 45 ± 5° Chain wrapped around undercarriage Centre line of machine

24.1.Make sure that both sides of the machine are restrained using the angles shown. Where the tracks are not shown, this is done for clarity. You do not need to remove the tracks to secure the machine. 25. Use either the hook, shackle or link as applicable, to secure the dipper arm to the transport trailer, as shown. Refer to Figure 176. 26. The correct tie down positions are identified on the machine by their labels. Refer to Figure 178. Figure 178.

27. Lift any stability jacks. 28. Measure the maximum height of the machine from the ground. Make sure that the transporter driver knows the maximum height before he drives away.

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Operation Transporting the Machine

Table 11. Tying-Down Accessories Restraint Specification Lashing capacity Minimum lashing breaking force

JS200/210/220/230 90,000N 143,000N

JS370 144,000N 231,000N

Unloading the Machine from the Transporting Vehicle/Trailer WARNING If the dozer blade is to the rear, the track controls will be reversed. Use extreme caution when tracking off the trailer. 1. Stop the transport vehicle on solid, level ground. 2. Apply the park brakes. 3. Lower any stability jacks. 4. Before the machine is driven off the transport trailer, make sure that the machine will not catch on the ramp/ trailer angle. Refer to Figure 179. 5. Make sure the ramps are in their correct positions and angle, then secure them. The ramps should not be at more than the specified angle: Angle: 15° Figure 179.

A A

Angle of the ramp

6. Remove the cover from the exhaust stack. 7. Remove the tying-down accessories and blocks from the machine and stow them. 8. Start the machine. Refer to: Operation > Starting the Engine (Page 57). 9. Enable the controls. Refer to: Operation > Locks > Control Lock (Page 64). 10. Disengage the slew lock. Refer to: About the Product > Console Switches > Slew Lock (Page 21). 11. Slew the cab to make sure the excavating equipment is in a position where it will not interfere with your view of the ramp and the transport trailer. Refer to: Operation > Operating Levers/Pedals (Page 97). 12. Lift the bucket. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 97). 13. If applicable, lift the dozer blade. 14. Drive the machine slowly to the ramps.

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Operation Transporting the Machine

15. Continue to drive the machine until the tracks are over the ramps. 16. Slowly drive the machine onto the ramps and off the transport trailer.

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Operation Operating Environment

Operating Environment General In low and high temperature conditions, take the following precautions. They will make it easier to start and prevent possible damage to your machine.

Operating in Low Temperatures NOTICE Do not connect two batteries in series to give 24V for starting as this can cause damage to the electrical circuits. 1. Use the correct viscosity engine lubricating oil. Refer to: Technical Data > Fluids, Lubricants and Capacities (Page 263). 2. If available, use a low temperature diesel fuel. 3. Use the correct coolant mixture. 4. Keep the battery at full charge. 5. Fill the fuel tank at the end of each work period, this will help to prevent condensation forming on the tank walls. 6. Protect the machine when its not in use. Park the machine inside a building or cover it with a tarpaulin. 7. Install a cold weather starting aid. In very low temperatures (less than the value shown) additional starting aids may be needed. Examples are fuel, oil and coolant heaters. Ask your JCB dealer for advice. Temperature: -20°C 8. Before the engine is started, remove any snow from the engine compartment or snow could get into the air filter.

Operating in Extremely Low Temperatures In extremely low temperatures (below 0°C) special care must be taken. Extend the warm up time and cover the front faces of the radiator and oil cooler. After warm up, remove the covers. 1. Until the machine is thoroughly warmed up never try to slew quickly or operate the travel system, or damage can occur. 2. Before the machine is operated after a warm up, make sure that the boom, dipper bucket, slew and travel services all operate correctly. A time lag may occur when selecting these services if the hydraulic oil is not sufficiently warm. 3. If the machine will be left outside for more than one day without being used, remove the battery and take it indoors. 4. Drain the water collected in the fuel system to prevent it freezing. 5. Clean the machine after use and put it on wooden blocks. Keep the rams as fully retracted as possible. Remove any water from the exposed portion of the piston rods. 6. Additional low temperature fuel and lubricants and batteries may be required. Contact your local JCB dealer for advice.

Operating in High Temperatures 1. Use the correct viscosity engine lubricating oil. 2. Use the correct coolant mixture. 3. Check the coolant system regularly, keep the coolant at the correct level. Make sure there are no leaks.

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Operation Operating Environment

4. Keep the cooling pack and engine clean, regularly remove dirt and debris from the cooling pack and the engine. 5. Check the fan belt regularly. 6. Check the air vents. Make sure that the air vents to and from the engine compartment are not blocked. 7. Check the engine pre-cleaner regularly (if installed). 8. Check the battery electrolyte level.

Cab Filters Cab Filters There are two different filters available for the cab heater unit/air-conditioning unit. The cab is not air tight or pressurised. The cab filter is provided for comfort only, it does not provide complete protection against the environment in which the machine is used. The appropriate PPE (Personal Protective Equipment) must be worn if the machine is used in hazardous environments.

Standard Filter A solid particle filter used for general applications which do not require special filtration.

Carbon Filter A solid particle, odour filter used for general applications which do not require special filtration.

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Operation Refuelling

Refuelling General 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. NOTICE Consult your fuel supplier or JCB dealer about the suitability of any fuel you are unsure of.

Low Fuel Levels If you operate the machine on very low fuel levels, then air can enter the fuel system. To prevent the entry of air, always add more fuel when the fuel gauge shows a low level of fuel. If air enters the fuel system, the engine speed will vary dramatically and low power will be experienced. The symptoms may be made worse when the machine operates on steep slopes. If you increase the engine speed or load when there is air in the fuel system, then damage to the engine can occur. If the fuel supply contains air, you must stop the engine, fill the fuel tank then bleed the fuel system to remove the air. Refer to: Maintenance > Fuel System > General > Bleed (Page 223). You must bleed the fuel system after changing the fuel filter(s).

Filling the Tank Refuelling the Machine Filling the Tank Before you add the fuel to the machine, Refer to: Maintenance > Maintenance Safety > Fluids and Lubricants (Page 180). If you use the incorrect type of fuel or fuel which is contaminated, then damage to the fuel injection system can occur. WARNING! Do not use petrol in this machine. Do not mix petrol with the diesel fuel. In storage tanks the petrol will rise to the top and form flammable vapours. 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 tank. Locate the fuel tank. Refer to: About the Product > Description (Page 8). 1. Park the machine on solid, level ground. 2. Lower the bucket to the ground. 3. Stop the engine. 4. Remove the ignition key. 5. Remove the fuel filler cap. 6. Add diesel through the filler point. 7. Replace the fuel filler cap. 8. We recommend that you lock the fuel filler cap to prevent theft and tampering.

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Operation Refuelling

Figure 180. A

A

Fuel filler cap

Fuel Level The amount of fuel in the tank is shown on the fuel gauge. Be alert for the red warning indicator on the gauge. Refer to: Operation > Instruments > General (Page 69). You should fill the tank at the earliest opportunity when the red warning indicator comes on.

Refuelling Pump The refuelling pump will not function when the engine is running. 1. Remove the fuel filler cap to let the air escape. 2. Remove the fuel hose from the securing clips and the support. 3. Make sure the suction end of the fuel hose is clean and open the close-off valve. If dirty, use a small container of fuel to clean the suction end. 4. Put the suction end of the fuel hose into the fuel container. 5. Push the switch to select Auto mode or Manual mode. 6. Auto Mode: 6.1. To start the pump, push the switch once for less than: Duration: 2s 6.2. Push the switch again to stop the pump. 6.3. The pump will automatically stop when the level gauge reaches the tank capacity. To fill the tank fully, use Manual mode. 7. Manual Mode: 7.1. Push and hold the switch until the required amount of fuel is pumped into the tank. 8. Remove the fuel hose from the fuel container. 9. Tighten the close-off valve down. 10. Stow the hose. 11. Replace the filler cap. 152

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Operation Refuelling

Figure 181. D

B

A

C A B C D

153

Filler cap Fuel hose Close-off valve Switch

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Notes:

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Attachments Working with Attachments

Attachments

Working with Attachments Introduction Attachments Use only the JCB approved attachments that are specified for your machine. Operating with non-specified attachments can overload the machine, causing possible damage and machine instability which could result in injury to yourself or others. The use of non-approved attachments could invalidate your warranty. Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or copper drift to remove and install metal pins. Always wear personal protective equipment. Attachments If you have an attachment which is not covered in the Operator's Manual do not install it, use it or remove it until you have obtained, read and understood the pertinent information. Install attachments only on the machines for which they were designed. Some attachments are supplied with the instructions on the safety, installation, removal, operation and maintenance procedures. Read and fully understand these procedures before the attachment is installed, used and serviced. If there is anything you do not understand, ask your JCB dealer. Before you use an attachment, make sure you understand how the attachment will affect the operational safety. When an attachment is installed, there may be changes in the machines centre of gravity or overall dimensions. These change can effect for example, the machine stability, the gradients on which it is safe to operate or the safe distance from power lines. Practice with an attachment off the job before you work with it for the first time. A JCB attachment is designed and manufactured specifically to suit the machines hydraulic system, mounting components and safe load requirements. An attachment which is not designed for use with the machine can cause damage and create a safety hazard for which JCB cannot be held responsible. Also the machines warranty and any other legislative compliance can be affected by the use of non JCB approved attachments. If your machine needs the hydraulic system adapting to use an auxiliary attachment, you must consult your JCB dealer. Only suitably qualified personnel must re-route the hydraulic hoses. All optional attachments will have limits on their operation for example, the lifting capacity, speeds, hydraulic flow rates. Always check the instructions supplied with the attachment or in the Specification section of this manual. Some specification limits may also be shown on the data/rating plate on the attachment. This section of the Operator's Manual includes general information on the operation of the attachment and the procedures for the installation and removal of the attachment.

Attachments for your Machine CAUTION Operation of this machine with an earth drill or breaker attached will alter machine stability. Attachments will help increase the productivity of your machine, for more information contact your JCB dealer. Remember, do not operate an attachment until you have read and fully understand the attachment operating instructions. Do not operate or work with attachments until the machine hydraulic oil has reached its normal working temperature.

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Attachments Working with Attachments

Notice: Some attachments may contact parts of the machine when in the fully folded position. Take extra care to avoid damage to the machine.

Connecting/Disconnecting Hydraulic Hoses WARNING Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear personal protective equipment. Hold a piece of cardboard close to suspected leaks and then examine the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately. WARNING Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Make sure the engine cannot be started while the hoses are open. Some attachments are hydraulically powered. The following procedures show how to connect and disconnect the hydraulic hoses safely.

Connecting the Hydraulic Hoses 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 190). 2. Vent the hydraulic system. Refer to: Maintenance > Hydraulic System > General > Discharge (Page 234). 3. Check the hoses and adaptors for damage. Refer to: Maintenance > Hydraulic System > General > Check (Condition) (Page 234). 4. Connect the hoses: 4.1. Make sure that the hose is not twisted. Pressure applied to a twisted hose can cause the hose to fail or the connections to loosen. Figure 182.

4.2. Make sure that the hose does not touch hot parts. High ambient temperatures can cause the hose to fail. 4.3. Make sure that the hose does not touch parts which can rub or cause abrasion. 4.4. Use the hose clamps (where possible) to support long hose runs and keep the hoses away from moving parts, etc. Figure 183.

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Attachments Working with Attachments

4.5. To allow for length changes when the hose is pressurised, do not clamp at the bend. The curve absorbs the change. Figure 184.

5. Check for leaks: 5.1. Start the engine. 5.2. Operate the related controls to increase the pressure in the hydraulic system. 5.3. Stop the engine then remove the ignition key. 5.4. Check for indications of leakage at the hose connections. Correct, as necessary.

Disconnecting the Hydraulic Hoses 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 190). 2. Vent the hydraulic system. Refer to: Maintenance > Hydraulic System > General > Discharge (Page 234). 3. Disconnect the hoses. 4. Check the hoses and adaptors for damage. Refer to: Preservation and Storage > Checking For Damage (Page 171). 5. If necessary, install the blanking caps. 6. Check for leaks: 6.1. Start the engine. 6.2. Operate the related controls to increase the pressure in the hydraulic system. 6.3. Stop the engine then remove the ignition key. 6.4. Check for indications of leakage at the hose connections. Correct, as necessary.

Quick Release Couplings WARNING The external surfaces of the couplings must be clean before connecting or disconnecting. Ingress of dirt will cause fluid leaks and difficulty in connecting or disconnecting. You could be killed or seriously injured by faulty quick release couplings. The flat face quick release couplings allow the operator to remove and install attachments swiftly and efficiently. Generally, your machine pipework will be installed with a female coupling and a male coupling. The optional attachment hoses will also be installed with a female coupling and a male coupling.

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Figure 185. A

A B

B

Female coupling Male coupling

The quick release couplings will be trouble free and relatively easy to connect and disconnect, if they are kept clean and used correctly. The recommendations listed below must always apply when using flat face quick release couplings. Read the correct connecting and releasing procedures before you install or remove any optional attachment connected with quick release couplings. Essential do's: • • • • • • • • •

Before connecting or removing any hydraulic hose, the residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing the hoses. Always wipe the two mating faces clean before connecting. Use caps and plugs when the couplings are disconnected. Always align the external locking ball (if used) with the notch in the locking sleeve and then pull the locking sleeve back fully to disconnect. If a coupling sticks, first check that pressure has been released. Make sure the locking ball and notch in the locking sleeve are aligned, pull back the sleeve and twist the couplings apart. Sticking is normally caused by dirt in the coupling or physical damage due to abuse. Connect and disconnect the new couplings two or three times to work the PTFE seals. Sometimes a new coupling will stick if the seal has not been worked. When connecting the couplings, only apply the spanner or grips to the hexagon and nowhere else. Avoid damage to the coupling faces. Burrs and scratches cause damage to the seals and cause leaks. They can also impede connection and disconnection of the couplings. Periodically lubricate the internal locking balls on the female half of the coupling with silicone grease.

Essential don'ts: • • • • • • • • • •

Never try to reconnect using a damaged half coupling as this will destroy the seals in the mating half and necessitate replacement of both halves. Do not leave the coupling where it may be run over by a machine or otherwise crushed, this will distort the sleeve and prevent connection and disconnection. Never try to turn the sleeve when the coupling is disconnected as this will cause the locking ball to jam under the locking sleeve and damage the coupling. Never try to strip the coupling down, there are no user serviceable parts. If the coupling is damaged it must be replaced with a new one. Never hit the centre poppet of the coupling to try and release the locked in pressure. This can cause irreparable damage to the coupling and serious injury. When connecting the couplings, never clamp on the sleeve of the female or nose of the male, this will cause distortion and/or damage. Never subject the couplings to external forces, especially side load. This can decrease the life of the coupling or cause failure. Never allow the torsional forces transmitted from the hoses to unscrew/screw together the couplings. Never use a coupling as a plug. Do not connect and disconnect with pressure in the line unless the coupling type is specifically designed to do so.

Connecting Quick Release Couplings 1. Remove any residual hydraulic pressure trapped in the service line hose. 2. Wipe the two faces of the male and female couplings and make sure they are clean. 158

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Attachments Working with Attachments

3. Make sure that ball in the female coupling is located in one of its slots. 4. Connect the male coupling into the female coupling. 5. Where applicable, rotate the sleeve half a turn and make sure that the locking ball does not align with the slot. Figure 186. D E C

C D E

Ball Slot Sleeve

Disconnecting Quick Release Couplings 1. Remove any residual hydraulic pressure trapped in the service line hose. 2. Where applicable, align the slot with ball. 3. Pull back the sleeve to release the coupling.

Impact Protection CAUTION When using an attachment for example a hydraulic breaker, where the risk of flying debris is present, a protective layer or screen guard must be attached to the front of the cab to protect the operator from flying debris which could cause injury. The safety label warns the operator against the risk of flying debris when they use an attachment. The attachment must not be used if a protective layer or screen guard has not been installed on the machine. Make sure that the attachment, for example a hydraulic breaker is positioned in front of the cab before it is operated. Do not slew the boom to the side during operation of the attachment. Consult your JCB dealer for further information. Figure 187. A

332/V3761-1

B

A B

159

Safety label Hydraulic breaker

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Attachments Direct-Mounted Attachments

Direct-Mounted Attachments General Removal 1. Move the boom straight in front of the machine. Refer to: Operation > Operating Levers/Pedals (Page 97). 2. Put the bucket on level ground, with the dipper approximately vertical and the bucket flat. 3. Put blocks around the bucket to prevent its movement. 4. Stop the engine. 5. Remove the ignition key. CAUTION! Stand clear and to one side of the bucket while you remove the pivot pins. With the pins removed, the bucket could roll over. WARNING! If two people are doing this job make sure that the person working 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. 6. At the bucket tipping-link, remove the locking pin from the pivot pin. Refer to Figure 188. 7. At the dipper nose, remove the locking pin from the pivot pin. Figure 188.

B

A

20mm A B

Bucket tipping-link: Pivot pin Dipper nose: Pivot pin

8. Lift the bucket from the ground by the specified distance. Distance: 20mm 9. Use the bucket ram to adjust the position of the bucket tipping-links, until there is no load on its pivot pin. 10. Use a hard wood, nylon or copper drift to remove the pivot pin from the bucket tipping-links. If necessary, the drift can be hit with a hammer. 11. Retract the bucket ram so that the bucket tipping-links are away from the bucket, then remove the O-ring seals. 160

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Attachments Direct-Mounted Attachments

12. Use the boom rams to carefully lower the dipper nose until there is no load on the pivot pin in the dipper tipping-links. 13. Use the drift to remove the pivot pin. 14. Move the dipper nose away from the bucket, then remove the O-ring seals.

Installation The installation procedure is not the reverse of the removal procedure. 1. Clean the pivot pins and the bores in the bucket bosses. 2. Make sure that the pivot pins slide through the bucket bosses. 3. Move the bucket in-line and in front of the machine. 4. Roll the two dipper tipping-link O-ring seals over the outside diameter of the inner bucket bosses. 5. Retract the bucket ram. 6. Move the nose of the dipper link between the bucket plates and align their bores, as shown at position 'C'. Refer to Figure 189. 7. Insert a solid steel bar with the specified diameter through the bores at position 'C'. Dimension: 50mm 7.1. The dipper should be approximately vertical. 8. Align the bucket link bores with the bucket bores, as shown at position 'D'. 9. Insert a solid steel bar with the specified diameter through the bores at position 'D'. Dimension: 50mm 10. Lift the boom until the bucket is off the ground hanging on the steel bars. Figure 189.

D

C D

161

C

Position 'C' Position 'D'

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Attachments Direct-Mounted Attachments

11. Move the bucket to the dump position so that the dipper link and the bucket bores are closely aligned (as shown at position 'C'), with the bucket teeth/toe plate above the ground by the specified distance. Distance: 20mm 11.1. In this position the bucket will be at a point of balance and will be suspended on the steel bar at position 'D', only through the tipping-link. 12. Remove the steel bar from position 'C', then push the pivot pin through. 13. Align the locking pin holes in the pivot pin and the boss, then install the locking pin. 14. Put the bucket flat on the ground in a suitable position. 15. Remove the second steel bar from position 'D'. 16. Swing the bucket link out and hold the O-ring seals in position. Refer to Figure 190. 17. Carefully move the bucket link forwards into alignment with the bucket bosses, as shown at position 'D'. 18. Push the pivot pin through the bores at position 'D'. Be careful, do not to put your fingers in a position where they can get trapped. 19. Align the locking pin holes in the pivot pin and the boss, then install the locking pin. 20. Make sure that the O-ring seals are in their correct positions. 21. Grease the pivot pins. Figure 190.

E

E

O-ring seals

Reversal 1. Do the bucket removal procedure. 2. Slightly lift the dipper, then turn the bucket by the specified angle. Angle: 180° 3. Do the bucket installation procedure.

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Attachments Quickhitch

Quickhitch Excavator Arm Quickhitch General CAUTION When the Quickhitch is installed and its attachment attached, there is a danger of the attachment hitting the machine. Operate the boom and dipper carefully when the Quickhitch and its attachment are attached. CAUTION When the Quickhitch is attached to the machine, allowance must be made for the weight of the Quickhitch on the rated operating load. The mass of the Quickhitch is stamped on the data plate. The excavator Quickhitch, which is attached to the dipper enables the fast removal and installation of buckets and other attachments. To prevent premature wear, failure and breakage, the Quickhitch assembly must be used with a rockbreaker for short periods only. If the machine is to be used for rock breaking for a long period of time, it is recommended that the rockbreaker is installed directly on the machine. When using a rockbreaker, it must be curled towards the machine (as a typical digging operation). Do not use the rockbreaker as a lever as this causes excessive loads on the locking mechanism.

Operation If at any point in the Quickhitch process, the operator can move the Quickhitch switch to position 1 to deactivate the system (confirm using the colour display when necessary), the operation will be cancelled and the system shall revert to an inactive state. 1. Start the machine and enable the controls. 2. Lift the Quickhitch off of the ground with the dipper approximately vertical. 3. Crowd the Quickhitch. 4. To activate Quickhitch move the Quickhitch switch to position 3. The switch LED (Light Emitting Diode) will illuminate red and the buzzer will sound constantly. Refer to: Attachments > Quickhitch > Excavator Arm Quickhitch (Page 163). Figure 191.

5. The colour display will display a reminder to the operator to disconnect the attachment hoses before continuing. The reminder screen is displayed for up to 5 seconds and the buzzer sounds constantly until the Quickhitch button on the right joystick is pressed to confirm Quickhitch mode. If the 5 second timer expires the system shall revert to an inactive state. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 97). Figure 192.

6. Press the Quickhitch button on the right joystick to confirm Quickhitch mode, the buzzer will sound intermittently and the Boom Warning light and switch LED will flash. If the Quickhitch button on the right joystick is not pressed then the system will return to the Quickhitch inactive state. 163

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Attachments Quickhitch

Refer to: Operation > Instruments > Instrument Panel (Page 70). 7. Align the boom and dipper so that the colour display displays the green boom and dipper symbols. A grey boom or dipper symbol signifies mis-alignment. When the boom and dipper are aligned, the Quickhitch is in the Quickhitch ready state. Refer to: Operation > Instruments > Instrument Panel (Page 70). Figure 193.

8. Crowd the bucket to raise system pressure. The boom warning light and switch LED will be illuminated constantly. 9. Press and hold the Quickhitch button on the right joystick to confirm unlock of the Quickhitch. The Quickhitch will start to unlock and will remain unlocked for as long as the button is pressed. Manoeuvre the machine to remove the attachment and fix on the new attachment. Once the Quickhitch button is released the Quickhitch will start to lock. 10. The Quickhitch display screen is displayed for 3 seconds as a reminder to the operator to re-connect any hoses. Figure 194.

11. Physically check the attachment is properly fitted. Rotate the rotary dial to select √ and press enter to acknowledge that you have inspected the security of the attachment. If the attachment is incorrectly fitted then re-start the QuickHitch Process Figure 195.

Installation This operation is easier done by two people, one person to operate the controls and one to line up the pivots. 1. Before the Quickhitch is installed, make sure that the tipping lever locking bolt assembly is attached with the nut. 2. Put the Quickhitch on solid, level ground. Use the safe and correct lifting equipment to move the Quickhitch. 3. Move the machine so that the dipper arm and Quickhitch are aligned. 4. Engage the dipper: 4.1. Operate the controls to line up the hole in the dipper arm with the holes in the Quickhitch. 4.2. Install the pivot pin and secure it with the nut and bolt.

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Attachments Quickhitch

5. Engage the tipping link: 5.1. Operate the controls to line up hole in the tipping link with hole in the Quickhitch. 5.2. Install the pivot pin and attach it with the nut and bolt.

Removal The removal of the Quickhitch is a reversal of the installation procedure. Pay particular attention to safety notices.

Maintenance Examine the Quickhitch daily for broken or missing parts. Remove any debris from the latch hook locking mechanism. If the Quickhitch is cleaned by high pressure water, always grease the latch hook pivot pin. Always grease the latch hook pin every week.

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Attachments Buckets

Buckets General For: JS370 .............................................................................................................................. Page 166 For: JS200., JS210., JS220., JS230. ..................................................................................... Page 166

(For: JS370) WARNING The bucket selected must be the correct width to suit the hole/trench to be excavated. However, if the hole width demands a larger bucket, consideration must 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 heavy duty bucket for maximum penetration when digging in hard, rocky or clay soils. Use the general purpose bucket for bulk shifting light or loose materials.

(For: JS200., JS210., JS220., JS230.) WARNING The bucket selected must be the correct width to suit the hole/trench to be excavated. However, if the hole width demands a larger bucket, consideration must 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 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. Notice: When buckets750mm or wider are attached to the machine, use extreme caution in operation to avoid contact with the cab.

Bucket Teeth Introduction This bucket teeth information relates only to the buckets supplied by JCB. If a bucket from another source is used, refer to the relevant manufacturers manual. A wide range of bucket teeth is available for your machine, which are suitable for all digging conditions. The bucket teeth consists of an adaptor, tooth and locking pin. Refer to Figure 196. The adaptor remains attached to the bucket and the teeth can be easily and quickly changed by one man. The method of removal/installation is the same for all types of teeth.

Removal 1. Make the machine safe. 2. Move the bucket into position. 2.1. Make sure the bucket is supported off the ground with sufficient space for the removal of the locking pin. 3. Stop the engine. 4. Remove the ignition key. 5. Remove the locking pin. Refer to Figure 196. 5.1. Use a hammer and suitable drift, to knock the locking pin down and out of its guide. 5.2. Discard the locking pin. 166

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Attachments Buckets

6. Remove the tooth from the adaptor. Refer to Figure 196. Figure 196.

A

C A B C

B

Adaptor Locking pin Tooth

Installation 1. Install the tooth over the adaptor. Refer to Figure 196. 2. Install a new locking pin. Make sure that the locking pin is in the correct position. Refer to Figure 196. 3. Carefully hit the locking pin with a hammer until it is flush with its guide and locks in position.

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Notes:

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Preservation and Storage Cleaning

Preservation and Storage Cleaning

General WARNING When using cleaning agents, solvents or other chemicals, you must adhere to the manufacturer's instructions and safety precautions. CAUTION To avoid burning, wear personal protective equipment when handling hot components. To protect your eyes, wear goggles when using a brush to clean components. NOTICE Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents. NOTICE The efficiency of the rams will be affected if they are not kept free of solidified dirt. Clean dirt from around the rams regularly. When leaving or parking the machine, close all rams if possible to reduce the risk of weather corrosion. NOTICE Never use water or steam to clean inside the cab. The use of water or steam could damage the on-board computer and render the machine inoperable. Remove dirt using a brush or damp cloth. Clean the product with water and/or steam. Do not let mud, debris etc. to collect on the product. Before you do any service procedures that require components to be removed: •

The cleaning must be done either in the area of components to be removed, or in the case of major work, or work on the fuel system, the whole engine and the surrounding product must be cleaned. When cleaning is complete, move the product away from the wash area or alternatively, remove the material washed from the product.

•

When you remove components, be aware of exposure to dirt and debris. Cover any open ports and remove the deposits before proceeding. Refer to the individual clean procedures throughout the Maintenance section. Refer to: Maintenance > Maintenance Schedules (Page 183).

Detergents Do not use a full strength detergent. Always dilute the detergents as per the manufacturer's recommendations, or damage to the paint finish can occur. Always obey the local regulations regarding the disposal of debris created from cleaning the product.

Pressure Washing and Steam Cleaning CAUTION When using a steam cleaner, wear safety glasses or a face shield as well as protective clothing. Steam can cause personal injury. NOTICE The engine and other components could be damaged by high pressure washing systems. Special precautions must be taken if the machine is to be washed using a high pressure system. Make sure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by the high pressure cleaning system. Do not aim the water jet directly at bearings, oil seals or the engine air induction system. Use a low pressure water jet and brush to remove dried mud or dirt. Use a pressure washer to remove soft dirt and oil. The product must always be greased (if appropriate) after pressure washing or steam cleaning.

Preparation 1. Make the product safe. Refer to: Maintenance > Maintenance Positions (Page 190). 169

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Preservation and Storage Cleaning

2. Stop the engine and let it cool for at least one hour. Do not try to clean any part of the engine while it is running. 3. Make sure that all of the electrical connectors are correctly coupled. If the connectors are open, attach the correct caps or seal with water proof tape.

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Preservation and Storage Checking For Damage

Checking For Damage General Refer to the individual condition checks throughout the Maintenance section. Refer to: Maintenance > Maintenance Schedules (Page 183).

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Preservation and Storage Storage

Storage General If the product will not be used for an extended period, you must store the product correctly. If you prepare the product carefully and apply on-going care you can prevent deterioration and damage to the product while it is in storage.

Storage Area The product can be stored in a temperature range of: -40°C to 54°C When possible, you must keep the product in a dry building or shelter. If only an outdoor storage area is available, look for a storage area with good drainage.

Prepare the Product for Storage 1. Clean the product to remove all unwanted material and corrosive products. 2. Dry the product to remove solvents and moisture. 3. Touch-up any damaged paint. 4. Apply grease to the moving parts (if applicable). 5. Examine the product for worn or damaged parts. Replace if necessary. 6. Fill the fuel tank to prevent a build up of condensation in the tank (if applicable). 7. Examine the coolant condition. Replace if necessary. 8. Examine all fluid levels. Top up if necessary.

Put into Storage 1. Park the machine on solid, level ground. 1.1. Park the machine in an area where it is easy to access. (In case the machine does not start at the end of the storage period). 1.2. Put suitable timbers under the machine to eliminate direct contact with the ground. 2. Retract all of the rams and lower the attachment to the ground. 3. Vent the hydraulic system. 4. Remove the ignition key. 5. Apply a thin layer of grease or petroleum jelly to all of the exposed ram piston rods. 6. Remove the battery. 6.1. Keep the battery in warm, dry conditions. 6.2. Charge the battery periodically. 7. If you keep the machine outdoors, cover the machine with tarpaulins or plastic sheets.

During Storage Operate the machine functions each week to prevent a build up of rust in the engine and hydraulic circuits, and to minimise the deterioration of the hydraulic seals. 1. Remove the grease or petroleum jelly from the ram piston rods. 2. Examine all fluid levels. If necessary, add more fuel. 172

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3. Install a charged battery. 4. Start the engine. 5. Operate the hydraulic controls. Make sure that the hydraulic functions operate correctly. 6. Prepare the machine for storage.

Take out of Storage 1. Examine the coolant condition. Replace if necessary. 2. Examine all fluid levels. If necessary, add more fluid. 3. Clean the machine to remove all unwanted material and corrosive products. Dry the machine to remove solvents and moisture 4. Remove the grease or petroleum jelly from the ram piston rods. 5. Install a charged battery. 6. Start the engine. 7. Operate the hydraulic controls. Make sure that the hydraulic functions operate correctly.

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Security General Vandalism and the theft of unattended machines is an ever increasing problem and JCB is doing everything possible to help stop this. Your JCB dealer will be pleased to provide information on any of these sensible precautions. Act now!

JCB Plantguard JCB Plantguard is a comprehensive package available to help you safeguard your machine. It includes such devices as vandal proof covers, window etching, immobiliser, concealed serial number, battery isolator, tracker security system etc. Remember that the installation of any one of these security devices will help to minimise not only the damage or loss of your machine, but also subsequent lost productivity. It could also help to reduce insurance premiums.

LiveLink Your JCB machine may be installed with LiveLink, JCB's advanced machine monitoring system. LiveLink monitors a range of information about your machine and sends it through cellular and satellite communication back to JCB's secure monitoring centre. The machine owners and JCB dealers can then view that information through the LiveLink website, by email and even through text message. If you want to know how LiveLink can help manage your JCB machines, contact your local dealer for more information.

Anti-Vandal Guards Anti-Vandalism Guards (option) The anti-vandalism guards are stored in a purpose built cage on the roof of the machine. Make sure the cage is locked before the machine is moved. CAUTION! Make sure the steps, handrails, and your footwear soles are clean and dry before climbing onto the machine. Always face the machine when climbing on and off it.

Unpacking the Guards Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 190). Unlock the cage and remove the guards. Leave the guards 2, 3 and 4 in the cage, they are installed from the top of the machine.

Installing the Guards It is recommended that a hard hat is worn during the installation procedure and that any part of the machine that you may need to climb on is clean. Access steps may be required to safely fit some of the guards. The guards are individually numbered to aid storage, install each numbered guard in the position shown.

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Figure 197.

C A

7

B

5

D

2

G

F E

4 3

1 6

A B C D E F G

175

Front top panel Front bottom panel Door front panel Door rear panel Boom side panel Boom side panel Rear window panel

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Guard 7, Front top panel - position A Hook the guard onto the rail above the front window, make sure the top lip of the guard is correctly installed on the rail.

Guard 6, Front bottom panel - position B Attach to the guard 7 and lock onto the two locking points on the cab front.

Guard 1, Door front panel - position C Make sure that the cut-out on the top of the guard aligns with the marker on the rail, then install the guard onto the roof rail. Lock onto the locking points on the guard 7 and the cab side.

Guard 5, Door rear panel - position D Put the top of the guard onto the roof rail and over the edge of the guard 1. Lock onto the locking point on the side of the machine.

Guards 3 and 4, Boom side panels - position E and F Open the guards and using the handle on top of the guard 3 slide onto the roof rail. Do not lock the guard 3 to the locking point on the guard 7 until the guard 2 has been installed.

Guard 2, Rear window panel - position G Install the guard with the cut-outs uppermost and lock to the four locking points on the guards 5 and 4. Lock onto the guard 5 first.

Removing the Guards Use the key provided to unlock and remove the guards in the reverse order of installation.

Storing the Guards The guards are numbered and can only be stored in the order and orientation shown below. The arrows on the guards should point towards the front of the cab when they are stowed. Close and lock the cage. Table 12. Guards 1 2 3 4 5 6 7

176

Guard 1 - number up Guard 2 - number up Guard 3 - number up Guard 4 - number up Guard 5 - number down Guard 6 - number up Guard 7 - number down

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Maintenance Introduction

Maintenance Introduction

General Your product has been designed and built to give maximum performance, economy and ease of use under a wide variety of operating conditions. Prior to delivery, your product was inspected both at the factory and by your dealer to make sure that it reaches you in optimum condition. To maintain this condition and trouble free operation it is important that the routine services, as specified in this manual, are done by an approved JCB dealer at the recommended specified intervals and it is recommended that this is done by an approved JCB dealer using genuine JCB parts. This section of the manual gives full details of the service requirements necessary to maintain your JCB product at peak efficiency. A service manual for your product is available from your JCB dealer. The service manual contains information on how to repair, disassemble and assemble your product correctly. It can be seen from the service schedules on the following pages that many essential service checks must only be done by a JCB trained specialist competent person. Only the Your JCB dealer service engineers have been trained by JCB to do such specialist tasks, and only the JCB dealer service engineers are equipped with the necessary special tools and test equipment to do such tasks, thoroughly, safely, accurately and efficiently. JCB regularly updates its dealers to advise them of any product developments, changes in specifications and procedures. Therefore only a JCB dealer is fully able which makes them best placed to maintain and service your product. A service record sheet or book is provided which will enable you to plan your service requirements and keep a service history record. It must be dated, signed and stamped by your dealer each time your product is serviced. Remember, if your product has been correctly maintained, not only will it give you improved reliability but its resale value will be greatly enhanced.

Owner/Operator Support JCB together with your dealer wants you to be completely satisfied with your new JCB product. However, if you do have a problem, you can contact your dealers service department who are there to help you! You will have been given the names of the relevant service contacts at your dealer when the product was supplied. To get the most from your dealer please help them to satisfy you by: 1. Giving your name, address and telephone number. 2. Quoting your product model and serial number. 3. Date of purchase and hours of work. 4. Nature of the problem. Remember, only your JCB dealer has access to the vast resources available at JCB to help support you. In addition, your dealer is able to offer a variety of programmes covering warranty, fixed price servicing, safety inspections, including weight tests, covering both legal and insurance requirements.

Service/Maintenance Agreements To help plan and spread the costs of maintaining your product, we strongly recommend you take advantage of the many service and maintenance agreements your dealer can offer. These can be tailor made to meet your operating conditions, work schedule etc. Please consult your JCB dealer for details.

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Obtaining Spare Parts If you use non-genuine JCB parts or consumables, then you can compromise the health and safety of the operator and cause machine failure. A parts book for your machine is available from your JCB dealer. The parts book will help you identify parts and order them from your JCB dealer. Your dealer will need to know the exact model, build and serial number of your machine. Refer to: About the Product > Product and Component Identification (Page 10). The data plate also shows the serial numbers of the engine, transmission and axle(s), where applicable. Remember, if any of these units have been changed, the serial number on the data plate may be wrong. Check on the unit itself.

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Maintenance Safety General Compressed Air Compressed air is dangerous. Wear personal protective equipment. Never point a compressed air jet at yourself or others. Springs Always wear personal protective equipment when dismantling assemblies containing components under pressure from springs. This will protect against eye injury from components accidentally flying out. Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or copper drift to remove and install metal pins. Always wear personal protective equipment. Communications Bad communications can cause accidents. If two or more people are working on the machine, make sure each is aware of what the others are doing. Before starting the engine make sure the others are clear of the danger areas. Examples of danger areas are: the rotating blades and belt on the engine, the attachments and linkages, and anywhere beneath or behind the machine. People can be killed or injured if these precautions are not taken. Repairs If your machine does not function correctly in any way, get it repaired straight away. Neglect of necessary repairs could result in an accident or affect your health. Do not try to do repairs or any other type of maintenance work you do not understand. To avoid injury and/or damage get the work done by a specialist engineer. Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Make sure the engine cannot be started while the hoses are open. 'O' rings, Seals and Gaskets Badly installed, damaged or rotted 'O' rings, seals and gaskets can cause leakages and possible accidents. Renew whenever disturbed unless otherwise instructed. Do not use Triochloroethane or paint thinners near 'O' rings and seals. Arc Welding To prevent the possibility of damage to electronic components, disconnect the battery and the alternator before arc-welding on the machine or attached implements. If the machine is equipped with sensitive electrical equipment, i.e. amplifier drivers, electronic control units (ECUs), monitor displays, etc., then disconnect them before welding. Failure to disconnect the sensitive electrical equipment could result in irreparable damage to these components. Parts of the machine are made from cast iron, welds on cast iron can weaken the structure and break. Do not weld cast iron. Do not connect the welder cable or apply any weld to any part of the engine. Always connect the welder earth (ground) cable to the same component that is being welded to avoid damage to pivot pins, bearings and bushes. Attach the welder earth (ground) cable a distance from the part being welded no more than 0.6m. Counterweights Your machine may be installed with counterweights. They are extremely heavy. Do not attempt to remove them. Accumulators The accumulators contain hydraulic fluid and gas at high pressure. Prior to any work being carried out on systems incorporating accumulators, the system pressure must be discharged by a JCB dealer, as the sudden release of the hydraulic fluid or gas may cause injury. Hot Components Touching hot surfaces can burn skin. The engine and machine components will be hot after the unit has been running. Allow the engine and components to cool before servicing the unit.

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Soft Ground A machine can sink into soft ground. Never work under a machine on soft ground. Working Under the Machine Make the machine safe before getting beneath it. Make sure that any attachments on the machine are correctly attached. Engage the park brake (if installed), remove the ignition key, disconnect the battery. If the machine has wheels use blocks to prevent unintentional movement. Lifting the Machine Under no circumstances must the engine be run with the transmission in gear and only one driving wheel jacked clear of the ground, since the wheel on the ground will move the machine. Chemicals Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such as Viton®, FluorelTM and Technoflon®. Fluoroelastomeric materials subjected to high temperatures can produce highly corrosive hydrofluoric acid. This acid can severely burn. New fluoroelastomeric components at ambient temperature require no special safety precautions. Used fluoroelastomeric components whose temperatures have not exceeded 300°C require no special safety precautions. If evidence of decomposition (e.g. charring) is found, refer to the next paragraph for safety instructions. Do not touch component or surrounding area. Used fluoroelastomeric components subjected to temperatures greater than 300°C (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn: Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains. Thoroughly wash contaminated area with detergent and water. Contain all removed material, gloves etc. used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations. Do not burn fluoroelastiometric materials. Hydraulic Hoses Never re-use hydraulic hose end crimps or use reusable hose end crimps.

Fluids and Lubricants Oil Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oil thoroughly in warm soapy water. Do not use petrol, diesel fuel or paraffin to clean your skin. Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear personal protective equipment. Hold a piece of cardboard close to suspected leaks and then examine the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately. Fuel Fuel is flammable, keep naked flames away from the fuel system. Stop the engine immediately if a fuel leak is suspected. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. Completely wipe off any spilt fuel which could cause a fire. There could be a fire and injury if you do not follow these precautions.

Hygiene JCB lubricants are not a health risk when used correctly for their intended purposes. However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation. Low viscosity oils are more likely to do this, so take special care when handling used oils, which might be diluted with fuel contamination. Whenever you are handling oil products you must maintain good standards of care and personal and plant hygiene. For details of these precautions we advise you to read the relevant publications issued by your local health authority, plus the following. 180

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Storage Always keep lubricants out of the reach of children. Never store lubricants in open or unlabelled containers.

Waste Disposal CAUTION It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants. Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites. CAUTION Damaged or spent batteries and any residue from fires or spillage must be put in a closed acid proof receptacle and must be disposed of in accordance with local environmental waste regulations. All waste products must be disposed of in accordance with all the relevant regulations. The collection and disposal of used oil must be in accordance with any local regulations. Never pour used engine oil into sewers, drains or on the ground.

Handling CAUTION The temperature of the hydraulic oil will be high soon after stopping the engine. Wait until it cools before beginning maintenance.

New Oil There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene practices.

Used Oil Used engine crankcase lubricants contain harmful contaminants. Here are precautions to protect your health when handling used engine oil: • •

• • • •

Avoid prolonged, excessive or repeated skin contact with used oil Apply a barrier cream to the skin before handling used oil. Note the following when removing engine oil from skin: • Wash your skin thoroughly with soap and water • Using a nail brush will help • Use special hand cleansers to help clean dirty hands • Never use petrol, diesel fuel, or paraffin for washing Avoid skin contact with oil soaked clothing Don't keep oily rags in pockets Wash dirty clothing before re-use Throw away oil-soaked shoes

Battery Warning Symbols The following warning symbols may be found on the battery.

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Maintenance Maintenance Safety

Figure 198. A

A B C D E F

B

C

D

E

F

Keep away from children Shield eyes No smoking, no naked flames, no sparks Explosive gas Battery acid Note operating instructions

First Aid - Oil Eyes In the case of eye contact, flush with water for 15min. If irritation persists, get medical attention.

Swallowing If oil is swallowed do not induce vomiting. Get medical advice.

Skin In the case of excessive skin contact, wash with soap and water.

Spillage Absorb with sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area.

Fires WARNING Do not use water to put out an oil fire. This will only spread it because oil floats on water. Extinguish oil and lubricant fires with carbon dioxide, dry chemical or foam. Fire fighters must use self contained breathing apparatus.

First Aid - Electrolyte Eyes In the case of eye contact, flush with water for 15min. always get medical attention.

Swallowing Do not induce vomiting. Drink large quantities of water or milk. Then drink milk of magnesia, beaten egg or vegetable oil. Get medical help.

Skin Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help.

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Maintenance Maintenance Schedules

Maintenance Schedules General WARNING Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe, it must be correctly parked on solid, level ground. To prevent anyone starting the engine, remove the ignition key. Disconnect the battery when you are not using electrical power. If you do not take these precautions you could be killed or injured. A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular maintenance and lubrication tasks listed in the service schedules are done to keep the machine in a safe and efficient working condition. Apart from the daily tasks, the schedules are based on the machine running hours. Keep a regular check on the hourmeter readings to correctly gauge the service intervals. When there is no hourmeter installed, use the calendar equivalents to determine the service intervals. Do not use a machine which is due for a service. Make sure any defects found during the regular maintenance checks are corrected immediately. More frequent checks of engine components than the engine manufacturer recommends do not invalidate emissions warranty.

How to Use the Maintenance Schedules The schedules show the service tasks which must be done and their intervals. The services must be done at either the hourly interval or the calendar equivalent, whichever occurs first. The intervals given in the schedules must not be exceeded. If the machine is operated under severe conditions (high temperature, dust, water, etc.) shorten the intervals. Table 13. Service task can be completed by a competent operator. Details of how to complete the service task are given in the Operator's Manual. We recommend that a Service Engineer completes the service task. Details of how to complete the service task are given in the Service Manual.

Maintenance Intervals General Table 14. Interval (h) 10 50 250 500 1000 2000 4000 8000

Calendar Equivalent Daily Weekly Monthly Three months Six months Yearly Two years Four Years

Attachments When using a breaker, crusher or pulveriser, contamination and degradation of the hydraulic oil occurs much more quickly than in normal excavating use. If the machine is used with increasingly degrading oil it can cause 183

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Maintenance Maintenance Schedules

problems in the control valve, premature wear of the hydraulic pump and damage to the hydraulic system as a whole. The servicing of the hydraulic oil and filters must be done more frequently according to the percentage of total operating hours involving use of the breaker, crusher or pulverizer. When a breaker, crusher or pulverizer is installed, make sure that the oil and filters are changed at the intervals shown in the table below. The hydraulic oil must be sampled and checked for contamination and degradation at the intervals shown. Contact your JCB dealer who will have the facilities to do these tasks and make sure that the hydraulic system is correctly maintained. Table 15. Check the oil level, add more oil as required Change Clean Table 16. Item

Use Frequency Greater than 75% 50-75% 25-50% 10-25% Less than 10% 10h 100h 600h 10h 200h 1,000h 10h 300h 1,500h 10h 600h 3,000h 10h 800h 4,000h

Hydraulic oil Return filter

(1)

Suction filter Drain filter

(1)

(1)

Servo filter

(1)

Plexus filter (if (1) fitted) Breaker in-line (1) filter Hydraulic oil Every 200 hrs sampling

Every 200 hrs

Every 300 hrs

Every 600 hrs

Every 800 hrs

(1) The filters must be changed whenever the period of breaker/crusher/pulverizer use exceeds 100hrs, regardless of the total number of hours the machine has worked

Periodic Replacement of Safety Related Components Routinely replace the important components concerned with safety. It is difficult to determine by a visual inspection or from operation the service life of specific components, so routinely replace them as important components every 2 years. If any abnormality is found with any of these components before the replacement time, repair or replace them as you would normally do. When you replace the hoses, if the hose clamps are deformed or cracked, replace the hose clamps at the same time as the hoses. Regarding the hoses not included in the routine replacement of safety components, do the inspection described. Tighten, replace, etc, when any abnormality is found. Refer to Table 19. Replace the O-rings, gaskets at the same time as the hoses. Contact your JCB dealer for the replacement of the safety components. Do an inspection of the hydraulic hoses and the fuel hoses at the routine inspection described. Refer to Table 19.

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Table 17. Important Parts Fuel hose (Fuel tank - engine) Fuel hose (Fuel filter - injection pump)

Replacement Interval Every 2 years or every 4000 hours, whichever comes first. Table 18.

Important Parts Pump exit hose (Pump - operation valve) Boom ram line hose Dipper ram line hose Bucket ram line hose

Replacement Interval Every 2 years or every 4000 hours, whichever comes first.

Table 19. Inspection Classification Start-up inspection Special independent inspection (Monthly inspection) Special independent inspection (Yearly inspection)

Inspection Item Fuel, hydraulic hose connections, oil leakage from caulked parts. Fuel, hydraulic hose connections, oil leakage from caulked parts. Fuel, hydraulic hose damage (cracks, wear, picking) Fuel, hydraulic hose connections, oil leakage from caulked parts. Fuel, hydraulic hose interference, squeezing, aging, twisting, damage (cracks, wear, picking)

Pre-start Cold Checks, Service Points and Fluid Levels Table 20. Component Task Attachments/Optional Equipment As required Lubricate As required

10

50

250

500 1,000 2,000 4,000

Check (Condition)

Engine speed in breaker mode Check (Operation) Body and Framework General

Clean

General

Check (Condition)

Slew ring bearing

Lubricate

Slew ring pinion and gear teeth Pivot pins (except boom base and dipper) Pivot pins (boom base and dipper) Pivot pins (wet or severe conditions - except boom base and dipper pins) Hydraulic raised cab)

Lubricate Lubricate Lubricate Lubricate Lubricate

Operator Station Operator protective structure

Check (Condition)

Seat belt

Check (Condition)

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Maintenance Maintenance Schedules

Component Task Cab heater/air-conditioning fil- Replace ter Engine Oil Check (Leaks) Oil

10

250

500 1,000 2,000 4,000

Check (Level)

Oil and filter

Replace

FEAD belt

Check (Condition)

(4)

FEAD belt Fan belt

Replace

(9)

Check (Condition) Replace

Fan belt

(10)

(2)

Valves

Check (Condition)

Engine mounts

Check (Condition)

Air inlet security

Check (Condition)

Exhaust system security

Check (Condition)

Fuel tank water and sediment

Clean

Fuel level

Check (Level)

Fuel filler cap

Clean

Fuel filler cap (dusty conditions) Air Filter

Clean

Air filter (outer)

(5)

Replace

Air filter (inner)

Replace

Air filter (dust valve)

Clean

Pre cleaner (if installed)

Clean

Crankcase ventilation filter (if installed) Fuel System Fuel system

Replace

Main fuel filter/sedimenter

Replace

Main fuel filter/sedimenter

Clean

Engine fuel filter

Replace

Engine fuel filter

Drain/Clean

Primary fuel filter

Replace

Primary fuel filter

Clean

Check (Leaks)

Replace

Fuel injectors

(2, 11)

Fuel injectors leak-off rail

Replace

High pressure fuel lines Cooling System Coolant

Replace Check (Leaks)

Coolant

Check (Condition)

Coolant

Check (Level)

(2, 11)

(2, 11)

186

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Maintenance Maintenance Schedules

Component Coolant

Task Replace

Cooling pack

Check (Condition)

Gearbox Track gearbox security

Check (Condition)

Slew gearbox security

Check (Condition)

Track gearbox oil

Check (Level)

Slew gearbox oil

Check (Level)

(3)

(3)

Track gearbox oil

Replace

Slew gearbox oil

Replace

(3, 8)

(3, 8)

Tracks Track plate condition and bolt torque Idler wheels oil and seals

10

Track roller oil and seals

Check (Condition)

Hydraulics Hose and pipework

Check (Leaks)

Oil

Check (Level)

Oil (Biodegradable and nonbiodegradable) Oil (Biodegradable)

Sample

Oil (Non-biodegradable) Oil cooler

Replace

Replace Clean

Hydraulic tank breather

Replace

Rams

Check (Condition)

Return filter

Replace

Drain filter

Replace

(3, 6)

Suction strainer

Clean

Suction strainer

Replace

Cushion valve filter

Clean

Cushion valve filter

Replace

Security of the mounting bolts (7) on major components

Check (Condition)

(3)

Servo filter element

(3, 6)

Replace

Plexus filter element

Replace

Pump line exit hose

Replace

Boom ram hoses

Replace

Dipper line ram hoses

Replace

Bucket line ram hoses

Replace

Electrics Wiring

Check (Condition)

(6)

187

500 1,000 2,000 4,000

Check (Condition) Check (Condition)

(3, 6)

250

Check (Condition)

Track tension

(10)

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Maintenance Maintenance Schedules

Component Battery

Task Clean

10

Battery electrolyte level (if applicable) Battery isolator

Check (Level)

Starter motor

Check (Condition)

Alternator

Check (Condition)

Window washer fluid level

Check (Level)

Miscellaneous Fire extinguisher

Check (Condition)

50

250

500 1,000 2,000 4,000

Check (Operation)

(1) Dusty conditions only. (2) Tasks which must be done by a specialist. (3) These procedures are only to be done at the first 500 hours of use. Then sample/replace every 1000 hours. (4) If operating under arduous conditions, do an engine oil flush (use the normal recommended engine oil) every 250 hours and replace the engine oil and filter. Service times may depend on fuel used. (5) If operating in dusty condition do these tasks more frequently. (6) If using a breaker, crusher or pulveriser, refer to the service intervals for attachments in this manual. (7) Tighten the bolts and nut after the first 50 hours of first use and then every 250 hours. (8) Sample/replace every 500 hours if the tracking hours is greater than 20% machine hours. (9) Replace every 3000 hours. (10) Replace every 5000 hours. (11) Replace every 8000 hours.

Functional Tests and Final Inspection Table 21. Component Body and Framework Excavator lever and pedal locks Doors and locks

Task

Seat and seat belt

Check (Condition/Operation)

Engine Maximum no-load speed

Check (Operation)

Throttle calibration

Check (Operation)

Engine Stop

Check (Operation)

General

Check (Condition)

Cooling System Coolant

Check (Condition)

Hydraulics Hydraulic tank - water and sediment

10

250

500 1,000 2,000 4,000

Check (Operation) Check (Condition)

Drain/Clean

Relief valves

Check (Condition)

Services

Check (Operation)

(2)

50

Accumulator (engine stopped) Check (Condition) Fuel System Fuel system

Check (Leaks)

Transmission 188

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Maintenance Maintenance Schedules

Component Slew brake

Task Check (Operation)

Electrics General

Check (Operation)

Alternator - output

Check (Condition)

Miscellaneous Fit for purpose test

Check (Operation)

Optional Equipment Overload warning system

Check (Operation)

Refuel pump

Check (Operation)

(2)

10

50

250

500 1,000 2,000 4,000

(1) Dusty conditions only. (2) Tasks which must be done by a specialist.

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Maintenance Maintenance Positions

Maintenance Positions General DANGER Your machine may be fitted with a hydraulically raised cab. Do not, under any circumstances enter or work underneath an un-supported cab in the raised position. WARNING A machine can sink into soft ground. Never work under a machine on soft ground. WARNING Make the machine safe before getting beneath it. Make sure that any attachments on the machine are correctly attached. Engage the park brake (if installed), remove the ignition key, disconnect the battery. Make the machine safe before you start a maintenance procedure. Unless a maintenance procedure instructs you differently, you must lower the arm and lower the hydraulically raised cab (if fitted). Refer to: Maintenance > Maintenance Positions (Page 190).

Maintenance Position (Excavator Arm Lowered) 1. Park the machine on solid, level ground, with the upper structure parallel to the undercarriage.. Refer to: Operation > Stopping and Parking (Page 61). 2. If necessary, lower the dozer blade. 3. Lower the excavator so the dipper is flat on the ground. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 97). Figure 199.

A

A

Excavator lowered with the dipper flat on the ground

4. Stop the engine. 5. Remove the ignition key. 6. Release the hydraulic pressure and the tank pressure. Refer to: Maintenance > Hydraulic System > General > Discharge (Page 234). 7. Isolate the battery to prevent the accidental operation of the engine. Refer to: Maintenance > Electrical System > Battery Isolator > Check (Operation) (Page 238).

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Maintenance Service Points

Service Points General For: DE Engine, JS200., JS210., JS220., JS230. .................................................................. Page 191 For: EK Engine, JS370 .......................................................................................................... Page 196

(For: DE Engine, JS200., JS210., JS220., JS230.) CAUTION Make sure the steps, handrails, and your footwear soles are clean and dry before climbing onto the machine. Always face the machine when climbing on and off it.

Upper Structure E

G

Figure 200. F

D

A

C

B

A B C D E F G

191

Engine oil dipstick Radiator cap and expansion bottle Engine oil filler cap Diesel level indicator Fuel filler cap Hydraulic tank breather Hydraulic oil filler cap

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Maintenance Service Points

Access to the Upper Structure Figure 201.

Figure 202.

JCB

192

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Maintenance Service Points

Figure 203.

1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 190). 2. Hold the handrail with both hands, then use the step between the top and bottom tracks to climb onto the top of the track. Keep three points of contact with the machine at all times. Refer to Figure 201. 3. Keep hold of the handrail and use the steps on the toolbox to climb up to the top of the upper structure. Keep two points of contact with the machine at all times. Refer to Figure 202. Refer to Figure 203.

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Maintenance Service Points

Battery Compartment Figure 204.

A

B

E

D C

A B C D E

194

Air intake Radiator(s) Batteries Window washer fluid bottle Battery isolator

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Maintenance Service Points

Hydraulic Compartment Figure 205.

A

C

D

A B C D

195

B

Main fuel filter Hydraulic oil level indicator Primary fuel filter Engine fuel filter

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Maintenance Service Points

Undercarriage Figure 206. A

B

A B

Track rollers Track tensioner

(For: EK Engine, JS370) CAUTION Make sure the steps, handrails, and your footwear soles are clean and dry before climbing onto the machine. Always face the machine when climbing on and off it.

Upper Structure B

Figure 207. C

D

A

E F

G A 196

Diesel level indicator 9821/3250-3

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Maintenance Service Points

B C D E F G

Fuel filler cap Hydraulic oil filler cap Hydraulic tank breather Engine oil filler cap Engine oil dipstick Radiator expansion bottle and cap

Access to the Upper Structure Figure 208.

Figure 209.

JCB

197

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Maintenance Service Points

Figure 210.

1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 190). 2. Hold the handrail with both hands, then use the step between the top and bottom tracks to climb onto the top of the track. Keep three points of contact with the machine at all times. Refer to Figure 208. 3. Keep hold of the handrail and use the steps on the toolbox to climb up to the top of the upper structure. Keep two points of contact with the machine at all times. Refer to Figure 209. Refer to Figure 210.

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Maintenance Service Points

Battery Compartment Figure 211.

A

B

E

D

C

A B C D E

199

Air intake Radiator(s) Batteries Window washer fluid bottle Battery isolator

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Maintenance Service Points

Hydraulic Compartment Figure 212.

B

E D

C A

A B C D E

200

Main fuel filter/sedimenter Hydraulic oil level indicator Primary fuel filter/drain Engine fuel filter/sedimenter Engine oil filter

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200


Maintenance Service Points

Undercarriage Figure 213.

A

B

A B

201

Track rollers Track tensioner

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201


Maintenance Access Apertures

Access Apertures General When moved to their maintenance position, the access panels give you access to parts or areas of the machine that are not required during machine operation. Before you operate the machine, make sure that all of the access panels are correctly in their closed or installed positions.

Battery Cover For: JS200., JS210., JS220., JS230. ..................................................................................... Page 202 For: JS370 .............................................................................................................................. Page 203

(For: JS200., JS210., JS220., JS230.) Open 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 190). 2. Use the ignition key to unlock the cover. 3. Pull the handle to release the latch. 4. Open the cover until it latches in position. Figure 214.

A

C

A B C

B

Lock Handle Cover

Close 1. To release the latch pull it up. 2. Close the cover. 3. Make sure the cover is closed correctly. 4. Use the ignition key to lock the cover.

202

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Maintenance Access Apertures

(For: JS370) Open 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 190). 2. Use the ignition key to unlock the cover. 3. Pull the handle to release the latch. 4. Open the cover until it latches in position. Figure 215.

A

C

A B C

B

Lock Handle Cover

Close 1. To release the latch pull it up. 2. Close the cover. 3. Make sure the cover is closed correctly. 4. Use the ignition key to lock the cover.

Engine Compartment Cover For: JS200., JS210., JS220., JS230. ..................................................................................... Page 203 For: JS370 .............................................................................................................................. Page 204

(For: JS200., JS210., JS220., JS230.) Open 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 190). 2. Use the ignition key to unlock the cover.

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Maintenance Access Apertures

3. Pull the handle to release the latch. The cover opens automatically and is supported on a gas strut. 4. Ensure the support bar has fully engaged. Figure 216. B

A

C

A B C

Lock Handle Cover

Close 1. Hold the weight of the cover and pull the support bar towards you. 2. Push the cover down. 3. Make sure the cover is closed correctly. 4. Fasten the latches. 5. Use the ignition key to lock the cover.

(For: JS370) Open 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 190). 2. Use the ignition key to unlock the cover. 3. Pull the handle to release the latch. The cover opens automatically and is supported on a gas strut. 4. Ensure the support bar has fully engaged.

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Maintenance Access Apertures

Figure 217. B

A

C

A B C

Lock Handle Cover

Close 1. Hold the weight of the cover and pull the support bar towards you. 2. Push the cover down. 3. Make sure the cover is closed correctly. 4. Fasten the latches. 5. Use the ignition key to lock the cover.

Hydraulic Compartment Cover Open 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 190). 2. Use the ignition key to unlock the cover. 3. Pull the handle to release the latch. 4. Open the cover until it latches in position.

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Maintenance Access Apertures

Figure 218.

A C B A B C

Lock Handle Cover

Close 1. To release the latch pull it up. 2. Close the cover. 3. Make sure the cover is closed correctly. 4. Use the ignition key to lock the cover.

Radiator Cover For: DE Engine, JS200., JS210., JS220., JS230. .................................................................. Page 206 For: JS370 .............................................................................................................................. Page 207

(For: DE Engine, JS200., JS210., JS220., JS230.) Open 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 190). 2. Use the ignition key to unlock the cover. 3. Pull the handle to release the latch. 4. Open the cover until it latches in position. 5. Open the cap cover.

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Maintenance Access Apertures

Figure 219.

A

C

A B C D

B

Lock Handle Cover Cap Cover

Close 1. To release the latch pull it up. 2. Close the covers. 3. Make sure the covers are closed correctly. 4. Use the ignition key to lock the cover.

(For: JS370) Open 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 190). 2. Use the ignition key to unlock the cover. 3. Pull the handle to release the latch. 4. Open the cover until it latches in position. 5. Open the cap cover.

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Maintenance Access Apertures

Figure 220. D

A

C

A B C D

B

Lock Handle Cover Cap Cover

Close 1. To release the latch pull it up. 2. Close the covers. 3. Make sure the covers are closed correctly. 4. Use the ignition key to lock the cover.

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Maintenance Tools

Tools General When you carry tools onto the machine, you must keep three points of contact with the machine at all times. If necessary, lift the tools on to the machine in intervals. Put the tools down before you adjust your grips on the machine. Do not try to adjust your grips on the machine while holding tools.

Toolbox The grease gun is stowed in the toolbox. The toolbox can be locked with the key. Figure 221.

A

A

209

Toolbox

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Maintenance Lubrication

Lubrication General CAUTION Waxoyl contains turpentine substitute which is flammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area. You must grease the machine regularly to keep it working efficiently. Regular greasing will also lengthen the machine's working life. Refer to the individual condition checks throughout the Maintenance section. Refer to: Maintenance > Maintenance Schedules > Pre-start Cold Checks, Service Points and Fluid Levels (Page 185). The machine must always be greased after pressure washing or steam cleaning. Greasing must be done with a grease gun. Normally, two strokes of the grease gun is sufficient. Stop greasing when fresh grease appears at the joint. Use only the recommended type of grease. Do not mix different types of grease, keep them separate. Refer to: Technical Data > Fluids, Lubricants and Capacities (Page 263). Attach the dust caps after greasing (if installed).

Preparation Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 190). You can complete the greasing procedures with the excavator lowered.

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Maintenance Attachments

Attachments General Lubricate Where applicable, refer to the specific manufacturers manual for instructions on the lubrication of optional attachments.

Check (Condition) Where applicable, refer to the specific manufacturers manual for instructions on the maintenance of optional attachments.

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Maintenance Body and Framework

Body and Framework General Clean Debris can collect under the boom. Remove all debris from under the boom. Thoroughly dry the piston rams and protect them with clean transmission or hydraulic oil if necessary.

Check (Condition) 1. Make sure that all of the guards and protective devices are in position, secured by their locking devices and free from damage. 2. Inspect all of the steelwork for damage. Include the following: 2.1. Examine all of the lifting point welds. 2.2. Examine all of the pivot point welds. 2.3. Examine the condition of all the pivot pins. 2.4. Check that the pivot pins are correctly in position and secured by their locking devices. 3. Check the steps and handrails are undamaged and correctly attached. 4. Check for broken, cracked or crazed window glass and mirrors. Replace the damaged items. 5. Check that the lamp lenses are undamaged. 6. Check that all of the attachment teeth are undamaged and correctly attached. 7. Check that all of the safety and instructional labels are undamaged and in position. Install new labels where necessary. 8. Note any damaged paintwork for future repair. 9. Inspect the machine for broken or loose fasteners.

Slew Ring Bearings Lubricate Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 190). The slew ring bearings have two grease nipples on the front of the machine and one on the front of the slew ring. Make sure that grease extrudes from under the seal around all of the circumference. It is not possible to add too much grease. Figure 222.

D D 212

Grease nipples

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Maintenance Body and Framework

Pivot Pins Lubricate Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 190). Grease the pivot pins. Figure 223. C B

A

G A B C D E F G

F E

D

Boom base pin Boom ram, eye and pin Dipper ram, dump end pin Dipper ram, eye end pin Boom to dipper, connecting pin Bucket ram, dump end pin Boom ram, dump end pin H

J

Figure 224. K

C

B

D

A A B C D E F G H J K

213

G

F

E

Boom base pin Boom ram, eye and pin Dipper ram, dump end pin Dipper ram, eye end pin Boom to dipper, connecting pin Bucket ram, dump end pin Boom ram, dump end pin Positioning ram, dump end pin Positioning ram, eye end pin Upper/lower boom pin

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Maintenance Body and Framework

Figure 225. P

N

L

M L M N P

Bucket ram to bucket linkage pin Bucket linkage to bucket pin Dipper to bucket pin Dipper to bucket linkage pin Figure 226.

B C B B C

Boom ram, eye and pin Dipper ram, dump end pin

Hydraulically Raised Cab For machines fitted with a hydraulically raised cab the single point greasing system all the hydraulic cab grease points, except where indicated, will be automatically greased. Remove the cap and apply grease until grease appears at the grease points. A powered greaser may be required to provide the force needed to enable sufficient greasing. Figure 227.

A

A

214

Cap

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Maintenance Operator Station

Operator Station General Clean NOTICE Never use water or steam to clean inside the cab. The use of water or steam could damage the on-board computer and render the machine inoperable. Remove dirt using a brush or damp cloth. Remove debris and loose articles from inside the cab.

Operator Protective Structure Check (Condition) WARNING You could be killed or seriously injured if you operate a machine with a damaged or missing ROPS/FOPS/FOGS/TOPS. If the ROPS/FOPS/FOGS/TOPS has been in an accident, do not use the machine until the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS/FOGS/TOPS certification. WARNING When replacing or repairing the ROPS/FOPS/FOGS/TOPS structure you must replace the fixings. Never re-use fixings. Use only new genuine JCB fixings tightened to the torque figures specified in the operator's manual. All excavators are designed so that an operators protective structure can be installed. In certain applications for example demolition, the machines must have the optional FOPS (Falling Object Protective Structure) installed. It is the operators responsibility to identify the risk of an application. A failure to do these precautions can cause death or injury to the operator. For assistance, contact your JCB dealer. 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 190). 2. Check the structure for damage. 3. Make sure that all of the ROPS (Roll-Over Protective Structure)/FOPS/TOPS (Tip-Over Protective Structure) mounting bolts are undamaged and in position. 4. Make sure that the ROPS/FOPS/TOPS mounting bolts are tightened to the correct torque setting.

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Maintenance Operator Station

Figure 228. Cab Mounted FOPS

3

1

2 1 2 3

Torque tightness is 104N·m Torque tightness is 60N·m Torque tightness is 259N·m Figure 229. Frame Mounted FOPS - XD machines Only

1 2 1 3 1 4 1 2 3 4

216

Torque tightness is 259N·m Torque tightness is 104N·m Torque tightness is 104N·m Torque tightness is 259N·m

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Maintenance Operator Station

Figure 230. Frame Mounted ROPS (FOPS)

4 2

1

3 1 2 3 4

Torque tightness is 874N路m Torque tightness is 506N路m Torque tightness is 506N路m Torque tightness is 104N路mFOPS

Seat Check (Condition) Check that the seat adjustments operate correctly. Check the seat is undamaged. Check the seat mounting bolts are undamaged, correctly installed and tight. Make sure the seat is clear from unwanted materials and hazards at all times.

Seat Belt Check (Condition) WARNING When a seat belt is installed on your machine replace it with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident. Install a new seat belt every three years. WARNING If the seat belt does not 'lock' when you check if the seat belt is operating correctly, do not drive the machine. Get the seat belt repaired or replaced immediately. Make sure the seat belt can be adjusted. Examine the seat belt for signs of fraying and stretching. Check that the stitching is not loose or damaged. Check that the belt mounting bolts are undamaged, correctly installed and tight.

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Maintenance Operator Station

Check that the buckle assembly is undamaged and operates correctly.

Controls Check (Operation) Check the operation of the non-hydraulic and non-electrical operator station controls.

218

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218


Maintenance Engine

Engine General Check (Condition) Start the engine and check for: • • • • • •

Excessive smoke Excessive vibration Excessive noise Overheating Performance Unusual smells.

Oil Check (Leaks) Before you start the product, do a check for oil leaks: 1. Make the product safe. Refer to: Maintenance > Maintenance Positions (Page 190). 2. Get access to the engine compartment (if applicable) Refer to: Maintenance > Access Apertures (Page 202). 3. Check the engine and the area below for oil leaks. 4. Close the engine cover (if applicable). 5. If necessary, contact your JCB dealer.

Check (Level) WARNING Never check the oil level or add oil with the engine running. Be careful of hot lubricating oil. Danger of scalding. NOTICE Do not exceed the correct level of engine oil in the sump. If there is too much engine oil, the excess must be drained to the correct level. An excess of engine oil could cause the engine speed to increase rapidly without control. 1. Make the product safe. Refer to: Maintenance > Maintenance Positions (Page 190). 2. Wait for the oil to drain back into the engine sump before you take a reading. If not, a false low reading may be recorded which can cause the engine to be overfilled. 3. Get access to the engine compartment (if applicable). Refer to: Maintenance > Access Apertures (Page 202). 4. Remove and clean the dipstick. Refer to: Maintenance > Service Points (Page 191). 5. Replace the dipstick. 6. Remove the dipstick. 7. Check the oil level. The oil should be between the two marks on the dipstick. 8. If necessary, add more oil: 8.1. Remove the filler cap. 219

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Maintenance Engine

Refer to: Maintenance > Service Points (Page 191). 8.2. Add the recommended oil slowly through the filler point Refer to: Technical Data > Fluids, Lubricants and Capacities (Page 263). 8.3. Replace the dipstick. 8.4. Remove the dipstick. 8.5. Check the oil level, if necessary add more oil. 8.6. Replace the dipstick 8.7. Replace the filler cap. 9. Close and secure the engine cover (if applicable).

Replace NOTICE Do not exceed the correct level of engine oil in the sump. If there is too much engine oil, the excess must be drained to the correct level. An excess of engine oil could cause the engine speed to increase rapidly without control. WARNING Hot oil and engine components can burn you. Make sure the engine is cool before doing this job. Used engine crankcase lubricants contain harmful contaminants. In laboratory tests it was shown that used engine oils can cause skin cancer. CAUTION It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants. Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites. 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 190). 2. Get access to the engine compartment. Refer to: Maintenance > Access Apertures (Page 202). 3. Remove the oil filler cap. Refer to: Maintenance > Service Points (Page 191). 4. Remove the engine oil drain plug. Drain the oil in to a suitable container. Refer to: Maintenance > Service Points (Page 191). 5. Clean the drain plug. Install the drain plug. Tighten the drain plug to the correct torque value. Refer to: Technical Data > Torque Values (Page 267). 6. Remove the cap from the oil filter housing (if applicable). 7. Remove and discard the oil filter cartridge. 8. Fit a new filter with new gaskets. 9. Fit and tighten the cover on the oil filter housing (if applicable). Tighten the cover to the correct torque value. Refer to: Technical Data > Torque Values (Page 267). 10. Add the correct specification and quantity of oil. Refer to: Technical Data > Fluids, Lubricants and Capacities (Page 263). 11. Check the oil level. Refer to: Maintenance > Engine > Oil > Check (Level) (Page 219). 12. Install the oil filler cap. 220

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Maintenance Engine

13. Close and secure the engine cover. 14. Operate the engine at idle speed until the oil pressure low warning light has extinguished and the new filter has primed before the engine speed is increased above idle speed. 15. Check for leaks. 16. Check the oil level when the oil has cooled. 16.1.Fill with clean engine oil, if necessary.

Drive Belt Check (Condition) The drive belt is self tensioning. If the tensioner is adjusted to its maximum position the drive belt tension will be correct. Renew the belt if it has cracks or if it is frayed or has pieces of material missing.

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Maintenance Air Filter

Air Filter General Check (Condition) NOTICE Do not modify or fit non JCB approved components to the engine induction system, otherwise the engine emissions will be compromised. 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 190). 2. Get access to induction system. Refer to: Maintenance > Access Apertures (Page 202). 3. Check the system hoses for: 3.1. Condition. 3.2. Damage. 3.3. Security. 4. Replace the system hoses if necessary.

Pre-Cleaner Clean Refer to the pre-cleaner manufacturers instructions for specific maintenance/cleaning instructions.

Dust Valve Check (Condition) • • • •

222

Check the dust valve for rips/tears. Check there are no obstructions. Check that the dust valve is free of dirt and dust. Check that the dust valve securely attached to the air filter housing.

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Maintenance Fuel System

Fuel System General Bleed WARNING Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death. 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 190). 2. Open the engine cover. Refer to: Maintenance > Access Apertures (Page 202). 3. Loosen the bleed screw. Refer to Figure 231. Figure 231. A

A

Bleed screw

4. Turn the ignition key to the on position (this will start the electric fuel pump). 5. When all of the air has been released, tighten the bleed screw . 6. Close the engine cover. 7. Turn the ignition key to the off position.

Check (Leaks) 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 190). 2. Get access to the engine compartment (if applicable). Refer to: Maintenance > Access Apertures (Page 202). 3. Check the engine compartment (if applicable), fuel lines and the area below for leaks. 4. If necessary, contact your JCB dealer.

Tank Clean Draining Fuel Tank Impurities 1. Make the machine safe. 223

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Maintenance Fuel System

Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 190). 2. Remove the cover plate from below the fuel tank. 3. Put a suitable container below the self sealing drain plug. 4. Remove the outer threaded cover from the self sealing drain plug. 5. Connect the self sealing drain kit threaded union with attached pipe. Drain the water and deposits until there is clean diesel. 6. Remove the self seal drain kit. 7. Clean and install the outer threaded cover. Do not over tighten the cover. 8. Install the cover plate. Figure 232.

A B A B

Self sealing drain kit Pipe

Clean the Filler Cap 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 190). 2. Get access to the fuel filler cap. Refer to: Maintenance > Service Points > General (Page 191). 3. Clean the exterior of the cap with a clean cloth. 4. Remove the fuel filler cap. 5. Clean the interior of the fuel filler cap with a clean cloth. 6. Install the fuel filler cap.

Fuel Filter Replace 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 190). 224

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Maintenance Fuel System

2. Get access to the filter. Refer to: Maintenance > Access Apertures (Page 202). 3. Drain and remove the separator bowl. Refer to: Maintenance > Fuel System > Water Separator (Page 225). 4. Replace the fuel filter. 5. Install the separator bowl. 6. Bleed the fuel system. Refer to: Maintenance > Fuel System > General > Bleed (Page 223). Figure 233.

A

B

A B

Filter Bowl

Water Separator Clean Draining the Water Separator 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 190). 2. Get access to the filter. Refer to: Maintenance > Service Points (Page 191). 3. If there is water but no sediment, open the tap to drain the water. If there is any sediment in the bowl replace the fuel filter element. Do not disconnect the electrical connector (if installed). 4. Tighten the drain tap when all the water is drained.

225

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Maintenance Fuel System

Figure 234.

B A

A B

226

Tap Bowl

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226


Maintenance Cooling System

Cooling System General Check (Leaks) Before you start the machine, inspect the system for leaks: 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 190). 2. Get access to the cooling pack. Refer to: Maintenance > Access Apertures (Page 202). 3. Check the cooling system for leaks. 4. If necessary, contact your JCB dealer.

Coolant Check (Condition) Refer to: Technical Data > Fluids, Lubricants and Capacities > Coolant (Page 265).

Check (Level) For: JS200., JS210., JS220., JS230. ..................................................................................... Page 227 For: JS370 .............................................................................................................................. Page 228

(For: JS200., JS210., JS220., JS230.) 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 190). 2. Let the engine cool. 3. Get access to the coolant expansion bottle. Refer to: Maintenance > Access Apertures (Page 202). CAUTION! The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray out and burn you. Make sure that the engine is cool before you work on the cooling system. 4. Check the fluid level in the expansion bottle, if the fluid level is low: 4.1. Carefully loosen the cap on the expansion bottle and let the pressure release from the system. Refer to: Maintenance > Service Points (Page 191). 4.2. Remove the cap from the expansion bottle. 4.3. Add the recommended coolant up to the maximum mark. Refer to: Technical Data > Fluids, Lubricants and Capacities (Page 263). 4.4. Manipulate the top radiator hose to make sure that there are no air locks in the system. 4.5. Replace the cap. 5. Start the engine. 6. Turn the cab heater to hot and full blower speed. Refer to: Operation > Heating, Ventilating and Air-Conditioning (HVAC) > Air-Conditioning Controls (Page 131). 227

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Maintenance Cooling System

7. Turn the slew lock on. Refer to: Operation > Operating Levers/Pedals (Page 97). 8. Stall the 'dipper in' service until the coolant reaches the specified temperature. Temperature: 90°C Refer to: Operation > Instruments (Page 69). 9. Stop the engine. 10. Remove the ignition key. 11. Let the engine cool. 12. Check the level of coolant in the expansion bottle. If necessary, add more coolant.

(For: JS370) 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 190). 2. Let the engine cool. 3. Get access to the radiator cap and coolant expansion bottle. Refer to: Maintenance > Access Apertures (Page 202). CAUTION! The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray out and burn you. Make sure that the engine is cool before you work on the cooling system. 4. Check the fluid level in the radiator: 4.1. Carefully loosen the radiator cap and let the pressure release from the system. Refer to: Maintenance > Service Points (Page 191). 4.2. Remove the cap from the radiator. 4.3. Add the recommended coolant up to the top of the filler neck. Refer to: Technical Data > Fluids, Lubricants and Capacities (Page 263). 4.4. Manipulate the top radiator hose to make sure that there are no air locks in the system. 4.5. Replace the cap. 5. Check the fluid level in the expansion bottle, if the fluid level is low: 5.1. Remove the cap from the expansion bottle. 5.2. Add the recommended coolant up to the maximum mark. 5.3. .Replace the cap 6. Start the engine. 7. Turn the cab heater to hot and full blower speed. Refer to: Operation > Heating, Ventilating and Air-Conditioning (HVAC) > Air-Conditioning Controls (Page 131). 8. Turn the slew lock on. Refer to: Operation > Operating Levers/Pedals (Page 97). 9. Stall the 'dipper in' service until the coolant reaches the specified temperature. Temperature: 90°C Refer to: Operation > Instruments (Page 69). 228

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Maintenance Cooling System

10. Stop the engine. 11. Remove the ignition key. 12. Let the engine cool. 13. Check the level of coolant in the radiator. If necessary, add more coolant.

Cooling Pack Clean 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 190). 2. Let the engine cool. 3. Get access to the cooling pack. Refer to: Maintenance > Access Apertures (Page 202). 4. If necessary, use a soft bristle brush or compressed air to remove all debris from the cooling pack.

Check (Condition) 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 190). 2. Let the engine cool. 3. Get access to the cooling pack. Refer to: Maintenance > Access Apertures (Page 202). 4. Check the condition of the hoses, radiator and fan for: 4.1. Condition. 4.2. Damage. 4.3. Security. 5. Replace the system hoses/radiator if necessary.

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Maintenance Tracks

Tracks General 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 that you have no loose clothing (cuffs, ties etc.) which could get caught in moving parts. Keep people not involved with this job well away! CAUTION 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. 1. Stop the machine on solid, level ground. 2. Open the bucket. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 97). 3. Slew the boom until it is at the specified angle to the track. Angle: 90° 4. Lower the bucket to the ground. 5. Operate the controls to push the boom down so that the track nearest the bucket is lifted clear of the ground. Refer to Figure 235. Figure 235.

6. When it is safe to do so and you are sure that everyone is clear of the machine, operate the controls to turn the track which is off the ground. 7. Turn the track one way and then the other to shake off the mud. If necessary, the person outside can use water from a hose to help loosen the sticky material. 8. When the track is clean, stop the movement. 9. Examine the track, roller sprockets and idler wheels for damage or oil leaks. Replace any damaged parts. If in doubt contact your JCB dealer. 10. Operate the controls slowly to lower the track to the ground. 11. Operate the controls to slew the boom to the other side of the machine, then repeat the steps 2 to 10 and clean the other track.

230

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230


Maintenance Tracks

Steel Check (Operation) WARNING Recoil unit servicing must only be carried out by JCB dealers. You could be killed or injured if you tamper with it. NOTICE Always make sure that the track tension measurement is not less than specified or severe strain to the track will result.

Check/Adjust the Track Tension 1. Stop the machine on solid, level ground. 2. Move the machine backwards and forwards several times, then move the machine forwards and stop it on level ground. 3. Stop the engine. 4. Check the track tension. Figure 236. A

A

Track tension - measurement

4.1. Place a long, stiff and straight piece of steel or wood on top of the tracks touching above the front idler and the top roller. 5. Make sure the track tension is within the specified limits. Refer to: Technical Data > Tracks (Page 283). 6. If necessary, adjust the track tension. 6.1. To adjust the track tension, inject or release grease from the check valve. 6.2. Inject grease to increase the tension. 6.3. Release grease to decrease the tension. 6.4. When you open the check valve, always stand to one side and loosen it a slowly until the grease starts to release. 6.5. Do not loosen the check valve too much, grease can spurt out or the cover of the check valve can come off and cause serious injury. 7. Never attempt to disassemble the check valve or try to remove the grease point from the check valve. 8. If there is a clearance between the idler wheel shaft and the track frame, use pressure to apply the grease. 9. If there is no clearance after the application of grease, then contact your JCB dealer for any service requirements. 231

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Maintenance Tracks

10. Do not tension the tracks too much, this will cause the track rail to wear the drive rollers and sprocket. 11. Always make sure you adjust the track tension to the specified limits. Incorrect tension can cause wear to the drive sprocket and the track rail. Refer to: Technical Data > Tracks (Page 283). 12. Repeat the procedure for the other track.

Check (Condition) Check the condition of the track plates. Check the track plate bolt torques. Refer to: Technical Data > Torque Values (Page 267).

Idler Wheels Check (Condition) 1. Stop the machine on solid, level ground. 2. Do the steps 2 to 12 of Check/Adjust the Track Tension. Refer to: Maintenance > Tracks > Steel > Check (Operation) (Page 231). 3. Check the top and bottom rollers for oil leaks. If leaks are found contact your JCB dealer 4. Repeat the steps 2 to 3 for the other track.

Rollers Check (Condition) 1. Stop the machine on solid, level ground. 2. Do the steps 2 to 12 of Check/Adjust the Track Tension. Refer to: Maintenance > Tracks > Steel > Check (Operation) (Page 231). 3. Check the idler wheels for oil leaks. If leaks are found contact your JCB dealer. 4. Repeat the steps 2 to 3 for the other track.

232

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232


Maintenance Track Gearbox

Track Gearbox Oil Check (Level) 1. Make the machine safe, with the fill/level and drain plugs in the positions shown. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 190). A

Figure 237.

B

A B

Fill\level plug Drain plug

2. Clean the area around the fill/level plug. 3. Remove the fill/level plug. 4. Make sure that the oil inside the gearbox is level with the fill/level plug. 5. If necessary, add the recommended oil through the fill/level plug hole. Refer to: Technical Data > Fluids, Lubricants and Capacities (Page 263). 6. Clean the fill/level plug. 7. Install the fill/level plug. Tighten the fill/level plug to the correct torque value. Refer to: Technical Data > Torque Values (Page 267). 8. Check the oil level on the other side. Repeat the steps 1 to 7.

233

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233


Maintenance Hydraulic System

Hydraulic System General Discharge 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions > Maintenance Position (Excavator Arm Lowered) (Page 190). 2. Turn the ignition key to the on position. 3. Lower the controls isolation lever and push the controls isolation switch. Refer to: Operation > Locks > Control Lock (Page 64). 4. Operate the hand controllers in all directions to release the pressure from the hydraulic system. Refer to: Operation > Operating Levers/Pedals > Excavator Arm Controls (Page 97). 5. Turn the ignition key to the off position. 6. Remove the ignition key. 7. Push the rubber boot on the hydraulic tank breather to release the pressure from the tank. Refer to: Maintenance > Service Points (Page 191).

Check (Condition) Hydraulic Hoses WARNING Damaged hoses can cause fatal accidents. Examine the hoses regularly. Do not use the machine if a hose or hose fixture is damaged. Examine the hoses for: • • • • • •

Damaged hose ends Worn outer covers Ballooned outer covers Kinked or crushed hoses Embedded armouring in the outer covers Displaced hose end fittings.

Replace a damaged hose before you use the machine again. The replacement hoses must be of the same size and standard. If necessary, for more information contact your JCB dealer.

Accumulator 1. Stop the machine on solid, level ground. 2. Raise the boom and extend the dipper. Refer to: Operation > Operating Levers/Pedals (Page 97). 3. Stop the engine. Do not raise the controls isolation lever. Refer to: Operation > Locks (Page 64). 4. Lower the boom. Stop the boom several metres from the ground. 5. Lower the boom to the ground. There must be sufficient pressure stored in the accumulator to lower the boom to the ground in two stages. If this is not possible, contact your JCB dealer. 234

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234


Maintenance Hydraulic System

Check (Leaks) NOTICE If the fluid is cloudy, then water or air has contaminated the system. This could damage the hydraulic pump. Contact your JCB dealer immediately. 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 190). 2. Open the access covers. Refer to: Maintenance > Access Apertures (Page 202). 3. Check the hydraulic hoses for damage. Refer to: Maintenance > Hydraulic System > General > Check (Condition) (Page 234). 4. Close the access covers. 5. If necessary, contact your JCB dealer.

Services Check (Operation) Check the operation of all the hydraulic services. Check for: • • • •

Speed of operation Strength of operation Juddering Abnormal noises.

Do not use the machine if one or more of these faults are found. You must make sure that the hydraulic service is repaired immediately.

Oil Check (Level) 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 190). 2. Look at the hydraulic fluid in the sight tube. If the hydraulic fluid is cloudy, water or air is in the system. Water or air in the system can damage the hydraulic pump. Contact your JCB dealer if the hydraulic fluid is cloudy. Refer to: Maintenance > Service Points (Page 191). 3. The level of hydraulic fluid should be between the two marks on the sight tube. 4. If necessary, add the recommended hydraulic fluid: Refer to: Technical Data > Fluids, Lubricants and Capacities (Page 263). 4.1. Release the pressure from the hydraulic tank. Refer to: Maintenance > Hydraulic System > General > Discharge (Page 234). 4.2. Get safe access to the hydraulic filler port. Refer to: Maintenance > Service Points (Page 191). 4.3. Remove its cover plate to access the hydraulic filler port. 4.4. Use a suitable container to add the hydraulic fluid through the filler port. 4.5. Check the level of hydraulic fluid. 235

9821/3250-3

235


Maintenance Hydraulic System

4.6. Attach the cover plate.

Cylinder Rams Check (Condition) Extend each ram fully, one at a time and visually examine for score marks, dents, leaks or similar defects. Make the machine safe before inspecting each ram. If a ram piston appears defective, contact your service engineer or JCB dealer.

236

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236


Maintenance Electrical System

Electrical System General Check (Operation) Make sure all of the electrical equipment operates correctly, for example: • • • • • • • • •

Switches Warning lights Beacon Alarms Horn Wipers Hourmeter/display Battery Lights

All defective equipment must be repaired before the machine is used.

Check (Condition) WARNING Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery. Keep the electrolyte away from your clothes, skin, mouth and eyes. Wear safety glasses. DANGER Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery. Make sure there is good ventilation in closed areas where batteries are being used or charged. Do not check the battery charge by shorting the terminals with metal. Use a hydrometer or voltmeter. CAUTION Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage. Examine the electrical circuits regularly for: • • • • • •

Damaged connectors Loose connections Chafing on the wiring harnesses Corrosion Missing insulation Incorrect routing of the wiring harnesses.

Do not use the machine if one or more of these faults are found. You must make sure that the electrical circuit is repaired immediately.

Battery Clean WARNING Keep metal watch straps and any metal fasteners on your clothes, clear of the positive (+) battery terminal. Such items can short between the terminal and nearby metal work. If it happens you can get burned. 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 190). 2. Get access to the battery. Refer to: Maintenance > Access Apertures (Page 202). 3. If the terminal posts are corroded and covered with white powder wash them with hot water. If there is considerable corrosion, clean the terminal posts with a wire brush or abrasive paper. Refer to Figure 238.

237

9821/3250-3

237


Maintenance Electrical System

Figure 238.

4. Apply a thin layer of petroleum jelly to the terminal posts.

Connect CAUTION The machine is negatively earthed. Always connect the negative pole of the battery to earth. When connecting the battery, connect the earth (-) lead last. When disconnecting the battery, disconnect the earth (-) lead first. 1. Get access to the batteries. Refer to: Maintenance > Electrical System > Battery > Disconnect (Page 238). 2. Connect the battery leads. Connect the earth (-) terminal last. 3. If the machine has a battery isolator, move the switch to the on position. Refer to: Operation > Battery Isolator (Page 135).

Disconnect CAUTION The machine is negatively earthed. Always connect the negative pole of the battery to earth. When connecting the battery, connect the earth (-) lead last. When disconnecting the battery, disconnect the earth (-) lead first. NOTICE Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged. 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 190). 2. Get access to the batteries. Refer to: Maintenance > Access Apertures (Page 202). 3. If the machine has a battery isolator, move the switch to the off position then remove the key. Refer to: Operation > Battery Isolator (Page 135). 4. Disconnect the battery leads. Disconnect the earth (-) terminal first.

Battery Isolator Check (Operation) NOTICE Do not isolate the machine electrics when the engine is running, this may cause damage to the machine electrics. 238

9821/3250-3

238


Maintenance Electrical System

1. Isolate the machine electrics. Refer to: Operation > Battery Isolator (Page 135). 2. Make sure that the machine electrics are isolated. A defective isolator must be repaired before the machine is used. For more information, contact your JCB dealer.

Fuses Replace For: JS200., JS210., JS220., JS230. ..................................................................................... Page 239 For: EK Engine, JS370 .......................................................................................................... Page 240

(For: JS200., JS210., JS220., JS230.) NOTICE Always replace fuses with ones of correct ampere rating to avoid electrical system damage. The electrical circuits are protected by fuses. If a fuse blows, find out why before a new one is installed. For more information on the individual fuses:Refer to: Technical Data > Electrical System > Fuses (Page 274).

Fuse - Cab The fuses are installed in the rear stowage area. Open the cover to get access to the fuses. For fuse identification, a label is attached to the rear of cover. Figure 239.

A

A

Cover

Fuses - Battery Bay The fuses are installed in the battery bay. Remove the cover and open the box to get access to the fuses.

239

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239


Maintenance Electrical System

Figure 240. B B

A

A A B

Box Cover

(For: EK Engine, JS370) NOTICE Always replace fuses with ones of correct ampere rating to avoid electrical system damage. The electrical circuits are protected by fuses. If a fuse blows, find out why before a new one is installed. For more information on the individual fuses:Refer to: Technical Data > Electrical System > Fuses (Page 274).

Fuses - Cab The fuses are installed in the rear stowage area. Open the cover to get access to the fuses. For fuse identification, a label is attached to the rear of cover. Figure 241.

A

A

Cover

Fuses - Battery Bay The fuses are installed in the battery bay. Remove the cover and open the box to get access to the fuses.

240

9821/3250-3

240


Maintenance Electrical System

Figure 242.

A

B

A B

Box Cover

Fuses - Radiator Bay The fuses are installed in the radiator bay. Remove the cover and open the box to get access to the fuses. Figure 243.

A

B A B

Box Cover

Relays Replace For: JS200., JS210., JS220., JS230. ..................................................................................... Page 241 For: EK Engine, JS370 .......................................................................................................... Page 242

(For: JS200., JS210., JS220., JS230.) Introduction For more information on the individual relays: Refer to: Technical Data > Electrical System > Relays (Page 279).

241

9821/3250-3

241


Maintenance Electrical System

Relays - Cab The relay are installed in the rear stowage area. Open the cover to get access to the relays. For relay identification, a label is attached to the rear of cover. Figure 244.

A

A

Cover

Relays - Battery Bay The relays are installed in the battery bay. Remove the cover and open the box to get access to the relays. Figure 245. B B

A

A A B

Box Cover

(For: EK Engine, JS370) Introduction For more information on the individual relays: Refer to: Technical Data > Electrical System > Relays (Page 279).

Relays - Cab The relay are installed in the rear stowage area. Open the cover to get access to the relays. For relay identification, a label is attached to the rear of cover.

242

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242


Maintenance Electrical System

Figure 246.

A

A

Cover

Relays - Battery Bay The relays are installed in the battery bay. Remove the cover get access to the relays. Figure 247.

A

A

Cover

Relays - Radiator Bay The relays are installed in the radiator bay. Open the box to get access to the relays.

243

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243


Maintenance Electrical System

Figure 248.

A

B A

Box

Window Washer Check (Level) 1. Make the machine safe. Refer to: Maintenance > Maintenance Positions (Page 190). 2. Get access to the front window washer bottle. Refer to: Maintenance > Service Points > General (Page 191). 3. Remove the filler cap. 4. Fill the washer bottle with clean water. The liquid should contain a de-icing fluid to prevent it freezing. Refer to: Technical Data > Fluids, Lubricants and Capacities (Page 263). 5. Replace the filler cap. Do not use engine coolant antifreeze. Do not use the window washer when there is no liquid in the washer bottle as it will cause damage to the motor.

244

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244


Maintenance Miscellaneous

Miscellaneous Fire Extinguisher Check (Condition) In addition to the operator check the extinguisher must be serviced every 12 months by a suitably qualified person. 1. Examine the fire extinguisher for damage and leaks. 2. Make sure the fire extinguisher is correctly attached. 3. Make sure that the gauge indicates that the extinguisher is charged i.e. the needle is in the green segment 3.1. If the needle is in or very near the red segment at either end of the gauge, the extinguisher must be serviced or replaced. 4. Make sure the safety pin is correctly installed. Figure 249. B

A

A B

245

Gauge Safety Pin

9821/3250-3

245


Notes:

246

9821/3250-3

246


Technical Data Static Dimensions

Technical Data

Static Dimensions General For: JS200., JS210., JS220., JS230. ..................................................................................... Page 247 For: JS370 .............................................................................................................................. Page 247

(For: JS200., JS210., JS220., JS230.) Lifting the Machine Table 22. Item Lifting angle Height to lifting-hook for SC machines Height to lifting-hook for LC machines

Dimension 75° 4,500mm 5,000mm

Lifting Hook/Lug Options Refer to: Operation > Working with the Excavator Arm > Lifting With the Excavator Arm (Page 115). Table 23. Lifting hook Lifting lug

12.5t 17t

(For: JS370) Lifting Dimensions Refer to: Operation > Lifting the Machine (Page 142). Table 24. Item Lifting angle Height to lifting-hook for SC machines Height to lifting-hook for LC machines

Dimension 75° 4,900mm 5,400mm

Lifting Hook/Lug Options Refer to: Operation > Working with the Excavator Arm > Lifting With the Excavator Arm (Page 115). Table 25. Lifting hook Lifting lug

247

12.5t 25t

9821/3250-3

247


Technical Data Static Dimensions

Dimensions For: JS370 .............................................................................................................................. Page 248 For: JS200., JS210. ............................................................................................................... Page 249 For: JS220., JS230. ............................................................................................................... Page 250

(For: JS370) Monoboom Figure 250. E J

H

L K

F M

G

N

C D

A B Table 26.

A B C D D D D

Description Track length on ground Undercarriage overall length Track gauge Width over tracks (600 shoes) Width over tracks (700 shoes) Width over tracks (800 shoes) Width over tracks (900 shoes)

Length 4,021mm 4,954mm 2,600mm 3,200mm 3,300mm 3,400mm 3,500mm Table 27.

Dipper lengths E Transport length F Transport height

2,210mm 11,413mm 3,440mm

2,630mm 11,353mm 3,510mm

3,230mm 11,253mm 3,280mm

4,030mm 11,333mm 3,700mm

Table 28. G H J K L M N

248

Description Counterweight clearance Tailswing radius Width of superstructure Height over cab Height over grab rail Ground clearance Track height

Length 1,214mm 3,593mm 2,990mm 3,220mm 3,220mm 530mm 1,024mm

9821/3250-3

248


Technical Data Static Dimensions

(For: JS200., JS210.) Monoboom Figure 251. E

J

L

G H

K F M

G

N

C

A B

D Table 29. A B C D D D D D

Description Track length on ground Undercarriage overall length Track gauge Width over tracks (500 shoes) Width over tracks (600 shoes) Width over tracks (700 shoes) Width over tracks (800 shoes) Width over tracks (900 shoes)

Length 3,370mm 4,170mm 2,200mm 2,700mm 2,800mm 2,900mm

Table 30. Dipper lengths E Transport length F Transport height

3,000mm 9,440mm 3,025mm

2,400mm 9,560mm 3,060mm

Table 31. G H J K L M N

249

Description Counterweight clearance Tailswing radius Width of superstructure Height over cab Height over grab rail Ground clearance Track height

Length 1,066mm 2,825mm 2,549mm 2,946mm 3,025mm 486mm 885mm

9821/3250-3

249


Technical Data Static Dimensions

(For: JS220., JS230.) Monoboom Figure 252. E

J

L

G H

K F M

G

N

C

A B

D Table 32. A B C D D D D D

Description Track length on ground Undercarriage overall length Track gauge Width over tracks (500 shoes) Width over tracks (600 shoes) Width over tracks (700 shoes) Width over tracks (800 shoes) Width over tracks (900 shoes)

Length 3,660mm 4,460mm 2,390mm 2,700mm 2,990mm 3,090mm 3,190mm 3,290mm Table 33.

Dipper lengths E Transport length F Transport height

3,000mm 9,440mm 3,025mm

2,400mm 9,560mm 3,060mm

Table 34. G H J K L M N

250

Description Counterweight clearance Tailswing radius Width of superstructure Height over cab Height over grab rail Ground clearance Track height

Length 1,066mm 2,825mm 2,549mm 2,946mm 3,025mm 486mm 885mm

9821/3250-3

250


Technical Data Static Dimensions

Weights For: JS370 .............................................................................................................................. Page 251 For: JS220., JS230. ............................................................................................................... Page 251 For: JS200., JS210. ............................................................................................................... Page 251

(For: JS370) Shipping Weight An approximate weight when the machine has a monoboom, 2.63m length dipper, 1.9mÂł heavy duty bucket, operator and a full fuel tank. Table 35. LC Track shoe width 600mm 700mm

Weight 37,720kg 38,165kg

(For: JS220., JS230.) Shipping Weight An approximate weight when the machine has a monoboom, medium length dipper, bucket, operator and a full fuel tank. Table 36. JS220LC, JS230LC Track shoe width 600mm 700mm 800mm 900mm

Weight 22,800kg 23,696kg 23,336kg 23,604kg

(For: JS200., JS210.) Shipping Weight An approximate weight when the machine has a monoboom, medium length dipper, bucket, operator and a full fuel tank. Table 37. JS200SC, JS210SC Track shoe width 500mm 600mm 700mm

251

Weight 20,545kg 20,800kg 21,050kg

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251


Technical Data Performance Dimensions

Performance Dimensions Excavator Arm Dimensions and Performance For: JS370 .............................................................................................................................. Page 252 For: JS200., JS210. ............................................................................................................... Page 254 For: JS220., JS230. ............................................................................................................... Page 256

(For: JS370) Digging Monoboom Figure 253. A B G 11

36 35

10 32 9

30 28

8

26 24

7 22 6

D

20 18

5

E

4

16 14 12

3

10 8

2

1

6 4 2

0

0 2

1 4

F

2

6 8

3

C

10 12

4 14 5

16 18

6

20 22

7 24 8

26 25

9 12

11 30

28

10 26

24

9 22

8 20

18

7 16

6 14

12

5 10

16

4 14

3 12

10

2 8

1 6

4

0 Met res 2

Met res

Feet

0 Feet

Table 38. Boom length Dipper length A Maximum digging reach B Maximum digging reach (on ground) C Maximum digging depth D Maximum digging height E Maximum dumping height 252

6,450mm 2,210mm 10,060mm 9,850mm 6,250mm 9,510mm 6,800mm 9821/3250-3

2,630mm 10,460mm 10,255mm 6,680mm 9,730mm 7,000mm

3,230mm 11,020mm 10,820mm 7,270mm 10,020mm 7,260mm

4,030mm 11,760mm 11,570mm 8,070mm 10,220mm 7,570mm 252


Technical Data Performance Dimensions

Boom length Dipper length F Maximum vertical wall cut depth G Maximum swing radius

6,450mm 2,210mm 2,390mm 4,740mm

2,630mm 2,910mm 4,710mm

3,230mm 3,580mm 4,570mm

4,030mm 4,390mm 4,620mm

Lifting Figure 254.

A

6 .4

0.6m

JS370LC 34.8M Pa

5m 36.3M Pa 7300kg

C B Z1 Bm

C kg

1

4

5

6

7

8

15770

11650

9110

7370

6110

Z2

2

18420

3

15860

11130

8600

6990

5880

Z3

15690

10870

A = 2.21 m

Z1

9140

8890

15940

11830

9190

7400

6110

14240

15660

11080

8540

6930

5810

16280

10550

A = 2.63 m

Z1 Z2

A = 3.23 m

Z2

8710

8590

6980

15520

11650

9300

7450

6120

5110

10430

9260

13320

10970

8440

6820

5700

4890

Z3

15200

15300

10990

9040

8450

6830

5720

19890

14390

11650

9430

7500

6120

5080

4270 4120

Z1 A = 4.03 m

10

Z2

Z3 Z1

253

9

Z2

8290

7920

7640

15120

10700

8220

6620

5500

4690

Z3

11280

12940

14590

12080

7850

7800

6600

5500

4700

Z3

9821/3250-3

9 8 7 6 5 4 3 2 1 0 -1 -2 -3 -4 -5 -6 -7 10 9 8 7 6 5 4 3 2 1

253


Technical Data Performance Dimensions

(For: JS200., JS210.) Digging Monoboom Figure 255. A B

G

D E

C

F

Table 39. Boom length Dipper length A Maximum digging reach B Maximum digging reach (on ground) C Maximum digging depth D Maximum digging height E Maximum dumping height F Maximum vertical wall cut depth G Maximum swing radius

254

5,700mm 3,000mm 9,870mm 9,700mm 6,600mm 9,400mm 6,750mm 6,070mm 3,600mm

9821/3250-3

2,400mm 9,340mm 9,160mm 6,020mm 9,200mm 6,530mm 5,470mm 3,710mm

254


Technical Data Performance Dimensions

Lifting Figure 256.

Figure 257.

255

9821/3250-3

255


Technical Data Performance Dimensions

(For: JS220., JS230.) Digging Monoboom Figure 258. A B

G

D E

C

F

Table 40. Boom length Dipper length A Maximum digging reach B Maximum digging reach (on ground) C Maximum digging depth D Maximum digging height E Maximum dumping height F Maximum vertical wall cut depth G Maximum swing radius

256

5,700mm 3,000mm 9,870mm 9,700mm 6,600mm 9,400mm 6,750mm 6,070mm 3,600mm

9821/3250-3

2,400mm 9,340mm 9,160mm 6,020mm 9,200mm 6,530mm 5,470mm 3,710mm

256


Technical Data Performance Dimensions

Lifting Figure 259.

Figure 260.

Driving Performance The maximum travel speed of all JS Tracked Excavators is no more than 6 kph (3.7 mph).

257

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257


Technical Data Noise Emissions

Noise Emissions General These machines comply with Chinese standard GB 16710, the noise data values for this type of machine have been provided on the following page(s) and may be used for the assessment of risks to exposure from noise. For information relating to this machine when used with other JCB approved attachments, please refer to the literature accompanying the attachments. Table 41. Definition of terms Term LpA LwA

Definition A-weighted sound pressure level measured at the operator's station. Equivalent A-weighted sound power level emitted by the machine.

Notes Determined in accordance with the test method defined in ISO 6396 and GB/T 25615 Determined in accordance with the test method defined in ISO 6395 and GB/T 25614

Noise Data For: JS200., JS220., JS230. .................................................................................................. Page 258 For: JS210. ............................................................................................................................. Page 258 For: EK Engine, JS370 .......................................................................................................... Page 258

(For: JS200., JS220., JS230.) Table 42. Engine rating 129kW

(1)

LpA

LwA

77

103

LpA

LwA

75

103

LpA

LwA

75

101

(1) Net installed power.

(For: JS210.) Table 43. Engine rating 118kW

(1)

(1) Net installed power.

(For: EK Engine, JS370) Table 44. Engine rating 212kW

(1)

(1) Net installed power.

258

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258


Technical Data Vibration Emissions

Vibration Emissions General To assist in compliance with the European Directive 2002/44/EC, the duty specific vibration emission values for this machine type have been provided on the following page(s) and may be used for the assessment of risks to exposure from vibration. Unless otherwise indicated for a specific operating condition, the vibration values are calculated with the machine equipped with the standard attachments (for example bucket, shovel, fork, etc.) for the respective operating condition. The vibration values are calculated from measurements in three perpendicular axes (X, Y and Z). The highest weighted (RMS (Root Mean Square)) value is used to specify the vibration emission. The axis upon which the highest weighted (RMS) value occurs is shown on the vibration chart for each of the machine operating duties, see dominant axis (X, Y or Z). Figure 261. Z

Y

X

Exposure to Vibration Exposure to vibration can be minimised through: • • • • • • • • •

259

Selection of the correct size and capacity of machine, equipment and attachments for a particular application Use of a machine equipped with an appropriate seat, keeping the seat maintained and adjusted Checks to make sure that the machine is correctly maintained, reporting and correcting any faults Steering, braking, accelerating, shifting gears, moving the attachments and load smoothly Adjusting the machine speed and travel path to minimise the vibration level Keeping the terrain on worksites where the machine works and travels in good condition, removing any large rocks or obstacles and filling in any ditches and holes Choosing routes that avoid rough surfaces and, if this is not possible, drive more slowly to avoid bumping and jolting Travel over longer distances at an adjusted (medium) speed Avoiding bad postures, i.e. slumping in your seat, constantly leaning forward or sideways or driving with your back twisted.

9821/3250-3

259


Technical Data Vibration Emissions

Vibration Data For: JS210. ............................................................................................................................. Page 260 For: JS200., JS220., JS230. .................................................................................................. Page 261 For: JS370 .............................................................................................................................. Page 261

(For: JS210.) Figure 262. X

m/s² A(8)

Y

Z

0.47 0.33

0.01 D2

D1 X-Z D1 D2 D3

D3

Dominant axis Machine operating duty: Low idle Machine operating duty: Excavating Machine operating duty: Tracking (concrete)

The whole-body vibration emission under representative operating conditions (according to the intended use) are shown. Refer to Figure 262. The whole-body vibration emission calculated in accordance with ISO 2631-1:1997 for this machine type is 0.33m/s² normalised to an 8h reference period [A(8)] and based upon a test cycle defined in SAE J1166. The hand-arm vibration calculated in accordance with the dynamic test conditions defined in ISO 5349-2: 2001 does not exceed 2.5m/s². The errors bars are due to variations in vibration emissions due to measurement uncertainty (50% in accordance with EN 12096:1997).

260

9821/3250-3

260


Technical Data Vibration Emissions

(For: JS200., JS220., JS230.) Figure 263. X

Z

m/s² A(8)

Y

0.44

0.22 0.01 D2

D1 X-Z D1 D2 D3

D3

Dominant axis Machine operating duty: Low idle Machine operating duty: Excavating Machine operating duty: Tracking (concrete)

The whole-body vibration emission under representative operating conditions (according to the intended use) are shown. Refer to Figure 263. The whole-body vibration emission calculated in accordance with ISO 2631-1:1997 for this machine type is 0.22m/s² normalised to an 8h reference period [A(8)] and based upon a test cycle defined in SAE J1166. The hand-arm vibration calculated in accordance with the dynamic test conditions defined in ISO 5349-2: 2001 does not exceed 2.5m/s². The errors bars are due to variations in vibration emissions due to measurement uncertainty (50% in accordance with EN 12096:1997).

(For: JS370) The whole-body vibration emission under representative operating conditions (according to the intended use) are shown.

261

9821/3250-3

261


Technical Data Vibration Emissions

Figure 264. X

Y

Z

m/s² A(8)

0.30 0.22

0.02 D2

D1 X-Z D1 D2 D3

D3

Dominant axis Machine operating duty: Low idle Machine operating duty: Excavating Machine operating duty: Tracking (concrete)

The whole-body vibration emission calculated in accordance with ISO 2631-1:1997 for this machine type is 0.3m/s² normalised to an 8h reference period [A(8)] and based upon a test cycle defined in SAE J1166. The hand-arm vibration calculated in accordance with the dynamic test conditions defined in ISO 5349-2: 2001 does not exceed 2.5m/s². The errors bars are due to variations in vibration emissions due to measurement uncertainty (50% in accordance with EN 12096:1997).

262

9821/3250-3

262


Technical Data Fluids, Lubricants and Capacities

Fluids, Lubricants and Capacities General For: EK Engine, JS370 .......................................................................................................... Page 263 For: DE Engine, JS200., JS210., JS220., JS230. .................................................................. Page 263

(For: EK Engine, JS370) JCB recommend that you use the JCB lubricants shown as they have been verified by JCB for use on JCB machines. However, you could use other lubricants that are equivalent to the JCB standards and quality or offer the same machine component protection. Table 45. Fluids, Lubricants and Capacities Item Fuel Tank Engine (Oil)

(2)

Cooling System Track Gearbox (each) Slew Gearbox Track Rollers and Idler Wheels Recoil Spring Cylinder Hydraulic System

Slew Ring Bearings Slew Ring Gear Teeth All Other Grease

Capacity

Fluid/Lubricant

JCB Part Number

590L 25L

Diesel JCB Ultimate Performance 15W40 API CJ-4, ACEA E6, E9, JASO (3) DH-2 JCB Antifreeze HP/Coolant JCB HD90 Gear Oil

4001/2905

Container (1) Size 20L

4006/1120 4001/0301

20L 5L

JCB HD90 Gear Oil JCB HD90 Gear Oil

4000/0305 4000/0305

20L 20L

JCB Special HP Grease

4003/2017

0.4kg

JCB Hydraulic Fluid HP32-20°C to 15°C JCB Hydraulic Fluid HP46-10°C to 30°C JCB Hydraulic Fluid HP680°C to 40°C JCB Special HP Grease JCB Special HP Grease

4002/1024

200L

4002/0803

200L

4002/0701

200L

4003/2017 4003/2017

0.4kg 0.4kg

JCB Special HP Grease

4003/2006

12.5kg

45L 5L 14.5L

430L

As required

(1) For information about the different container sizes that are available (and their part numbers), contact your local JCB dealer. (2) Do not use ordinary engine oil. (3) Failure to use oil of the correct specification will decrease the life of the engine and the diesel particulate filter.

(For: DE Engine, JS200., JS210., JS220., JS230.) JCB recommend that you use the JCB lubricants shown as they have been verified by JCB for use on JCB machines. However, you could use other lubricants that are equivalent to the JCB standards and quality or offer the same machine component protection. Table 46. Fluids, Lubricants and Capacities Item Fuel Tank Engine (Oil)

(2)

263

Capacity

Fluid/Lubricant

343L 17.5L

Diesel -10°C to 50°C JCB Engine Oil EP 4001/1805 15W/40 -20°C to 50°C: JCB Cold Climate En- 4001/2705 gine Oil EP 5W40 9821/3250-3

JCB Part Number

Container (1) Size 20L 20L

263


Technical Data Fluids, Lubricants and Capacities

Item

Capacity

Fluid/Lubricant

JCB Part Number

Cooling System Track Gearbox (each) Slew Gearbox Track Rollers and Idler Wheels Recoil Spring Cylinder Hydraulic System

28L 4.7L

JCB Antifreeze HP/Coolant JCB HD90 Gear Oil

4006/1120 4001/0301

Container (1) Size 20L 5L

5L

JCB HD90 Gear Oil JCB HD90 Gear Oil

4000/0305 4000/0305

20L 20L

JCB Special HP Grease

4003/2017

0.4kg

4002/1024

200L

4002/0803

200L

4002/0701

200L

0.1kg 17kg

JCB Hydraulic Fluid HP32-20°C to 15°C JCB Hydraulic Fluid HP46-10°C to 30°C JCB Hydraulic Fluid HP680°C to 40°C JCB Special HP Grease JCB Special HP Grease

4003/2017 4003/2006

0.4kg 12.5kg

As required

JCB Special HP Grease

4003/2006

12.5kg

Slew Ring Bearings Slew Ring Gear Teeth All Other Grease

200L

(1) For information about the different container sizes that are available (and their part numbers), contact your local JCB dealer. (2) Do not use ordinary engine oil.

Fuel Types of Fuel Use good quality diesel fuel to get the correct power and performance from your engine.

Recommended Fuel Specification • • • •

EN590 Diesel Fuel Types - Auto/Co/C1/C2/C3/C4. BS2869 Class A2. ASTM D975-91 Class 2-2DA, US DF1, US DF2, US DFA. JIS K2204 (1992) Grades 1, 2, 3 and Special Grade 3.

Additives Where low sulfur/low aromatic fuels are used it is important that lubricity additives are used. The additives listed below are advertised as being suitable for bringing the lubricity levels of kerosene/low sulfur fuels up to those of diesel fuels. They have not been tested or approved by the engine manufacturer. They should be added by your fuel supplier who should understand the concentration level necessary. These products are given as examples only. The information is derived from the manufacturers data. The products are not recommended or endorsed by JCB. Contact your JCB dealer for further advice. • • •

Elf 2S 1750. Dosage 1000-1500 ppm (0.1 - 0.15%), specifically for Indian Superior Kerosene (SKO) but may be applicable to other fuels. Lubrizol 539N. Dosage (on Swedish low sulphur fuel) 250 ppm. Paradyne 7505 (from Infineum). Dosage 500 ppm (0.05%).

Acceptable Fuel Specification The fuel specification below is acceptable, however this fuel may reduce the life of the fuel injection equipment. The use of this fuel may also affect the engine performance.

264

9821/3250-3

264


Technical Data Fluids, Lubricants and Capacities

• • •

ASTM D975-91 Class 1-1DA. JP7, MIL T38219 XF63. NATO F63.

Sulphur Content CAUTION A combination of water and sulphur will have a corrosive chemical effect on fuel injection equipment. It is essential that water is eradicated from the fuel system when high sulphur fuels are used. High sulfur content can cause engine wear. (High sulfur fuel is not normally found in North America, Europe or Australia.) If you have to use high sulfur fuel you must change the engine oil more frequently. Table 47. Percentage of sulfur in the fuel (%) Less than 0.5 0.5 to 1.0 More than 1.0

Oil change interval Normal 0.75 of normal 0.50 of normal

Aviation Kerosene Fuels Aviation kerosene fuels are not approved and their use may cause damage to components. Warranty will not be allowed on any component where damage is found to have been caused by the use of aviation kerosene.

Low Temperature Fuels Special winter fuels may be available for engine operation at temperatures below 0°C. 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).

Fatty Acid Methyl Ester Fuels as a Replacement for diesel Fuels Fuel resources such as Rape Methyl Ester and Soybean Methyl ester, collectively known as Fatty Acid Methyl.

Coolant CAUTION Antifreeze can be harmful. Obey the manufacturer's instructions when handling full strength or diluted antifreeze. Check the strength of the coolant mixture at least once a year, preferably at the start of the cold period. Replace the coolant mixture according to the intervals shown in the machine's Service Schedule. You must dilute full strength antifreeze with clean water before use. Use clean water of no more than a moderate hardness (pH value 8.5). If this cannot be obtained, use de-ionized water. For further information advice on water hardness, contact your local water authority. The correct concentration of antifreeze protects the engine against frost damage in winter and provides year round protection against corrosion. The protection provided by JCB High Performance Antifreeze and Inhibitor is shown below. Table 48. Concentration 50% (Standard) 60% (Extreme Conditions Only)

Level of protection Protects against damage down to -40°C Protects against damage down to -56°C

Do not exceed a 60% concentration, as the freezing protection provided reduces beyond this point.

265

9821/3250-3

265


Technical Data Fluids, Lubricants and Capacities

If you use any other brand of antifreeze: • • • •

266

Make sure that the antifreeze complies with International Specification ASTM D6210 Always read and understand the manufacturer's instructions Make sure that a corrosion inhibitor is included. Serious damage to the cooling system can occur if corrosion inhibitors are not used Make sure that the antifreeze is ethylene glycol based and does not use Organic Acid Technology (OAT).

9821/3250-3

266


Technical Data Torque Values

Torque Values General For: JS370 .............................................................................................................................. Page 267 For: JS200., JS210. ............................................................................................................... Page 270 For: JS220., JS230. ............................................................................................................... Page 272

(For: JS370) Before and after daily work, check for loose or missing nuts and bolts. Tighten if loose and replace if missing. Tighten the nuts and bolts after the first 50h of the running-in stage and then every 250h. Tighten the nuts and bolts, Refer to Table 49. For the tightening torques of the bolts and nuts not listed, Refer to Table 50. Table 49.

1

(1)

2

(1)

3

(1)

4

(1)

5

(1)

6 7 8

(1)

9

(1)

10

(1)

11

(1)

12

(1)

13 14

(1)

15

(1)

16

(1)

17

(1)

18 19

(1)

20 21

(1)

Tightening Point

Bolt Diameter

Wrench (mm) 36

Tightening Torque (N.m) 923

Checking Torque (N.m) 831

Travel motor

M24

Drive sprocket

M20

30

506

456

Idler wheel

M16

24

330

297

Upper (carrier) roller

M16

24

259

233

Lower (track) roller

M20

30

506

456

Track guard

M20

30

506

456

Shoe bolt Counterweight Turntable bearing (undercarriage) Turntable bearing (slew frame) Slew equipment

M22 M27 M24

32 41 36

981-1128 1452 874

883-1015 1307 787

M24

36

874

787

M20/M24

30/36

410/874

369/787

Engine (engine mount)

M20

30

290

261

Engine bracket

M12

19

104

94

Radiator Hydraulic pump

M16 M10

24 17

260 60

211 54

Hydraulic oil tank

M16

24

259

233

Fuel tank

M16

24

259

233

Control valve

M16

24

259

233

Battery Rotary coupling

M6 M12

10 19

7 104

6 94

Cab

M16

24

196/245

176/221

(1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed. Table 50. Bolt Diameter (size) Hex. bolt Wrench Tightening torque

267

(mm) (N.m)

M6 10 12.5

M8 13 30

9821/3250-3

M10 17 60

M12 19 104

M14 22 167

M16 24 259

M18 27 506

M20 30 874

267


Technical Data Torque Values

Bolt Diameter (size) Hex. socket Wrench head bolt Tightening torque

268

(mm) (N.m)

M6 5 15

M8 6 36

9821/3250-3

M10 8 72

M12 10 125

M14 12 200

M16 14 311

M18 16 -

M20 17 607

268


Technical Data Torque Values

Figure 265. 10

9

1

4

2

3

7 12

13

5

6

13

12 11 8

15

16

14

19

18

17

269

9821/3250-3

269


Technical Data Torque Values

(For: JS200., JS210.) JS200 and Variants Before and after daily work, check for loose or missing nuts and bolts. Tighten if loose and replace if missing. Tighten the nuts and bolts after the first 50h of the running-in stage and then every 250h. Tighten the nuts and bolts, Refer to Table 51. For the tightening torques of the bolts and nuts not listed, Refer to Table 52. Table 51.

1

(1)

2

(1)

3

(1)

4

(1)

5

(1)

6 7 8

(1)

9

(1)

10

(1)

11

(1)

12

(1)

13 14

(1)

15

(1)

16

(1)

17

(1)

18 19

(1)

20 21

(1)

Tightening Point

Bolt Diameter

Wrench (mm) 24

Tightening Torque (N.m) 290

Checking Torque (N.m) 265

Travel motor

M16

Drive sprocket

M16

24

290

265

Idler wheel

M16

24

290

265

Upper (carrier) roller

M16/M20

24/30

290/550

265/515

Lower (track) roller

M16

24

290

265

Track guard

M16

24

290

265

Shoe bolt Counterweight Turntable bearing (undercarriage) Turntable bearing (slew frame) Slew equipment

M20 M30 M20

30 46 30

840-890 1147 525

756-801 1050 470

M20

30

525

470

M20/M24

30/36

550/950

515/900

Engine (engine mount)

M20/M16

27/24

529/271

476/244

Engine bracket

M12

19

125

113

Radiator Hydraulic pump

M12 M10

19 17

55 60

50 54

Hydraulic oil tank

M16

24

250

225

Fuel tank

M16

24

250

225

Control valve

M16

24

290

265

Battery Rotary coupling

M6 M12

10 19

7 116

6 105

Cab

M16

24

132

125

(1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed. Table 52. Bolt Diameter (size) Hex. bolt Wrench Tightening torque Hex. socket Wrench head bolt Tightening torque

270

(mm) (N.m)

M6 10 12.5

M8 13 30

M10 17 60

M12 19 104

M14 22 167

M16 24 259

M18 27 506

M20 30 874

(mm) (N.m)

5 15

6 36

8 72

10 125

12 200

14 311

16 -

17 607

9821/3250-3

270


Technical Data Torque Values

Figure 266. 10

9

1

4

2

3

7 12

13

5

6

13

12 11 8

15

16

14

19

18

17

271

9821/3250-3

271


Technical Data Torque Values

(For: JS220., JS230.) JS220 and Variants Before and after daily work, check for loose or missing nuts and bolts. Tighten if loose and replace if missing. Tighten the nuts and bolts after the first 50h of the running-in stage and then every 250h. Tighten the nuts and bolts, Refer to Table 53. For the tightening torques of the bolts and nuts not listed, Refer to Table 54. Table 53.

1

(1)

2

(1)

3

(1)

4

(1)

5

(1)

6 7 8

(1)

9

(1)

10

(1)

11

(1)

12

(1)

13 14

(1)

15

(1)

16

(1)

17

(1)

18 19

(1)

20 21

(1)

Tightening Point

Bolt Diameter

Wrench (mm) 24

Tightening Torque (N.m) 290

Checking Torque (N.m) 265

Travel motor

M16

Drive sprocket

M16

24

290

265

Idler wheel

M16

24

290

265

Upper (carrier) roller

M16/M20

24/30

290/550

265/515

Lower (track) roller

M16

24

290

265

Track guard

M16

24

290

265

Shoe bolt Counterweight Turntable bearing (undercarriage) Turntable bearing (slew frame) Slew equipment

M20 M30 M20

30 46 30

840-890 1147 525

756-801 1050 470

M20

30

525

470

M20/M24

30/36

550/950

515/900

Engine (engine mount)

M20/M16

27/24

529/271

476/244

Engine bracket

M12

19

125

113

Radiator Hydraulic pump

M12 M10

19 17

55 60

50 54

Hydraulic oil tank

M16

24

250

225

Fuel tank

M16

24

250

225

Control valve

M16

24

290

265

Battery Rotary coupling

M6 M12

10 19

7 116

6 105

Cab

M16

24

132

125

(1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed. Table 54. Bolt Diameter (size) Hex. bolt Wrench Tightening torque Hex. socket Wrench head bolt Tightening torque

272

(mm) (N.m)

M6 10 12.5

M8 13 30

M10 17 60

M12 19 104

M14 22 167

M16 24 259

M18 27 506

M20 30 874

(mm) (N.m)

5 15

6 36

8 72

10 125

12 200

14 311

16 -

17 607

9821/3250-3

272


Technical Data Torque Values

Figure 267. 10

9

1

4

2

3

7 12

13

5

6

13

12 11 8

15

16

14

19

18

17

273

9821/3250-3

273


Technical Data Electrical System

Electrical System General Table 55. Item System voltage

Specification 24V

Fuses For: JS200., JS210., JS220., JS230. ..................................................................................... Page 274 For: EK Engine, JS370 .......................................................................................................... Page 276

(For: JS200., JS210., JS220., JS230.) Fuses - Cab Figure 268.

F9 F8 F7 F6 F5 F4 F3 F2 F1 F11 F10

F16 F15 F14 F13 F12 F20 F19 F18 F17 F29 F28 F27 F26 F25 F24 F23 F22 F21

R2

R3

R4

R1

R5

Table 56. Fuse Identification Fuse F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 274

Circuit(s) Protected Beacon Backlight Cushion solenoid Ignition wakeup Livelink 2 ECU (Electronic Control Unit) ignition Auxiliary ignition supplies Spare 1 Heated/Suspension/Ventilated seat Camera system HVAC (Heating Ventilation Air Conditioning) 9821/3250-3

Rating 10A 5A 7.5A 5A 5A 15A 10A 10A 5A 20A 274


Technical Data Electrical System

Fuse F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29

Circuit(s) Protected Engine crank Engine ignition Revolver ignition Livelink 2 ECU ground Livelink 2 ECU B+ Cab worklight Machine ECU B+ Hydraulic ECU B+ Ignition and refuelling pump switch Diagnostic connector Interior light 12–24V connector Standard worklamps Horn Wash wipe Engine stop Refuelling pump Display ECU

Rating 30A 10A 5A 3A 3A 10A 30A 20A 20A 20A 10A 5A 15A 15A 10A 10A 10A 15A 5A

Fuses - Battery Bay Figure 269.

F1-12 R1-7

PFA

PFC

PFB

PFD

R1

R2

R3

R4

F8 F9 F10 F1 F2 F3 F4

PFA-D

F5 F6 F7

F11

F12 R5 R6

R7

Table 57. Fuse Identification Fuse F1 F2 F3 F4 F5 275

Circuit(s) Protected Engine ECM (Engine Control Module) supply 4 Engine ECM supply 3 Engine ECM supply 1 Engine ECM supply 2 EGR (Exhaust Gas Recirculation) 9821/3250-3

Rating 10A 10A 10A 10A 10A 275


Technical Data Electrical System

Fuse F6 F7 F8 F9 F10 F11 F12 PFA PFB PFC PFD

Circuit(s) Protected VGT (Variable Geometry Turbocharger) Not used Power hold Ignition Fuel lift pump Fuel lift pump Engine ECM ignition Fuse box battery supply Alternator JCB engine/pod box Ignition relay/fuse box ignition supply

Rating 10A 3A 3A 10A 15A 3A 3A 50A 50A 50A 50A

(For: EK Engine, JS370) Fuses - Cab Figure 270.

F9 F8 F7 F6 F5 F4 F3 F2 F1 F11 F10

F16 F15 F14 F13 F12 F20 F19 F18 F17 F29 F28 F27 F26 F25 F24 F23 F22 F21

R3

R2

R4

R1

R5

Table 58. Fuse Identification Fuse F1 F2 F3 F4 F5 F6 F7 F8 276

Circuit(s) Protected Beacon Backlight Cushion solenoid Ignition wakeup Livelink 2 ECU ignition Auxiliary ignition supplies Spare 1 Heated/Suspension/Ventilated seat

Rating 10A 5A 7.5A 5A 5A 15A 10A 10A 9821/3250-3

276


Technical Data Electrical System

Fuse F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29

Circuit(s) Protected Camera system HVAC Engine crank Engine ignition Revolver ignition Livelink 2 ECU ground Livelink 2 ECU B+ Cab worklight Machine ECU B+ Hydraulic ECU B+ Ignition and refuelling pump switch Diagnostic connector Interior light 12–24V connector Standard worklamps Horn Wash wipe Engine stop Refuelling pump Display ECU

Rating 5A 20A 30A 10A 5A 3A 3A 10A 30A 20A 20A 20A 10A 5A 15A 15A 10A 10A 10A 15A 5A

Fuses - Battery Bay Figure 271. PFA

PFC

PFB

PFD

Table 59. Fuse Identification Fuse PFA PFB PFC PFD

277

Circuit(s) Protected Fuse box battery supply Alternator JCB engine/pod box Ignition relay/fuse box ignition supply

Rating 50A 50A 50A 50A

9821/3250-3

277


Technical Data Electrical System

Fuses - Radiator Bay Figure 272.

RL3

F1 F2 F3 F4 F5 F6 F7 F8 F9

RL2

RL1 F10 F11 F12 F13 F14 F15 F16 F17

Table 60. Fuse Identification Fuse F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17

278

Circuit(s) Protected

Not used Not used Not used Not used

Not used Not used Not used Not used Not used

Rating 3A 10A 3A

10A 10A

3A

10A 10A

9821/3250-3

278


Technical Data Electrical System

Relays For: JS200., JS210., JS220., JS230. ..................................................................................... Page 279 For: EK Engine, JS370 .......................................................................................................... Page 281

(For: JS200., JS210., JS220., JS230.) Relay - Cab Figure 273.

F9 F8 F7 F6 F5 F4 F3 F2 F1 F11 F10

F16 F15 F14 F13 F12 F20 F19 F18 F17 F29 F28 F27 F26 F25 F24 F23 F22 F21

R2

R3

R4

R1

R5

Table 61. Relay Identification Relay R1 R2 R3 R4 R5

279

Circuit(s) Engine crank Horn Wash wipe Engine stop Refuel pump

9821/3250-3

279


Technical Data Electrical System

Relay - Battery Bay Figure 274.

F1-12 R1-7

PFA

PFC

PFB

PFD

R1

R2

R3

R4

F8 F9 F10 F1 F2 F3 F4

PFA-D

F5 F6 F7

F11

F12 R5 R6

R7

Table 62. Relay Identification Relay RL1 RL2 RL3 RL4 RL5 RL6 RL7

280

Circuit(s) Power hold 12V Fuel lift pump 12V Ignition sense 24V Not used Voltage dropper 24V Voltage dropper 12V Not used

9821/3250-3

280


Technical Data Electrical System

(For: EK Engine, JS370) Relay - Cab Figure 275.

F9 F8 F7 F6 F5 F4 F3 F2 F1 F11 F10

F16 F15 F14 F13 F12 F20 F19 F18 F17 F29 F28 F27 F26 F25 F24 F23 F22 F21

R2

R3

R4

R1

R5

Table 63. Relay Identification Relay R1 R2 R3 R4 R5

Circuit(s) Engine crank Horn Wash wipe Engine stop Refuel pump

Relay - Radiator Bay Figure 276.

RL3

F1 F2 F3 F4 F5 F6 F7 F8 F9

RL2

RL1 F10 F11 F12 F13 F14 F15 F16 F17

281

9821/3250-3

281


Technical Data Electrical System

Table 64. Relay Identification Relay RL1 RL2 RL3

282

Circuit(s) Power hold 12V Ignition sense 24V Fuel lift pump12V

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282


Technical Data Tracks

Tracks General Refer to: Maintenance > Tracks (Page 230). Table 65. Track Tension Minimum Track Tension 25mm

283

Maximum Track Tension 30mm

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283


Technical Data Warranty Information

Warranty Information Service Record Sheet Table 66. Date

Annual Insurance (Yes)

Hours

Signature and stamp

Figure 277. Installation Checklist

/

/

h

/

h

/

h

Figure 278. 500h/3 Month

/

Figure 279. 1000h/6 Month

/

284

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284


Technical Data Warranty Information

Figure 280. 1500h/9 Month

/

/

h

/

h

/

h

/

h

Figure 281. 2000h/12 Month

/

Figure 282. 2500h/15 Month

/

Figure 283. 3000h/18 Month

/

285

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285


Technical Data Warranty Information

Figure 284. 3500h/21 Month

/

/

h

/

h

/

h

/

h

Figure 285. 4000h/24 Month

/

Figure 286. 4500h/27 Month

/

Figure 287. 5000h/30Month

/

286

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286


Technical Data Warranty Information

Figure 288. 5500h/33 Month

/

/

h

/

h

/

h

/

h

Figure 289. 6000h/36 Month

/

Figure 290. 6500h/39 Month

/

Figure 291. 7000h/42 Month

/

287

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287


Technical Data Warranty Information

Figure 292. 7500h/45 Month

/

/

h

/

h

/

h

/

h

Figure 293. 8000h/48 Month

/

Figure 294. 8500h/51 Month

/

Figure 295. 9000h/54 Month

/

288

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288


Technical Data Warranty Information

Figure 296. 9500h/57 Month

/

/

h

Figure 297. 10000h/60 Month

/

/

h

Figure 298. 10500h/63 Month

/

/

h

/

h

Figure 299. 11000h/66 Month

/

289

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289


Notes:

290

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290


Section B Body and Framework Service Manual - JS 200 Series Tracked Excavators Section 1 - General Information Section 2 - Operator’s Manual Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track & Running Gear Section K - Engine

Publication No.

9813/5550-1

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


Section B - Body and Framework

Notes:

B-0

9813/5550-1

B-0


Section B - Body and Framework Contents Page No. Technical Data Air Conditioning (option) ........................................................................... B-1 Automatic Temperature Control (ATC) System .................................... B-1 Basic Operation Automatic Temperature Control (ATC) System ........................................ B-3 Heater/Air Conditioning Controls (ATC) ............................................... B-6 Heater Controls ................................................................................. B-6 Air Conditioning System Operation ...................................................... B-7 ATC Control Panel ................................................................................ B-8 Inputs ................................................................................................ B-8 Outputs ............................................................................................. B-8 Safety Procedures .............................................................................. B-10 Fault Finding Air Conditioning ....................................................................................... B-11 Preliminary Checks .............................................................................B-11 Error Codes / Error Diagnosis (Automatic Temperature Control (ATC) System) .................................................................................................... B-12 Service Procedures HV/HVAC Unit ........................................................................................ B-19 Removal ............................................................................................. B-19 Replacement ...................................................................................... B-19 Air Conditioning Compressor .................................................................. B-21 Removal and Replacement ................................................................ B-21 Removal .......................................................................................... B-21 Replacement ................................................................................... B-21 Cab Structure ......................................................................................... B-22 Direct Glazing ..................................................................................... B-22 Removing the Broken Glass and Old Sealant ................................ B-22 Preparing the Cab Frame Aperture ................................................. B-24 Preparing the New Glass ................................................................ B-24 Installing the New Glass ................................................................. B-26 Checks ............................................................................................... B-28 Checking the FOPS Structure ............................................................ B-29 Torque Setting ................................................................................. B-29 Cab Panels Removal and Replacement .................................................................... B-31 Routine Maintenance Procedures Scheduled Tasks .................................................................................... B-35 Doors and Locks ..................................................................................... B-36 Check (Condition) ............................................................................... B-36 Excavator Lever and Pedal Locks .......................................................... B-37 Check (Operation) .............................................................................. B-37 Slew Ring Pinion and Gear Teeth ........................................................... B-38 General ............................................................................................... B-38 Lubricate ............................................................................................. B-38 Fit For Purpose Test ............................................................................... B-39 Fit for Purpose Tests for Lifting Equipment ......................................... B-39 Cab Heater/Air-Conditioning Filter .......................................................... B-40 General ............................................................................................... B-40 Replace .............................................................................................. B-40

B-i

B-i


Section B - Body and Framework Contents

B-ii

Page No.

B-ii


Section B - Body and Framework

Technical Data Air Conditioning (option) Automatic Temperature Control (ATC) System Table 1. Pressure Switch Setting Low Pressure Cut In

Bar

lbf/in2

1.4 (+/- 0.1)

20 (+/- 1.5)

Low Pressure Cut Out

0.3 (+/- 0.1)

4 (+/- 1.5)

High Pressure Cut In

17.2 (+/- 0.7)

250 (+/- 10)

High Pressure Cut Out

27.6 (+/- 0.7)

400 (+/- 10)

Table 2. Refrigerant Gas

Charge Weight

R-134a

1400 g +/- 10g Table 3.

Lubrication Oil PAG (PolyAlkylene Gycol) oil to ISO 100

B-1

Oil Quantity Full System

150 g +/- 5 g

Evacuation/Charge

If the system is being evacuated, add 57 g (59 ml) of lubrication oil to the system before or during the charge.

B-05-00 issue 01

B-1


Section B - Body and Framework Technical Data Air Conditioning (option)

B-2

B-05-00 issue 01

B-2


Section B - Body and Framework Basic Operation Automatic Temperature Control (ATC) System

Basic Operation Automatic Temperature Control (ATC) System B H D

E C

X

Y

F

A G X

Y

C132090

Fig 1. System components

B-3

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B-3


Section B - Body and Framework Basic Operation Automatic Temperature Control (ATC) System Item

Description

A

ATC HVAC Unit

B

Condenser

C

High Pressure Switch

D

Receiver/Drier

E

Compressor

F

Control Panel

G

Low Pressure Recharge Point

H

High Pressure Recharge Point

J

ATC Electronic Control Module

K

Pulse Width Modulation (PWM) Module

L

Cab Air Sensor

M

Thermal Expansion Valve (TXV)

N

Low Pressure Switch

P

Water Valve

Q

Air-off Sensor

R

Evaporator Temperature Sensor

S

Evaporator Matrix

T

Blower Motor

U

Actuator

V

Recirculation Air Filter

W

Fresh Air Filter

X

Heater Hose, heater inlet (red)

Y

Heater Hose, heater outlet (blue)

B-4

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B-4


Section B - Body and Framework Basic Operation Automatic Temperature Control (ATC) System

P

T

S

Q J

N

M U

W L

R

K

V T014090-C1

Fig 2. ATC HVAC unit components

B-5

9813/5550-1

B-5


Section B - Body and Framework Basic Operation Automatic Temperature Control (ATC) System

Heater/Air Conditioning Controls (ATC)

2

Rotate control 5 to set the desired temperature.

The heater/air conditioning can be set for automatic temperature control (ATC).

3

The set temperature will be displayed on panel 7.

4

The fan speed will be automatically set to reach and then maintain the set temperature.

The heater system is controlled by the following switches:

Note: If control 6 is moved, Auto mode will have to be reset. Press switch 2 to reactivate.

7

5

In hot weather or dusty environments, re-circulation mode should be used. Select switch 3.

Defrost/Demist Mode To activate press switch 4, the LED will illuminate and switch symbol will be displayed on 7.

1

2

3

4

5

1

6

In hot weather to produce comfortable working conditions.

T006520

Fig 3.

a

Close the door and windows.

1

On/Off switch.

b Select re-circulation switch 3.

2

Auto mode switch.

c

3

Re-circulation switch.

4

Defrost/Demist switch.

5

Temperature control switch.

6

Fan speed switch.

7

Display.

Rotate control 6 clockwise and direct air into the body of the cab.

d Rotate control 5 fully counter-clockwise for maximum defrost. If the in cab temperature drops to low turn control clockwise. 2

In cold/damp weather, to minimise misting. a

Close the door and windows.

b Select re-circulation switch 3.

Heater Controls

c Hot air can be directed to the front window (for demisting) and/or the cab floor by adjusting the air vents. To activate controls press switch 1, the switch LED and panel 7 will illuminate.

Set control 6 fully clockwise and direct air onto the front window.

d Set control 5 fully clockwise to heat the dehumidified conditioned air, de-mist the screen and generally de-humidify the cab air.

Auto Mode The heater can be set to a selected temperature. The fan speed and temperature control will then be automatically controlled to maintain the set temperature. 1

B-6

Auto mode is activated by switch 2, the LED will illuminate and an `A' will appear on the display 7.

9813/5550-1

B-6


Section B - Body and Framework Basic Operation Automatic Temperature Control (ATC) System

Air Conditioning System Operation To maintain optimum operator comfort in warm climates or during seasons of high ambient temperature, the air conditioning system re-circulates, clean, dehumidified air into the cab. Cooling is provided by passing the recirculated air, over an evaporator coil in the air conditioning unit. The air conditioning system is a closed circuit through which the refrigerant is circulated, its state changing from gas to liquid and back to gas again, as it is forced through the system.

refrigerant is now considerably below that of the air being drawn across the evaporator matrix by the blowers. Heat is transferred from the ambient and re-circulated air to the refrigerant, causing the low pressure liquid to vaporise and become a low pressure gas. Moisture in the air condenses on the evaporator matrix and is drained away via condensate. K Fig 1. ( T B-3). Cool de-humidified air is emitted through air vents into the cab. The low temperature, low pressure, high heat content refrigerant gas, is now drawn by suction back to the compressor, where the cycle is completed.

The major components of the system are the compressor E, condenser B, receiver drier D, expansion valve L and evaporator matrix A.K Fig 1. ( T B-3). Air conditioning system power is generated from the engine, via an electromagnetic clutch to the compressor. The electromagnetic clutch is controlled by the ATC Electronic Control Unit (ECU). The ATC ECU therefore controls when the air conditioning system operates. The compressor E, draws in low pressure refrigerant gas from the suction line (evaporator to compressor) and increases refrigerant pressure through compression. This process also increases the refrigerant temperature. K Fig 1. ( T B-3). High pressure refrigerant is forced from the compressor to the condenser B, which is mounted on the radiator on the side of the engine. Ambient air is drawn across the condenser by the engine-driven cooling fan. In the condenser, the refrigerant changes state to a high pressure, high temperature liquid but with a lower heat content. K Fig 1. ( T B-3). The refrigerant passes through the receiver drier D, which contains a desiccant to remove moisture from the system. K Fig 1. ( T B-3).The receiver drier serves as a reservoir for refrigerant and also includes a filter to remove foreign particles from the system. The high temperature, high pressure refrigerant is forced by compressor action into the expansion valve L, which meters the amount of refrigerant entering the evaporator. In the expansion valve the refrigerant instantaneously expands to become a low pressure, low temperature liquid. K Fig 1. ( T B-3). The refrigerant is drawn through the evaporator matrix A, by the suction of the compressor. The temperature of

B-7

9813/5550-1

B-7


Section B - Body and Framework Basic Operation Automatic Temperature Control (ATC) System

ATC Control Panel

T013670

Fig 4. The ATC system includes an electronic control system that protects the system components if a problem occurs. The electronic control system also lets the operator control the cab temperature, fan speed and air flow direction at the ATC control panel. The ATC control panel (user Interface) on the right hand side console in the cab is connected to an electronic control module (ECM). The ECM is attached to the top of the ATC unit. The ECM monitors the inputs and controls the outputs in the system as selected by the operator and as the temperature conditions change. If a system problem occurs, the LCD display shows an error code.

Cab Temperature Sensor The cab temperature sensor is on the inlet vent in the ATC unit in the cab. The sensor operates with the outlet temperature sensor to let the ATC control panel know when the cab temperature is correct. Outlet Temperature Sensor (Air Off) The outlet temperature sensor is on the outlet vent in the ATC unit in the cab. The outlet temperature sensor operates with the cab temperature sensor to let the ATC control panel know when the cab temperature is correct.

Inputs Outputs High Pressure Switch PWM Module (Pulse Width Modulation) The high pressure switch is on the receiver drier. The switch is an input used to monitor the fluid pressure in the high pressure side of the system. The switch tells the ATC control panel when the high pressure is abnormal.

The PMW module is in the ATC unit above the filter panel, access is through a removable plate. The PMW module controls the output signals from the ECU through actuators and a fan motor.

Low Pressure Switch The low pressure switch is in the ATC unit. The switch is used to monitor the low pressure gas on the low pressure side of the system. The switch tells the ATC control panel when the low pressure is abnormal. Evaporator Temperature Sensor The evaporator temperature sensor is in between the evaporator cores in the ATC unit in the cab. The sensor tells the ATC control panel the evaporator temperature. This temperature is for control of the compressor clutch and output to stop the evaporator cores freezing

B-8

The components controlled by the PWM module are as follows: – Blower Motor. The PWM module changes the signal to the blower motor as requested on the fan speed dial on the ATC control panel to increase or decrease the motor speed. – Re-circulation Motor (Actuator). The PWM module changes the signal to the re-circulation motor (Actuator) as requested on the ATC control panel to

9813/5550-1

B-8


Section B - Body and Framework Basic Operation Automatic Temperature Control (ATC) System change where the inlet air is drawn in from by moving a control flap. – Water valve (Actuator). The PWM module changes the signal to the Water valve as requested on the temperature dial on the ATC control panel. This adjusts the quantity of heater coolant into the heater core to obtain the correct cab temperature. – Compressor Drive Clutch. The compressor drive clutch is in the compressor mounted on the engine. The compressor drive clutch receives an output signal from the ATC control panel to control when the clutch must be engaged or disengaged. This depends upon what temperature is selected on the ATC control panel. When the clutch is engaged, a snowflake symbol is shown in the top right hand corner of the LCD display. The drive clutch can automatically disengage if an error occurs in the system and an error code shows on the LCD display. This is to prevent the system from more damage.

B-9

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B-9


Section B - Body and Framework Basic Operation Automatic Temperature Control (ATC) System

Safety Procedures

refrigerant system must be conducted in a well ventilated area.

The air conditioning system includes a pressurised closed circuit containing a non-CFC, environmentally friendly refrigerant, Type R-134a. Any service procedure which breaks into the closed circuit and therefore requires discharging of the system, must only be carried out by service personnel with specialist knowledge of air conditioning systems. The following guidelines should be adhered to by all personnel servicing the air conditioning system.

!MWARNING

2

Containers of refrigerant should be stored in a cool environment away from direct sunlight.

!MWARNING Do not carry out welding operations close to the air conditioning refrigerant circuit. A poisonous gas is produced when refrigerant comes into contact with naked flames. Do not smoke or allow naked flames close to the refrigerant circuit. BF-1-9

The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be disconnected until the system has been discharged by a refrigeration engineer or a suitably trained person. You can be severely frostbitten or injured by escaping refrigerant. 4-3-4-1_2

3

Do Not perform welding operations close to refrigerant hoses (maintain a distance of at least 0.5m from hoses).

4

Do Not steam clean refrigerant system components.

5

When charging or discharging the refrigerant system refrain from smoking. Naked flames must not be allowed in the immediate vicinity. The refrigerant does not give off a poisonous odour, however, when it comes into contact with a naked flame, a poisonous gas is produced.

6

When handling refrigerant, rubber gloves and goggles should be worn. Operators should ensure that no refrigerant comes into contact with the skin. Particular care should be taken when connecting or disconnecting charging hoses or pressure switches. When these components are connected to the system, a short release of refrigerant occurs. This results in a high velocity, very cold gas being emitted from the connection point.

!MWARNING The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be disconnected until the system has been discharged by a refrigeration engineer or a suitably trained person. You can be severely frostbitten or injured by escaping refrigerant. 4-3-4-1_2

!MWARNING The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be disconnected until the system has been discharged by a refrigeration engineer or a suitably trained person. You can be severely frostbitten or injured by escaping refrigerant. 4-3-4-1_2

!MCAUTION Do not operate the air conditioning system when there is no refrigerant in the system, otherwise the compressor will be damaged. 4-3-4-4

1

It is critical that the correct refrigerant (R-134a) is used and that charging is done only by qualified personnel. As a precaution, in case of accidental leakage, discharging and charging of the vehicle

B-10

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B-10


Section B - Body and Framework

Fault Finding Air Conditioning TB-010_2

Preliminary Checks Before any checks are carried out on the refrigerant circuit the following checks should be made: 1

Check the compressor drive belt is serviceable and correctly tensioned.

2

Check the condenser and engine radiator are not blocked by debris, clean with compressed air or water if necessary.

3

Check that the condenser fins are not flattened or damaged, the fins must allow air to pass freely.

4

Check the cab fresh air inlet filter for blockage.

5

Check that, with the ignition switch on (engine not running), the blower operates over whole speed range.

6

Check that, with the ignition switch on (engine not running), the blower and air conditioning switched on, the compressor clutch engages.

Charge level: Note: It is not possible to check refrigerant charge level with R134a systems using the receiver drier sightglass. Any bubbles seen at the sight glass on the receiver drier may be bubbles of oil and are perfectly normal. – Gas -1400g R134A +/- 10g – Oil - 150g +/- 5g PAG (PolyAlkylene Gycol) oil to ISO 100 Fault finding: Important: Refer to appropriate remove and replace procedures before working on any system component

B-11

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B-11


Section B - Body and Framework Fault Finding Air Conditioning

Error Codes / Error Diagnosis (Automatic Temperature Control (ATC) System) Table 4. Error Code 1 - High Pressure Lock Out Causes

Effect

Description

The unit cannot cool the cab The compressor disengages.

The high pressure switch operates twice In 1 minute.

The system is overcharged.

Remedy Check the continuity of switch (usually open switch). Check the gas in system and recharge, refer to table.

There is no power to the high pressure switch.

Check for 24V at the switch. Check the continuity between ATC control module pin 33 and switch.

There is a bad earth on the high Check the earth wire between pressure switch. ATC control module pin 34 and switch. There is a defective switch. Note: If, an Error code shows after one minute this can show a system Error.

Note: If, an Error code shows instantly this can show a wiring Error.

Table 5. Error Code 2 - Low Pressure Lock Out Causes

Effect

Description

The unit cannot cool the cab The compressor disengages.

The low pressure switch opens for longer than 1 minute.

Replace the switch.

The system is undercharged.

Remedy Check the continuity of switch (usually closed switch). Check the gas in system and recharge, refer to table.

There is no power to the low pressure switch.

Check for 24V at the switch.

There is a bad earth on the low pressure switch.

Check the earth wire between ATC control module pin 36 and switch.

There is a defective switch.

Replace the switch.

Check the continuity between ATC control module pin 35 and switch.

Note: If an Error code shows after one minute this can show a system error. Note: If an Error code shows instantly this can show a wiring error. Note: Battery reset may be required to remove the error after repair.

B-12

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B-12


Section B - Body and Framework Fault Finding Air Conditioning Effect

Table 6. Error Code 3 - Blower Potentiometer Error (User Interface / Control Panel) Causes Remedy

The Blower motor speed is irregular in Wiring Error (open or short-circuit). Auto mode.The Blower motor speed is fixed or cannot be changed in manual mode. There is no blower speed signal from the user interface to the ATC Control Module.

Check for 24V at blower motor. Check the continuity from blower motor earth to Pin 7 on PWM. Check the continuity from pin C15 on user interface to pin 28 on ATC control module. (Expected reading on Pin 28 0.5V to 3.0 V).

There is no signal from the ATC control Check the continuity from Pin 5 on ATC module to the PWM. control module to Pin 6 on PWM unit.

Effect

Defective potentiometer.

Replace user interface / control panel.

There is no temperature signal from the user interface to the ATC control module.

Check the continuity from Pin D1 on the user interface to pin 29 on ATC control Module. (Expected reading on Pin 29 - 0.5V to 3.0 V).

There is no temperature signal from the ATC control module to the PWM.

Check the continuity from Pin 3 on ATC control module to Pin D on water valve. Check the continuity from Pin A on water valve to Pin 5 on PWM.

There is a bad earth on water valve / PWM.

Check for good earth as shown on schematic.

Defective potentiometer.

Replace user interface / control panel.

Table 8. Error Code 7 - Cab Air Sensor Error (Air Inlet Temperature Sensor) Causes Remedy

The unit cannot cool the cab. The compressor disengages.The Demist mode does not work / The Recirculation Mode is O.K.There is no temperature change / the fan speed operates correctly in Auto mode. The temperature changes on LCD display. The cab temperature does not correspond.

B-13

Check for good earth as shown on schematic.

Table 7. Error Code 4 - Water Valve Potentiometer Error (User Interface / Control Panel) Causes Remedy

The temperature shown on the display cycles between 22 degrees and error code 4.There is no temperature change There is no fan speed in Manual Mode.There is no temperature change / the fan speed operates correctly in Auto mode.

Effect

Bad earth on blower motor / PWM.

There is no temperature signal from Check the continuity between pin1 on the sensor to the ATC control module. the cab temperature sensor to pin 21 on ATC control module. There is a bad earth on the cab air sensor.

Check for good earth as shown on schematic.

There is a defective sensor.

Replace the cab air sensor.

9813/5550-1

B-13


Section B - Body and Framework Fault Finding Air Conditioning Effect

Table 9. Error Code 8 - Evaporator Temperature Sensor Error Causes Remedy

The unit cannot cool the cab The compressor disengages.

There is no temperature signal from the sensor to ATC control module.

Check the continuity between pin1 on the evaporator temperature sensor to pin 23 on ATC control module.

There is a bad earth on the evaporator Check for good earth as shown on temperature sensor. schematic. There is a defective sensor.

Effect

Make sure the sensor connections are correct. Replace the evaporator temperature sensor.

Table 10. Error Code 9 - Outlet Temperature Sensor Error Causes Remedy

The fan speed stays at maximum in AUTO mode. The manual mode blower operates as normal.

There is no temperature signal from the sensor to ATC control module.

Check the continuity between pin1 on the outlet temperature sensor to pin 22 on ATC control module.

There is a bad earth on The outlet temperature sensor.

Check for good earth as shown on schematic.

There is a defective sensor

Make sure the sensor connections are correct. Replace the outlet temperature sensor.

Table 11. Error Code E19 - No Communications Between User Interface / Control Panel and ATC Control Module. Effect Causes Remedy The unit cannot cool the cab / The compressor disengages.The ATC / Heater control does not operate.The fan speed stays at maximum in Auto mode / The fan speed operates as normal in Manual mode.

Wiring Error

Check power at pins on User Interface and ATC control module. Check Earth at pins on User Interface and ATC control module. Check the Continuity between the wires that connect the User Interface and the ATC control module.

Connector Error

Check the connector plugs between User Interface and ATC control module are in good condition.

Defective user interface / Control panel Replace the defective unit or ATC control unit

Effect

Table 12. PWM Failure (No Fault Code Displayed) Causes Remedy

The unit cannot cool the cab / The compressor disengages.Fan speed unable to adjust in both auto and manual modes (fan speed defaults to max or min.) Temperature will be on maximum hot or maximum cold and unable to change.

B-14

Wiring Error

Check power and earths on PWM as shown on schematic. Expected readings for inputs to WM during normal operation.Pin 5 and Pin 6 Minimum 0.016 volts to maximum 11.18 volts

9813/5550-1

B-14


Fig 5. Electrical Schematic (Automatic Temperature Control (ATC) System)

T013690-1

Section B - Body and Framework Fault Finding Air Conditioning

B-15

9813/5550-1

B-15


B-16

0.75

0.75

0.75

0.75

0.75

0.75

0.75

20

21

22

23

24

25

26

9813/5550-1

0.75

0.75

44

0.75

64

BL/BK

BL/BK

BL/BK

0.75

0.75

62

63

-

BL/GN

-

0.75

61

BL/WH

WH/BK

WH/YW

-

RD/BN

-

-

RD

RD/OR

OR/WH

60

0.75

1.50

55

59

-

54

-

0.75

53

0.75

-

0.75

-

51

52

57

1.5

50

56

RD/BN

0.75

49

58

-

0.75

48

W

W

W

W

W

W

-

W

W

W

-

W

-

W

-

-

W

910D

910C

910A

910B

-

957

956

955

-

55

-

160B

-

-

950

953

952

10

-

W

W

150F

BN/OR

2.00

0.75

213

30H

201

160A

950A

160

946A

30M

921

124

951

-

-

909

916

915

-

907

30

913

908

30A

30B

30C

30J

30K

30L

-

47

W

W

W

W

W

W

W

W

W

W

W

-

-

W

W

W

-

W

W

W

W

W

W

W

W

W

W

-

914

912

30E

46

RD/BN

W

W

W

918

920

923

30D

150B

911

150A

548

150

202

211

210

Ident

45

GN/BN

BK

RD/BN

GN/OR

0.75

RD

0.75

1.50

40

RD/BN

41

0.75

39

BK

BK

RD/BL

43

1.50

GN

BK

-

-

BL/OR

BL/BK

BL

-

BL/RD

BK

BK

BK

BK

BK

BK/RD

BK

-

42

0.75

1.50

36

38

34

37

-

1.50

0.75

33

-

31

32

35

0.75

0.75

30

-

0.75

19

0.75

0.75

18

27

BL

0.75

17

28

YW/BK

-

16

YW/BL

BK/RD

YW/GN

0.75

0.75

13

W

BK/OR

0.75

0.75

12

W

W

W

W

W

W

W

W

W

W

W

Type

OR

14

0.75

11

YW

BK

RD/BN

BL/RD

RD/BN

RD/YW

RD/BN

GN/BL

GN/YW

GN/WH

Colour

15

0.75

10

0.75

6

0.75

0.75

5

0.75

0.75

4

0.75

0.75

3

7

0.75

2

8

0.75

1

9

Size mm

Wire No

100

250

380

350

-

970

970

1060

-

235

-

2010

-

-

480

970

330

215

165

-

750

370

860

380

450

200

725

810

990

945

930

-

-

590

490

730

-

945

70

990

990

340

950

850

480

850

260

-

970

970

90

970

970

970

520

475

970

475

1190

475

720

1230

1330

Length mm

From

N

-

AMP 5-160558-2

2

PACKARD 12048074

A

-

34

PACKARD 12084912

-

PACKARD 12103881

5 ATC CONTROLLER

-

B

17 LOW PRESSURE SENSOR

SP8

PACKARD 12084912

-

PACKARD 12089649

PACKARD 12089649

PACKARD 12089649

-

-

-

PACKARD 12084912

36

-

D13

D12

C1

-

-

-

11

5 ATC CONTROLLER

-

2 USER INTERFACE

2 USER INTERFACE

2 USER INTERFACE

-

SP6

-

I VEHICLE HARNESS

-

-

-

-

AMP 770008-3

-

PACKARD 12084912

DEUTSCH 1060-16-0122

2

3 D8

-

DEUTSCH 1060-16-0122

-

MOLEX 5558

-

8

-

1

MOLEX 5558

2

PACKARD 12048074 PACKARD 12048074

D

A

AMP 5-160558-2

AMP 770008-3

1

AMP 770008-3

1

PACKARD 12089649

5

D14

PACKARD 12089649

-

C2

DEUTSCH 1060-16-0122

-

DEUTSCH 1060-16-0122

2

1

PACKARD 12084912

35

PACKARD 12089649

DEUTSCH 1060-16-0122

10 C10

PACKARD 12089649

PACKARD 12089649

C16

C11

PACKARD 12048074

PACKARD 12047757

11 PWM UNIT

2 USER INTERFACE

1 VEHICLE HARNESS

SP6

1 VEHICLE HARNESS

-

6 OUTLET TEMP SENSOR

6 OUTLET TEMP SENSOR

4 RECIRC ACTUATOR

4 RECIRC ACTUATOR

11 PWM UNIT 10 WATER VALVE ACTUATOR 13 BLOWER MOTOR

11 PWM UNIT

2 USER INTERFACE

2 USER INTERFACE

13 BLOWER MOTOR

-

-

1 VEHICLE HARNESS

1 VEHICLE HARNESS

5 ATC CONTROLLER

-

2 USER INTERFACE

1 VEHICLE HARNESS

2 USER INTERFACE

2 USER INTERFACE

2 C

MOLEX 5558

2

10 WATER VALVE ACTUATOR

PACKARD 12048074

42281-2

AMP 5-160558-2

-

C

1

85

-

PACKARD 12084912

PACKARD 12084912 PACKARD 12084912

28 29

7 CAB AIR TEMP SENSOR

8 EVAP TEMP SENSOR

4 RECIRC ACTUATOR

18B C/F CONNECTOR

15 COMP CLUTCH RELAY

-

5 ATC CONTROLLER

5 ATC CONTROLLER

5 ATC CONTROLLER

5 ATC CONTROLLER

27

N

31 PACKARD 12084912

2 USER INTERFACE

26

2 USER INTERFACE

N

PACKARD 12084912

-

SP6

5 ATC CONTROLLER

15 COMP CLUTCH RELAY 15 COMP CLUTCH RELAY

SP6

-

5 ATC CONTROLLER

SP2

5 ATC CONTROLLER

SP5

SP6

SP5

SP6

SP2

SP2

SP4

11 PWM UNIT

-

-

-

-

N N

Fig 6.

SP9

SP9

SP8

-

SP8

-

5 ATC CONTROLLER

5 ATC CONTROLLER

1 VEHICLE HARNESS

N

-

N

N

SP4

-

-

-

-

-

-

-

16

25

12

-

-

-

-

-

-

-

32

87

30

-

-

22

-

11

-

-

-

-

-

-

-

4

-

-

33

N

N

Seal

-

-

-

-

-

N

N

N

-

-

-

PACKARD 12084912

DEUTSCH 0462-201-16141 PACKARD 12084912

-

-

-

-

-

-

-

-

-

N -

N

N

-

-

N

-

N

-

-

-

-

-

-

-

-

-

N

-

N

-

-

-

-

-

-

-

-

-

-

-

-

N

N

-

N

N

N

-

-

-

-

N

-

PACKARD 12048046

To

PACKARD 12084912

AMP 5-160558-2

AMP 5-160558-2

-

-

PACKARD 12084912

-

PACKARD 12084912

-

-

-

-

-

-

-

AMP 770008-3

-

-

PACKARD 12084912

-

PACKARD 12103881

-

-

-

-

-

-

SP9

-

-

-

-

-

-

-

-

-

-

-

A

5 ATC CONTROLLER

AMP 42460-2

PACKARD 12089649

PACKARD 12089649

-

-

-

-

-

SP5

N

1 D1

C15

17 LOW PRESSURE SENSOR

N N

D7 PACKARD 12089649

PACKARD 12089649

D5

PACKARD 12089649

D10

-

-

-

-

-

AMP 5-160558-2

86 -

-

AMP 770008-3

-

PACKARD 12048074

MOLEX 5558

PACKARD 12047757

Terminal

-

3

SP4

SP2

SP2

SP2

SP2

SP2

SP2

SP2

SP2

SP2

-

2 USER INTERFACE

2 USER INTERFACE

18A C/F CONNECTOR

2 USER INTERFACE

-

-

N

N

N

-

N

-

N

N

PACKARD 12048046

PACKARD 12048046

N

PACKARD 12048046

N

N

N

N

N

-

-

N

N

N

-

N

N

N

N

PACKARD 12048046

N

N

PACKARD 12048046

N

N

-

N

N

N

N

SP2

PACKARD 12084912

SP4

15 Comp Clutch Relay

20

N

5 ATC CONTROLLER

N

5 ATC CONTROLLER

5 ATC CONTROLLER PACKARD 12084912

PACKARD 12084912

SP4

11 PWM UNIT

-

D

SP4

1

1

10 WATER VALVE ACTUATOR

7 CAB AIR TEMP SENSOR 8 EVAP TEMP SENSOR

Cavity

Connector

PACKARD 12084912

15

N

N

N

N

N

N

Seal

17

PACKARD 12084912

PACKARD 12084912

PACKARD 12084912

PACKARD 12084912

PACKARD 12084912

PACKARD 12084912

Terminal

12

5

4

3

23

21

Cavity

18

5 ATC CONTROLLER

5 ATC CONTROLLER

5 ATC CONTROLLER

5 ATC CONTROLLER

5 ATC CONTROLLER

5 ATC CONTROLLER

5 ATC CONTROLLER

5 ATC CONTROLLER

Connector

SP2

30

CONSTRUCTION DETAILS - SPLICE 2

55

CONSTRUCTION DETAILS - SPLICE 4

SP4

160 SP 5

160B

SP 6

55

CONSTRUCTION DETAILS - SPLICE 6

SPLICE TO BE COVERED WITH ADHESIVE LINED HEATSHRINK (ATUM OR EQUIVALENT)

946A

950A

950

150F

SPLICE TO BE COVERED WITH ADHESIVE LINED HEATSHRINK (ATUM OR EQUIVALENT)

160A

CONSTRUCTION DETAILS - SPLICE 5

SPLICE TO BE COVERED WITH ADHESIVE LINED HEATSHRINK (ATUM OR EQUIVALENT)

907 150 150A 124 150B

SPLICE TO BE COVERED WITH ADHESIVE LINED HEATSHRINK (ATUM OR EQUIVALENT)

30L 30M

921 30B 30H 30C 30J 30A

30K 913 908 30D

= = = = = = = = = =

RED WHITE GREEN BLACK BLUE PINK YELLOW BROWN PURPLE ORANGE

SP 8

SP 9

SPLICE TO BE COVERED WITH ADHESIVE LINED HEATSHRINK ( ATUM OR EQUIVALENT )

910D

CONSTRUCTION DETAILS - SPLICE 9

SPLICE TO BE COVERED WITH ADHESIVE LINED HEATSHRINK ( ATUM OR EQUIVALENT )

910A

CONSTRUCTION DETAILS - SPLICE 8

RD WH GN BK BL RS YW BN PU OR

COLOUR CODES:

910C 910

910C 910B

T013690-2

Section B - Body and Framework Fault Finding Air Conditioning

B-16


B-17

5

1

Cavity A B

Colour BL BL/BK

RD/BN

BK RD/BN WH/YW

46

25 53 57

30 160B 955

150F

Ident 910 917 952

9813/5550-1

SP2 SP5 2

SP6

To SP9 5 15

11 49 31

64 28

61

34 35

36

15

14

BL/GN

BL/BK BL

YW/GN OR RD/OR YW/BL

GN/YW WH/BK BK/OR BK/RD YW/BL

YW GN/WH GN/BN

2 58 12 13

RD/BN BK

10 1 44

29 31 32 33

23 25 26 27 28

21 22

17 18 20

BL/WH

59 8 9

RD/BN BL/RD

RD/BN RD/YW GN/OR

4 5

42 6

4 5

11

7

3

3

12 15 16

Colour GN/BL

Wire

Cavity

910B

910D 915

914 920 953 917

912

211 956 918 30E

210 213

150B 30D 923

150A 911 957

201

202 150 948

Ident

SP8

SP9 17

2 2 1

2

2

8 2 2 18

7 6

SP4 SP2 2

SP4 2 2

11 4

10 SP4

To

C1

-

-

-

A

D1 D7 D8 2

C15

1 D12 D5 1

1 1

D10

C14 D13

D 3 D

Cavity

Seals :- 12110489 + 12110488

Terminals :- 12084912

Wire 47 7 17 48

Cavity 33 87

Cavity 30 86 85 87

1

Colour BN/OR WH/OR BK OR/WH

12

Cavity C3 3

280

To SP6 2 SP2 1

LABEL LOCATION

Ident 10 900 30L 952

Seals :- N/A

Terminals :- AMP.250 FASTON/Equivalent

Part No :- 500-002 or Equivalent

Manufacturer :- STEWART AUTOMOTIVE

Part No :- 12110487 + 12110490

Manufacturer :- PACKARD

Cavity 35 -

COMPRESSOR CLUTCH RELAY

ATC CONTROLLER

Colour BL/BK YW/BL OR/WH

Wire 30 31 48

Wedge :- W12P

Terminals :- 1060-16-0122

Part No :- DTO4-12P-CL06

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

15

Ident 915 910A

VEHICLE HARNESS

Wire 28 62

Seals :- N/A

30

SP9

86

85

100

87

190

150

2

80

70

100

50

40 18B

18A

360

F E D

20

C to

FCONNECTOR

FCONNECTOR

To 5

Cavity 1 Wire 18

Colour BK/RD

Receptical housing: Ident 30E

To SP2

480054

MANUFACTURER:- AMP / TYCO Receptical 42281-2

C to

Ident 30E

480053-3 Colour BK/RD

42460-2 Wire 13

Tab Housing Cavity 1

Tab

MANUFACTURER:- AMP / TYCO

Anti-backout inserts: 12045890 x1 / 12045889 x1 Cavity Cavity Wire Colour Ident To C1 57 WH/YW 955 1 11 35 C2 GN 124 SP4 C3 C9 C10 26 BL/RD 907 SP4 C11 23 YW/BK 908 SP2 C12 C13 C14 C15 14 YW/BL 912 5 28 C16 24 SP2 BL 913 D1 15 YW/GN 914 5 29 D2 D3 D4 12 BK/OR 5 26 D5 918 D6 D7 11 OR 920 5 31 49 5 D8 RD/OR 953 32 D10 10 YW 923 5 20 D12 58 WH/BK 956 5 25 D13 59 BL/WH 957 5 16 36 921 SP2 D14 BK -

Terminals :- 12089649

Part No :- 12110207

25

SP4

11

Cavity

F E D

CONVELUTE TO BE ADDED IN THIS AREA APPLY BLACK INSULATION TAPE AT EACH END OF CONVELUTE & AT 150mm INTERVALS

SP8

40

30

To SP5 SP2 5

25

Ident 160A 3OJ 201

640

Colour RD/BN BK GN/OR

USER INTERFACE

SP2

70

Wire 41 19 42

Manufacturer :- Packard

CONNECTOR EXTERNAL FROM CONVELUTE

70

Cavity A C D

Seals :- 12048086,12052850,12059168

Terminals :- 12048074

Terminals :- 12103881

Part No :- 12052848

Part No :- 12162443

To 5 SP8

RECIRC ACTUATOR

Manufacturer :- PACKARD

Manufacturer :- PACKARD

LOW PRESSURE SENSOR

Manufacturer :- DEUTSCH

17

4

A B C

6

Cavity

A B C

10 WATER VALVE ACTUATOR

290

280

380

PWM UNIT

210

Wire 44 43

Cavity -

Cavity 27

SP5

20

Cavity 1 2

20

Colour GN/BN BK

Ident 213 30H

30

22 -

13

20

Cavity 1 2 Wire 40 34

Colour RD BK

To SP6 11

1

90

Cavity 4

To SP5 SP2 5

Fig 7.

Ident 950A 951

Seals :- N/A

Terminals :- 160917-2

Part No :- N/A

Ident 160 30A 202

130

Colour RD/BN BK GN/BL

BLOWER MOTOR

170

Wire 39 22 3

110

Cavity A C D

Cavity 3

Seals :- 12048086,12052850,12059168

Terminals :- 12048074

Manufacturer :- AMP / TYCO

2

SP6

100

110

F E D

F E D

Manufacturer :- PACKARD Part No :- 12052848

7

Wire 38 50 5 34 37 -

Ident 946A 950 948 951 30M -

Wire 1 21

Colour GN/WH BK

Ident 210 30B

Seals :- N/A

Terminals :- 12047767

Part No :- 12047662

Cavity A B

To SP7 SP6 5 13 SP2 -

Cavity 21 -

Cavity 5 2 -

To 5 SP2

CAB TEMP SENSOR

Colour RD/BL RD RD/YW BK BK -

Wedge :- N/A

Manufacturer :- PACKARD

Cavity 1 2 3 4 5 6

Terminals :- 770008-3

Part No :- 770020

11 Manufacturer :- TYCO /AMP

Seals :- N/A

Terminals :- 5558 To 5 SP2

OUTLET TEMP SENSOR Part No :- 39-01-3023

Manufacturer :- MOLEX

8

Wire 2 20

Colour GN/YW BK

Ident 211 30C

Seals :- N/A

Terminals :- 5558

Part No :- 39-01-3023

Manufacturer :- MOLEX

Cavity 1 2

RED WHITE GREEN BLACK BLUE PINK YELLOW BROWN PURPLE ORANGE

To 5 SP2

EVAP TEMP SENSOR

= = = = = = = = = =

COLOUR CODES: RD WH GN BK BL RS YW BN PU OR

Cavity 23 -

T013690-3

NOTES:1. ALL CABLES TO BE THIN WALL AUTOMOTIVE - FLRYW. 2. CABLE TIE AT BREAKOUTS AND AT 100mm INTERVALS. 3. ALL SPLICES TO BE SOLDERED AND INSULATED WITH HEAT SHRINK. 4. WIRE HARNESSES TO BE FULLY TESTED FOR CORRECT PINOUTS. 5. TOLERANCES TO CONFORM TO SPECIFICATIONS IN WIRE HARNESS TOLERANCE DIAGRAM. 6. GROMMET: STRAIN RELIEF COLLAR TYPE. TO FIT 20 HOLE IN 1mm THK MATERIAL. 7. ALL FASTON .250 TYPE TERMINALS TO INCORPORATE LOCKING PIP.

Section B - Body and Framework Fault Finding Air Conditioning

B-17


Section B - Body and Framework Fault Finding Air Conditioning

Page left intentionally blank

B-18

9813/5550-1

B-18


Section B - Body and Framework

Service Procedures HV/HVAC Unit Removal K Fig 8. ( T B-20) The machine can be fitted with a HV unit (Heating and Ventilation) or a HVAC unit (Heating Ventilation and Air Conditioning). Before removing the HVAC unit, the air conditioning system must be discharged. K Safety Procedures ( T B-10) 1

Working in the cab, remove the operators seat from its runners.

2

Remove the plastic panel from the rear of the cab to get access to the HV/HVAC unit 1. Refer to Cab Panels.

3

Remove two bolts and lift the bracket 4 together with harness connectors 2 clear of the HV/HVAC unit.

4

Disconnect the connector 3.

5

Disconnect the ventilation hoses 7 at the HV/HVAC unit

6

Label the water hoses 9 and disconnect them at the HV/HVAC unit.

7

Label the air conditioning hoses 8 (if applicable) and disconnect them at the HVAC unit.

8

Remove four mounting screws 6 from both sides of the HVAC unit and lift the unit from the machine.

HV/HVAC

electrical

harness

Replacement Replacement is the reverse of the removal procedure. Note: Ensure the two drain hoses 5 are threaded through the holes in the cab floor and are not trapped under the HVAC unit.

B-19

9813/5550-1

B-19


Section B - Body and Framework Service Procedures HV/HVAC Unit

3 1

9 9

2

8

7

4

7

1

1

1

7

7

6

6 5 C130360

Fig 8.

B-20

9813/5550-1

B-20


Section B - Body and Framework Service Procedures Air Conditioning Compressor

Air Conditioning Compressor Removal and Replacement Removal

3

Disconnect the electrical connector 1 at the compressor 7.

4

Remove bolt 4 and disconnect the low pressure hose 6 from the compressor.

5

Remove bolt 3 and disconnect the high pressure hose 5 from the compressor.

6

Cap all open contamination.

7

Support the compressor and remove three bolts 2. Lift the compressor from the machine.

!MWARNING Make sure the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5

1

2

Discharge the air conditioning system refrigerant. K Safety Procedures ( T B-10) Remove the FEAD belt 9 from the compressor pulley 8. Refer to Section K, Routine Maintenance.

ports

and

hoses

to

prevent

Replacement Replacement is the reverse of the removal procedure.

1

2

3

2 4

6

7 9

8

2

5

7 C130500

Fig 9.

B-21

9813/5550-1

B-21


Section B - Body and Framework Service Procedures Cab Structure

Cab Structure Direct Glazing

Removing the Broken Glass and Old Sealant TB-002_4

The following procedures explain how to correctly remove and install panes of glass that are directly bonded to the cab frame apertures. When carrying out the procedures, relevant safety precautions must be taken. 1

Always wear safety glasses during both removal and replacement.

2

Use protective gloves - heavy duty leather gauntlet type gloves when cutting out the broken glass; 'nonslip' type gloves when handling/moving panes of glass; surgical type gloves when using the polyurethane adhesives.

3

Wear protective overalls.

4

Do not smoke - the activators and primers used in the procedures are highly flammable.

5

Do not attempt to handle or move panes of glass unless you are using glass lifters.

!MWARNING Always wear safety glasses when removing or installing screen glass. Never use a power operated knife when removing the sealant around a toughened glass screen. The action of the knife could cause particles of glass to be thrown with sufficient force to cause serious injury, even when safety glasses are being worn. Use only hand operated tools when working with toughened glass. BF-2-3_1

1

Position the machine on level ground and apply the parking brake. Stop the engine. Put protective covers over the cab seat and control pedestals.

2

If a laminated pane breaks it will stay in one piece even though the glass is cracked. A toughened pane will shatter and fall apart. The method of removal of the glass depends upon which type it is. a

Several special tools are required to successfully complete the removal and replacement procedures. Reference is made to the tools in the text. The majority of these tools can be obtained locally and the remainder from JCB Service (see Service Tools). The work must only be carried out in a dry, frost free environment. A protective canopy may be required or the machine/frame must be moved to a sheltered area. In damp or wet conditions, hinged doors and window frames can be removed from the machine and taken to a more suitable (dry) environment.

Laminated glass - leave installed until the old sealant has been cut away, after which it will be possible to lift the broken screen away from its frame housing in one piece.

b Toughened glass - remove as much of the shattered glass as possible prior to cutting out the old sealant. 3

Cut out the old sealant, leaving approximately 1 to 2 mm on the cab frame. There are several tools and techniques for doing this: a

Glass should not be replaced at temperatures below 5°C (41°F).

!MWARNING

Pneumatic Knife. K Fig 10. ( T B-23). This provides one of the easiest methods of removing the sealant around laminated glass. The tool, powered by compressed air, should be sourced locally.

Laminated glass must be handled with extra care to prevent breakage. Wherever possible, store and handle it in a vertical attitude. When placing or lifting the glass in a horizontal attitude it must be supported over its whole area, not just at the edges. BF-1-8_1

B-22

9813/5550-1

B-22


Section B - Body and Framework Service Procedures Cab Structure ii

Insert the braided cutting wire 11-B down the centre of the steel tube. If necessary, from the outside, cut out local sealant at the point of the tube to gain access to the wire.

iii Using suitable pliers, pull the cutting wire through the sealant to the outer side of the glass. Fig 10. Pneumatic Knife i

iv Secure each end of the braided cutting wire in the special handles 11-C.

Press the handle to start the knife blade oscillating.

v Important: This tool must not be used on toughened glass. ii

Move the cutting wire backwards and forwards in a sawing motion and at the same time gently push or pull the wire to cut through the old sealant.

Insert the knife blade into the sealant. c

iii Slowly move the knife along the sealant with the blade positioned as close to the glass as possible. Do not allow the knife blade to overheat or the sealant will melt.

Cut-out Knife. K Fig 12. ( T B-23). The cut-out knife can be used as a left handed or right handed tool.

b Braided Cutting Wire and Handles. K Fig 11. ( T B-23). This method uses a 3-core wire, a wire starter tube and two handles. i

Insert the steel tube 11-A into the old sealant on the inside of the glass.

Fig 12. Cut-out Knife i

Insert the knife blade into the sealant.

ii

Make sure that the blade of the knife is against the glass 12-A.

iii Use the 'pull-handle' to pull the knife along and cut out the old sealant. d Craft Knife. K Fig 13. ( T B-24). The blades 13-A are replaceable. Fig 11. Braided Cutting Wire and Handles

B-23

9813/5550-1

i

Insert the knife blade into the sealant.

ii

Pull the knife along and cut out the old sealant.

B-23


Section B - Body and Framework Service Procedures Cab Structure 2

Use 'Active Wipe 205' to thoroughly clean and 'prime' the trimmed sealant. Use a lint free cloth to apply the 'Active Wipe 205', allow 5 minutes flash off (drying) time.

Note: Do not use any other type of cleaning fluids, otherwise they may be absorbed into the old sealant and ultimately prevent the new glass from bonding.

Preparing the New Glass

!MWARNING

Fig 13. Craft Knife 4

Laminated glass - lift out the broken pane using glass lifters. Toughened glass - remove the cut off sealant and all remaining particles of shattered glass.

5

If necessary, trim off the remaining old sealant to leave approximately 1 to 2 mm on the upright face of the cab frame aperture. K Fig 14. ( T B-24)

Laminated glass must be handled with extra care to prevent breakage. Wherever possible, store and handle it in a vertical attitude. When placing or lifting the glass in a horizontal attitude it must be supported over its whole area, not just at the edges. BF-1-8_1

1

Make sure that the new glass correctly fits the frame aperture 15-A. a

1-2 mm

Put two spacer blocks 15-B onto the bottom part of the frame aperture.

b Install the new glass on the spacer blocks Always use glass lifters 15-C. Check that there is an equal sized gap all round the edge of the glass. Note: The spacer blocks are rectangular in section to give two common gap widths. If necessary they can be trimmed to a smaller size to give an equal sized gap around the glass. Fig 14.

6

Apply a coat of 'Black Primer 206J' to the paintwork if: a

Important: The glass edges must not touch the frame, otherwise movement of the frame will chip and eventually break the newly installed glass.

Paintwork was damaged or scratched during the glass/sealant removal procedures.

b The old sealant was inadvertently cut back to the cab frame during the glass/sealant removal procedures.

Preparing the Cab Frame Aperture 1

If damp or wet, dry the aperture area using a hot air gun (sourced locally).

B-24

9813/5550-1

B-24


Section B - Body and Framework Service Procedures Cab Structure

Fig 17.

Fig 15. 2

3

Make sure the glass is positioned on the stand the correct way up (i.e. with the black ceramic ink band upwards) ready for application of primer etc.

4

Clean the glass a

After checking for size, remove the new glass and place it on a purpose made glass stand. K Fig 16. ( T B-25).

Use 'Active Wipe 205' to thoroughly clean and 'prime' the black ceramic ink band printed on the glass (see Note). Use a lint free cloth to apply the 'Active Wipe 205', allow 5 minutes flash off (drying) time.

Note: Do not touch the glass after cleaning with the 'Active Wipe 205'. b If the glass does not have a black ceramic ink band, paint a band on the glass using 'Black Primer 206J'. The band should be approximately 25mm (1in) wide, and the edge should be a neat straight line. K Fig 18. ( T B-25).

Fig 16. Glass Stand Small panes of glass will need locating on a 600 x 700 mm x 15 to 19 mm thick plywood board 17-A, sourced locally to fit the glass stand. It is recommended that an access hole is cut in the board to accommodate the glass lifter, making it easier and safer to handle small panes of glass. The board should be covered with felt or carpet to give an anti-scratch surface. Resting the glass on four spacer blocks will ensure clearance of the cartridge nozzle tip during application of the polyurethane sealant.

B-25

Fig 18. 5

9813/5550-1

Install the Ultra Fast Adhesive cartridge (see Sealing and Retaining Compounds, Section 1 and Note) into a suitable applicator gun:

B-25


Section B - Body and Framework Service Procedures Cab Structure a

Remove the aluminium disc cover from the base of the cartridge and discard the 'dessicant capsule'.

b Make sure that the rolled edge of the cartridge is not damaged - if necessary, the edges should be pressed flat, otherwise it will be difficult to remove the cartridge from the applicator gun. c

Pierce the front 'nozzle' end of the cartridge to its maximum diameter.

Note: Once the pre-heated adhesive has been applied to the glass, install the glass in the aperture as soon as possible. After approximately 10 minutes the sealant will form a 'skin', this will prevent the glass from bonding. 7

Installing the New Glass 1

If the internal trim strip is damaged, renew it (cut to length as required) before fitting the new glass. Make sure the two spacer blocks are in position. K Preparing the New Glass ( T B-24) - step 1.

2

Install the glass in the frame aperture:

d Fit the pre-cut nozzle. K Fig 19. ( T B-26). e

Install the cartridge in the applicator gun.

Note: Cold material will be very difficult to extrude. The cartridges must be pre-heated in a special oven for 1 hour to a temperature of 80°C (176°F). Pre-heating the cartridges makes the adhesive more workable and also brings the 'curing' time down to 30 minutes.

After applying the adhesive, leave a small amount of sealant protruding from the nozzle. This will prevent any adhesive left in the cartridge from 'curing'.

a

Always use the special lifting tools when moving the glass. Use a lifting strap to hold large panes of glass in position. K Fig 21. ( T B-26)

Fig 19. 6

Apply the pre-heated adhesive to the glass (do not start in a corner). Keep the nozzle guide 20-A against the edge of the glass and make sure that the adhesive forms a continuous 'pyramid' shape. K Fig 20. ( T B-26)

Fig 21. Typical M/c. Installation b Sit the bottom edge of the glass on the spacer blocks. K Fig 22. ( T B-27)

Fig 20.

B-26

9813/5550-1

B-26


Section B - Body and Framework Service Procedures Cab Structure minutes, but it must not be used during the curing period of 30 minutes. c

6

Clean the glass using a purpose made glass cleaner

On completion of the glass installation procedures tidy the work area: a

Remove all broken glass from the cab area.

b Remove the protective covers from the cab seat and control pedestals. c

Renew all 'warning' and 'information' decals so that the new installation conforms with the original cab installation.

Fig 22. c

3

Make sure that the glass is correctly positioned, then gently press around the edges of the glass and ensure full adhesive contact is achieved. Do not press too hard or too much adhesive will squeeze out.

Make the inside seal smooth: a

Wearing surgical gloves, dip your finger in a soapy water solution.

b Use your finger to make the inside seal smooth. 4

All exposed edges must be sealed using Black Polyurethane Sealant (see Sealing and Retaining Compounds, Section 1).

Important: Use extreme caution when wiping the inside of the new glass - pushing too hard on the inside of the glass will affect the integrity of the bonded seal. 5

Clean the glass after installation: a

Small amounts of sealant can be cleaned from the glass using the 'Active Wipe 205'.

b Large amounts of excess sealant should be left to 'cure' and then cut off with a sharp knife. Note: On completion of the glass replacement procedures, the sealant 'curing' time is 30 minutes. This means that the machine can be driven and used after 30

B-27

9813/5550-1

B-27


Section B - Body and Framework Service Procedures Cab Structure

Checks

bolt torques. Tighten them to the correct torque if necessary.

Failure to take these precautions could result in death or injury to the operator. Check the structure for damage. Check that the six mounting bolts A are installed and undamaged. Check the

Item

Table 13. Torque Settings Nm Kgf m lbf ft

A

132

14

97

A

Fig 23.

B-28

9813/5550-1

B-28


Section B - Body and Framework Service Procedures Cab Structure

Checking the FOPS Structure

Torque Setting

All excavators are designed so that an operator's protective structure can be fitted. In certain applications such as demolition, machines must be fitted with the optional Falling Objects Protection Structure (FOPS). It is the operator's responsibility to identify the risk of an application.

!MWARNING You could be killed or seriously injured if you operate a machine with a damaged or missing ROPS/FOPS. If the Roll Over Protection Structure (ROPS)/Falling Objects Protection Structure (FOPS) has been in an accident, do not use the machine until the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS certification. INT-2-1-9_6

Check that all the FOPS mounting bolts are in place and undamaged. Check the FOPS mounting bolts for correct torque tightness.

Fig 24.

B-29

1

Torque tightness is 78 Nm (57.5 lbf ft)

2

Torque tightness is 343 Nm (253 lbf ft)

3

Torque tightness is 343 Nm (253 lbf ft)

4

Torque tightness is 78 Nm (57.5 lbf ft)

5

Torque tightness is 343 Nm (253 lbf ft)

6

Torque tightness is 137 Nm (101 lbf ft)

9813/5550-1

B-29


Section B - Body and Framework Service Procedures Cab Structure

Page left intentionally blank

B-30

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B-30


Section B - Body and Framework Cab Panels Removal and Replacement

Cab Panels Removal and Replacement The cab is fitted with five plastic trim panels. The panels are fixed to the cab frame with screws.

5

LH ‘C’ Post Cover. K Fig 26. ( T B-33)

5A

Fixings - 4 x screws and nylon washers

Components, such as electrical switches, locate in some of the cab panels. During removal and replacement be sure to disconnect and reconnect the applicable harness connectors.

5B

Coat hook

5C

Fixings - 2 x screws and nylon washers

Remove the rear panel 2 to get access to the fixings Remove / replace the coat hook 5B

Do not force the panels away from the cab frame, be sure to remove all the fixings. If a cab panel is replaced with a new one transfer the applicable components to the new panel. The table lists the cab panels and their fixings: 1

RH ‘C’ Post Panel. K Fig 25. ( T B-32)

1A

Fixings - 4 x screws and nylon washers

1B

Emergency hammer

Remove the emergency hammer 1B to get access to the fixings. Remove the centre console panel 3 to get access to the fixings 2

Rear Panel. K Fig 25. ( T B-32)

2A

Fixings - 7 x screws and nylon washers

Disconnect / connect the ventilation hoses at the rear of the panel 3

Centre Console Panel. K Fig 25. ( T B-32)

3A

Fixings - 8 x screws and nylon washers

3B

Fixing - 1 x bolt and nylon washer

3C

Stowage plate

3D

Cover

Remove the rear panel 2 to get access to the fixings Remove the cover 3D to get access to the fixing Remove / replace the stowage plate 3C 4

‘A’ Post Panel. K Fig 25. ( T B-32)

4A

Fixings - 2 x screws and nylon washers

4B

Fixings - 2 x bolts and nylon washers

Remove / replace the stowage plate 3C Remove / replace the DECU ECU. Refer to Section C.

B-31

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B-31


Section B - Body and Framework Cab Panels Removal and Replacement

1B 1

1A 1A 2A

1A

2A

2

2A

2A

3A 3 3B

3A

4B

3A

3B

4A 3A 3A

3A

2A

2A

2A

4 3C 4B

4A

3A

3A

C130450

Fig 25.

B-32

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B-32


Section B - Body and Framework Cab Panels Removal and Replacement

5B 5A

5 5A

5A

5C

5C

C130490

Fig 26.

B-33

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Section B - Body and Framework Cab Panels Removal and Replacement

Page left intentionally blank

B-34

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Section B - Body and Framework

Routine Maintenance Procedures Scheduled Tasks The table below lists the Body and Framework related Scheduled tasks. The tasks are in addition to the Daily/ Weekly scheduled tasks. For details of all applicable maintenance schedules refer to Section 2.

Note: Maintenance schedules can vary according to machine operating conditions and environments. Refer to Section 2.

Table 14. Item

Task

Refer to

Doors and locks

Check (Condition)

K Check (Condition) ( T B-36)

Excavator lever and pedal locks

Check (Operation)

K Check (Operation) ( T B-37)

Seat and seat belt

Check (Condition)

Section 2, Maintenance, Operator Station.

Seat and seat belt

Check (Operation)

Section 2, Maintenance, Operator Station.

Slew ring pinion and gear teeth

Lubricate

K Lubricate ( T B-38)

Pivot pins (boom base and dipper) Lubricate

Section 2, Maintenance, Body and Framework, Pivot Pins.

Fit for purpose test

Check (Operation)

K Fit For Purpose Test ( T B-39)

Cab heater/air-conditioning filter

Replace

K Cab Heater/Air-Conditioning Filter ( T B-40)

B-35

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B-35


Section B - Body and Framework Routine Maintenance Procedures Doors and Locks

Doors and Locks Check (Condition) Check the condition of the cab doors and locks as follows: – Check the operation of the latches and locks. Replace worn or defective components if the latches fail to latch, release, lock or unlock correctly. – Lubricate the locks and latches with light lubricating oil. – Check that the machine doors and access covers open and close correctly. Make sure that the hinges and retaining devices operate correctly. replace missing, worn or defective components. – Lubricate the door and access cover pivots with light lubricating oil.

B-36

9813/5550-1

B-36


Section B - Body and Framework Routine Maintenance Procedures Excavator Lever and Pedal Locks

Excavator Lever and Pedal Locks Check (Operation) Check the operation of the machine control locks. refer to Section 2, Operation, Machine Locks. If the control locks do not operate correctly, carry out the necessary procedures to repair them. Important: DO NOT operate the machine if the control locks are defective.

B-37

9813/5550-1

B-37


Section B - Body and Framework Routine Maintenance Procedures Slew Ring Pinion and Gear Teeth

Slew Ring Pinion and Gear Teeth General Ensure slew ring is kept full of grease. Always grease whenever the machine has been steam-cleaned.

Lubricate Lubricate the slew ring pinion and gear teeth as follows: 1

Prepare the machine Maintenance.

2

Grease the slew ring as follows: a

Refer

to

Section

2,

Remove the inspection port cover A (on the lower centre section).

b Remove the grease discharge port cover B (on the lower inner side). c

Remove contaminated grease.

d Replace the discharge port cover. e

Apply grease to the slew ring via aperture C.

JS03672-C1

Fig 27. Tracked Machines 3

Start the engine and slew the machine a few degrees. Stop the engine, remove the starter key and apply grease again. Repeat until the whole ring is greased. Check that grease exudes around the entire circumference.

4

Refit the inspection port cover.

C

812270

Fig 28. Wheeled Machines

B-38

9813/5550-1

B-38


Section B - Body and Framework Routine Maintenance Procedures Fit For Purpose Test

Fit For Purpose Test Fit for Purpose Tests for Lifting Equipment T3-097

All lifting equipment (for example forks, lifting hooks and shackles) need regular inspection and testing by a competent person to ensure they are fit for purpose. This may be needed every six months or at least annually in some countries to meet and comply with legislation and for insurance purposes. Check with your local JCB distributor for further advice.

B-39

9813/5550-1

B-39


Section B - Body and Framework Routine Maintenance Procedures Cab Heater/Air-Conditioning Filter

Cab Heater/Air-Conditioning Filter General There are two cab heater/air-conditioning filters. A fresh air filter 2 and a re-circulation filter 3. The filters are located in

the Heating Ventilation and Air-Conditioning (HVAC) unit 1 inside the cab. The HVAC unit is located at the rear of the operator’s seat.

1

2

6 3 5 4

C130140

Fig 29.

Replace

5

1

Prepare the machine. Refer to Section Maintenance, Maintenance Positions.

2

Slide the cover 5 up and remove it from the HVAC unit 1.

3

Remove the re-circulation filter 3.

4

Remove the fresh air filter 2.

B-40

2,

9813/5550-1

Install the new filters followed by the cover. Make sure that the cover sealing strips 4 and 6 locate correctly at each end of the cover.

B-40


Section C Electrics Service Manual - JS 200 Series Tracked Excavators Section 1 - General Information Section 2 - Operator’s Manual Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track & Running Gear Section K - Engine

Publication No.

9813/5550-1

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


Section C - Electrics

Notes:

C-0

9813/5550-1

C-0


Section C - 1 Contents Page No. Overview and Schematics Circuit Symbols ......................................................................................... C-1 Inputs and Outputs ............................................................................... C-1 Circuit Concepts ....................................................................................... C-3 Inputs .................................................................................................... C-3 Digital inputs (on/off switch type inputs) ............................................ C-3 Analogue input (i.e. sensor type inputs) ............................................ C-4 Outputs ................................................................................................. C-5 Pulse Width Modulation (PWM) ................................................................ C-6 Using a Multimeter .................................................................................... C-7 Measuring DC Voltage ......................................................................... C-8 Measuring Resistance .......................................................................... C-8 Measuring Continuity ............................................................................ C-9 Measuring Frequency ........................................................................... C-9 Testing a Diode or a Diode Wire ......................................................... C-10 Schematic Diagrams - Machines with Ecomax Engines ........................ C-11 Component Keys ................................................................................ C-30 Schematic Diagrams - Machines with Dieselmax Engines ..................... C-35 Component Keys ................................................................................ C-54 Battery Maintenance ........................................................................................... C-59 Test Procedures ...................................................................................... C-60 High Rate Discharge Test ................................................................... C-60 Specific Gravity Testing ...................................................................... C-61 Disconnection and Connection ............................................................... C-62 ........................................................................................................... C-62 Battery Disconnection/Connection .................................................. C-62 Fuses and Relays Introduction ............................................................................................. C-63 Cab Fuse and Relay Box - Connector Identification ............................... C-64 Harness Systems Installation and Interconnections ............................................................ C-65 Earth Points ............................................................................................ C-70 Harness Drawing List, JS200 - JS235 .................................................... C-72 Drawings ................................................................................................. C-74 333/K8486 Issue 3 ............................................................................. C-75 334/J4255 Issue 1 .............................................................................. C-81 333/K5337 Issue 1 ............................................................................. C-87 333/K8487 Issue 2 ............................................................................. C-93 333K9798 Issue 1 .............................................................................. C-95 333/K8491 Issue 1 ............................................................................. C-97 333/K8818 Issue 1 ........................................................................... C-103 333/K8490 Issue 1 ........................................................................... C-109 333/K8813 Issue 1 ........................................................................... C-115 333/K0017 Issue 1 ........................................................................... C-121 333/K3883 Issue 1 ........................................................................... C-123 333/K4284 Issue 1 ........................................................................... C-124 333/K4283 Issue 1 ........................................................................... C-125 333/K4639 Issue 1 ........................................................................... C-126 333/K5288 Issue 1 ........................................................................... C-127 334/J2060 Issue 1 ............................................................................ C-128 Connector Codes .................................................................................. C-130

C-1

C-1


Section C - 1 Contents

Contents Page No. Wire Numbers and Functions ............................................................... C-134 Wires 000-199 .................................................................................. C-135 Wires 200-399 .................................................................................. C-135 Wires 400-599 .................................................................................. C-135 Wires 600-799 .................................................................................. C-135 Wires 800-999 .................................................................................. C-135 Wires In Splices ................................................................................ C-135 General Points .................................................................................. C-135 Wiring Harness Repair ......................................................................... C-136 Introduction ....................................................................................... C-136 Repair Procedure ............................................................................. C-136 ECUs and CANbus CANbus System ................................................................................... C-139 CANbus Communications System ................................................... C-140 ECU Set-up ...................................................................................... C-142 Machine Electronic Control Unit (MECU) ............................................. C-143 Location ............................................................................................ C-143 Operation Overview .......................................................................... C-143 Wires and Connectors ...................................................................... C-144 Removal and Replacement Guide ................................................... C-146 Removal ........................................................................................ C-146 Replacement ................................................................................. C-146 Hydraulic Electronic Control Unit (HECU) ............................................ C-147 Location ............................................................................................ C-147 Operation Overview .......................................................................... C-147 Wires and Connectors ...................................................................... C-148 Removal and Replacement Guide ................................................... C-150 Removal ........................................................................................ C-150 Replacement ................................................................................. C-150 Test Procedures ............................................................................... C-150 Display ECU (DECU) ............................................................................ C-151 Location ............................................................................................ C-151 Operation Overview .......................................................................... C-151 Wires and Connectors ...................................................................... C-152 Removal and Replacement Guide ................................................... C-154 Removal ........................................................................................ C-154 Replacement ................................................................................. C-154 Engine ECU .......................................................................................... C-156 Location ............................................................................................ C-156 Description ....................................................................................... C-156 Wires and Connectors ...................................................................... C-157 Removal and Replacement Guide ................................................... C-158 Test Procedures ............................................................................... C-158 Testing of ECU Inputs + Outputs .......................................................... C-159 Testing Low Side Input ..................................................................... C-159 Testing High Side Input .................................................................... C-159 Testing Low Side Output .................................................................. C-159 Testing High Side Output .................................................................. C-159 Engine and Power Control Battery Power Supply and Distribution ................................................. C-161 Overview .......................................................................................... C-161 Wires and Connectors ...................................................................... C-162

C-2

C-2


Section C - 1 Contents

Contents Page No. Ignition Power Supply and Distribution ................................................. C-166 Overview .......................................................................................... C-166 Wires and Connectors ...................................................................... C-166 Engine Start/Stop - Ecomax Engines .................................................... C-169 Engine Fuses and Relays ................................................................ C-169 Engine Run ....................................................................................... C-169 Engine Stop ...................................................................................... C-169 Wires and Connectors ...................................................................... C-170 Engine Start/Stop - Dieselmax Engines ................................................ C-171 Engine Fuses and Relays ................................................................ C-171 Engine Run ....................................................................................... C-171 Engine Stop ...................................................................................... C-172 Wires and Connectors ...................................................................... C-173 Engine Cranking ................................................................................... C-174 Overview .......................................................................................... C-174 Wires and Connectors ...................................................................... C-175 Engine 24V to 12V Converter ............................................................... C-176 Location ............................................................................................ C-176 Overview .......................................................................................... C-176 Wires and Connectors ...................................................................... C-177 Engine Fuse and Relay Box ................................................................. C-178 Location ............................................................................................ C-178 Overview .......................................................................................... C-178 Wires and Connectors ...................................................................... C-178 Engine Fuel Lift Pump .......................................................................... C-179 Location ............................................................................................ C-179 Overview .......................................................................................... C-179 Wires and Connectors ...................................................................... C-179 Engine Throttle and Power Mode Control ............................................ C-180 Overview .......................................................................................... C-180 Power Band Maps ........................................................................ C-181 Engine Speed Sensing ................................................................. C-183 Engine Stall Prevention ................................................................. C-183 Engine Idle Control ....................................................................... C-184 Hand Throttle Control Unit ............................................................ C-185 Wires and Connectors ...................................................................... C-186 Removal and Replacement Guide ................................................... C-188 Removal ........................................................................................ C-188 Replacement ................................................................................. C-188 Engine Cold Idle ................................................................................... C-189 Ambient Air Temperature Sensor ......................................................... C-190 Location ............................................................................................ C-190 Overview .......................................................................................... C-190 Wires and Connectors ...................................................................... C-190 Engine Automatic Warm Up ................................................................. C-191 Overview .......................................................................................... C-191 Engine Automatic Idle ........................................................................... C-193 Variable Geometry Turbo (VGT) Actuator ............................................. C-194 Location ............................................................................................ C-194 Overview .......................................................................................... C-194 Wires and Connectors - VGT Actuator Power Supply ...................... C-195 Removal and Replacement .............................................................. C-195 Test Procedures ............................................................................... C-195

C-3

C-3


Section C - 1 Contents

Contents Page No. Exhaust Gas Recirculation (EGR) Actuator .......................................... C-196 Location ............................................................................................ C-196 Overview .......................................................................................... C-196 Wires and Connectors ...................................................................... C-197 Removal and Replacement Guide ................................................... C-197 Test Procedures ............................................................................... C-197 TMAF Sensor ....................................................................................... C-198 Location ............................................................................................ C-198 Overview .......................................................................................... C-198 Wires and Connectors ...................................................................... C-199 Removal and Replacement Guide ................................................... C-199 Removal ........................................................................................ C-199 Replacement ................................................................................. C-199 Test Procedures ............................................................................... C-199 Electro Viscous Fan .............................................................................. C-200 Location ............................................................................................ C-200 Overview .......................................................................................... C-200 Viscous Coupling Clutch Operation .............................................. C-200 Fan Speed Sensor ........................................................................ C-200 Wires and Connectors ...................................................................... C-201 Testing .............................................................................................. C-203 Engine Coolant Temperature Switch .................................................... C-204 Engine Coolant Level Switch ................................................................ C-205 Location ............................................................................................ C-205 Description ....................................................................................... C-205 Wires and Connectors ...................................................................... C-206 Removal and Replacement Guide ................................................... C-207 Test Procedures ............................................................................... C-207 Engine Oil Level Switch ........................................................................ C-208 Location ............................................................................................ C-208 Overview .......................................................................................... C-208 Wires and Connectors ...................................................................... C-209 Removal and Replacement Guide ................................................... C-209 Test Procedures ............................................................................... C-209 Vacuum Switch ..................................................................................... C-210 Location ............................................................................................ C-210 Overview .......................................................................................... C-210 Wires and Connectors ...................................................................... C-211 Fuel Level Sensor ................................................................................. C-212 Location ............................................................................................ C-212 Overview .......................................................................................... C-212 Wires and Connectors ...................................................................... C-212 Testing .............................................................................................. C-214 Water In Fuel (WIF) Sensor .................................................................. C-215 Location ............................................................................................ C-215 Overview .......................................................................................... C-215 Wires and Connectors ...................................................................... C-215 Alternator .............................................................................................. C-216 Location ............................................................................................ C-216 Overview .......................................................................................... C-216 Wires and Connectors ...................................................................... C-217

C-4

C-4


Section C - 1 Contents

Contents Page No. Refuelling Pump ................................................................................... C-219 Location ............................................................................................ C-219 Overview .......................................................................................... C-219 Wires and Connectors ...................................................................... C-220 Automatic Refill Mode ................................................................... C-220 Manual Mode ................................................................................ C-220 Hydraulic Systems Control 8 Station Solenoid Valve ....................................................................... C-223 Overview .......................................................................................... C-223 Solenoid Control Valves ................................................................... C-223 Removal and Replacement .............................................................. C-224 Pressure Switches ................................................................................ C-225 Overview .......................................................................................... C-225 Removal and Replacement .............................................................. C-226 3-Speed Travel ..................................................................................... C-227 Overview .......................................................................................... C-227 Auto Gear Change (Fast travel mode) .......................................... C-227 Wires and Connectors ...................................................................... C-228 Controls Enable (Lever Lock) ............................................................... C-230 Overview .......................................................................................... C-230 Wires and Connectors ...................................................................... C-230 Controls Enable (Lever Lock ISO) ........................................................ C-232 Overview .......................................................................................... C-232 Wires and Connectors ...................................................................... C-232 Slew Brake and Slew Lock ................................................................... C-234 Overview .......................................................................................... C-234 Slew Brake .................................................................................... C-234 Slew Lock ..................................................................................... C-234 Wires and Connectors ...................................................................... C-235 Slew Brake .................................................................................... C-235 Slew Lock ..................................................................................... C-235 Pump Proportional Control Solenoid ................................................... C-237 Operation .......................................................................................... C-237 Wires and Connectors ...................................................................... C-237 Cushion Control .................................................................................... C-239 Overview .......................................................................................... C-239 Wires and Connectors ...................................................................... C-239 Overload Caution (option) .................................................................... C-241 Overview .......................................................................................... C-241 Wires and Connectors ...................................................................... C-241 Boost Pressure ..................................................................................... C-243 Overview .......................................................................................... C-243 Wires and Connectors ...................................................................... C-243 Maximum Flow Cut Solenoid ................................................................ C-245 Overview .......................................................................................... C-245 Wires and Connectors ...................................................................... C-245 Hydraulic Oil Temperature Sensor ........................................................ C-246 Overview .......................................................................................... C-246 Wires and Connectors ...................................................................... C-246 Quickhitch (option) ................................................................................ C-248 Overview .......................................................................................... C-248 Wires and Connectors ...................................................................... C-249

C-5

C-5


Section C - 1 Contents

Contents Page No. Cab Systems and Lighting Camera System .................................................................................... C-253 Component Location ........................................................................ C-253 Overview .......................................................................................... C-253 Wires and Connectors ...................................................................... C-253 Standard Work Lights ........................................................................... C-255 Component Location ........................................................................ C-255 Overview .......................................................................................... C-255 Wires and Connectors ...................................................................... C-255 Cab Work Lights ................................................................................... C-257 Component Location ........................................................................ C-257 Overview .......................................................................................... C-257 Wires and Connectors ...................................................................... C-257 Beacon ................................................................................................. C-259 Component Location ........................................................................ C-259 Overview .......................................................................................... C-259 Wires and Connectors ...................................................................... C-259 Horn ...................................................................................................... C-261 Overview .......................................................................................... C-261 Wires and Connectors ...................................................................... C-261 Wipers and Washers ............................................................................ C-263 Overview .......................................................................................... C-263 Wires and Connectors ...................................................................... C-264 Upper/Main Wiper Switch and Motor ............................................ C-264 Lower Wiper Switch and Motor ..................................................... C-264 Washer Switch .............................................................................. C-265 Cab Interior Lamp ................................................................................. C-267 Overview .......................................................................................... C-267 Wires and Connectors ...................................................................... C-267 24 to 12 Volt Converter ......................................................................... C-269 Component Location ........................................................................ C-269 Overview .......................................................................................... C-269 Wires and Connectors ...................................................................... C-269 HVAC Control ....................................................................................... C-272 Component Location ........................................................................ C-272 Overview .......................................................................................... C-272 Wires and Connectors ...................................................................... C-272 Machines without Air Conditioning ................................................ C-272 Machines with Air Conditioning ..................................................... C-274 Machine Diagnostic Modes Overview .................................................................................................... 1-1 Selecting the Diagnostic Mode Screen ...................................................... 1-2 Test Run Mode ......................................................................................1-3 Pressure Switch Status Mode ...............................................................1-3 Fan Test Mode .......................................................................................1-4 Fault Code SYSTEM Operation Overview .................................................................................. C-5 Fault Code Display ............................................................................... C-5 Service/Operator Fault ...................................................................... C-5 Critical Fault ...................................................................................... C-6 Fault Code Log ................................................................................. C-7 Engine ‘P’ Codes ...................................................................................... C-8 Cab Area ‘B’ Codes .................................................................................. C-9

C-6

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Section C - 1 Contents

Contents Page No. Chassis ‘C’ Codes .................................................................................. C-10 CANbus ‘U’ Codes .................................................................................. C-15 Servicemaster SYSTEM Introduction ................................................................................................ 1-1 Why Use ServiceMaster? .......................................................................... 1-2 Fault Finding ..........................................................................................1-2 Identify Poor Maintenance .....................................................................1-2 Access Machine Set-up Data ................................................................1-2 Re-Programming ECUs .........................................................................1-2 Summary ...............................................................................................1-2 What is Servicemaster? ............................................................................. 1-3 Introduction ............................................................................................1-3 CANbus Communications System ........................................................1-3 Servicemaster Structure ........................................................................1-3 Tool Sets ............................................................................................ 1-3 How to Set-up Servicemaster .................................................................... 1-5 New Installation of JCB ServiceMaster DVD .........................................1-6 New Installation of JCB ServiceMaster WebUpdate .............................1-9 Authorising JCB WebUpdate Downloads ............................................1-12 Using JCB WebUpdate to Download Updates ....................................1-13 JCB ServiceMaster ..............................................................................1-14 ServiceMaster Front End .....................................................................1-14 Selecting Service Tool Applications .....................................................1-15 Start Servicemaster .............................................................................1-16 Load the DLA Laptop Driver Software .................................................1-17 Configure the DLA Type and Communications Port ............................1-18 Check the DLA Firmware File .............................................................1-19 Connect Servicemaster to the Machine CANbus ................................1-21 Servicemaster Tools Set Introduction ............................................................................................. C-23 Tools Suites ............................................................................................ C-24 Machine Tools .................................................................................... C-24 Engine Tools ....................................................................................... C-26 Diagnostics Connectors .......................................................................... C-28 Flash Loading the DECU .................................................................... C-28 Servicemaster Machine Selection .......................................................... C-29 Servicemaster Engine Selection ............................................................. C-30 Routine Maintenance Procedures Scheduled Tasks ....................................................................................... 1-1 Starter Motor .............................................................................................. 1-2 Check (Condition) ..................................................................................1-2 Alternator ................................................................................................... 1-3 Check (Condition) ..................................................................................1-3 Overload Warning System ......................................................................... 1-4 Check (Operation) .................................................................................1-4

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Section C - 1 Contents

Contents

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Page No.

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Section C - Electrics Overview and Schematics Circuit Symbols

Overview and Schematics Circuit Symbols TC-013

The following notations are used in the description circuit, drawings.

C005310GB-2

Fig 1.

Inputs and Outputs The letters i/p and o/p refer to input and output. The letters in brackets i.e. (C-21) refer to the connector and pin number.

C001660-2

Fig 2.

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Section C - Electrics Overview and Schematics Circuit Symbols

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Section C - Electrics Overview and Schematics Circuit Concepts

Circuit Concepts Inputs There are two main types of input, Digital and Analogue. Digital type inputs are on/off type inputs (i.e. switches) and can be Low side inputs or High side inputs. Low side inputs are inputs that provide a ground to the ECU. High side inputs are inputs that provide a positive feed to the ECU. Analogue Inputs are sensor type inputs that provide a varying type input to the ECU, this input could be a resistance or frequency type input.

Digital inputs (on/off switch type inputs) 1

C007180GB-2

Fig 4.

Low side input. The low side input is the most frequently used input on the A.M.S system. The low side input can be in the form of rocker switches or pressure switches.

C007170GB-2

Fig 3. 2

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High side input. The high side input is used on circuits that require a positive feed when the ignition is switched off, i.e. sidelights or hazard lights. The high side input is also used on the engine preheat circuit.

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Section C - Electrics Overview and Schematics Circuit Concepts Analogue input (i.e. sensor type inputs)

C045960GB-2

Fig 5.

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Section C - Electrics Overview and Schematics Circuit Concepts

Outputs There are three main types of outputs Low side output, High side output and Modulated output. In the Low side output circuit the actuator (solenoid, relay etc.) which is being driven already has a positive feed available, the ECU then provides the ground side of the circuit. In the High side output circuit the actuator which is being driven already has a ground available, the ECU provides the positive side of the circuit.

C007230GB-2

Fig 7. In the Modulated Output circuit the ECU provides a PWM (Pulse Width Modulation) signal to a proportional valve. As the ECU varies the duty cycle of the signal the proportional valve will select more or less depending on the change in duty cycle. 1

3

Modulated outputs. Circuits using the modulated output are throttle control, pump control and boom priority.

Low side output. Circuits using low side output are pre heat relay, stop solenoid relay and work lights.

C007240GB-2

Fig 8.

C007220GB-2

Fig 6. 2

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High side output. The high side output is used to operate solenoids, bulbs and horn.

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Section C - Electrics Overview and Schematics Pulse Width Modulation (PWM)

Pulse Width Modulation (PWM) Ohms law states that, the amount of current flow in a circuit is determined by the voltage, and the resistance. A 24v circuit with a resistance of 6 ohms, would draw a current of 4 amps. This would be the case for a standard solenoid, which is either on or off. Once the voltage is applied to the circuit, it is present 100% of the time. This would be known as a 100% duty cycle. Therefore the circuit will draw 4 amps constantly.

The graph A although unstable would give a current rating of three amps. To stabilize the current in the circuit, the frequency would need to be increased. If the time scale on the graph A was one second, the frequency would be 4Hz (Hertz (cycles per second)). The graph B shows the same duty cycle, but at a higher frequency of 32 Hz. The proportional solenoids fitted to JS machines operate at a frequency of 75 Hz.

C007260GB-2

Fig 9.

C007270GB-2

Fig 10.

A proportional solenoid requires differing amounts of current, depending on its condition. As the coil has a fixed resistance, changing the current rating can be done in either of two ways, 1

Having lots of different resistors switched in and out of the circuit at different times to change the current flowing.

2

To change the duty cycle of the solenoid.

It is easier, more economical, and more reliable to change the duty cycle of the circuit, especially using today's computer/ controller technology. The duty cycle is the amount of time a component is switched on compared to the time it is switched off. If a solenoid is on for three seconds, then off for one second, on for three, off for one etc. this would be a 75% duty cycle.

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Section C - Electrics Overview and Schematics Using a Multimeter

Using a Multimeter TC-002

In order to obtain maximum benefit from the fault finding information contained in Section C it is important that the technician fully understands the approach to fault finding and the use of the recommended test equipment, in this case a FLUKE 85 or AVO 2003 digital multimeter, or a moving pointer (analogue) multimeter. The approach is based on a fault finding check list. In tracing the fault from the symptoms displayed you will be directed to make measurements using a multimeter. These instructions are intended to cover the use of the recommended multimeters.

Fig 12. AVO 2003

Fig 11. FLUKE 85

Fig 13. A Typical Analogue Meter 1

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Make sure that the test leads are plugged into the correct sockets. The black test lead should be

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Section C - Electrics Overview and Schematics Using a Multimeter plugged into the black socket (sometimes, this socket is also marked by a "-", or "E" or marked as "COMMON" or "COM"). The red test lead should be plugged into the red socket marked with "+", "V" or "立". 2

When making measurements ensure that the test probes have a good clean contact with bare metal, free from grease, dirt, and corrosion as these can cause a false reading.

3

When measuring voltage: Make sure that the correct range is selected, that is set the selector to a value equal to or greater than that you are about to measure. e.g. If asked to measure 12 Volts, set the selector to the 12V range. If there is no 12V range, set the selector to the next range higher, 20V for instance. If the meter is set to a range that is too low, it may be damaged. e.g. setting to the 2V range to measure 12V.

Measuring Resistance 1

Make sure there is no power to the part of the circuit you are about to measure.

2

Connect one probe at one end of the component or wire to be checked and the other probe at the other end. It does not matter which way round the two probes are placed.

3

Select the correct range on the multimeter. a

On the FLUKE 85. i

Measuring DC Voltage 1

Select the correct range on the multimeter. a

b On the AV0 2003.

On the FLUKE 85.

i

Turn the switch to position 11-B. b On the AV0 2003.

c

Move the right slider switch to position 12-A, and the left hand slider switch to the appropriate range. c

Turn the switch to position 11-C and check that the W sign at the right hand side of the display window is on. If the F sign is on instead, press the blue button 11-G to change the reading to 立. Touch the meter lead probes together and press the REL3 key on the meter to eliminate the lead resistance from the meter reading.

Move the right hand slider switch to position 12-B, and the left hand slider switch to the appropriate Ohms (立) range.

On an analogue meter. i

Move the dial to the appropriate Ohms (立) range.

On an analogue meter. Turn the dial to the appropriate DC Volts range.

2

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Connect the black probe to the nearest available suitable earth point, usually this will be the starter motor earth, the battery negative, or the chassis. Connect the red probe to the wire or contact from which you are measuring the voltage.

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Section C - Electrics Overview and Schematics Using a Multimeter

Measuring Continuity

Measuring Frequency

1

Make sure there is no power to the part of the circuit you are checking for continuity.

The AVO 2003 and the analogue meter are not capable of measuring frequency, therefore a Fluke 85 digital multimeter must be used.

2

Connect one probe to one end of the component or wire to be checked and the other probe to the other end. It does not matter which way round the two probes are placed.

3

1

Insert the black plug into the COM socket on the meter and attach the probe to the nearest suitable earth point on the chassis, for example, the battery negative terminal.

2

Insert the red probe into socket 11-J.

3

Turn the selector switch to position 11-A and depress 11-G repeatedly until 11-F is highlighted on the top row of the display.

4

Press button 11-H once.

5

Touch or connect the red probe to the frequency source to be measured. Press and hold button if an average reading is required.

Select the correct range on the multimeter. a

On the FLUKE 85. Turn the switch to position 11-C and check that the beeper symbol appears at the left hand side of the display window. If the F sign is on instead, press the button labelled 11-F in the meter drawing. If there is continuity in the circuit, the beeper will sound. If there is no continuity (open circuit), the beeper will not sound.

b On the AV0 2003. Move the right hand slider switch to position 12-B, and the left hand slider switch to position 12-C. If there is continuity (i.e. very low resistance) between two points the buzzer will sound. c

On an analogue meter. Turn the dial to the lowest Ohms (Ί) range. If there is continuity (i.e. very low resistance) between two points the needle will move across fully (or almost fully) to the right hand side of the scale.

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Section C - Electrics Overview and Schematics Using a Multimeter

Testing a Diode or a Diode Wire

c

A diode wire is a diode with male connector fitted on one end and a female connector fitted on the other end. The diode is sealed in heatshrink sleeving. 1

On an analogue meter. i

Connect the black probe to the end of the diode marked with a band, or to the male connector of the diode wire, the red probe should be connected to the other end of the diode or diode wire. The meter should read 20-400 kΊ, if it reads more than this the diode is faulty.

To test a Diode or a Diode Wire a

On the FLUKE 85. i

Turn the switch to position 11-D.

ii

Press the HOLD button and check that the H sign appears at the top right hand side of the display window.

iii Connect the black probe to the end of the diode with a band or to the male connector of the diode wire. Connect the red probe to the other end of the diode or diode wire. If the beeper does not sound the diode or diode wire is faulty.

Select the Ohms 1000s (1k) range.

ii

Select the Ohms 100s range. Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe should be connected to the other end of the diode or diode wire. The meter should read 300-400Ί, if it reads less than this the diode is faulty.

iv Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe should be connected to the other end of the diode or diode wire. If the beeper sounds or the meter does not read O.L., the diode or diode wire is faulty. v

Press the HOLD button and check that the H sign disappears from the right hand side of the display window.

b On the AV0 2003. i

Move the right hand slider to position 12-A, and the left hand slider switch to position 12-C.

ii

Connect the black probe to the end of the diode marked with a band, or to the male connector of the diode wire, the red probe should be connected to the other end of the diode or diode wire. If the Avometer does not buzz the diode is faulty.

iii Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe should be connected to the other end of the diode or diode wire. If the Avometer does not read "1" the diode is faulty.

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K Component Keys ( T C-30)

(1) The machine electrical harnesses connect to the engine electrical harnesses at connector IC23. For details of the engine electrical harness and devices refer to the applicable engine Service Manual.

K Sheet 19 of 19 - JCB Ecomax Engine ( T C-29)(1)

K Sheet 18 of 19 - Heating Ventilation and Air Conditioning (HVAC) Option ( T C-28)

K Sheet 17 of 19 - Heater Only Option, Hydrauilc Raise Cab ( T C-27)

K Sheet 16 of 19 - Options - Arm Limiter, Dual ISO/SAE Controls, Auxiliary Hydraulics, Reversing Fan ( T C-26)

K Sheet 15 of 19 - Hydraulic ECU (HECU) Connector J2 ( T C-25)

K Sheet 14 of 19 - Hydraulic ECU (HECU) Connector J1 ( T C-24)

K Sheet 13 of 19 - CANbus ( T C-23)

K Sheet 12 of 19 - Earth Connections (Cab) ( T C-22)

K Sheet 11 of 19 - Earth Connections (Revolving Frame) ( T C-21)

K Sheet 10 of 19 - DECU J1 and J2, Livelink, Cameras ( T C-20)

K Sheet 9 of 19 - Cab Roof Electrical Components - Wiper, Worklights, Radio Speakers ( T C-19)

K Sheet 8 of 19 - Worklights and Beacon, Operator Seat Electrical Functions ( T C-18)

K Sheet 7 of 19 - Screen Wash and Wipers ( T C-17)

K Sheet 6 of 19 - Machine ECU (MECU) - Connector J2 ( T C-16)

K Sheet 5 of 19 - Machine ECU (MECU) - Connector J1 ( T C-15)

K Sheet 4 of 19 - Secondary Fuses and Power Distribution ( T C-14)

K Sheet 3 of 19 - Ignition, 12 Volt Distribution, Switch Backlighting ( T C-13)

Table 1. Sheets K Sheet 2 of 19 - High Current and Power Distribution - Ecomax Engines ( T C-12)

Schematic Diagrams - Machines with Ecomax Engines

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 14. Sheet 2 of 19 - High Current and Power Distribution - Ecomax Engines

333-K8484-5 Sheet 2.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 15. Sheet 3 of 19 - Ignition, 12 Volt Distribution, Switch Backlighting

333-K8484-5 Sheet 3.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

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C-14

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 16. Sheet 4 of 19 - Secondary Fuses and Power Distribution

333-K8484-5 Sheet 4.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 17. Sheet 5 of 19 - Machine ECU (MECU) - Connector J1

333-K8484-5 Sheet 5.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 18. Sheet 6 of 19 - Machine ECU (MECU) - Connector J2

333-K8484-5 Sheet 6.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 19. Sheet 7 of 19 - Screen Wash and Wipers

333-K8484-5 Sheet 7.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 20. Sheet 8 of 19 - Worklights and Beacon, Operator Seat Electrical Functions

333-K8484-4 Sheet 8.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

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C-19

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 21. Sheet 9 of 19 - Cab Roof Electrical Components - Wiper, Worklights, Radio Speakers

333-K8484-5 Sheet 9.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

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C-20

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 22. Sheet 10 of 19 - DECU J1 and J2, Livelink, Cameras

333-K8484-5 Sheet 10.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

C-20


C-21

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 23. Sheet 11 of 19 - Earth Connections (Revolving Frame)

333-K8484-5 Sheet 11.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

C-21


C-22

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 24. Sheet 12 of 19 - Earth Connections (Cab)

333-K8484-5 Sheet 12.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

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Section C - Electrics Overview and Schematics

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K Sheets ( T C-11) K Component Keys ( T C-30)

Fig 25. Sheet 13 of 19 - CANbus

333-K8484-5 Sheet 13.eps

Schematic Diagrams - Machines with Ecomax Engines

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 26. Sheet 14 of 19 - Hydraulic ECU (HECU) Connector J1

333-K8484-5 Sheet 14.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

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C-25

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 27. Sheet 15 of 19 - Hydraulic ECU (HECU) Connector J2

333-K8484-5 Sheet 15.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 28. Sheet 16 of 19 - Options - Arm Limiter, Dual ISO/SAE Controls, Auxiliary Hydraulics, Reversing Fan

333-K8484-5 Sheet 16.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 29. Sheet 17 of 19 - Heater Only Option, Hydrauilc Raise Cab

333-K8484-5 Sheet 17.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

C-27


C-28

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K Component Keys ( T C-30)

K Sheets ( T C-11)

Fig 30. Sheet 18 of 19 - Heating Ventilation and Air Conditioning (HVAC) Option

333-K8484-5 Sheet 18.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Ecomax Engines

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Section C - Electrics Overview and Schematics

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K Sheets ( T C-11) K Component Keys ( T C-30)

Fig 31. Sheet 19 of 19 - JCB Ecomax Engine

333-K8484-5 Sheet 19.eps

Schematic Diagrams - Machines with Ecomax Engines

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Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Ecomax Engines

Component Keys Connector Code

Device

Connector Code Harness Location

Device

Harness Location

Sheet

Sheet

C026

Motor: Revolver Screenwash Pump Harness

7

C001

ECU: JCB Engine

Revolver Harness

2

C027

Sensor: Air Filter Restriction

Revolver Harness

5

C002

Resistor: CAN Termination

Revolver Harness

13

C028

Sensor: Coolant Level

Revolver Harness

6

C003

Module: JCB Engine Fuse & Relay

Revolver Harness

2

C030

Fusebox: Primary

Revolver Harness

2

C033

Relay: Ignition

Converter: Voltage Revolver 24/12V Harness

2

Revolver Harness

3

C004

C036

Pump: Fuel Lift

Revolver Harness

2

Sensor: Pressure - Revolver Upper Pilot Harness

5

C006

C037

Sensor: Water In Fuel

Revolver Harness

2

Sensor: Pressure Travel Pilot

Revolver Harness

6

C007

C038

Sensor: Engine Oil Revolver Level Harness

6

Solenoid: Cooling Fan Control

Revolver Harness

5

C008

C039

Solenoid: Engine Starter Motor

Revolver Harness

2

Sensor: Pressure - Revolver AC Harness

16

C009

C040

Motor: Starter+

Revolver Harness

2

Solenoid: AC Compressor Clutch

Revolver Harness

16

C010 C012

Switch: Battery Isolator

Revolver Harness

2

C041

Alarm Travel

Revolver Harness

6

C015

ECU: Machine Control (J1)

Cab Harness

5

C042

Alternator: 24V 55A

Revolver Harness

2

C016

ECU: Machine Control (J2)

Cab Harness

6

C045

Solenoid: Pump Control

Revolver Harness

6

C018

Light: Working Revolver RH

Revolver Harness

8

C046

Sensor: Hydraulic Oil Temperature

Revolver Harness

5

C019

Pump: Re-fuelling

Revolver Harness

4

C047

Solenoid: Max Flow

Revolver Harness

6

C020

Switch: ReFuelling Pump

Revolver Harness

3

C048

Solenoid: Travel Speed

Revolver Harness

5

C021

Sensor: Fuel Level Revolver Harness

5

C049

Solenoid: Swing Lock

Revolver Harness

6

C022

Alarm Horn

Revolver Harness

4

C050

Solenoid: Swing Isolate

Revolver Harness

6

C023

Sensor: Boom Overload

Revolver Harness

3

C051

Solenoid: Controls Revolver Enable Harness

6

C024

Diode: Alternator Suppression

Revolver Harness

2

C052

Solenoid: MRV Boost

Revolver Harness

6

C025

Socket: Beacon Main

Revolver Harness

8

C053

Solenoid: Swing Brake

Revolver Harness

5

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Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Ecomax Engines Connector Code

Device

Harness Location

Sheet

Connector Code

Device

Harness Location

Sheet

C054

Solenoid: Cushion Revolver Harness

4

C077

LED: Heater Panel Heater Illumination Harness

17

C055

Light: Working Cab RH

Roof Harness

9

C078

Sensor: Hammer Pilot pressure

Cab Harness

6

C056

Light: Working Cab LH

Roof Harness

9

C079

Sensor: Boom Up

Cab Harness

6

C080

6

C057

Connector: Radio Power

Roof Harness

9

Sensor: Pressure - Cab Harness Swing Pilot

C081

Motor: Wiper Upper

Roof Harness

9

Relay: Ignition (24V Input)

Revolver Harness

3

C058

C082

17

Light: Interior Illumination

Roof Harness

9

Module: Heater Unit

Cab Harness

C059

C085

Joystick: LH Handle

Cab Harness

15

Light: Quickhitch Boom Status

Boom Harness 15

C060

C086

Switch: Lever Lock Cab Harness 1

6

Switch: Seat Ventilation

Cab Harness

C063

C090

C064

Converter: Voltage Revolver 24/12V Harness

2

Sensor: Pressure Pilot Hydraulics

C091

Connector: Vehicle Cab Harness Diagnostic

4

Solenoid: Boom Priority

Revolver Harness

5

C065

C092

8

Connector: Camera Power

10

Element: Heated Seat

Cab Harness

C066

C093

8

Converter: Voltage Cab Harness 24/12V

3

Motor: Seat Ventilation

Cab Harness

C067

C094

Camera: Counterweight

Camera Harness

10

Potentiometer: Cab Harness Throttle Set/Adjust

6

C068

C095

15

Camera: Offside

Camera Harness

10

Joystick: RH Handle

Cab Harness

C069

C097

3

Sensor: Temperature Ambient °C

Boom Harness 6

Switch: Ignition Keyswitch

Cab Harness

C070

C100

Fuse & Relay Module - Cab

Cab Harness

4

C071

Connector: HVAC CAN

Cab Harness

16

C107

Switch: Heated Seat

Cab Harness

8

C072

Connector: Heater Cab Harness / Air Conditioning

16

C109

ECU: Display (J1)

Fascia Harness

10

C073

Socket: Auxiliary IGN 24V (1)

4

C110

ECU: Display (J2)

Fascia Harness

10

C074

Switch: Fan Speed Heater Harness

17

C111

Switch: Radio Mute

Cab Harness

9

C075

Switch: ReCirculation

Heater Harness

17

C113

Switch: Worklights Fascia Std Harness

C076

Potentiometer: Temperature

Heater Harness

17

C-31

Cab Harness

Cab Harness

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8

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Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Ecomax Engines Connector Code

Device

Harness Location

Sheet

Connector Code

Device

Harness Location

Sheet

C114

Switch: Worklights Fascia Cab Harness

8

C142

Switch: Wiper Interlock

Roof Harness

9

C115

Switch: Beacon

Fascia Harness

8

C143

Connector: Radio Speakers

Roof Harness

9

C116

Switch: Main Wipers

Fascia Harness

7

C145

Revolver Harness

2

C117

Switch: Screenwash

Fascia Harness

7

Connector: Primary Fuse Supply

C147

Fascia Harness

7

Fascia Harness

7

Switch: Lower Wiper

Light: Console Illumination

C148

Roof Harness

9

Switch: Engine Stop

Fascia Harness

10

Sensor: Door Open

C149

Fascia Harness

10

Revolver Harness

2

Switch: Swing Lock

Sensor: TMAP Sensor

C150

Cab Harness

8

Switch: Quickhitch Fascia Harness

15

Motor: Seat Suspension

C151

Fascia Harness

6

Fascia Harness

3

Switch: Controls Enable

Socket: Auxiliary 12V (1)

C152

Cab Harness

4

Switch: Module Auto Idle/H+/ Speed

Cab Harness

6

Socket: Auxiliary IGN 24V (2)

C153

ECU: Hydraulic Control ECU (J1)

Cab Harness

14

C124

Light: Worklight Boom LH

Boom Harness 8

C154

ECU: Hydraulic Control ECU (J2)

Cab Harness

15

C125

Light: Worklight Counterweight

Revolver Harness

8

C155

Solenoid: Quickhitch

Revolver Harness

14

C126

Motor: Wiper Lower

Cab Harness

7

C156

Sensor: Pressure - Revolver Quickhitch Harness

15

C127

Diode: Wake-up - Cab Harness Refuel/Door Open

5

C157

Sensor: Alignment Boom Harness 15 - Boom

C128

Switch: Cushion

Fascia Harness

4

C158

Sensor: Alignment Boom Harness 15 - Arm

C129

ECU: Livelink Telematics

Fascia Harness

10

C159

Solenoid: Arm Limiter

Options Harness

16

C130

Connector: USB

Fascia Harness

10

C160

Solenoid: Low Flow ‘A’

Revolver Harness

16

C138

Connector: LH Rear Beacon

Revolver Harness

8

C161

Solenoid: Low Flow ‘B’

Revolver Harness

16

C139

Connector: RH Rear Beacon

Revolver Harness

8

C162

Light: Worklight Boom RH

Boom Harness 8

C140

Speaker: RH

Roof Harness

9

C163

Cab Harness

C141

Speaker: LH

Roof Harness

9

Socket: Auxiliary 12V (2)

C118 C119 C120 C121 C122 C123

C-32

9813/5550-1

3

C-32


Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Ecomax Engines Connector Code

Device

Harness Location

Sheet

Connector Code

Device

Harness Location

Sheet

C225

Switch:Lever Lock 2

6

C226

Switch: Cab Raise (cab)

17

C231

Diode: HRC- Low Flow Priority

17

C240

Solenoid: HRC Low Flow Priority

17

C243

Solenoid: HRC Raise

17

C244

Solenoid: HRC Lower

17

C245

Sensor: Cab lowered and docked

17

C164

Solenoid: Proportional High Flow ‘A’

Cab Harness

16

C165

Solenoid: Proportional High Flow ‘B’

Cab Harness

16

C167

Solenoid: Auxiliary/Hammer Changeover

Revolver Harness

C169

Sensor: Seat Belt / Cab Harness Occupancy

10

C171

Sensor: Pressure Lo Flow Aux

Revolver Harness

16

C172

Sensor: Pressure Hi Flow Aux

Revolver Harness

16

C173

Solenoid: Merge Flow ‘A’

Cab Harness

16

C246

Switch: Cab Raise (revolving chassis)

17

C174

Solenoid: Merge Flow ‘B’

Cab Harness

16

C269

Fuse: Inlet Manifold Heater

2

C175

Solenoid: Low Cab Harness Flow Variable ARV

16

C268

Relay: Inlet Manifold Heater

2

C176

Solenoid: Hi Flow Variable ARV

Cab Harness

16

C270

Inlet Manifold Heater

2

C178

Solenoid: Dual Controls (A)

Options Harness

16

C318

Relay: LiveLink

10

C179

Solenoid: Dual Controls (B)

Options Harness

16

C30-X1

Sensor: Arm Limit Proximity

Arm Harness

16

Revolver Harness

2

C194

Connector: Primary Fuse B+

C42-X1

Antenna: FM Radio

Roof Harness

9

Revolver Harness

2

C195

Alternator: R Terminal

C42-X2

Resistor: CAN Termination

Fascia Harness

13

Revolver Harness

2

C200

Alternator: L Terminal

C214

Switch: Reversing Fan

16

Splice Code

Function

C215

Controller: Reversing Fan

16

C216

Fuse: Reversing Fan

16

C217

Sensor: Low Flow Pilot

16

C218

Sensor: High Flow Pilot

16

C-33

6

Main Wire

Harness Location

Sheet

S001

Splice: Earth Roof

6093 Roof Harness 9

S004

Splice: Forward Worklights

8002 Revolver Harness

8

S006

Splice: 24V B+ MECU

3002 Cab Harness

5

S008

Splice: 24V Ign Wash/Wipe

8100 Cab Harness

7

9813/5550-1

C-33


Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Ecomax Engines Splice Code

Function

Main Wire

Harness Location

Sheet

Splice Code

Function

Main Wire

Harness Location

Sheet

S009

Splice: 0V MECU 4000 Cab Harness - Cab

6

S032

Splice: 24V Ign Cab

1010 Cab Harness

4

S010

Splice: 5V MECU 4005 Cab Harness - Cab

5

S033

Splice: 24V Ign ECU Wake Up

1006 Cab Harness

3

S011

Splice: 24V Ign Wash/Wipe

8100 Cab Harness

7

S034

Splice: Cab Worklights

8004 Roof Harness 9

S012

Splice: Backlighting Fascia

1009 Fascia Harness

3

S035

Splice: Earth - Hi- 6091 Cab Harness Current

12

S039

3

Splice: Screenwash Pump

8008 Cab Harness

7

Splice: Backlighting Cab

1009 Cab Harness

S014

S041

3007 Cab Harness

3

S016

Splice: 24V Ign Revolver

1001 Revolver Harness

3

Splice: 24V B+ Re-Fuelling/Ign Switch

S042

Splice: Crank

4023 Cab Harness

3

S017

Splice: Dual Controls

8093 Options Harness

16

S053

Splice: Worklights 8002 Fascia Standard Harness

8

S019

Splice: Earth Revolver 2

6020 Revolver Harness

11

S056

Splice: Worklights 8002 Cab Harness Standard

8

S020

Splice: Earth Revolver 3

6033 Revolver Harness

11

S057

Splice: Lightning - 8005 Cab Harness Interior

5

S021

Splice: Earth JCB Engine

6054 Revolver Harness

11

S060

Splice: 24V B+ HECU

14

S022

Splice: Earth Options Harness

6200 Options Harness

17

S062

Splice: Worklights 8002 Boom - Boom B Harness

8

S023

Splice: 12V B+ Fused

3009 Revolver Harness

2

S063

Splice: Earth MECU

6153 Cab Harness

14

S024

Splice: 12V Ign Fused

1008 Fascia Harness

3

S070

Splice: 0V HECU Revolver

4110 Aux Hydraulic 16 Harness

S025

Splice: 24V Ign Engine Stop

1012 Cab Harness

10

S026

Splice: Earth Fascia

6075 Fascia Harness

12

S027

Splice: Camera Power +

1023 Camera Harness

10

S028

Splice: Camera Power -

6110 Camera Harness

10

S029

Splice: Earth Heater Only

6092 Heater Harness

17

S030

Splice: 24V Ign Fascia

1006 Fascia Harness

10

S031

Splice: 12V Heater Only

1008 Heater Harness

17

C-34

9813/5550-1

3012 Cab Harness

C-34


C-35 Table 2. Sheets

9813/5550-1

K Component Keys ( T C-54)

K Sheet 19 of 19 - JCB Dieselmax - Engine Side ( T C-53)

K Sheet 18 of 19 - HVAC System - ATC Option ( T C-52)

K Sheet 17 of 19 Heater Only Builds, Reversing Fan ( T C-51)

K Sheet 16 of 19 - Options - Arm Limiter, Dual ISO/SAE Controls, Auxiliary Hydraulics, Hyd Raise Cab ( T C-50)

K Sheet 15 of 19 - Hydraulic ECU (HECU) Connector J2 ( T C-49)

K Sheet 14 of 19 - Hydraulic ECU (HECU) Connector J1 ( T C-48)

K Sheet 13 of 19 - CANbus Network ( T C-47)

K Sheet 12 of 19 - Cab Earthing ( T C-46)

K Sheet 11 of 19 - Revolver Earthing ( T C-45)

K Sheet 10 of 19 - Display, Livelink, Camera System ( T C-44)

K Sheet 9 of 19 - Cab Roof - Worklights/Wiper/Radio ( T C-43)

K Sheet 8 of 19 - Worklights/Beacon, Seats ( T C-42)

K Sheet 7 of 19 - Screen Wash/Wipers ( T C-41)

K Sheet 6 of 19 - Machine ECU (MECU) Connection J2 ( T C-40)

K Sheet 5 of 19 - Machine ECU (MECU) Connection J1 ( T C-39)

K Sheet 4 of 19 - Secondary Fusing/Power Distribution ( T C-38)

K Sheet 3 of 19 - Key Switch/Ignition Relay,12V, Backlighting ( T C-37)

K Sheet 2 of 19 - Hi-Current and Power Distribution ( T C-36)

Schematic Diagrams - Machines with Dieselmax Engines

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-35


C-36

9813/5550-1

K Component Keys ( T C-54)

K Sheets ( T C-35)

Fig 32. Sheet 2 of 19 - Hi-Current and Power Distribution

333-K8485-4_Sheet2.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-36


C-37

9813/5550-1

K Component Keys ( T C-54)

K Sheets ( T C-35)

Fig 33. Sheet 3 of 19 - Key Switch/Ignition Relay,12V, Backlighting

333-K8485-4_Sheet3.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-37


C-38

9813/5550-1

K Component Keys ( T C-54)

K Sheets ( T C-35)

Fig 34. Sheet 4 of 19 - Secondary Fusing/Power Distribution

333-K8485-4_Sheet4.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-38


C-39

9813/5550-1

K Component Keys ( T C-54)

K Sheets ( T C-35)

Fig 35. Sheet 5 of 19 - Machine ECU (MECU) Connection J1

333-K8485-4_Sheet5.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-39


C-40

9813/5550-1

K Component Keys ( T C-54)

K Sheets ( T C-35)

Fig 36. Sheet 6 of 19 - Machine ECU (MECU) Connection J2

333-K8485-4_Sheet6.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-40


Section C - Electrics Overview and Schematics

C-41

9813/5550-1

K Sheets ( T C-35) K Component Keys ( T C-54)

Fig 37. Sheet 7 of 19 - Screen Wash/Wipers

333-K8485-4_Sheet7.eps

Schematic Diagrams - Machines with Dieselmax Engines

C-41


Section C - Electrics Overview and Schematics

C-42

9813/5550-1

K Sheets ( T C-35) K Component Keys ( T C-54)

Fig 38. Sheet 8 of 19 - Worklights/Beacon, Seats

333-K8485-4_Sheet8.eps

Schematic Diagrams - Machines with Dieselmax Engines

C-42


C-43

9813/5550-1

K Component Keys ( T C-54)

K Sheets ( T C-35)

Fig 39. Sheet 9 of 19 - Cab Roof - Worklights/Wiper/Radio

333-K8485-4_Sheet9.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-43


C-44

9813/5550-1

K Component Keys ( T C-54)

K Sheets ( T C-35)

Fig 40. Sheet 10 of 19 - Display, Livelink, Camera System

333-K8485-4_Sheet10.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-44


Section C - Electrics Overview and Schematics

C-45

9813/5550-1

K Sheets ( T C-35) K Component Keys ( T C-54)

Fig 41. Sheet 11 of 19 - Revolver Earthing

333-K8485-4_Sheet11.eps

Schematic Diagrams - Machines with Dieselmax Engines

C-45


Section C - Electrics Overview and Schematics

C-46

9813/5550-1

K Sheets ( T C-35) K Component Keys ( T C-54)

Fig 42. Sheet 12 of 19 - Cab Earthing

333-K8485-4_Sheet12.eps

Schematic Diagrams - Machines with Dieselmax Engines

C-46


Section C - Electrics Overview and Schematics

C-47

9813/5550-1

K Sheets ( T C-35) K Component Keys ( T C-54)

Fig 43. Sheet 13 of 19 - CANbus Network

333-K8485-4_Sheet13.eps

Schematic Diagrams - Machines with Dieselmax Engines

C-47


C-48

9813/5550-1

K Component Keys ( T C-54)

K Sheets ( T C-35)

Fig 44. Sheet 14 of 19 - Hydraulic ECU (HECU) Connector J1

333-K8485-4_Sheet14.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-48


C-49

9813/5550-1

K Component Keys ( T C-54)

K Sheets ( T C-35)

Fig 45. Sheet 15 of 19 - Hydraulic ECU (HECU) Connector J2

333-K8485-4_Sheet15.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-49


C-50

9813/5550-1

K Component Keys ( T C-54)

K Sheets ( T C-35)

Fig 46. Sheet 16 of 19 - Options - Arm Limiter, Dual ISO/SAE Controls, Auxiliary Hydraulics, Hyd Raise Cab

333-K8485-4_Sheet16.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-50


C-51

9813/5550-1

K Component Keys ( T C-54)

K Sheets ( T C-35)

Fig 47. Sheet 17 of 19 Heater Only Builds, Reversing Fan

333-K8485-4_Sheet17.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-51


C-52

9813/5550-1

K Component Keys ( T C-54)

K Sheets ( T C-35)

Fig 48. Sheet 18 of 19 - HVAC System - ATC Option

333-K8485-4_Sheet18.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-52


C-53

9813/5550-1

K Component Keys ( T C-54)

K Sheets ( T C-35)

Fig 49. Sheet 19 of 19 - JCB Dieselmax - Engine Side

333-K8485-4_Sheet19.eps

Section C - Electrics

Overview and Schematics

Schematic Diagrams - Machines with Dieselmax Engines

C-53


Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Dieselmax Engines

Component Keys Connector Code

Device

Connector Code Harness Location

Device

Harness Location

Sheet

Sheet

C026

Motor: Revolver Screenwash Pump Harness

7

C001

ECU: JCB Engine

Revolver Harness

2

C027

Sensor: Air Filter Restriction

Revolver Harness

5

C002

Resistor: CAN Termination

Revolver Harness

13

C028

Sensor: Coolant Level

Revolver Harness

6

C003

Module: JCB Engine Fuse & Relay

Revolver Harness

2

C030

Fusebox: Primary

Revolver Harness

2

C033

Relay: Ignition

Converter: Voltage Revolver 24/12V Harness

2

Revolver Harness

3

C004

C036

Pump: Fuel Lift

Revolver Harness

2

Sensor: Pressure - Revolver Upper Pilot Harness

5

C006

C037

Sensor: Water In Fuel

Revolver Harness

2

Sensor: Pressure Travel Pilot

Revolver Harness

6

C007

C038

Sensor: Engine Oil Revolver Level Harness

6

Solenoid: Cooling Fan Control

Revolver Harness

5

C008

C039

Solenoid: Engine Starter Motor

Revolver Harness

2

Sensor: Pressure - Revolver AC Harness

16

C009

C040

Motor: Starter+

Revolver Harness

2

Solenoid: AC Compressor Clutch

Revolver Harness

16

C010 C012

Switch: Battery Isolator

Revolver Harness

2

C041

Alarm Travel

Revolver Harness

6

C015

ECU: Machine Control (J1)

Cab Harness

5

C042

Alternator: 24V 55A

Revolver Harness

2

C016

ECU: Machine Control (J2)

Cab Harness

6

C045

Solenoid: Pump Control

Revolver Harness

6

C018

Light: Working Revolver RH

Revolver Harness

8

C046

Sensor: Hydraulic Oil Temperature

Revolver Harness

5

C019

Pump: Re-fuelling

Revolver Harness

4

C047

Solenoid: Max Flow

Revolver Harness

6

C020

Switch: ReFuelling Pump

Revolver Harness

3

C048

Solenoid: Travel Speed

Revolver Harness

5

C021

Sensor: Fuel Level Revolver Harness

5

C049

Solenoid: Swing Lock

Revolver Harness

6

C022

Alarm Horn

Revolver Harness

4

C050

Solenoid: Swing Isolate

Revolver Harness

6

C023

Sensor: Boom Overload

Revolver Harness

3

C051

Solenoid: Controls Revolver Enable Harness

6

C024

Diode: Alternator Suppression

Revolver Harness

2

C052

Solenoid: MRV Boost

Revolver Harness

6

C025

Socket: Beacon Main

Revolver Harness

8

C053

Solenoid: Swing Brake

Revolver Harness

5

C-54

9813/5550-1

C-54


Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Dieselmax Engines Connector Code

Device

Harness Location

Sheet

Connector Code

Device

Harness Location

Sheet

C054

Solenoid: Cushion Revolver Harness

4

C077

LED: Heater Panel Heater Illumination Harness

17

C055

Light: Working Cab RH

Roof Harness

9

C078

Sensor: Hammer Pilot pressure

Cab Harness

6

C056

Light: Working Cab LH

Roof Harness

9

C079

Sensor: Boom Up

Cab Harness

6

C080

6

C057

Connector: Radio Power

Roof Harness

9

Sensor: Pressure - Cab Harness Swing Pilot

C081

Motor: Wiper Upper

Roof Harness

9

Relay: Ignition (24V Input)

Revolver Harness

3

C058

C082

17

Light: Interior Illumination

Roof Harness

9

Module: Heater Unit

Cab Harness

C059

C085

Joystick: LH Handle

Cab Harness

15

Light: Quickhitch Boom Status

Boom Harness 15

C060

C086

Switch: Lever Lock Cab Harness 1

6

Switch: Seat Ventilation

Cab Harness

C063

C090

C064

Converter: Voltage Revolver 24/12V Harness

2

Sensor: Pressure Pilot Hydraulics

C091

Connector: Vehicle Cab Harness Diagnostic

4

Solenoid: Boom Priority

Revolver Harness

5

C065

C092

8

Connector: Camera Power

10

Element: Heated Seat

Cab Harness

C066

C093

8

Converter: Voltage Cab Harness 24/12V

3

Motor: Seat Ventilation

Cab Harness

C067

C094

Camera: Counterweight

Camera Harness

10

Potentiometer: Cab Harness Throttle Set/Adjust

6

C068

C095

15

Camera: Offside

Camera Harness

10

Joystick: RH Handle

Cab Harness

C069

C097

3

Sensor: Temperature Ambient °C

Boom Harness 6

Switch: Ignition Keyswitch

Cab Harness

C070

C100

Fuse & Relay Module - Cab

Cab Harness

4

C071

Connector: HVAC CAN

Cab Harness

16

C107

Switch: Heated Seat

Cab Harness

8

C072

Connector: Heater Cab Harness / Air Conditioning

16

C109

ECU: Display (J1)

Fascia Harness

10

C073

Socket: Auxiliary IGN 24V (1)

4

C110

ECU: Display (J2)

Fascia Harness

10

C074

Switch: Fan Speed Heater Harness

17

C111

Switch: Radio Mute

Cab Harness

9

C075

Switch: ReCirculation

Heater Harness

17

C113

Switch: Worklights Fascia Std Harness

C076

Potentiometer: Temperature

Heater Harness

17

C-55

Cab Harness

Cab Harness

9813/5550-1

8 19

8

C-55


Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Dieselmax Engines Connector Code

Device

Harness Location

Sheet

Connector Code

Device

Harness Location

Sheet

C114

Switch: Worklights Fascia Cab Harness

8

C142

Switch: Wiper Interlock

Roof Harness

9

C115

Switch: Beacon

Fascia Harness

8

C143

Connector: Radio Speakers

Roof Harness

9

C116

Switch: Main Wipers

Fascia Harness

7

C145

Revolver Harness

2

C117

Switch: Screenwash

Fascia Harness

7

Connector: Primary Fuse Supply

C147

Fascia Harness

7

Fascia Harness

7

Switch: Lower Wiper

Light: Console Illumination

C148

Roof Harness

9

Switch: Engine Stop

Fascia Harness

10

Sensor: Door Open

C149

Fascia Harness

10

Revolver Harness

2

Switch: Swing Lock

Sensor: TMAP Sensor

C150

Cab Harness

8

Switch: Quickhitch Fascia Harness

15

Motor: Seat Suspension

C151

Fascia Harness

6

Fascia Harness

3

Switch: Controls Enable

Socket: Auxiliary 12V (1)

C152

Cab Harness

4

Switch: Module Auto Idle/H+/ Speed

Cab Harness

6

Socket: Auxiliary IGN 24V (2)

C153

ECU: Hydraulic Control ECU (J1)

Cab Harness

14

C124

Light: Worklight Boom LH

Boom Harness 8

C154

ECU: Hydraulic Control ECU (J2)

Cab Harness

15

C125

Light: Worklight Counterweight

Revolver Harness

8

C155

Solenoid: Quickhitch

Revolver Harness

14

C126

Motor: Wiper Lower

Cab Harness

7

C156

Sensor: Pressure - Revolver Quickhitch Harness

15

C127

Diode: Wake-up - Cab Harness Refuel/Door Open

5

C157

Sensor: Alignment Boom Harness 15 - Boom

C128

Switch: Cushion

Fascia Harness

4

C158

Sensor: Alignment Boom Harness 15 - Arm

C129

ECU: Livelink Telematics

Fascia Harness

10

C159

Solenoid: Arm Limiter

Options Harness

16

C130

Connector: USB

Fascia Harness

10

C160

Solenoid: Low Flow ‘A’

Revolver Harness

15

C138

Connector: LH Rear Beacon

Revolver Harness

8

C161

Solenoid: Low Flow ‘B’

Revolver Harness

15

C139

Connector: RH Rear Beacon

Revolver Harness

8

C162

Light: Worklight Boom RH

Boom Harness 8

C140

Speaker: RH

Roof Harness

9

C163

Cab Harness

C141

Speaker: LH

Roof Harness

9

Socket: Auxiliary 12V (2)

C118 C119 C120 C121 C122 C123

C-56

9813/5550-1

3

C-56


Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Dieselmax Engines Connector Code

Device

Harness Location

Sheet

Connector Code C225

Switch:Lever Lock 2

6

C226

Switch: HRC - Cab Raise (cab)

16

C231

Diode: HRC - Low Flow Priority

16

C240

Solenoid: HRC low flow priority

16

C243

Solenoid: HRC Cab Raise

16

C244

Solenoid: HRC Cab Lower

16

C245

Sensor: Cab lowered and docked

16

C246

Switch: HRC - Cab Raise (revolving chassis)

16

C318

Relay: LiveLink

10

C30-X1

Connector: Primary Fuse B+

Revolver Harness

2

C42-X1

Alternator: R Terminal

Revolver Harness

2

C42-X2

Alternator: L Terminal

Revolver Harness

2

Function

C164

Solenoid: Proportional High Flow ‘A’

Cab Harness

14

C165

Solenoid: Proportional High Flow ‘B’

Cab Harness

14

C166

Potentiometer: Aux Hyds (High Flow)

Cab Harness

15

C167

Solenoid: Auxiliary/Hammer Changeover

Revolver Harness

14

Device

Harness Location

Sheet

C169

Sensor: Seat Belt / Cab Harness Occupancy

10

C171

Sensor: Pressure Lo Flow Aux

Revolver Harness

16

C172

Sensor: Pressure Hi Flow Aux

Revolver Harness

16

C173

Solenoid: Merge Flow ‘A’

Cab Harness

16

C174

Solenoid: Merge Flow ‘B’

Cab Harness

16

C175

Solenoid: Low Cab Harness Flow Variable ARV

16

C176

Solenoid: Hi Flow Variable ARV

Cab Harness

16

C178

Solenoid: Dual Controls (A)

Options Harness

16

C179

Solenoid: Dual Controls (B)

Options Harness

16

Splice Code

C194

Sensor: Arm Limit Proximity

Arm Harness

16

S001

Splice: Earth Roof

6093 Roof Harness 9

C195

Antenna: FM Radio

Roof Harness

9

S004

Splice: Forward Worklights

8002 Revolver Harness

8

C200

Resistor: CAN Termination

Fascia Harness

13

S006

Splice: 24V B+ MECU

3002 Cab Harness

5

C216

Fuse: Reversing Fan

17

S008

Splice: 24V Ign Wash/Wipe

8100 Cab Harness

7

C214

Switch: Reversing Fan

17

S009

Splice: 0V MECU 4000 Cab Harness - Cab

6

C215

Controller: Reversing Fan

17

S010

Splice: 5V MECU 4005 Cab Harness - Cab

5

C-57

9813/5550-1

Main Wire

Harness Location

Sheet

C-57


Section C - Electrics Overview and Schematics Schematic Diagrams - Machines with Dieselmax Engines Splice Code

Function

Main Wire

Harness Location

Sheet

Splice Code

Function

Main Wire

Harness Location

Sheet

S011

Splice: 24V Ign Wash/Wipe

8100 Cab Harness

7

S034

Splice: Cab Worklights

S012

Splice: Backlighting Fascia

1009 Fascia Harness

3

S035

Splice: Earth - Hi- 6091 Cab Harness Current

12

S039

3

Splice: Screenwash Pump

8008 Cab Harness

7

Splice: Backlighting Cab

1009 Cab Harness

S014

S041

3007 Cab Harness

3

S016

Splice: 24V Ign Revolver

1001 Revolver Harness

3

Splice: 24V B+ Re-Fuelling/Ign Switch

S042

Splice: Crank

4023 Cab Harness

3

S017

Splice: Dual Controls

8093 Options Harness

16

S053

Splice: Worklights 8002 Fascia Standard Harness

8

S019

Splice: Earth Revolver 2

6020 Revolver Harness

11

S056

Splice: Worklights 8002 Cab Harness Standard

8

S020

Splice: Earth Revolver 3

6033 Revolver Harness

11

S057

Splice: Lightning - 8005 Cab Harness Interior

5

S021

Splice: Earth JCB Engine

6054 Revolver Harness

11

S060

Splice: 24V B+ HECU

14

S022

Splice: Earth Options Harness

6200 Options Harness

17

S062

Splice: Worklights 8002 Boom - Boom B Harness

8

S023

Splice: 12V B+ Fused

3009 Revolver Harness

2

S063

Splice: Earth MECU

6153 Cab Harness

14

S024

Splice: 12V Ign Fused

1008 Fascia Harness

3

S070

Splice: 0V HECU Revolver

4110 Aux Hydraulic 16 Harness

S025

Splice: 24V Ign Engine Stop

1012 Cab Harness

10

S026

Splice: Earth Fascia

6075 Fascia Harness

12

S027

Splice: Camera Power +

1023 Camera Harness

10

S028

Splice: Camera Power -

6110 Camera Harness

10

S029

Splice: Earth Heater Only

6092 Heater Harness

17

S030

Splice: 24V Ign Fascia

1006 Fascia Harness

10

S031

Splice: 12V Heater Only

1008 Heater Harness

17

S032

Splice: 24V Ign Cab

1010 Cab Harness

4

S033

Splice: 24V Ign ECU Wake Up

1006 Cab Harness

3

C-58

9813/5550-1

8004 Roof Harness 9

3012 Cab Harness

C-58


Section C - Electrics

Battery Maintenance To ensure that the battery provides optimum performance the following steps should be observed: 1

Make sure that the electrical connections are clean and tight. Smear petroleum jelly on connectors to prevent corrosion.

2

When applicable - never allow the electrolyte level to fall below the recommended level - 6 mm (1/4 in) above the plates. Use only distilled water for topping up.

3

Keep the battery at least three quarters charged, otherwise the plates may become sulphated (hardened) - this condition makes recharging the battery very difficult.

– Never boost-charge a maintenance free battery. – Never charge a maintenance free battery at a voltage in excess of 15.8 Volts. – Never continue to charge a maintenance free battery after it begins to gas.

Extra precautions must be taken when bench charging maintenance free batteries, they are more prone to damage by overcharging than the standard type of battery:

!MWARNING Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames. Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear personal protective equipment (PPE). Handle the battery carefully to prevent spillage. Keep metallic items (watches, rings, zips etc) away from the battery terminals. Such items could short the terminals and burn you. Set all switches to OFF before disconnecting and connecting the battery. When disconnecting the battery, take off the earth (-) lead first. Re-charge the battery away from the machine, in a well ventilated area. Switch the charging circuit off before connecting or disconnecting the battery. When you have installed the battery in the machine, wait five minutes before connecting it up. When reconnecting, fit the positive (+) lead first. 5-3-4-12_2

C-59

9813/5550-1

C-59


Section C - Electrics Battery Test Procedures

Test Procedures High Rate Discharge Test

Note: Do not hold the switch in the LOAD position for more than 10 seconds.

This test is to determine the electrical condition of the battery and to give an indication of the remaining useful `life'. Before testing ensure that the battery is at least 75% charged (SG of 1.23 to 1.25 for ambient temperature up to 27°C).

Check the results against the table: Table 1. Tester Readings and Remedies Battery Tester Readings Remedy CHECK: 0 - 12.6 volts

Ensure that the battery is completely disconnected from the machine.

Renew battery

LOAD: Less than 6 volts CHECK: 6 - 12.4 volts

Recharge and re-test. If LOAD: less than 9 Volts and tests still unsatisfactory falls steadily but remains in renew battery. yellow zone. CHECK: less than 10 volts LOAD: Less than 3 volts

Indicates battery has been over-discharged and unlikely to recover. Renew battery.

CHECK: more than 11 volts Charge battery which will probably recover. LOAD: 6 - 10 volts

C096270

Fig 1. Battery Tester Check: 1

Connect the battery tester to the battery. Ensure that the positive terminal is connected first.

2

Use rocker switch A to select the correct battery voltage.

3

Hold switch B to the ‘Check’ position. The battery noload voltage should be at least 12.4 volts.

Test: 1

Hold down switch B to the ‘Load’ position for 5-10 seconds until the meter reading stabilises. The reading should be at least 9 volts.

C-60

9813/5550-1

C-60


Section C - Electrics Battery Test Procedures

Specific Gravity Testing The specific gravity of the electrolyte gives an idea 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 on charge, wait approximately one hour (or slightly discharge the battery) to dissipate the surface charge before testing.

Readings should be as tabulated and should not vary between cells by more than 0.04. A greater variation indicates an internal fault on that particular cell. If the electrolyte temperature is other than 15°C (60°F) a 'correction factor' must be applied to the reading obtained. Add 0.07 per 10°C (18°F) if the temperature is higher than 15°C (60°F) and subtract the same if the temperature is lower.

Table 2. Specific Gravity at 15°C (60°F) Fully Charged Half Discharged

Fully Discharged

Ambient temperature up to 27°C (80°F)

1.270 - 1.290

1.190 - 1.210

1.110 - 1.130

Ambient temperature above 27°C (80°F)

1.240 - 1.260

1.170 - 1.190

1.090 - 1.110

C-61

9813/5550-1

C-61


Section C - Electrics Battery Disconnection and Connection

Disconnection and Connection

Battery Disconnection/Connection

!MWARNING

T3-019_2

Keep metal watch straps and any metal fasteners on your clothes, clear of the positive (+) battery terminal. Such items can short between the terminal and nearby metal work. If it happens you can get burned. 5-2-2-4

Disconnection 1

Open the battery compartment. See Battery Cover.

2

Remove the leads. Disconnect the earth (-) terminal first.

Connection 1

Check the battery. a

If the terminal is dirty, clean the post.

Fig 2. b If the terminal post is corroded and generates white powder wash the terminal with hot water. If considerable corrosion is detected, clean with a wire brush or abrasive paper. c

After cleaning, apply a thin coat of petroleum jelly to the terminal.

2

Re-connect the leads. Connect the earth (-) terminal last.

3

Close and lock the battery compartment.

C-62

9813/5550-1

C-62


Section C - Electrics

Fuses and Relays Introduction

!MCAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5

For details of the machine fuses and relays refer to Section 2, Technical Data.

C-63

9813/5550-1

C-63


Section C - Electrics Fuses and Relays Cab Fuse and Relay Box - Connector Identification

Cab Fuse and Relay Box - Connector Identification ST2 ST3

C100 - X1

C100 - X3 10 7 4 1 11 8 5 2 12 9 6 3

1 3 5 7 2 4 6 8

C100 - X4

C100 - X2

16 13 10 7 4 1 17 14 11 8 5 2 18 15 12 9 6 3

7 4 1 8 5 2 9 6 3

C129520.eps

Fig 1.

C-64

9813/5550-1

C-64


C-65

9813/5550-1

Cab harness

Facia harness

Revolving chassis harness

Boom harness

Hydraulic ECU (HECU) (cab)

Machine ECU (MECU) (cab)

Printed Circuit Board (PCB) mounted fuses and relays (cab)

Voltage converter (cab)

Engine ECU connector

Engine fuse and relay box (engine compartment)

Voltage converter (engine compartment)

Multi function display connector (cab)

Throttle controller (cab)

Batteries

1

2

3

4

5

6

7

8

9

10

11

12

13

14

The harness and interconnect numbers refer to and correspond with the annotations in the drawing. K Fig 2. ( T C-66)

Description

Item

The illustration shows a representation of the basic routing of the main machine harnesses. Some of the main electrical components are also shown to give an indication of harness positioning within the machine structure. K Fig 2. ( T C-66)

Installation and Interconnections

Harness Systems

Section C - Electrics Harness Systems

Installation and Interconnections

C-65


C-66

IC08

IC03

IC01

IC10

IC07

IC22

4

9813/5550-1

2

12

Fig 2. Harness and Interconnector Locations

3

13

IC04

5

6

1

9

7

IC23

14

8

11

10

C132350

Section C - Electrics Harness Systems

Installation and Interconnections

C-66


C-67

1 - Cab

Harness

IC08

IC03

IC22

IC10

IC01

IC07 IC03 IC07 IC12 IC15

Cab Roof Option Harness Auxiliary Hydraulics Harness

IC01

3 - Revolving Chassis 3 - Revolving Chassis

IC08

IC10

2 - Facia

IC22

2 - Facia 2 - Facia

RH rear corner of cab structure above HVAC unit

RH rear corner of cab structure above HVAC unit

RH rear corner of cab structure above HVAC unit

Inside cab to rear of RH facia

Inside cab to rear of RH facia

Inside cab to rear of RH facia

Table 1. Harness Interconnections Connecting Interconnect Location Harness

K Table 5. ( T C-69)

K Table 8. ( T C-69)

K Table 3. ( T C-69)

K Table 6. ( T C-69)

K Table 4. ( T C-69)

K Table 8. ( T C-69)

Connector Pins

Section C - Electrics Harness Systems

Installation and Interconnections

9813/5550-1

C-67


C-68 IC23

Engine

IC23

IC04

4 - Boom

3 - Revolving Chassis Above engine rocker cover

Interconnect Location

Connecting Harness

Harness

K Table 2. ( T C-69)

K Table 7. ( T C-69)

Connector Pins

Section C - Electrics Harness Systems

Installation and Interconnections

9813/5550-1

C-68


C-69

K

C

N

H

A

J

B

D

P

J

B

D

P

A

H

E

K

C

N

G

F

L

M

9813/5550-1

Bulkhead connectors.

Details

Table 3. Harness interconnectors IC01 Connector Pins

L

M

G

F

E

Bulkhead connectors with threaded coupling ring.

Table 2. Harness interconnectors IC23 Connector Pins Details

6 7 8 9 10

6

5 4 3 2 1

20 19 18 17 16 15 14 13 12 11

10 9 8 7

In - line connectors.

Details

5

11 12 13 14 15 16 17 18 19 20

1 2 3 4

Table 5. Harness interconnectors IC07 Connector Pins

In - line connectors.

Details

Table 4. Harness interconnectors IC10 Connector Pins

2

In - line connectors.

Table 8. Harness interconnectors IC22, IC03 Connector Pins Details

3

1

3

2

4

4 1

In - line connectors.

Table 7. Harness interconnectors IC04 Connector Pins Details

In - line connectors.

Table 6. Harness interconnectors IC08 Connector Pins Details

Section C - Electrics Harness Systems

Installation and Interconnections

C-69


C-70

9813/5550-1

Earth strap cab

ES01

Earth cable, battery

Earths, cab harness

EP07 EP08

Earth strap cab to revolving chassis

Earths, engine

EP04

EC01

Earths, revolving chassis harness

EP03

ES02

Description

Item

K Fig 3. Earth Points ( T C-71)

Inside battery compartment on the revolving chassis to the rear of the washer fluid bottle

Under the cab below ES01

Inside cab on the floor to the rear of the LH facia and adjacent to the HVAC unit

Inside cab on the floor to the rear of the LH facia and adjacent to the HVAC unit

Inside engine compartment below engine ECU

Inside battery compartment below primary fuses

Access

The illustration shows the machine electrical earth point locations. This can be useful when tracing

Earth Points

EP07 EP08

ES01

electrical faults, typically when several electrical devices are malfunctioning.

Section C - Electrics Harness Systems Earth Points

C-70


Section C - Electrics Harness Systems

EP07

ES01

Fig 3. Earth Points

ES02

EP04

EP03 EC01

C128220

Earth Points

C-71

9813/5550-1

C-71


Section C - Electrics Harness Systems Harness Drawing List, JS200 - JS235

Harness Drawing List, JS200 - JS235 Drawings are reproduced from production electrical harness drawings. Each harness drawing includes tables showing wire connections and destinations for all the connectors on the harness.

Harness No. 1

The harness number refers to and corresponds with the annotations in the drawing. K Fig 2. ( T C-66) Refer to the table for the connector code key. K Connector Codes ( T C-130)

Issue Remarks

Drawing

Cab 333/K8486

3

To April 2014

K Fig 4. ( T C-75)

334/J4255

1

May 2014 On

K Fig 10. ( T C-81)

333/K5337

1

High Rise Cab (HRC) variant To april 2014

K Fig 16. ( T C-87)

Main components connected to this harness:

Printed Circuit Board (PCB) mounted fuses and relays LH joystick RH joystick Heating Ventilation and Air Conditioning (HVAC) unit Machine ECU (MECU) Hydraulic ECU (HECU) Hydraulic control valve solenoids Throttle control unit Ignition switch

2

Facia 333/K8487

2

To April 2014

K Fig 22. ( T C-93)

333/K9798

1

May 2014 On

K Fig 24. ( T C-95)

Main components connected to this harness:

Facia switches Multi function display CANbus termination resistor Livelink ECU (if fitted)

3

Revolving Chassis 333/K8491

1

Machines with Dieselmax Engines, to Dec 2013 K Fig 26. ( T C-97)

333/K8818

1

Machines with Dieselmax Engines, Jan 2014 on K Fig 32. ( T C-103)

333/K8490

2

Machines with Ecomax Engines, to Dec 2013

K Fig 38. ( T C-109)

333/K8813

1

Machines with Ecomax Engines, Jan 2014 on

K Fig 44. ( T C-115)

Main components connected to this harness:

Gearbox control solenoids Hydraulic control valve solenoids Alternator TMAF sensor Engine cooling fan Starter motor Engine oil level switch AC compressor clutch Engine fuses and relays module

C-72

9813/5550-1

C-72


Section C - Electrics Harness Systems Harness Drawing List, JS200 - JS235 Voltage converter Primary fuses Engine ECU CANbus termination resistor Fuel lift pump Water In Fuel (WIF) sensor Auxiliary Hydraulics 333/K6657 4

Low flow / Super High Flow (SHF)

Boom 333/K0181

1

Main components connected to this harness:

Boom work lights Ambient temperature sensor

Cab Roof 333/K0017

K Fig 50. ( T C-121)

1

Main components connected to this harness:

Radio speakers Interior lights Door and window switches Cab work lights

Heater Harness 333/K3883

Heater unit (machines without air conditioning) K Fig 52. ( T C-123)

1

Heater controls Heating, Ventilation and Air Conditioning (HVAC)

Refer to Section B

Camera Harness 333/K4284

1

Dual camera system

K Fig 53. ( T C-124)

333/K4283

1

Single camera system

K Fig 54. ( T C-125)

Auxiliary Hi/Lo Flow Hydraulics 333/K4639

K Fig 55. ( T C-126)

1

HRC Harness 334/J2060

1

Main components connected to this harness:

May 2014 On Switch: Cab raise - Chassis Solenoid: HRC lower Solenoid: HRC raise Diode: HRC low flow priority Solenoid: HRC low flow priority

C-73

9813/5550-1

C-73


Section C - Electrics Harness Systems Drawings

Drawings Drawings are reproduced from production electrical harness drawings. Each harness drawing includes tables showing wire connections and destinations for all the connectors on the harness. To identify the correct harness drawing for a particular machine refer to the relevant Harness Drawings table.

C-74

9813/5550-1

C-74


333/K8486 Issue 3

Fig 4. 333-K8486-3 Sheet 1

333-K8486-2_Sheet1.eps

Section C - Electrics Harness Systems Drawings

C-75

9813/5550-1

C-75


Section C - Electrics Harness Systems

Fig 5. 333-K8486-3 Sheet 2

333-K8486-3_Sheet2.eps

Drawings

C-76

9813/5550-1

C-76


Section C - Electrics Harness Systems

Fig 6. 333-K8486-3 Sheet 3

333-K8486-3_Sheet3.eps

Drawings

C-77

9813/5550-1

C-77


Section C - Electrics Harness Systems

Fig 7. 333-K8486-3 Sheet 4

333-K8486-3_Sheet4.eps

Drawings

C-78

9813/5550-1

C-78


Section C - Electrics Harness Systems

Fig 8. 333-K8486-3 Sheet 5

333-K8486-3_Sheet5.eps

Drawings

C-79

9813/5550-1

C-79


Section C - Electrics Harness Systems

Fig 9. 333-K8486-3 Sheet 6

333-K8486-3_Sheet6.eps

Drawings

C-80

9813/5550-1

C-80


Section C - Electrics Harness Systems

334/J4255 Issue 1

Fig 10. 334-J4255-1 Sheet 1

334-J4255-1_sheet1

Drawings

C-81

9813/5550-1

C-81


Section C - Electrics Harness Systems

Fig 11. 334-J4255-1 Sheet 2

334-4255-1_Sheet2.eps

Drawings

C-82

9813/5550-1

C-82


Section C - Electrics Harness Systems

Fig 12. 334-J4255-1 Sheet 3

334-J4255-1_Sheet3.eps

Drawings

C-83

9813/5550-1

C-83


Section C - Electrics Harness Systems

Fig 13. 334-J4255-1 Sheet 4

334-J4255-1_Sheet4.eps

Drawings

C-84

9813/5550-1

C-84


Section C - Electrics Harness Systems

Fig 14. 334-J4255 Sheet 5

334-J4255-1_Sheet5.eps

Drawings

C-85

9813/5550-1

C-85


Section C - Electrics Harness Systems

Fig 15. 334-J4255 Sheet 6

334-J4255-1_Sheet6.eps

Drawings

C-86

9813/5550-1

C-86


333/K5337 Issue 1

Fig 16. 333-K5337 SHEET-1

333-K5337-1-SHEET-1.eps

Section C - Electrics Harness Systems Drawings

C-87

9813/5550-1

C-87


Section C - Electrics Harness Systems

Fig 17. 333-K5337 SHEET-2

333-K5337-1-SHEET-2.eps

Drawings

C-88

9813/5550-1

C-88


Fig 18. 333-K5337 SHEET-3

817/17260

4

3

2

1

4

3

2

C-89 333-K5337-1-SHEET-3.eps

1

Section C - Electrics Harness Systems Drawings

9813/5550-1

C-89


Section C - Electrics Harness Systems

Fig 19. 333-K5337 SHEET-4

333-K5337-1-SHEET-4.eps

Drawings

C-90

9813/5550-1

C-90


Section C - Electrics Harness Systems

Fig 20. 333-K5337 SHEET-5

333-K5337-1-SHEET-5.eps

Drawings

C-91

9813/5550-1

C-91


Section C - Electrics Harness Systems

Fig 21. 333-K5337 SHEET-6

333-K5337-1-SHEET-6.eps

Drawings

C-92

9813/5550-1

C-92


333/K8487 Issue 2

B

C

A

Fig 22. 333-K8487-2 Sheet 1

C-93

9813/5550-1 C

A

333-K8487-2_Sheet1.eps

B

Section C - Electrics Harness Systems Drawings

C-93


Section C - Electrics Harness Systems

Fig 23. 333-K8487-2 Sheet 2

333-K8487-2_Sheet2.eps

Drawings

C-94

9813/5550-1

C-94


333K9798 Issue 1

Fig 24. 333-K9798-1 Sheet 1

333-K9798-1_Sheet1.eps

Section C - Electrics Harness Systems Drawings

C-95

9813/5550-1

C-95


Section C - Electrics Harness Systems

Fig 25. 333-K9798-1 Sheet 2

333-K9798-1_Sheet2.eps

Drawings

C-96

9813/5550-1

C-96


333/K8491 Issue 1

C-97

1

2 3

6

5 4

2 3

1

6 5 4

Fig 26. 333-K8491-1 Sheet 1

333-K8491-1_Sheet1.eps

Section C - Electrics Harness Systems Drawings

9813/5550-1

C-97


1

2

A B

BLUE

GREY

A B

Fig 27. 333-K8491-1 Sheet 2

B C

A

333-K8491-1_Sheet2.eps

Section C - Electrics Harness Systems Drawings

C-98

9813/5550-1

C-98


Section C - Electrics Harness Systems

C-99

9813/5550-1

Fig 28. 333-K8491-1 Sheet 3

2

1

333-K8491-1_Sheet3.eps

Drawings

C-99


Section C - Electrics Harness Systems

Fig 29. 333-K8491-1 Sheet 4

333-K8491-1_Sheet4.eps

Drawings

C-100

9813/5550-1

C-100


Section C - Electrics Harness Systems

Fig 30. 333-K8491-1 Sheet 5

333-K8491-1_Sheet5.eps

Drawings

C-101

9813/5550-1

C-101


Section C - Electrics Harness Systems

Fig 31. 333-K8491-1 Sheet 6

333-K8491-1_Sheet6.eps

Drawings

C-102

9813/5550-1

C-102


333/K8818 Issue 1

C-103

1

2

3

6

5

4

3

2

1

6

4

5

817/17268

Fig 32. 333-K8818 SHEET-1

333-K8818-1-SHEET-1.eps

Section C - Electrics Harness Systems Drawings

9813/5550-1

C-103


Section C - Electrics Harness Systems

Fig 33. 333-K8818 SHEET-2

333-K8818-1-SHEET-2.eps

Drawings

C-104

9813/5550-1

C-104


Section C - Electrics Harness Systems

Fig 34. 333-K8818 SHEET-3

333-K8818-1-SHEET-3.eps

Drawings

C-105

9813/5550-1

C-105


Section C - Electrics Harness Systems

Fig 35. 333-K8818 SHEET-4

333-K8818-1-SHEET-4.eps

Drawings

C-106

9813/5550-1

C-106


Section C - Electrics Harness Systems

Fig 36. 333-K8818 SHEET-5

333-K8818-1-SHEET-5.eps

Drawings

C-107

9813/5550-1

C-107


Section C - Electrics Harness Systems

Fig 37. 333-K8818 SHEET-6

333-K8818-1-SHEET-6.eps

Drawings

C-108

9813/5550-1

C-108


333/K8490 Issue 1

C-109

2

3

3

5 4

1

1

2

6

6

5

4

817/17268

Fig 38. 333-K8490 SHEET-1

333-K8490-2-SHEET-1.eps

Section C - Electrics Harness Systems Drawings

9813/5550-1

C-109


1

2

A B

BLUE

GREY

A B

C-110

9813/5550-1

Fig 39. 333-K8490 SHEET-2

B

B

C

C

A

A

333-K8490-2-SHEET-2.eps

Section C - Electrics Harness Systems Drawings

C-110


Section C - Electrics Harness Systems

C-111

9813/5550-1

Fig 40. 333-K8490 SHEET-3

2

1

333-K8490-2-SHEET-3.eps

Drawings

C-111


Section C - Electrics Harness Systems

Fig 41. 333-K8490 SHEET-4

333-K8490-2-SHEET-4.eps

Drawings

C-112

9813/5550-1

C-112


Section C - Electrics Harness Systems

Fig 42. 333-K8490 SHEET-5

333-K8490-2-SHEET-5.eps

Drawings

C-113

9813/5550-1

C-113


Section C - Electrics Harness Systems

Fig 43. 333-K8490 SHEET-6

333-K8490-2-SHEET-6.eps

Drawings

C-114

9813/5550-1

C-114


333/K8813 Issue 1

C-115

1

2

3

6

5

4

3

2

1

6

5

4

817/17268

Fig 44. 333-K8813 SHEET-1

333-K8813-1-SHEET-1.eps

Section C - Electrics Harness Systems Drawings

9813/5550-1

C-115


Section C - Electrics Harness Systems

Fig 45. 333-K8813 SHEET-2

333-K8813-1-SHEET-2.eps

Drawings

C-116

9813/5550-1

C-116


Section C - Electrics Harness Systems

Fig 46. 333-K8813 SHEET-3

333-K8818-1-SHEET-3.eps

Drawings

C-117

9813/5550-1

C-117


Section C - Electrics Harness Systems

Fig 47. 333-K8818 SHEET-4

333-K8813-1-SHEET-4.eps

Drawings

C-118

9813/5550-1

C-118


Section C - Electrics Harness Systems

Fig 48. 333-K8813 SHEET-5

333-K8813-1-SHEET-5.eps

Drawings

C-119

9813/5550-1

C-119


Section C - Electrics Harness Systems

Fig 49. 333-K8813 SHEET-6

333-K8813-1-SHEET-6.eps

Drawings

C-120

9813/5550-1

C-120


Section C - Electrics Harness Systems

333/K0017 Issue 1

Fig 50. 333-K0017 SHEET-1

333-K0017-1-SHEET-1

Drawings

C-121

9813/5550-1

C-121


Section C - Electrics Harness Systems

Fig 51. 333-K0017 SHEET-2

333-K0017-1-SHEET-2

Drawings

C-122

9813/5550-1

C-122


Section C - Electrics Harness Systems

333/K3883 Issue 1

Fig 52. 333-K3883 SHEET-1

333-K3883-1-SHEET-1.eps

Drawings

C-123

9813/5550-1

C-123


Section C - Electrics Harness Systems

333/K4284 Issue 1

Fig 53. 333-K4284 SHEET-1

333-K4284-1-SHEET-1.eps

Drawings

C-124

9813/5550-1

C-124


333/K4283 Issue 1

Fig 54. 333-K3883 SHEET-1.eps

333-K3883-1-SHEET-1.eps

Section C - Electrics Harness Systems Drawings

C-125

9813/5550-1

C-125


Section C - Electrics Harness Systems

333/K4639 Issue 1

Fig 55. 333-K4639 SHEET-1

333-K4639-1-SHEET-1.eps

Drawings

C-126

9813/5550-1

C-126


Section C - Electrics Harness Systems

333/K5288 Issue 1

Fig 56. 333-K5288 SHEET-1

333-K5288-1-SHEET-1.eps

Drawings

C-127

9813/5550-1

C-127


334/J2060 Issue 1

Fig 57. 334-J2060-1 SHEET-1

334-J2060-1-SHEET-1.eps

Section C - Electrics Harness Systems Drawings

C-128

9813/5550-1

C-128


Section C - Electrics Harness Systems

Fig 58. 334-J2060-1 SHEET-2

334-J2060-1-SHEET-2.eps

Drawings

C-129

9813/5550-1

C-129


Section C - Electrics Harness Systems Connector Codes

Connector Codes Connector Code

Device

Connector Code

Harness Location

Device

Harness Location

C001

ECU: JCB Engine

Revolver Harness

C030

Fusebox: Primary

Revolver Harness

C002

Resistor: CAN Termination

Revolver Harness

C033

Relay: Ignition

Revolver Harness

C036

Module: JCB Engine Fuse & Relay

Revolver Harness

Sensor: Pressure Excavator Pilot

Revolver Harness

C003

C037

Converter: Voltage 24/ Revolver Harness 12V

Sensor: Pressure Travel Pilot

Revolver Harness

C004

C038

Pump: Fuel Lift

Revolver Harness

Solenoid: Cooling Fan Control

Revolver Harness

C006 C007

Sensor: Water In Fuel

Revolver Harness

C039

Sensor: Pressure - AC Revolver Harness

C008

Sensor: Engine Oil Level

Revolver Harness

C040

Solenoid: AC Compressor Clutch

C009

Solenoid: Engine Starter Motor

Revolver Harness

Revolver Harness or Engine Harness(1)

C041

Alarm Travel

Revolver Harness

C010

Motor: Starter+

Revolver Harness

C042

Alternator: 24V 55A

Revolver Harness

C012

Switch: Battery Isolator Revolver Harness

C045

Revolver Harness

C015

ECU: Machine Control Cab Harness (J1)

Solenoid: Pump Control

C046

Revolver Harness

Sensor: Engine Oil Pressure

Sensor: Hydraulic Oil Temperature

C047

Solenoid: Max Flow

Revolver Harness

Solenoid: Travel Speed Revolver Harness

C014

Engine Harness

C016

ECU: Machine Control Cab Harness (J2)

C048 C049

Solenoid: Swing Lock

Revolver Harness

C018

Light: Working Revolver RH

Revolver Harness

C050

Solenoid: Swing Isolate

Revolver Harness

C019

Pump: Re-fuelling

Revolver Harness

C051

Revolver Harness

C020

Switch: Re-Fuelling Pump

Revolver Harness

Solenoid: Controls Enable

C052

Solenoid: MRV Boost

Revolver Harness

C021

Sensor: Fuel Level

Revolver Harness

C053

Solenoid: Swing Brake Revolver Harness

C022

Alarm Horn

Revolver Harness

C054

Solenoid: Cushion

Revolver Harness

C023

Sensor: Boom Overload

Revolver Harness

C055

Light: Working - Cab RH

Roof Harness

C024

Diode: Alternator Suppression

Revolver Harness

C056

Light: Working - Cab LH

Roof Harness

C025

Socket: Beacon - Main Revolver Harness

C057

Motor: Screenwash Pump

Revolver Harness

Connector: Radio Power

Roof Harness

C026

C058

Motor: Wiper -Upper

Roof Harness

C027

Sensor: Air Filter Restriction

Revolver Harness

C059

Light: Interior Illumination

Roof Harness

C028

Sensor: Coolant Level

Revolver Harness

C060

Joystick: LH Handle

Cab Harness

C-130

9813/5550-1

C-130


Section C - Electrics Harness Systems Connector Codes Connector Code

Device

Harness Location

Connector Code

C063

Switch: Lever Lock 1

C064

Converter: Voltage 24/ Revolver Harness 12V

Cab Harness

Device

Harness Location

C094

Potentiometer: Throttle Cab Harness Set/Adjust

C095

Joystick: RH Handle

Cab Harness Cab Harness

C065

Connector: Vehicle Diagnostic

Cab Harness

C097

Switch: Ignition Keyswitch

C066

Connector: Camera Power

Cab Harness

C100

Fuse & Relay Module - Cab Harness Cab

C067

Converter: Voltage 24/ Cab Harness 12V

C107

Switch: Heated Seat

C109

ECU: Display (J1)

Fascia Harness

C068

Camera: Counterweight

Camera Harness

C110

ECU: Display (J2)

Fascia Harness

C069

Camera: Offside

Camera Harness

C111

Switch: Radio Mute

Fascia Harness

C070

Sensor: Temperature - Boom Harness Ambient °C

C113

Switch: Worklights Std

Fascia Harness

C114

Switch: Worklights Cab Fascia Harness Switch: Beacon

Cab Harness

Cab Harness

C071

Connector: HVAC CAN Cab Harness

C115

C072

Connector: Heater / Air Cab Harness Conditioning

C116

Switch: Main Wipers

Fascia Harness

C117

Switch: Screenwash

Fascia Harness

C073

Socket: Auxiliary IGN 24V (1)

Cab Harness

C118

Switch: Lower Wiper

Fascia Harness

C119

Switch: Engine Stop

Fascia Harness

C074

Switch: Fan Speed

Heater Harness

C120

Switch: Swing Lock

Fascia Harness

C075

Switch: Re-Circulation

Heater Harness

C121

Switch: Quickhitch

Fascia Harness

C076

Potentiometer: Temperature

Heater Harness

C122

Switch: Controls Enable

Fascia Harness

C077

LED: Heater Panel Illumination

Heater Harness

C123

Switch: Module - Auto Idle/H+/Speed

Cab Harness

C078

Sensor: Hammer Pilot

Cab Harness

C124

Sensor: Boom Up

Cab Harness

Light: Worklight Boom LH

Boom Harness

C079 C080

Sensor: Pressure Swing Pilot

Cab Harness

C125

Light: Worklight Counterweight

Revolver Harness

C081

Relay: Ignition (24V Input)

Revolver Harness

C126

Motor: Wiper - Lower

Cab Harness

C127

Cab Harness

C082

Module: Heater Unit

Heater Harness

Diode: Wake-up Refuel/Door Open

C085

Light: Quickhitch Boom Boom Harness Status

C128

Switch: Cushion

Fascia Harness

C129

Switch: Seat Ventilation

ECU: Livelink Telematics

Fascia Harness

C086

C130

Connector: USB

Fascia Harness

C090

Sensor: Pilot Pressure Cab Harness

C138

Solenoid: Boom Priority

Revolver Harness

Connector: LH Rear Beacon

Revolver Harness

C091

C139

Element: Heated Seat

Cab Harness

Connector: RH Rear Beacon

Revolver Harness

C092 C093

Motor: Seat Ventilation Cab Harness

C140

Speaker: RH

Roof Harness

C-131

Cab Harness

9813/5550-1

C-131


Section C - Electrics Harness Systems Connector Codes Connector Code

Device

Connector Code

Harness Location

C141

Speaker: LH

C142

Switch: Wiper Interlock Roof Harness

C143

Connector: Radio Speakers

C145

Harness Location

C168

Sensor: Cold Start Advance

Engine Harness

Roof Harness

C169

Sensor: Seat Belt / Occupancy

Cab Harness

Connector: Primary Fuse Supply

Revolver Harness

C171

Sensor: Pressure Lo Flow Aux

Revolver Harness

C147

Light: Console Illumination

Fascia Harness

C172

Sensor: Pressure Hi Flow Aux

Revolver Harness

C148

Sensor: Door Open

Roof Harness

C173

Cab Harness

C149

Sensor: TMAP Sensor Revolver Harness

Solenoid: Merge Flow ‘A’

C150

Motor: Seat Suspension

Cab Harness

C174

Solenoid: Merge Flow ‘B’

Cab Harness

C151

Socket: Auxiliary 12V (1)

Fascia Harness

C175

Solenoid: Low Flow Variable ARV

Cab Harness

C152

Socket: Auxiliary IGN 24V (2)

Cab Harness

C176

Solenoid: Hi Flow Variable ARV

Cab Harness

C153

ECU: Hydraulic Control Cab Harness ECU (J1)

C177

RH Joystick Handle AUX

Cab Harness

C154

ECU: Hydraulic Control Cab Harness ECU (J2)

C178

Solenoid: Dual Controls (A)

Options Harness

C155

Solenoid: Quickhitch

Revolver Harness

C179

Solenoid: Dual Controls (B)

Options Harness

C156

Sensor: Pressure Quickhitch

Revolver Harness

C194

Sensor: Arm Limit Proximity

Arm Harness

C157

Sensor: Alignment Boom

Boom Harness

C195

Antenna: FM Radio

Roof Harness

C158

Sensor: Alignment Arm

Boom Harness

C200

Resistor: CAN Termination

Fascia Harness

C159

Solenoid: Arm Limiter

Options Harness

C225

Switch: Lever Lock 2

Cab Harness

C160

Solenoid: Low Flow ‘A’ Auxiliary Harness

C226

Switch: Cab Raise (HRC)

Cab Harness

C161

Solenoid: Low Flow ‘B’ Auxiliary Harness

C231

Light: Worklight Boom RH

Boom Harness

Diode: Cab Low Flow Priority (HRC)

Revolver Harness

C162

C241

Socket: Auxiliary 12V (2)

Cab Harness

Solenoid: Low Flow Priority (HRC)

Revolver Harness

C163

C243

Solenoid: Proportional High Flow ‘A’

Auxiliary Harness

Solenoid: Cab Raise (HRC)

Revolver Harness

C164

C244

Solenoid: Proportional High Flow ‘B’

Auxiliary Harness

Solenoid: Cab Lower (HRC)

Revolver Harness

C165

C245

Solenoid: Auxiliary/ Hammer Changeover

Revolver Harness

Sensor: Cab Lowered and Docked (HRC)

Cab Harness

C167

C246

Switch: Cab Raise (HRC)

Revolver Harness

C-132

Roof Harness

Device

9813/5550-1

C-132


Section C - Electrics Harness Systems Connector Codes Connector Code

Device

Harness Location

C318

Relay: LiveLink

Facia Harness

C348(1)

Relay: Fuel Lift Pump

Cab Harness

C30-X1

Connector: Primary Fuse B+

Revolver Harness

C42-X1

Alternator: R Terminal

Revolver Harness

C42-X2

Alternator: L Terminal

Revolver Harness

(1) Depending on machine variant

C-133

9813/5550-1

C-133


Section C - Electrics Harness Systems Wire Numbers and Functions

Wire Numbers and Functions This section details the allocation of wire numbers and the identification of wires in the wiring harness.

Fig 59. Typical Wire and Harness Number K Fig 59. ( T C-134). The illustration shows a typical connector and wires. Each wire has an individual identification number permanently marked on it, at regular intervals along it's length.

The number stamped on the wire identifies the following:

Table 9. Wire and Harness Number Identification Ident. No.

Description

#

The # indicates the start of the identification number. It is always printed to the left of the identification number.

B

If applicable - The colour of the flying lead that the harness wire should mate with. For instance, if wire 819 from harness 719/37100 mated with a flying lead coloured black (colour code B) then the number printed on the wire would be B-819 9/371.

819

The wire's unique identification number. The wire functions and numbers allocated to them are consistent through out the JCB range of products. K Wire Numbers and Functions ( T C-134).

9/371

If applicable - The part number of the harness that the wire originates from. If the harness part number is 719/37100, the number printed on the harness wires will be 9/371 (71 and 00 are common numbers and therefore deleted).

C-134

9813/5550-1

C-134


Section C - Electrics Harness Systems Wire Numbers and Functions

Wires 000-199

Wires 800-999

These numbers are reserved for ignition feeds, heater start circuits and start circuits. These can be further categorised by:

These numbers are reserved for switched supplies to electrical loads, i.e. to lights, etc.

Wires In Splices – Wires 000 - 099 are allocated to unfused ignition feeds.

Note: Feeds via ignition relays are classed as ignition feeds.

The main input wire is allocated with a wire number and a suitable description, i.e. Wire 640 earth splice to earth. The additional wires in the splice are allocated the same wire number and a postfix, i.e. 640A, 640B, etc. K Fig 61. ( T C-135).

Wires 200-399

Note: The letters I, O, Q and S are not used.

– Wires 100 - 199 are allocated to fused ignition feeds.

These numbers are reserved for battery feeds, They can be further categorised by: – Wires 200 - 299 are allocated to unfused battery feeds. – Wires 300 - 399 are allocated to fused battery feeds.

Wires 400-599 These numbers are reserved for instruments, i.e. alternators to tachos, temperature switches to warning lights, etc. and signal wires used in electronic systems.

Wires 600-799

Fig 61.

These numbers are used for earth wires. When the number is printed onto a wire A it is prefixed by the Earth symbol B. K Fig 60. ( T C-135). This symbol is printed onto the wire, it may however be omitted from harness drawings.

General Points 1

Wires continue to have the same number even after passing through a connector block to another harness.

2

If all the numbers in a category have been allocated, then the category is re-used with an additional prefix '1', i.e. 1832.

Fig 60. Where a load is switched negative, the wire number from the load to the switch shall be different to that of the wire from the switch to the earth.

C-135

9813/5550-1

C-135


Section C - Electrics Harness Systems Wiring Harness Repair

Wiring Harness Repair TC-004

!MCAUTION

Introduction Instances do occur where it is necessary to incorporate auxiliary electrical components into existing electrical circuits and, although unlikely with present wiring harnesses, repair or replace specific individual wires within a harness. This will also apply to other machines in addition to those of manufacture.

When the heater is in use, the reflector and the air coming out are extremely hot. Keep away to avoid accidental burns. Do not touch the reflector until it has had time to cool down after switching off. If flame reappears at the reflector when the heater is in use, the catalytic element is damaged or used up. Stop work immediately and replace the heater.

To ensure that either the inclusion of an auxiliary electrical component or a repair within a harness is completed to an acceptable standard it is strongly recommended that the following tools, equipment and procedures are always used. Note that JCB harnesses have an International Protection rating of 67 (I.P.67).

ELEC-2-3

The sheath covering of the recommended splice is heat shrunk onto the original wire insulation. This results in a seal and corresponding joint to IP 67 specifications.

!MCAUTION When installing Auxiliary Electrical Components always ensure that the additional load rating is suitable for that particular circuit. It is unacceptable to simply increase the fuse rating as this can cause overloading and consequential failure of wiring, along with failure of integral circuit components, which the fuse is protecting.

Repair Procedure Part No.

Table 10. Tools Required Description

892/00350

Butane Heater assembly

1

892/00349

Crimp tool

1

892/00351

Splice 0.5-1.5 mm (Red)

50

892/00352

Splice 1.5-2.5 mm (Blue)

50

892/00353

Splice 3.0-6.0 mm (Yellow)

50

1

Qty

Cut the wire and remove the protective insulation for a suitable distance dependent upon the size of wire and splice to be used. For the splices detailed in K Table 10. ( T C-136), the dimension is 7mm.

ELEC-2-1

!MWARNING In addition to the warnings incorporated into this procedure, extreme care should be taken when handling the gas heating tool to ensure that the flame does not damage or set fire to any items in the vicinity of the repair, i.e. other wires, floor panels, floor mats, sound proofing, paintwork, etc. This tool should not be used in any restricted location prohibiting the use of "Naked Flames" or where risk of explosive gas or similar safety parameters apply. No other heat source should be used to attempt a sealed joint.

Fig 62.

ELEC-2-2

2

C-136

9813/5550-1

Using the correct sized splice, attach the new section of wire required or auxiliary flying lead to the existing harness and secure using the crimp tool. K Fig 62. ( T C-136). Note that each of the splices detailed is colour-coded to make size and range

C-136


Section C - Electrics Harness Systems Wiring Harness Repair readily visible. They are secured using the corresponding size and matching colour-coded jaws of the crimp tool to ensure joint security. This tool also incorporates a ratchet closing mechanism which will not release until the splice is fully closed to the correct compression size. 3

With the Butane heater assembly, connection. K Fig 63. ( T C-137). a

seal

the

Remove the cap 64-A from the end of the disposable gas cartridge 64-B.

Fig 65. d Turn the small ring 66-E so that the air holes at 66F are completely closed. Fig 63. b Before assembling the gas cartridge to the reflector element 65-C, turn the red ring 65-D to the left, (in the direction of the minus sign marked on the ring).

Fig 66. e Fig 64. c

C-137

Position the tube hanging down from inside the reflector assembly into the hole at the top of the gas cartridge. Then press the gas cartridge up into the reflector assembly as far as possible until the two elements are clasped firmly together. K Fig 65. ( T C-137). A click will be heard.

Turn the red ring 67-D to the right (in the direction of the plus sign) in order to turn on the gas.

Important: Before turning the heater on, make sure that the cartridge is not hotter than the reflector element. This may occur if the cartridge is held in the hand for a long time. The temperature difference between the cartridge and the reflector element may cause long yellow flames to appear on ignition.

9813/5550-1

C-137


Section C - Electrics Harness Systems Wiring Harness Repair i

Side wings 69-G down, reflector head completely open. In this mode the infra-red heat waves are dominant (recommended for the light coloured plastic splices).

Fig 67. f

Hold the heater vertically and, using a match or cigarette lighter, light the gas as shown. Fig 69. Hold the heater vertically for 1 to 2 minutes until the catalytic reaction occurs. This is indicated when the blue flame fades and the ceramic element glows red. Then turn the small ring 68-E until the air holes at 68-F are completely open. The tool is ready for use.

ii

Side wings 70-G up, reflector head opening reduced. In this mode the heating is done only by the hot gas (use for dark coloured plastic splices).

Note: The fact that the sound of liquid cannot be heard when the cartridge is shaken does not mean it is empty. No sound will be heard even when the cartridge is full.

Fig 70. h To switch off the heater, turn the red ring 70-D to the left (in the direction of the minus sign). Fig 68. g The heater can be used in two modes:

C-138

9813/5550-1

C-138


Section C - Electrics

ECUs and CANbus CANbus System Modern machines use Electronic Control Units (ECU’s) to control machine systems such as hydraulics, transmission and engine. In much the same way as office computers can be ‘networked’ to communicate with each other the machine ECU’s can be ‘networked’. Some advantages of networking are: – Improved, more intelligent control systems – More comprehensive instrumentation

and

reliable

in-cab

– Service software tools can be used for fault finding and machine control set-up. For example the engine ECU can communicate with other machine ECU’s using a CANbus network system.

C-139

9813/5550-1

C-139


Section C - Electrics ECUs and CANbus CANbus System

CANbus Communications System C

Controller

A

Area

N

Network

An electronic communications system that connects all the machine ECU’s to one pair of data wires called the CANbus. Coded data is sent to and from the ECU’s on the CANbus. By connecting Servicemaster diagnostic software to the CANbus, data is seen and decoded for use by a service engineer.

3

1

4

2

8

9

6

5

9

7 C128140

Fig 71. CANbus System Item

Description

Harness Connectors

1

Engine ECU (bound)(1)

C001

2

Livelink ECU (if fitted) (bound)(1)

3

Display ECU (DECU) (bound)

(1)

4

Automatic Temperature Control (ATC) ECU (if fitted)

5

Machine control ECU (MECU)

C015 J1

6

Hydraulic control ECU (HECU) (if fitted)

C153 J1

7

Servicemaster diagnostics connector (cab fuse and relay PCB)

C100 X2

8

CANbus wires

-

9

CAN termination resistor

C200, C002

C129 C110 J1 C071

(1) The ECU is ‘bound’ on the CANbus. Refer to ‘ECU Set-up’ for information about bound ECU’s. K Fig 72. Circuit ( T C-141)

C-140

9813/5550-1

C-140


C-141

C001

C001

C001

C002

9813/5550-1

C015

C015

C015

C100 X2

C100 X2

Fig 72. Circuit

C153

C153

C153

C071

C071

C129

C129

C129

C129570

C110

C110

C110

C200

Section C - Electrics ECUs and CANbus CANbus System

C-141


Section C - Electrics ECUs and CANbus CANbus System

ECU Set-up When replacing an ECU or operating software - a set-up procedure must be completed. Some ECU’s installed on the machine have a unique identification to enable them to communicate (bind) with other ECU’s, the electronic immobiliser system and LiveLink system (if fitted). These ECU’s are called ‘bound ECU’s. A new ECU or software update will require the following set-up procedures: – Bound ECU’s must be unlocked from the CANbus before removal of ECU’s or installation of operating software. For security reasons an unlock code must be obtained from JCB Service to enable completion of the procedure. Refer to the Servicemaster documentation and JDS Technical Information for the correct procedures. – The correct ECU software must be installed if the ECU is blank. – The ECU must be configured to match the machine build options. – A bound ECU must be registered on the CANbus system and LiveLink system. Refer to the Servicemaster documentation and JDS Technical Information for the correct procedures. – Machines fitted with an immobiliser must have the unlock and lock codes updated within 24 hours of installation of replacement bound ECUs or operating software. Refer to the Servicemaster documentation and JDS Technical Information for the correct set-up procedures. If the ECU is not configured to the machine build options correctly there may be a loss of some machine functions. If a bound ECU is not registered on the CANbus or to the LiveLink system the machine will not operate.

C-142

9813/5550-1

C-142


Section C - Electrics ECUs and CANbus Machine Electronic Control Unit (MECU)

Machine Electronic Control Unit (MECU) Location The MECU 2 is located inside the cab on the rear bulkhead 3. To get access to the MECU remove the rear access panel 1. Refer to Section B.

2 1

3

C128250-C3

Fig 73.

Operation Overview The MECU receives inputs from various switches and sensors. The MECU is also connected to the CANbus and is capable of sending and receiving CAN messages to and from other CAN enabled ECUs on the machine. The main function of the MECU is control of the machine power bands and modes. This is achieved by control of the engine rpm/torque and the power setting for the main and Power hydraulic pump. K Engine Control ( T C-161) Internal software data enables the MECU to process inputs and respond with the applicable outputs and CAN messages.

C-143

9813/5550-1

C-143


Section C - Electrics ECUs and CANbus Machine Electronic Control Unit (MECU)

Wires and Connectors

C015 J1

C016 J2

C128270

Fig 74. Harness Connectors C015, C016 Harness Connector C015 - J1 (black)

21

-

Pins Details

22

Power signal - wake up (door open, refuel)

1

Output - cooling fan solenoid

23

CAN shield

2

Battery (+ 24V)

24

High side output - travel speed solenoid

3

Battery (+ 24V)

25

-

4

Battery (+ 24V)

26

High side output - cab interior light

5

Battery (+ 24V)

27

High side output - refuel pump relay

6

Battery (+ 24V)

28

Regulated sensor supply (+ 5V)

7

Analog input - fuel level sensor

29

Not used

8

Not used

30

Not used

9

Digital input - excavator pilot pressure switch

31

Analog input - engine oil temperature sensor

10

Not used

32

Digital input - slew lock switch

11

Power signal - ignition

33

CAN_L

12

Low side output - hydraulic pump proportional solenoid

34

CAN_H

35

Not used

13

High side output - slew brake solenoid

14

Earth - sensors

15

Earth

16

Earth

17

Earth

18

Analog input - ambient temperature sensor

19

Not used

20

Digital input - air filter vacuum switch

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Section C - Electrics ECUs and CANbus Machine Electronic Control Unit (MECU) 35

Digital input - boom overload pressure switch

Harness Connector C016 - J2 (grey) Pins Details 1

Low side output - cooling fan PWM return

2

Digital input - coolant level switch

3

Digital input - boom up pressure switch

4

High side output - travel alarm

5

High side output - MRV boost solenoid

6

High side output - controls enable solenoid

7

High side output - starter relay

8

High side output - warning buzzer, Malfunction Indicator Light (MIL)

9

High side output - slew lock solenoid

10

High side output - auxiliary/hammer change over solenoid

11

High side output - slew shut solenoid

12

High side output (PWM) - hydraulic pump proportional solenoid

13

Digital input - engine oil level switch

14

Digital input - swing pilot pressure switch

15

Digital input - one touch idle button

16

Digital input - travel speed mode select button

17

Digital input - auto idle enable/disable button

18

Not used

19

Analog input - refuel pump button

20

Digital input - engine start/stop switch

21

Analog input - hand throttle potentiometer

22

Earth

23

High side output - maximum flow cut solenoid

24

Low side output - controls isolate indicator LED

25

Digital input - controls isolate switch

26

Digital input - travel pilot pressure switch

27

Digital input - boom priority button

28

Digital input - H+ power mode switch

29

Digital input - boost button

30

Input - cab interior light switch

31

Analog input - alternator

32

Digital input - engine stop switch

33

Frequency input - cooling fan speed

34

Digital input - lever lock switch

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Section C - Electrics ECUs and CANbus Machine Electronic Control Unit (MECU)

Removal and Replacement Guide The MECU is a reliable and robust component. Before removing and replacing the MECU carry out all the relevant diagnostic and fault finding procedures. Most faults are usually due to damaged wires, connectors or connected devices such as sensors or solenoids.

5

Disconnect the black harness connector 3 (J1) and the grey harness connector 4 (J2) at the MECU. Do not touch the connector pins. Put some tape over the connectors to protect the pins.

6

Remove four screws 2 and their associated washers.

Replacement

1 2

Replace the MECU as follows: 1

Connect the harness connectors at the correct sockets on the MECU.

2

Carry out the correct power up procedure. K ECU Set-up ( T C-142)

3

Use Servicemaster to install the ECU software. Refer to Servicemaster SYSTEM.

4

Use Servicemaster to enter the applicable machine set-up options. Refer to Servicemaster SYSTEM.

5

Use Servicemaster to bind the machine ECU’s. K ECU Set-up ( T C-142)

6

Use Servicemaster to update the immobiliser lock and unlock codes. K ECU Set-up ( T C-142)

3

4 C128250-C4

Fig 75.

Removal The MECU is bound on the CANbus system. Do not remove or disconnect the MECU unless you have access to the applicable JCB Servicemaster software tools. 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2, Maintenance.

2

Use Servicemaster to view the machine Set-up. Record the details from the Set-up screen. Refer to Servicemaster SYSTEM.

3

Carry out the unlock binding procedure. Refer to the ECU Set-up instructions. K ECU Set-up ( T C-142)

4

Carry out the correct power down sequence. K ECU Set-up ( T C-142)

C-146

Note: Do not replace the MECU with a unit from another machine. ECU’s may look the same but have different software installations.

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C-146


Section C - Electrics ECUs and CANbus Hydraulic Electronic Control Unit (HECU)

Hydraulic Electronic Control Unit (HECU) Location The HECU 2 (if fitted) is located inside the cab on the rear bulkhead 3. To get access to the HECU remove the rear access panel 1. Refer to Section B.

2 1

3

C128250

Fig 76.

Operation Overview The HECU is a programmed to control some of the machine hydraulic systems. It receives inputs from the LH and RH joystick control thumb wheels, various switches and sensors. Outputs control solenoid valves for control of the auxiliary hydraulics. The system is designed for simple set-up of the auxiliary hydraulics for efficient and safe operation of the machine.

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Section C - Electrics ECUs and CANbus Hydraulic Electronic Control Unit (HECU)

Wires and Connectors

C153 J1

C154 J2

C128270-C1

Fig 77. Harness Connectors C153, C154 Harness Connector C153 - J1 (black)

19

Not used

Pins Details

20

Not used

1

High side output - proportional solenoid - high flow A

21

Digital input - arm limit proximity switch

22

Not used

2

Battery (+ 24V)

23

CAN shield

3

Battery (+ 24V)

24

Not used

4

Battery (+ 24V)

25

High side output - quickhitch solenoid

5

Battery (+ 24V)

26

High side output - arm limit solenoid

6

Battery (+ 24V)

27

7

Not used

High side output - quichitch boom status indicator LED

8

Not used

28

Regulated sensor supply (+ 5V)

9

Not used

29

Not used

10

Digital input - hammer pilot pressure switch

30

Not used

11

Power signal - ignition

31

Analog input - low flow auxiliary pressure sensor

12

Low side output - low flow auxiliary proportional solenoid

32

Digital input - High Rise Cab (HRC) cab lowered and docked sensor

13

High side output - high flow proportional solenoid B

33

CAN_L

34

CAN_H

14

Earth - sensors

35

Low side output - high flow variable ARV solenoid

15

Earth

16

Earth

17

Earth

18

Analog input - high flow auxiliary pressure sensor

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C-148


Section C - Electrics ECUs and CANbus Hydraulic Electronic Control Unit (HECU) 35

Digital input - quickhitch pressure switch

Harness Connector C154 - J2 (grey) Pins Details 1

Low side output - high flow auxiliary proportional solenoids return

2

Not used

3

Digital input - quickhitch switch

4

Not used

5

High side output - merge flow A solenoid

6

High side output - merge flow B solenoid

7

High side output - dual controls solenoids

8

High side output - quickhitch switch status LED (red)

9

High side output - low flow variable ARV solenoid

10

High side output - high flow variable ARV solenoid

11

Not used

12

High side output - low flow B proportional solenoid

13

Not used

14

Not used

15

Digital input - quickhitch switch

16

Digital input - quickhitch button (RH joystick)

17

Not used

18

Not used

19

Analog input - LH joystick thumbwheel

20

Not used

21

Not used

22

Earth

23

High side output - low flow A solenoid

24

Low side output - low flow variable ARV solenoid

25

Not used

26

Not used

27

Not used

28

Digital input - constant auxiliary button (LH joystick)

29

Digital input - arm alignment switch

30

Analog input - RH joystick thumbwheel

31

Not used

32

Not used

33

Not used

34

Digital input - boom alignment switch

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Section C - Electrics ECUs and CANbus Hydraulic Electronic Control Unit (HECU)

Removal and Replacement Guide

– Connect the harness connectors at the correct sockets on the HECU.

The HECU is a reliable and robust component. Before removing and replacing the HECU carry out all the relevant diagnostic and fault finding procedures. Most faults are usually due to damaged wires, connectors or connected devices such as sensors or solenoids.

– If the HECU is a replacement unit refer to the ECU Set-up instructions. K ECU Set-up ( T C-142)

1

Note: Do not replace the HECU with a unit from another machine. ECU’s may look the same but have different software installations.

Test Procedures

2

Use Servicemaster to identify possible faults with the relevant wiring, connectors or electrical devices. Do not use a multimeter on the ECU connector pins. Do not touch the ECU connector pins.

3

4

C128250-C1

Fig 78.

Removal The HECU is not a ‘bound ECU’. 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2, Maintenance.

2

Disconnect the battery.

3

Disconnect the black harness connector 3 (J2) and the grey harness connector 4 (J1) at the HECU. Do not touch the connector pins. Put some tape over the connectors to protect the pins.

4

Remove four screws 2 and their associated washers.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:

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Section C - Electrics ECUs and CANbus Display ECU (DECU)

Display ECU (DECU) Location The DECU is part of the LCD monitor mounted in the cab.

3

4

2

5

6

1

C128570

Fig 79.

Operation Overview The DECU 3 controls the information shown on the LCD monitor 4. The controls 6 and LCD monitor are part of the ECU. The DECU is connected to the CANbus and is capable of sending and receiving CAN messages to and from other CAN enabled ECUs on the machine. Internal software data enables the DECU to process inputs and respond by configuring the LCD to show the applicable graphics and data. Note: Two LCD variants are available. The 3.5 in variant (shown) has two mechanical gauges 5. The 7 in variant replaces the mechanical gauges with digital gauges shown by the LCD. This variant also uses the LCD to display the input from the camera visibility system. To get access to the electrical connectors on the DECU remove three screws 1 and cover 2.

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Section C - Electrics ECUs and CANbus Display ECU (DECU)

Wires and Connectors K Fig 81. Circuit ( T C-153)

C109 J1

C128580

Fig 80. Harness Connectors C109 Harness Connector C109 - J1 (grey) Pins Details 1

Digital input - work lights switch

2

Wake up signal (+ 24V ignition)

3

Not used

4

Not used

5

Not used

6

CAN shield

7

CAN_L

8

CAN_H

9

Earth

10

Battery (+ 24V)

11

Digital input - seat occupant switch, seat belt switch

12

Not used

13

Not used

14

Not used

15

Not used

16

Not used

17

Not used

18

Not used

19

Not used

20

High side input - MECU (warning buzzer Malfunction Indicator Light (MIL) activation)

C-152

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C-152


C-153

C016 MECU (J2)

CAN HI

CAN LO

CAN SHD

C113

CANbus

24V ICN ECU WAKE - UP

4094

4014

4071

3017

4093

6090

Fig 81. Circuit

4092 4091

4102L

4101L

4100L

1006D

8002D

C109/C110

C068/C069 CAMERA MONITORS: COUNTERWEIGHT AND OFFSIDE

C129140

Section C - Electrics ECUs and CANbus Display ECU (DECU)

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C-153


Section C - Electrics ECUs and CANbus Display ECU (DECU)

Removal and Replacement Guide The DECU is a reliable and robust component. Before removing and replacing the DECU carry out all the relevant

1

diagnostic and fault finding procedures. Most faults are usually due to damaged wires, connectors or connected devices such as switches or sensors.

2

7

3

6

4

5 C128590

Fig 82.

Removal

7

The DECU is bound on the CANbus system. Do not remove or disconnect the DECU unless you have access to the applicable JCB Servicemaster software tools.

Replacement

Support the DECU and remove four screws 3. Remove the DECU from the machine.

Replace the DECU as follows: 1

2

3

4

5

6

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2, Maintenance.

1

Connect the harness connectors at the correct sockets on the MECU.

2

Torque tighten the screws 7 and 3 to 4 Nm.

3

Carry out the correct power up procedure. K ECU Set-up ( T C-142)

Carry out the unlock binding procedure. Refer to the ECU Set-up instructions. K ECU Set-up ( T C-142)

4

Use Servicemaster to install the ECU software. Refer to Servicemaster SYSTEM.

Carry out the correct power down sequence. K ECU Set-up ( T C-142)

5

Use Servicemaster to enter the applicable machine set-up options. Refer to Servicemaster SYSTEM.

6

Use Servicemaster to bind the machine ECU’s. K ECU Set-up ( T C-142)

7

Use Servicemaster to update the immobiliser lock and unlock codes. K ECU Set-up ( T C-142)

Use Servicemaster to view the machine Set-up. Record the details from the Set-up screen. Refer to Servicemaster SYSTEM.

Disconnect the harness connectors 5 (J1) and the grey harness connector 6 (J2) at the DECU. Do not touch the connector pins. Put some tape over the connectors to protect the pins. Remove three screws 7 and cover 1.

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C-154


Section C - Electrics ECUs and CANbus Display ECU (DECU) Note: Do not replace the DECU with a unit from another machine. ECU’s may look the same but have different software installations.

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C-155


Section C - Electrics ECUs and CANbus Engine ECU

Engine ECU Location The engine ECU 1 is located on the LH side of the engine.

1

C125650

Fig 83.

Description For details about the engine ECU refer to the applicable engine documentation.

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Section C - Electrics ECUs and CANbus Engine ECU

Wires and Connectors The engine ECU is bound on the CANbus system. Do not remove or disconnect the engine ECU unless you have access to the applicable JCB Servicemaster software tools.

The engine ECU has two harness connectors, the machine harness connector 2 and the engine harness connector 3. For details of the engine harness connector refer to the applicable engine documentation. Important: Do not touch the connector pins 1 on the engine ECU. Do not use a multi-meter on the engine ECU connector pins, only use a multi-meter on the harness connector pins.

2

1 62

4

60

1

3 C125650-C1

Fig 84. Harness Connector C001 Harness Connector C001 Pins Details 1

Not Used

2

Engine fuse and relay box - 12V power hold relay

3

Not Used

4

Not Used

5

Not Used

6

Not Used

7

Not Used

8

Not Used

9

Not Used

10

Not Used

11

Not Used

12

Not Used

13

Not Used

14

Not Used

15

Not Used

C-157

16

Not Used

17

Not Used

18

TMAF sensor air temperature Input

19

CANbus Shield

20

Not Used

21

Not Used

22

TMAF sensor airflow speed input

23

CANbus Low

24

Not Used

25

Not Used

26

Not Used

27

CANbus High

28

Not Used

29

Not Used

30

Not Used

31

Not Used

32

Not Used

33

Not Used

9813/5550-1

C-157


Section C - Electrics ECUs and CANbus Engine ECU 34

Not Used

35

Not Used

36

Not Used

37

Not Used

38

TMAF Sensor earth

39

Engine fuse and relay box - crank request relay

2

40

Engine fuse and relay box - lift pump relay

41

Not Used

42

Not Used

43

Not Used

44

Engine fuse and relay box - 24V power hold relay

45

Engine CANbus High

46

Not Used

47

Not Used

48

Inlet manifold heater relay

49

Engine fuse and relay box - Fuse F1

50

Engine CANbus Low

51

Not Used

52

TMAF Sensor voltage supply

53

Engine fuse and relay box - Fuse F2

54

Not Used

55

Water in fuel sensor input

56

Not Used

57

Engine fuse and relay box - Fuse F3

58

Earth

59

Earth

60

Engine fuse and relay box - Fuse F4

61

Earth

62

Earth

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

Removal and Replacement Guide For removal and replacement procedures refer to the applicable engine documentation.

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Rectify as required.

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Section C - Electrics ECUs and CANbus Testing of ECU Inputs + Outputs

Testing of ECU Inputs + Outputs Care should be taken when testing the inputs + outputs of the ECU to ensure that correct test method is used to determine if the ECU is functioning normally.

Testing Low Side Output

Testing Low Side Input

With the output on the meter will read 24-28v.

With the output off the meter will read 0v.

With the switch open the meter will read 0v. Actuator; relay coils

ECU

With the switch closed the meter will read 24-28v.

Output

ECU Switch (rocker, momentary, pressure, level, etc.)

Red lead

V Input Black lead

Red lead

+24 C005860GB

Fig 87.

V Black lead

Testing High Side Output C005840GB

Fig 85.

With the output off the meter will read 0v.

Testing High Side Input

With the output on the meter will read 24-28v.

With the switch open the meter will read 0v. With the switch closed the meter will read 24-28v.

ECU

Actuator (solenoid, motor, bulb, horn relay)

ECU

Output

Switch (lights, engine preheat, etc.)

Red lead

V

Input

Black lead

Red lead

C005870GB

Fig 88.

V Black lead C005850GB

Fig 86.

The ECU is internally configured to give short circuit protection and detection of short circuit / open circuit, this is done by internal resistors. This internal configuration can give some confusing results when testing the outputs on the ECU. Voltage at point A:

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Section C - Electrics ECUs and CANbus Testing of ECU Inputs + Outputs Solenoid connected output off = 0.1 V approx. Solenoid connected output on = battery voltages nominal. Solenoid disconnected output off = reduced voltage (15 V - 22 V). Solenoid disconnected output on = battery voltage nominal. Shorted to ground = 0 V. Shorted high (to positive) = battery voltage.

ECU

Âľ IN

Output supply +24v

ST

Vbb

OUT

A A

Driver

*

Pull up Resistor 10k

C005880GB

Fig 89.

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Section C - Electrics Engine and Power Control Battery Power Supply and Distribution

Engine and Power Control Battery Power Supply and Distribution Overview

enables isolation of the complete machine electrical system during maintenance procedures.

The machine has two 12V batteries 2 and 3 connected in series to give a 24V power supply. The batteries are located in a compartment on the LH side of the machine. A battery isolator switch 1 is connected in the earth cable between the batteries and the revolving chassis. This

Power from the batteries connects directly to four primary fuses A, B, C and D. The primary fuses distribute power to the ignition relay 4, engine fuse and relay box and the main fuse PCB inside the cab. This connects some devices and circuits permanently to the battery supply.

B 2

A 4

3

D

C

1 C132170

Fig 90.

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Section C - Electrics Engine and Power Control Battery Power Supply and Distribution

Wires and Connectors

Primary Fuse B

K Fig 91. Batteries and Primary Fuses ( T C-163)

Main feed from the alternator (C042) to the batteries

K Fig 92. Main PCB Fuses and Circuits - Sheet 1 of 2 ( T C-164)

Primary Fuse C

K Fig 93. Main PCB Fuses and Circuits - Sheet 2 of 2 ( T C-165)

Engine fuse and relay Voltage converter relays (RA, box (C003) RB)

For harness connector details at the main Printed Circuit Board (PCB) (C100), refer to Fuses and Relays in this section.

Feed

Devices

Primary Fuse D Feed to the ignition relay (C033)

For harness connector details at the engine fuse and relay box (C003). K Engine Fuse and Relay Box ( T C-178) Primary Fuse A Feed

Circuits and Devices

Main PCB fuses Ignition switch (C097) and and relays refuelling pump switch (C100) (C020)

C-162

Fuse F19

MECU (C015 J1)

F18

HECU (C153 J1)

F17

Cab interior light

F22

Livelink ECU (C129)

F15

DECU (C109)

F29

Work lights switch (C113)

F24

Cab 12 to 24V converter (C067)

F23

Work lights switch (cab) (C114)

F16

9813/5550-1

C-162


C-163

C145-1

2

9813/5550-1

C030-X3-B

D

C030-X3-A

C

C030-X2-B

A

C030-X2-A

B

C030

3

3014

3015

3000

3018

C009-1

C010-1

C042

C003

RB

RA

ENGINE FUSE AND RELAY BOX

C012

1

C042 -X3-1

C042 -X2-1

C042 -X1-1

Fig 91. Batteries and Primary Fuses

C100 -X3

C100 -X1

ST3

C033 -X1-1

C033 -X1-2

C033 -X3-1

5

C033

C033 -X2-1

C100-X2

PCB (C100)

C128880

C100 -X4

Section C - Electrics

Engine and Power Control

Battery Power Supply and Distribution

2000

C-163


C-164

C153 J1

HECU

C020

MECU

C015 J1

Fig 92. Main PCB Fuses and Circuits - Sheet 1 of 2

C097

PCB (C100)

C059

C148

C128890

Section C - Electrics

Engine and Power Control

Battery Power Supply and Distribution

9813/5550-1

C-164


C-165

C100 -X3

C100 -X1

ST3

3000

C100-X2

9813/5550-1 3005

3011

C100 -X4

3004

3017

3019

C113

C129

Fig 93. Main PCB Fuses and Circuits - Sheet 2 of 2

PCB (C100)

C114

C067

C109

C129580

Section C - Electrics

Engine and Power Control

Battery Power Supply and Distribution

C-165


Section C - Electrics Engine and Power Control Ignition Power Supply and Distribution

Ignition Power Supply and Distribution Overview

When the engine stop switch is set to engine run the engine shut down relay energises.

When the ignition switch 1 is set to position I power from the batteries connects to pins 5 and 6 of the switch (harness connector C097 - X1). This connects power from the batteries to the following devices and circuits via the main fuse and relay PCB inside the cab:

When the engine stop switch is set to engine stop, power connects to an input on the MECU. The MECU logs the operation of the engine stop switch.

K Fig 95. Main PCB Feed ( T C-167) K Fig 96. Main PCB Distribution ( T C-168)

Wires and Connectors

Ignition Switch - Supply from Pin 5 (C097 X1)

X1

Feed

Circuits and Devices

Fuse

Main PCB fuses and relays (C100)

F13 Ignition relay coil energises (C033). The relay contacts close connecting battery power to the following: Beacon switch (C115)

F1

Heated and ventilated seat functions (C107, C086)

F8

Auxiliary power sockets (24V) (C073, C152)

F6

1

Wake up signal to MECU, HECU F4 and DECU (via splice (S033)) Switch illumination (via splice (S039))

F2

Camera systems (C068, C069)

F9

Livelink system (C129)

F5

X2 C128910

Fig 94. Harness connector C097

Cushion switch (C128), wiper F3 switch (C116), arm limit switch (C194), horn switch (LH joystick) (C060) Engine crank relay

F11

Ignition Switch - Supply from Pin 6 (C097 X1) Feed

Circuits and Devices

Fuse

Main PCB Power supply to the engine stop F12 fuses and switch (C119). relays

C-166

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C-166


C-167

J2

C016 J2 MECU

0.75 4023

0.5 1012B

0.5 6079

1.0 1012

+ve 24V

C119

C097

engine stop on

engine stop off

Fig 95. Main PCB Feed

+ve 24V

C097

C065

10018

8.0 3015

R4

0.5 6023

8.0 1000

RELAY: IGNITION

PCB (C100)

C128900

Section C - Electrics

Engine and Power Control

Ignition Power Supply and Distribution

9813/5550-1

C-167


C-168

C072

C107

C086

C115

C073

C152

S033

S039

C068

C069

C129

C116

C194

C169

C060

C128

HEATER/ATC CONNECTOR

SWITCH- HEATED SEAT

SWITCH- SEAT VENTILATION

SWITCH- BEACON

SOCKET - AUXILIARY IGNITION 24V (2)

SOCKET - AUXILIARY IGNITION 24V (1)

SPLICE - ECU WAKE-UP

SPLICE - BACKLIGHTING

CAMERA 1 - COUNTERWEIGHT

9813/5550-1

CAMERA 2 - OFFSIDE

LIVELINK ECU

SWITCH - MAIN WIPER

SENSOR - ARM LIMIT PROXIMITY

SENSOR - SEAT BELT/OCCUPANCY

JOYSTICK: L/H HANDLE

SWITCH - CUSHION

Fig 96. Main PCB Distribution

1010

1019

1023

1009

1006

1028

1024

1018

1017

R1

+ve 24V

C097

C065

10018

R4

0.5 6023

8.0 1000

RELAY: IGNITION 8.0 3015

PCB (C100)

C129600

Section C - Electrics

Engine and Power Control

Ignition Power Supply and Distribution

C-168


Section C - Electrics Engine and Power Control Engine Start/Stop - Ecomax Engines

Engine Start/Stop - Ecomax Engines K Fig 97. Circuits ( T C-170) 12V feed via power hold relay

Engine Fuses and Relays The engine electrical system is powered via the engine fuse and relay box. K Engine Fuse and Relay Box ( T C-178) The engine 24V to 12V converter C supplies 12V power for the operation of the engine 12V electrical system. K Engine 24V to 12V Converter ( T C-176)

Pin(1)

Pin(2)

The power hold relay D energises via an X earth from the engine ECU.

2

12V power supply to the engine ECU.

J

49

K

53

L

57

M

60 -

Engine Run

12V power supply to the Variable P Geometry Turbocharger (VGT) actuator (CE033).

K Fig 97. Circuits ( T C-170)

12V power supply to the Exhaust Gas Regeneration (EGR) valve (CE008).

-

When the ignition switch is set to position I, 24V energises the ignition relay E and voltage converter relay A. For the relays to operate the engine stop switch in the right hand console must be in the engine run position. K Ignition Power Supply and Distribution ( T C-166) The voltage converter C is switched ON and a 12V power supply enters the engine fuse and relay box at pin B. There is a 12V supply to the power hold relay coil D. There is a 12V power supply to the ignition relay E. The engine devices operate as follows: 12V feed via ignition relay E

Pin(1)

Pin(2)

Engine ECU (C001) ignition signal

M

44

Fuel lift pump relay F energises via an A earth from the engine ECU. The ECU will switch off the earth after a period of 24 seconds if the engine is not started, switching off the fuel pump.(3)

40

The fuel lift pump operates via the H closed contacts of (C006) the fuel pump relay.

-

12V power supply energises voltage converter relay B and latches the voltage converter C ON. (1) Engine fuse and relay box connector C003 (2) Engine ECU C001

Engine Stop When the ignition switch is set to O (OFF) or the engine stop switch is set to engine STOP, the 24V supply is isolated at pin C of the engine fuse and relay box. The voltage converter relay A and ignition relay E de-energise. The 12V input at pin 44 on the engine ECU is switched off. The engine ECU responds by starting the engine shut down sequence. To complete the engine shut down sequence the engine ECU requires a 12V supply. Although the voltage converter relay A de-energises, the voltage converter remains ON via a 24V supply from converter relay B.

(1) Engine fuse and relay box connector C003 (2) Engine ECU C001 (3) This feature enables measurement of fuel flow during engine fault finding procedures. The pump should deliver at least 1 litre in 24 seconds.

C-169

N

The engine ECU continues to keep the power hold relay energised for a period of 32 seconds. This allows the engine ECU to complete the engine shut down cycle and reset ready for the next engine start. After a period of 32 seconds the engine ECU de-energises the power hold relay D by turning off its earth connection. The voltage converter relay B de-energises and voltage converter switches OFF, isolating the engine fuse and relay box.

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C-169


C-170

Battery supply

From engine shutdown relay

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C064

C004

24V

24V R

24V D

24V

C

C004/C064

C

Wires and Connectors

B

A

12V

B

D

E

C003

12V

12V

Fig 97. Circuits

12V

C008

C033

C007

C007

F

12V

C006

C001

C128920

Section C - Electrics

Engine and Power Control

Engine Start/Stop - Ecomax Engines

C-170


Section C - Electrics Engine and Power Control Engine Start/Stop - Dieselmax Engines

Engine Start/Stop - Dieselmax Engines K Fig 97. Circuits ( T C-170) 12V feed via power hold relay

Engine Fuses and Relays The engine electrical system is powered via the engine fuse and relay box. K Engine Fuse and Relay Box ( T C-178) The engine 24V to 12V converter C supplies 12V power for the operation of the engine 12V electrical system. K Engine 24V to 12V Converter ( T C-176)

Engine Run K Fig 97. Circuits ( T C-170) When the ignition switch is set to position I, 24V energises the ignition relay E and voltage converter relay A. For the relays to operate the engine stop switch in the right hand console must be in the engine run position. K Ignition Power Supply and Distribution ( T C-166) The voltage converter C is switched ON and a 12V power supply enters the engine fuse and relay box at pin J. There is a 12V supply to the power hold relay coil D. There is a 12V power supply to the ignition relay E. The engine devices operate as follows: 12V feed via ignition relay E

Pin(1)

Pin(2)

Engine ECU (C001) ignition signal

M

44

Pin(1)

Pin(2)

The power hold relay D energises via an W earth from the engine ECU.

2

12V power supply to the engine ECU.

N

49

P

53

R

57

S

60

Fuel lift pump relay F energises via an U earth from the engine ECU. The ECU will switch off the earth after a period of 24 seconds if the engine is not started, switching off the fuel pump.(3)

40

The fuel lift pump operates via the T closed contacts of (C006) the fuel pump relay.

-

12V power supply energises voltage converter relay B and latches the voltage converter C ON. (1) Engine fuse and relay box connector C003 (2) Engine ECU C001 (3) This feature enables measurement of fuel flow during engine fault finding procedures. The pump should deliver at least 1 litre in 24 seconds.

(1) Engine fuse and relay box connector C003 (2) Engine ECU C001

C-171

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C-171


Section C - Electrics Engine and Power Control Engine Start/Stop - Dieselmax Engines

Engine Stop When the ignition switch is set to O (OFF) or the engine stop switch is set to engine STOP, the 24V supply is isolated at pin A of the engine fuse and relay box. The voltage converter relay A and ignition relay E de-energise. The 12V input at pin 44 on the engine ECU is switched off. The engine ECU responds by starting the engine shut down sequence. To complete the engine shut down sequence the engine ECU requires a 12V supply. Although the voltage converter relay A de-energises, the voltage converter remains ON via a 24V supply from converter relay B. The engine ECU continues to keep the power hold relay energised for a period of 32 seconds. This allows the engine ECU to complete the engine shut down cycle and reset ready for the next engine start. After a period of 32 seconds the engine ECU de-energises the power hold relay D by turning off its earth connection. The voltage converter relay B de-energises and voltage converter switches OFF, isolating the engine fuse and relay box.

C-172

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C-172


C-173

Battery supply

From engine shutdown relay

24V

24V

Wires and Connectors

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C004

F C 24V

B

A

C

B

A

N

L

R

X M

P

Fig 98. Circuits

D H K J 12V

D

E

C003

12V

S 12V

F

C007

T

U

W

C006

C001

C131450

Section C - Electrics

Engine and Power Control

Engine Start/Stop - Dieselmax Engines

C-173


Section C - Electrics Engine and Power Control Engine Cranking

Engine Cranking Overview K Fig 99. Engine Cranking ( T C-175) To enable engine cranking (operation of the starter motor), the engine stop switch (C119) in the RH cab console must be set to the engine RUN position. When the engine stop switch (C097) is in the STOP position the cranking function is disabled in addition to the engine stop function. When the starter switch (C097) is turned to select engine cranking power is supplied to the engine stop switch via pin 4 of the starter switch. With the engine stop switch in the run position power is connected from pin 4 to the MECU connector J2 pin 20 (C016). The MECU responds with an output at connector J2 pin 7 which energises the engine crank relay R1 located on the cab fuse and relay PCB. The relay contacts close and the starter motor relay energises which in turn operates the starter motor M.

C-174

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C-174


Wires and Connectors

C-175 C009

C097

Fig 99. Engine Cranking

0.75 4023

0.5 6079

C119

R1

C016 MECU (J2)

C128960

Section C - Electrics

Engine and Power Control Engine Cranking

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C-175


Section C - Electrics Engine and Power Control Engine 24V to 12V Converter

Engine 24V to 12V Converter Location The engine 24V to 12V converter 2 is located in the battery compartment behind access cover 1.

1 2

C132160

Fig 100.

Overview The machine electronic fuel injected engine operates on a 12V electrical system. The engine 24V to 12V converter enables engine operation from the 24V machine electrical system. For details of the electrical operation of the voltage converter refer to the engine start/stop topic. K Engine Start/Stop - Ecomax Engines ( T C-169)

C-176

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C-176


Section C - Electrics Engine and Power Control Engine 24V to 12V Converter

Wires and Connectors

C004

C130010-C1

Fig 101. Harness connector C004

C-177

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C-177


Section C - Electrics Engine and Power Control Engine Fuse and Relay Box

Engine Fuse and Relay Box Location The engine fuse/relay box 1 is located in the cooling pack compartment.

1

C132150

Fig 102.

Overview The engine fuse/relay box contains fuses and relays for control and protection of engine related devices. The fuses and relays are mounted on a printed circuit board. The circuit board connects to the machine electrical system via connector C003. For location and identification of the fuses and relays, Refer to Section 2, Technical Data, Electrical System.

Wires and Connectors

C003 C128670-C1

Fig 103. Harness connector C003 For details of the electrical operation of the relays in the engine fuse/relay box refer to the engine start/stop topic. K Engine Start/Stop - Ecomax Engines ( T C-169)

C-178

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C-178


Section C - Electrics Engine and Power Control Engine Fuel Lift Pump

Engine Fuel Lift Pump Location The fuel lift pump 1 is located on the side on the hydraulic tank inside the RH rear compartment.

1

C129620

Fig 104.

Overview The water in fuel (WIF) sensor 3 detects presence of water above a pre-determined level in the pre-filter/water separator bowl. Its electrical resistance range changes when sensor probe is submerged in water. The signal from the sensor is monitored by the engine ECU. When the signal indicates water is present the engine ECU broadcasts a message on the CANbus.

Wires and Connectors The WIF sensor power supply (12V) is controlled by the ignition relay. K Engine Start/Stop - Ecomax Engines ( T C-169)

C129450-C2

Fig 105. WIF sensor harness connector C006 Harness connector C006 Pins

Details

1

Supply (+ 12V)

2

Earth

C-179

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C-179


Section C - Electrics Engine and Power Control Engine Throttle and Power Mode Control

Engine Throttle and Power Mode Control Overview

2

1

3 6 4 5

C128310-C1

Fig 106. The machine power output setting can be selected by the operator by means of the hand throttle control 1. Rotation of the control changes the no load engine rpm and output from the main hydraulic pump. The hand throttle control signal is input to the MECU 6. The MECU responds to the signal value by controlling the engine rpm and the current output to the hydraulic pump power control proportional solenoid 5. The MECU software incorporates a ‘map’ of pre-set engine rpm and power control current values. These values depend on the input value from the hand throttle control.

C-180

The MECU transmits the required engine rpm to the engine ECU on the CANbus. Note: The engine rpm display value 4 is the actual engine rpm. This may not be the same as the engine rpm value requested by the MECU. The selected power output is displayed on the DECU 3 in the form of a ‘power band’ bar graph 2. The display monitor uses a message transmitted by the MECU on the CANbus to display the applicable bars (from 1 bar to 8 bars).

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C-180


Section C - Electrics Engine and Power Control Engine Throttle and Power Mode Control Power Band Maps

Note: The amount of rotation depends on the speed of rotation. K Hand Throttle Control Unit ( T C-185)

Each machine model is mapped with the most applicable engine rpm and corresponding hydraulic pump output. The applicable graphs show the no load engine rpm and output in mA to the pump proportional solenoid valve. The mA+ line is the output when the machine hydraulic services are operating. The mA- line shows the minimum output under maximum load. K Engine Stall Prevention ( T C-183) The values are plotted against the position of the hand throttle control knob from 0 to 120% rotation.

The total rotation of the hand throttle control knob is divided into seven ‘power bands’. The range of each power band is plotted on the graphs. Note: The hand throttle control knob does not select the H+ power band. The H+ button selects the H+ power band. K H+ Button ( T C-181) For reference the bar graph as shown on the DECU is also shown together with power band identification. As can be seen from the graphs the engine rpm and hydraulic pump output change within the power bands, depending on the rotation of the hand throttle control knob.

C133970

Fig 107. JS200 - JS235 - power band mapping H+ Button

Pressing the H+ button again de-selects the H+ power band. The H+ button sends and input to the MECU.

Pressing the H+ button 2 selects the H+ power band.

C-181

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C-181


Section C - Electrics Engine and Power Control Engine Throttle and Power Mode Control The MECU will not select the H+ power band unless the hand throttle knob 1 is first set to the H power band. When the H+ power band is selected the MECU uses the machine power map to request the applicable no load engine rpm and output the applicable output in mA to the pump proportional solenoid valve. If the hand throttle knob turns to reduce the machine power setting the MECU deselects the M+ power band.

1

2

C128380-C1

Fig 108.

C-182

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C-182


Section C - Electrics Engine and Power Control Engine Throttle and Power Mode Control Engine Speed Sensing

a pre-set value the power output to the pump proportional solenoid valve starts to reduce.

When the load from the hydraulic pump is high the engine may not have enough power to maintain the pre-set rpm. The MECU monitors the actual engine rpm and if it falls to

The graph shows an example of the control function.

Key 1

Pump solenoid power setting (machine power setting)

600 mA

2

Engine rpm (machine power setting)

2150 rpm

3

Point for pump power reduction start - engine speed drop start pre-set

- 20 rpm(1)

4

Point for pump power reduction end - engine speed drop end pre-set

- 70 rpm(1)

5

Reduced pump solenoid power setting pre-set

- 15%(1)

(1) MECU default value

3

mA

1

610 600 590 580 570 560 550 540 530

5

2

4

520 510 500 1900

1980

2000

2130

2150

2100

rpm C128360

Fig 109.

Engine Stall Prevention If the load from the hydraulic pump causes the engine to get close to stalling, the MECU will override the applicable power band map and reduce the output to the hydraulic pump proportional solenoid valve. This happens when the engine speed reduces to a pre-set value and remains active until the engine reaches a preset ‘stall recovery’ speed. The default values are minimum 1200 rpm and stall recovery 1400 rpm.

C-183

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C-183


Section C - Electrics Engine and Power Control Engine Throttle and Power Mode Control Engine Idle Control

2

When the operator selects this function the MECU switches off the output to the pump proportional solenoid valve (set to 0 mA) and requests the engine idle rpm setting from the engine ECU by means of a CAN message.

By use of the one touch idle control button 1. The button is located in the RH joystick control lever 2.

1

2

When the engine is in idle mode the power band bar graph on the LCD monitor is shown in grey. The engine can be set to a no load idle position in one of two ways: 1

By use of the auto idle button 1.

1

C128390

Fig 111. Pressing the one touch idle button sets the engine speed to idle. Pressing the button again returns control of the engine speed to the hand throttle control. If the one touch idle button is set to engine idle when the engine is not running the engine will remain at idle after start up.

C128380

Fig 110. Pressing the auto idle button activates the auto idle function. Pressing the button again de-activates the auto idle function. When auto idle is active an icon displays on the LCD monitor. When auto idle is active the engine rpm will automatically be set to idle if the machine is not working for a pre-set period of time. The time period can be set by the operator.

The automatic warm up function operates normally. If the one touch idle button is set to engine idle during the warm up sequence automatic warm up is cancelled and the engine speed is set to idle. The engine idle is also controlled by the automatic warm up and cold idle functions. Refer to the applicable topic. K Engine Automatic Warm Up ( T C-191)

To prevent the auto idle function setting the engine speed to idle when the machine is working or resume working from idle, the MECU monitors several inputs. The MECU will not set the engine speed to idle if one or more of the following inputs are active: – The pilot pressure switch input. – The travel pilot pressure switch input. – The auxiliary hydraulic controls (detected by the HECU and sent to the MECU by means of a CAN message) (if fitted). – The hammer hydraulic control (detected by the HECU and sent to the MECU by means of a CAN message) (if fitted). – Overload caution pressure switch (if fitted).

C-184

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C-184


Section C - Electrics Engine and Power Control Engine Throttle and Power Mode Control Hand Throttle Control Unit

simply detects falling or rising voltage from the potentiometer. The output from the hand throttle potentiometer is shown on the graph.

The hand throttle control knob 1 operates a potentiometer 2 which gives and analogue output between 0 and 4.5V.

The MECU monitors the rate of change of the hand throttle potentiometer. When the control knob turns slowly the MECU responds with fine step changes to the engine rpm and output to the hydraulic pump proportional solenoid valve. The knob must rotate 360 degrees to go from minimum to maximum engine rpm. When the control knob rotates quickly the engine rpm and pump solenoid outputs change in large steps. Minimum to maximum engine rpm only requires the knob to rotate 120 degrees This allows the operator to choose coarse or fine adjustment of the machine power setting.

The potentiometer has no stops and the control knob can turn continuously in both clockwise and anti-clockwise directions. When the control knob turns clockwise the output rises from a minimum of 0V to a maximum of 4.5V. When the control knob turns anti-clockwise the voltage output falls. The MECU is programmed not to respond when the output changes (‘flips’) from 0 to 4.5V or 4.5 to 0V. The MECU

V

1

0

0

0

0

2 C128340

Fig 112. Hand throttle potentiometer output / control knob rotation

C-185

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C-185


Section C - Electrics Engine and Power Control Engine Throttle and Power Mode Control

Wires and Connectors

C128400

Fig 113. Harness connectors C123, C094 The 5V reference voltage is also connected to the cooling Harness connector C123 - Mode switches fan control module (C038). K Electro Viscous Pins Details Fan ( T C-200) 1 Not used The throttle potentiometer has a shared 0V reference with 2 Switch illumination power the travel, auto idle and H+ mode switches (C123) 3 H+ power mode switch (low side output) connected to the MECU at connector J1 pin 14. 4

Travel speed mode select switch (low side output). Refer to Hydraulic Control in this section

5

Common earth (0V)

6

Auto idle switch (low side output)

The throttle potentiometer feed back signal (0 to 4.5V) is connected to the MECU at connector J1, pin 21.

Harness connector C094 - Throttle potentiometer Pins Details 1

Power supply (+ 5V reference)

2

Signal (0 to + 4.5V)

3

Earth (0V)

K Fig 114. Circuits - Throttle Potentiometer and Mode Buttons ( T C-187) The throttle potentiometer (C094) is connected to a 5V reference voltage supplied by the MECU from connector J1, pin 28 (C015).

C-186

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C-186


C-187

9813/5550-1

C

D

30

FREQUENCY02

VSENSOR 29

28

OUTPUT08

27

GND

15

SENSOR GND

14

OUTPUT04

OUTPUT18 13

C015 MECU (J1)

F

B

A

E

C038 COOLING FAN CONTROL

0.5 1009S

0.5 1009W

0.5 1009K

0.5 1009D

0.5 1009B

0.5 1009N

0.5 1009V

Fig 114. Circuits - Throttle Potentiometer and Mode Buttons

C016 MECU (J1) C100

C094/C123

C128940

Section C - Electrics

Engine and Power Control

Engine Throttle and Power Mode Control

C-187


Section C - Electrics Engine and Power Control Engine Throttle and Power Mode Control

Removal and Replacement Guide If the engine throttle and power mode control unit 1 is faulty it must be replaced.

3 1

2

6 4 5 C128400

Fig 115.

Removal 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2, Maintenance.

2

Disconnect the battery. Refer to Section 2, Maintenance, Electrical System.

3

Release the clips 2 and 5 from the side console and pull the control unit clear of the console.

4

Disconnect the harness connectors at the connectors 3 and 4.

Replacement Replacement is the opposite of the removal procedure. Note: The throttle potentiometer 6 does not require calibration.

C-188

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C-188


Section C - Electrics Engine and Power Control Engine Cold Idle

Engine Cold Idle The engine cold idle function restricts the engine to idle speed for different periods of time when the engine coolant or ambient air temperatures are less than pre-set values. The MECU uses pre-set data to calculate the cold idle time period depending on the engine coolant and ambient air temperature values. The MECU transmits an engine idle speed requirement to the engine ECU on the CANbus. When the engine cold idle function is active the hand throttle control is disabled. A sensor located on the boom transmits a signal to the MECU. The MECU converts the signal into the ambient air Air Temperature temperature. K Ambient Sensor ( T C-190)

C-189

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C-189


Section C - Electrics Engine and Power Control Ambient Air Temperature Sensor

Ambient Air Temperature Sensor Location

Overview

The ambient air temperature sensor 1 is located on a bracket on the LH side of the boom.

The ambient air temperature sensor transmits a signal to the MECU. The MECU converts the signal into the ambient air temperature. The MECU transmits the ambient air temperature on the CANbus which is displayed on the DECU. The MECU also uses the signal from the ambient air temperature sensor to operate the engine cold idle function. K Engine Cold Idle ( T C-189)

Wires and Connectors

1 C129150

C070

Fig 116.

C129170

Fig 117. Ambient air temperature sensor harness connector C070 C015 MECU J1 C070

C129180

Fig 118. Circuit

C-190

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C-190


Section C - Electrics Engine and Power Control Engine Automatic Warm Up

Engine Automatic Warm Up Overview

2 8

MECU 7 CANbus

1

6 5

4

Engine ECU

3

C128680

Fig 119. This feature allows the engine to quickly warm up to normal operating temperature if the vehicle is not being used (working).

3

The upper pilot pressure switch 8 is open (excavator services not selected).

4

The travel pilot pressure switch 7 is open (travel service not selected, machine stationary).

The automatic warm up sequence starts 15 seconds after engine start provided the following conditions are satisfied: 1

The cold idle function is NOT active. K Engine Cold Idle ( T C-189)

2

The coolant temperature is less than 50 ยบC engine coolant temperature is sent from the engine ECU 3 via a CANbus. The engine ECU derives the coolant temperature from the coolant temperature sensor 4.

C-191

When the automatic warm up sequence is activate the DECU displays the symbol 2. The MECU 1 sends an engine rpm target to the engine ECU via the CANbus so that the engine will run at the hand throttle setting for five minutes. The MECU sends messages on the CANbus and the engine ECU engine

9813/5550-1

C-191


Section C - Electrics Engine and Power Control Engine Automatic Warm Up increases the engine speed in 300 rpm steps at three minute intervals up to the maximum of 1800 rpm. After three minutes of running at 1800 rpm the engine revs will return to the hand throttle setting. If during the automatic warm up sequence the required conditions change i.e. engine water temperature reaches 50 ยบC or the operator selects an excavator service the MECU will cancel the automatic warm up sequence. If the operator selects the one touch idle function 6 or moves the hand throttle 5 the MECU will cancel the automatic warm up sequence

C005450GB-2

Fig 120. Example of auto warm up cycle if machine is started at idle

C-192

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C-192


Section C - Electrics Engine and Power Control Engine Automatic Idle

Engine Automatic Idle The engine automatic idle function is set to ON or OFF by pressing button 1. For a full description of how the system works refer to the applicable data in this section. K Engine Idle Control ( T C-184)

1

C128380

Fig 121.

C-193

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C-193


Section C - Electrics Engine and Power Control Variable Geometry Turbo (VGT) Actuator

Variable Geometry Turbo (VGT) Actuator Location The VGT actuator 1 is part of the turbocharger 2. Refer to the Engine Service Manual, 9806/4300.

1

2 C125690

Fig 122.

Overview For an overview of the VGT actuator, Refer to the Engine Service Manual, 9806/4300.

C-194

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C-194


Section C - Electrics Engine and Power Control Variable Geometry Turbo (VGT) Actuator

Wires and Connectors - VGT Actuator Power Supply The engine ECU power supply is controlled by the power hold relay. K Engine Fuse and Relay Box ( T C-178)

C125690-C1

Fig 123. VGT harness connector CE033 Harness connector CE033 Pins Details 1

Power supply (+ 12V) (via power hold relay)

2

Not used

3

Not used

4

Earth

5

CAN_L

6

CAN_L

Removal and Replacement For removal and replacement procedures, Refer to the Engine Service Manual, 9806/4300.

Test Procedures For test procedures, Refer to the Engine Service Manual, 9806/4300.

C-195

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C-195


Section C - Electrics Engine and Power Control Exhaust Gas Recirculation (EGR) Actuator

Exhaust Gas Recirculation (EGR) Actuator Location The EGR actuator 1 is part of the EGR valve 2 which is mounted on the engine exhaust manifold. Refer to the Engine Service Manual, 9806/4300.

1

2 C125680

Fig 124.

Overview For an overview of the EGR valve and actuator, Refer to the Engine Service Manual, 9806/4300.

C-196

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C-196


Section C - Electrics Engine and Power Control Exhaust Gas Recirculation (EGR) Actuator

Wires and Connectors The EGR actuator power supply is controlled by the voltage converter relay. K Engine Fuse and Relay Box ( T C-178)

C125680-C1

Fig 125. EGR harness connector CE008 Harness Connector CE008 Pins Details 1

Power supply (+ 12V) (via power hold relay)

2

Earth

3

CAN_L

4

CAN_H

Removal and Replacement Guide For removal and replacement procedures, Refer to the Engine Service Manual, 9806/4300.

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Rectify as required.

2

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

C-197

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C-197


Section C - Electrics Engine and Power Control TMAF Sensor

TMAF Sensor Location The Temperature Mass Air Flow (TMAF) sensor 4 is located in the induction hose 1 between the air filter and turbocharger.

1

4 3 2 C128690

Fig 126.

Overview There are two sensor areas on the TMAF sensor, area 3 senses the induction air flow and area 2 senses the induction air temperature.

C-198

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C-198


Section C - Electrics Engine and Power Control TMAF Sensor

Wires and Connectors The TMAF sensor is connected to the engine ECU. Refer to Machine ECUs and CANbus in this section.

6 5 4 3 2 1

C124160-C3

Fig 127. TMAF harness connector C083 Details

Pins

Details

1

Not used

4

Earth

2

Inlet air temperature output

5

Power (12V)

3

Air flow output

6

Not used

Pins

Removal and Replacement Guide

1 1

2

2

4 3 C124160-C4

Fig 128.

Removal

4

Remove the screws 2.

Note: The temperature sensor area 3 in the TMAF unit 1 may be hot. Do not touch this area.

5

Remove the TMAF sensor 1 from the induction hose.

Replacement Note: Do not touch the temperature sensor area 3, air flow sensor area 4 or connector pins. Note: Do not use a TMAF sensor which has been dropped or damaged. Replace with a new one. 1

Park the machine and make it safe. Obey the care and safety procedures.

2

Disconnect the battery.

3

Disconnect the electrical harness connector at the TMAF sensor 1.

C-199

Replacement of the TMAF sensor is the reverse of the removal procedure.

Test Procedures Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

9813/5550-1

C-199


Section C - Electrics Engine and Power Control Electro Viscous Fan

Electro Viscous Fan Location

Viscous Coupling Clutch Operation

The electro viscous fan 1 is located at the front of the engine.

Using a suitable PWM frequency the speed of the fan can be controlled by partially disengaging the viscous clutch. The fan target speed is determined by the MECU and based on the hydraulic oil and engine coolant temperatures.

1

If the target speed of the fan is not correct, the MECU changes the frequency of the PWM signal to the control solenoid. The solenoid controls the flow of oil inside the viscous coupling which in turn controls the clutch engagement and speed of the fan. Once the fan has reached the target speed the fan speed is maintained by a 50% PWM signal. The PWM frequency range for the fan is 0.5Hz to 20Hz. If a 100% PWM signal is applied (24V DC), the clutch will disengage after the hydraulic oil has drained and the fan will free wheel on the pulley.

2

If the electrical control of the clutch fails the clutch will fully engage and the fan will run at 100% speed.

3

Fan Speed Sensor

4 C128700-C2

Fig 129.

Overview

The fan speed sensor enables a closed loop feed back to the MECU. The actual fan speed can be compared to a target speed for any given set of oil and coolant temperatures. If necessary the MECU responds by changing the PWM signal to the fan. The sensor operates on a 5V supply. For each revolution of the fan there are six pulses from the signal output.

The fan 1 draws air through the machine cooling pack. The fan consists of a electrically controlled solenoid 3 and viscous clutch 4. A 24V PWM signal controls the solenoid and fan speed. A speed sensor assembly 2 operates on a 5V supply. The fan viscous clutch is driven by the engine pulley with a ratio of 0.95 : 1. If the engine rpm is 1000, then the viscous clutch rpm is 950

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Section C - Electrics Engine and Power Control Electro Viscous Fan

Wires and Connectors C

B

A

D

E

F

C128700-C1

Fig 130. Electro viscous fan harness connector C038 Harness Connector C038 Pins

Details

A

Speed sensor supply (+ 5V )

B

PWM signal - solenoid (24V)

C

Return - solenoid

D

Return - speed sensor (0V)

E

Speed sensor signal

K Fig 131. Circuit ( T C-202)

C-201

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C-201


C015 MECU J1

C-202

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4002

4005

4000

4001

4048

C038

Fig 131. Circuit

+24 V

FAN PWM CONTROL

C016 MECU J2

C128990

Section C - Electrics

Engine and Power Control Electro Viscous Fan

C-202


Section C - Electrics Engine and Power Control Electro Viscous Fan

Testing

is 100 0C and the hydraulic oil is 70 0C the fan will run at 925 rpm not 740 rpm.

The expected fan speed for different engine coolant and hydraulic coolant temperatures are given in the tables.

Use the fan test mode to test the fan and its solenoid control valve. Refer to Machine Diagnostic Modes.

Important: The MECU sets the fan to the target speed for the highest temperature. For example if the engine coolant Engine coolant Hydraulic oil Expected fan speed rpm (H+ power band selected) temperature 0C temperature 0C

Required fan speed %

Less than 90

65

700 (approx.)

Idle

97

70

740

40

99

72

925

50

101

73

1110

60

103

74

1295

70

105

79

1480

80

107

84

1850

100

The 100% fan speeds for different engine speeds are given in the table. These speeds are expected when there is no PWM signal to the fan control solenoid. Engine rpm

Fan speed rpm

2050

1850

1900

1750

1700

1570

1500

1390

1200

1110

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Section C - Electrics Engine and Power Control Engine Coolant Temperature Switch

Engine Coolant Temperature Switch The coolant temperature switch is connected to the engine ECU. The coolant temperature status is broadcast on the CANbus by the engine ECU. For details of the coolant temperature switch refer to the applicable engine documentation.

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Section C - Electrics Engine and Power Control Engine Coolant Level Switch

Engine Coolant Level Switch Location The coolant level switch 1 is located in the coolant expansion bottle 4. The switch is located in a cavity on the

outside of the bottle. Float 2 is located over the switch cavity inside the bottle. The float is retained by a float stop 3.

4

3 2

1 C124270

Fig 132.

Description When the coolant is above the minimum level, the float 2 causes the coolant level switch contacts to close. When the coolant falls to the minimum level or below the float causes the coolant level switch contacts to open. The coolant level switch state is monitored by the MECU. When the switch contacts are open (low coolant level) the MECU activates operator warnings.

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Section C - Electrics Engine and Power Control Engine Coolant Level Switch

Wires and Connectors

C130270-C1

Fig 133. Harness connector C028

C016 MECU J2

C028

C130290

Fig 134. Circuit

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Section C - Electrics Engine and Power Control Engine Coolant Level Switch

Removal and Replacement Guide To remove the coolant level switch, proceed as follows: Note: There is no need to drain the coolant. Coolant will not be lost when the coolant level switch is removed. 1

Disconnect the electrical harness connector at the coolant level switch.

2

Using a flat blade screwdriver carefully prise the coolant level switch from the coolant expansion bottle. Keep the screwdriver as close to the base of the coolant level switch as possible. Do not lever against the moulded electrical connector. Do not use excessive force.

When replacing the coolant level switch press the switch into its cavity in the coolant expansion bottle. Ensure that the switch correctly clips into place.

Test Procedures The coolant level switch design means that the switch is most likely to default to the open state in the event of a faulty reed or float. This will activate the low coolant level warnings even if the coolant level is correct. Ensure that the float location inside the coolant expansion bottle is correct. Ensure that the float is free to move and that there is no sediment in the bottom of the coolant expansion bottle.

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Section C - Electrics Engine and Power Control Engine Oil Level Switch

Engine Oil Level Switch Location

Note: The engine oil level switch 2 is mounted inside the engine oil pan.

The engine oil level switch electrical connector 1 is located in the engine oil pan adjacent to the starter motor S.

1 S

2

1 C124800-C3.eps

Fig 135.

Overview The oil level switch 2 comprises a reed type switch and a float which moves depending on the oil level in the engine oil pan. When the oil level falls below a pre-set level the contacts of the reed switch open. The oil level switch state is monitored by the MECU. If the switch state is open for more than a pre-set time interval the MECU sends a message on the CANbus which activates the applicable operator warnings.

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Section C - Electrics Engine and Power Control Engine Oil Level Switch

Wires and Connectors

C124800-C2

Fig 136. Engine oil level switch harness connector C008

C016 MECU J2 C008

C129630

Fig 137. Circuit

Removal and Replacement Guide

connectors for continuity before replacing the oil level switch.

Important: Do not attempt to remove the oil level electrical connector from the oil pan, the connector can fall inside the oil pan. Removal and replacement the oil level electrical connector and switch requires removal of the engine oil pan. For removal and replacement procedures refer to the applicable engine documentation.

Test Procedures The oil level switch design means that the switch is most likely to default to the open state in the event of a faulty reed or float. This will activate the low oil level warnings even if the oil level is correct. Since replacement of the oil level switch requires removal of the engine oil pan check all the relevant wires and

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Section C - Electrics Engine and Power Control Vacuum Switch

Vacuum Switch Location The vacuum switch 1 is located in the induction hose between the air filter and turbocharger.

1 C128690-C1

Fig 138.

Overview If the air flow to the engine induction system is restricted, by a blocked air filter element for example, the air pressure inside the air filter housing is reduced. When the air pressure inside the air filter housing is below a pre-set value the air filter vacuum switch 1 contacts close. The digital signal is transmitted to the MECU.

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Section C - Electrics Engine and Power Control Vacuum Switch

Wires and Connectors

C12370-C2

Fig 139. Vacuum switch harness connector C027 MECU J1 C027

C129200

Fig 140. Circuit

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Section C - Electrics Engine and Power Control Fuel Level Sensor

Fuel Level Sensor Location

Wires and Connectors

The fuel level sensor 1 is located in the fuel tank.

1

C129250

Fig 142. Fuel level sensor harness connector C021 C129640

Fig 141.

Table 11. Harness connector C021

Overview

Pins

Details

A level sensor is fitted in the fuel tank to measure the level of fuel in the tank.

A

Sensor supply (24V)

B

Earth

The level sensor consists of a rod surrounded by a tube and a micro controller and resistance emulator. The rod and tube act as a capacitor. Depending on the fuel level, the remaining air volume between the rod and the tube varies. The resultant capacitive change is recorded and processed by the micro controller. The emulator converts the capacitance into a resistance which is sent to the MECU.

C

Sensor signal

K Fig 143. Circuit ( T C-213)

The MECU converts the resistance value to a percentage fuel content. The percentage value is sent via the CANbus to the display monitor. The display monitor drives the analog fuel gauge. Note: Machines with a 7 in display monitor have a digital representation of an analog fuel gauge.

C-212

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C-212


C015 MECU J1

C-213

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4002

4005

4000

4001

4048

C038

Fig 143. Circuit

+24 V

FAN PWM CONTROL

C016 MECU J2

C128990

Section C - Electrics

Engine and Power Control Fuel Level Sensor

C-213


Section C - Electrics Engine and Power Control Fuel Level Sensor

Testing The tables list the expected fuel level sensor outputs for different fuel tank contents.

Fuel Sensor Resistance (Ohms)

Fuel Remaining (%)

107.5

0 (‘no fuel’ alarm active) gauge needle points to red segment

102.5

5 (‘no fuel’ alarm active) gauge needle points to red segment

97.5

10 (‘low fuel’ alarm active) gauge needle points to red segment

92.5

15

87.5

20

82.5

25

77.5

30

72.5

35

67.5

40

62.5

45

57.5

50

52.5

55

47.5

60

52.5

65

37.5

70

32.5

75

27.5

80

22.5

85

17.5

90

12.5

95

12

100

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Section C - Electrics Engine and Power Control Water In Fuel (WIF) Sensor

Water In Fuel (WIF) Sensor Location The WIF sensor is integral with the pre-filter/water separator assembly 2. The sensor consists of an electronic module 1 mounted to pre-filter/water separator body and probe 3 at the separator bowl.

A

B

C

1

2

C124830-C5

Fig 145. WIF harness connector C007 Harness connector C007 Pins

Details

A

Sensor supply (+ 12V)

B

Switch signal

C

Earth

3 C124110

Fig 144.

Overview The water in fuel sensor 3 detects presence of water above a pre-determined level in the pre-filter/water separator bowl. Its electrical resistance range changes when sensor probe is submerged in water. The signal from the sensor is monitored by the engine ECU. When the signal indicates water is present the engine ECU broadcasts a message on the CANbus.

Wires and Connectors The WIF sensor power supply (12V) is controlled by the ignition relay. K Engine Start/Stop - Ecomax Engines ( T C-169)

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Section C - Electrics Engine and Power Control Alternator

Alternator Location The alternator 1 is located on the engine driven by the engine Front End Accessory Drive belt (FEAD).

1

C128800

Fig 146.

Overview The 24V 55 A alternator is a three phase generator having a rotating field winding and static power windings. Output is controlled by a solid state regulator and rectifier. The regulator varies the field current in accordance with electrical demand. The rectifier converts the AC output from the alternator to a DC supply for the machine batteries (24V). Both the regulator and rectifier are integral parts of the alternator.

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Section C - Electrics Engine and Power Control Alternator

Wires and Connectors

Power from the alternator is fed into the machine circuits and to charge the batteries via primary fuse B. K Battery Power Supply and Distribution ( T C-161)

L W

The L terminal is connected to the MECU (C025) which monitors the voltage output from the alternator (C042). The MECU broadcasts the value of the voltage output on the CANbus. If the voltage is too high or too low the MECU broadcasts a fault code on the CANbus. The charging voltage is displayed on the display monitor in the machine status menu.

B+

R

K Fig 148. Charging Circuit ( T C-218)

C128790

Fig 147. Connector Posts (C042) Alternator Harness Connections Pins

Details

R

To ignition relay C033 (24V)

L

Alternator output voltage

B+

Battery voltage (24V)

When the starter key is set to position I a 24V supply connects to the alternator at terminal R. The voltage provides a field current to the alternator windings via the voltage regulator. When the engine is running the output from the trio diode rectifier is fed to regulator which now provides the field current. Important: Although the alternator circuit is self sustaining once the engine is running, do not disconnect or isolate the batteries. Disconnection or isolation of the batteries while the engine is running can cause severe damage to the machine electrical systems. The regulator changes the field current depending on the load from the machine electrical system.

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Section C - Electrics Engine and Power Control

Fig 148. Charging Circuit

3014

3015

3000

3018

C015

MECU (J1)

C128960

Alternator

C100

2000

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Section C - Electrics Engine and Power Control Refuelling Pump

Refuelling Pump Location The refuelling pump 1 is mounted inside the machine toolbox compartment.

1

2 C128830

Fig 149.

Overview The refuelling pump is operated by a momentary switch located in the machine toolbox. The refuelling pump can be used in two different modes: automatic or manual refill. Automatic refill mode enables automatic shut off of the refuelling pump when the fuel in the fuel tank reaches a pre-set percentage of the total capacity. The fuel quantity can be set by the operator so as to allow a safe maximum fuel level when the machine is on uneven ground. The manual refill mode allows operation of the refuelling pump by manually holding the refuelling switch down.

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Section C - Electrics Engine and Power Control Refuelling Pump

Wires and Connectors

signal is sent via the diode to an input on the MECU at connector J1 pin 22. The DECU turns ON.

K Fig 152. Circuit ( T C-221)

A signal is also sent to an input on the MECU at connector J2 pin 19.

Automatic Refill Mode When the refuelling pump switch (C020) is pressed for less than two seconds, there is an output from pin 2 to the wake up diode (C127). A ‘wake up’ signal is sent via the diode to an input on the MECU at connector J1 pin 22 (C015). The DECU turns ON. A signal is also sent to an input on the MECU at connector J2 pin 19 (C016). The MECU monitors the fuel quantity. If the fuel quantity is at or below the pre-set ‘auto refuel percentage’ the refuelling pump relay R5 energises via an output from the MECU at connector J1 pin 27. The refuelling pump (C019) operates.

As long as the refuelling pump switch is held down the refuelling pump relay energises via an output from the MECU at connector J1 pin 27. The output remains on until the refuelling switch is released. The MECU will deenergise the refuelling pump relay and manual refuelling will stop. Note: If manual mode is entered from automatic mode, then automatic mode is NOT resumed when the refuelling pump switch is released.

When the fuel reaches the ‘auto refuel percentage’, the MECU will de-energise the refuelling pump relay and refuelling pump will stop. If during automatic refuelling the fuel quantity does not increase by at least 5% within 30 seconds (because the source of fuel has run out or there is a blocked filter for example) the MECU will de-energise the refuelling pump relay and the refuelling pump will stop.

C019

C020 C129290

Fig 150. Harness connectors C019, C020

Note: The MECU will not energise the refuelling pump relay if the engine is cranking or running. If the engine is started during automatic refuelling the MECU will deenergise the refuelling pump relay and refuelling will stop. Note: If there are active fault codes related to the fuel level sensor the MECU will de-energise the refuelling pump relay and the refuelling pump will stop. A second short press of the fuel pump momentary switch will turn off the automatic refuelling mode and refuelling will stop.

Manual Mode When the refuelling pump switch (C020) is pressed and held for more than two seconds the MECU sets the refuelling pump operation to manual mode.

C129300

Fig 151. Wake up diode harness connector C127

When the refuelling pump switch is pressed and held there is an output from pin 2 to the wake up diode. A ‘wake up’

C-220

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C-220


C020

C-221

C127

C016 MECU (J2)

C015 MECU (J1)

Fig 152. Circuit

C100

C019

R5

C015 MECU (J1)

C128980

CAB BASE EARTH POINT (INT)

Section C - Electrics

Engine and Power Control Refuelling Pump

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C-221


Section C - Electrics Engine and Power Control Refuelling Pump

C-222

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C-222


Section C - Electrics Hydraulic Systems Control 8 Station Solenoid Valve

Hydraulic Systems Control 8 Station Solenoid Valve Overview

The 8 station solenoid valve is located on a bracket at the LH side of the main pump compartment.

The 8 station solenoid valve 1 distributes servo pressure to activate machine functions automatically or when selected by the operator.

1

C132080

Fig 153. The 8 station solenoid valve is located on a bracket at the LH side of the main pump compartment.

Table 12. Solenoid

Function

Electrical Harness Connector Details

CT1

Slew Brake

C053

CT2

Controls Enable

C051 - Red

CT3

Slew Lock

C049

CT4

Max Flow Cut

C047

CT5

Travel Speed

C048 - Blue

CT6

Slew Shut Off

C050 - Red

CT7

Boost

C052 - Yellow

CT8

Cushion Control

C054 - Blue

Solenoid Control Valves

CT2 CT1 CT3 CT4

CT8 CT7 CT6 CT5 C129380-C1

Fig 154. Solenoid Valves

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Section C - Electrics Hydraulic Systems Control 8 Station Solenoid Valve

Removal and Replacement For removal and replacement procedures refer to Section E - 8 Station Solenoid Valve.

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Section C - Electrics Hydraulic Systems Control Pressure Switches

Pressure Switches Overview The electrical system detects operation on the different hydraulic services by means of servo pressure switches.

When a hydraulic service is selected oil pressure in the applicable servo circuit increases and the servo pressure switch contacts close. A digital signal is sent to the applicable electrical control component.

The switches are located in the applicable servo circuit.

1 2

3 4

C132190

Fig 155.

C-225

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C-225


Section C - Electrics Hydraulic Systems Control Pressure Switches Table 13. Item

Identification

Location

Pressure Range Colour Electrical Harness Code Connector Details

1

Slew Pressure Switch

Shuttle Valve Block

Green

C080

2

Boom Up Pressure Switch

Shuttle valve Block

Green

C079 - White

3

Travel Pressure Switch

Main Control Valve Block Blue

C037 - Yellow

4

Excavator Pressure Switch

Main Control Valve Block Red

C036

Removal and Replacement When replacing pressure switches install the correct pressure range switch in the correct port. Connect the correct harness connector.

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Section C - Electrics Hydraulic Systems Control 3-Speed Travel

3-Speed Travel Overview

2 3

MECU

10 9 Boost Sol. Valve

CANbus

4

8 1

5

7

6

mode C128710

Fig 156. Three travel speeds can be selected by changing the main hydraulic pump flow and swash plate position of the travel motor. The maximum flow cut solenoid valve controls the pump flow and the travel speed solenoid valve controls the swash plate angle in the travel motor.

Note: The last selected travel speed mode when machine is stopped is re-instated when the machine is re-started.

The boost solenoid valve is also energised when travel is selected to ensure maximum hydraulic pressure is available from the pump.

Auto Gear Change (Fast travel mode)

The travel speed mode is set by pressing travel button 6. Each press of the button selects the next travel speed mode in the cycle as follows: – Slow - Fast - Creep The selected travel speed mode is indicated on the display monitor 2 as either a hare 5 (Fast), tortoise 4 (Slow), or snail 3 (Creep).

C-227

Changing the engine speed with the throttle control knob varies the travel speed within the selected mode.

The auto gear change function operates in fast travel mode only. If the hydraulic system pressure in the travel motor rises above 259 bar the hydraulic pressure from the travel solenoid valve no longer holds the motor swash plate in minimum angle. The system pressure causes the swash plate to move to its maximum angle and the travel mode changes to slow for increased torque. The display monitor continues to show the hare symbol.

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Section C - Electrics Hydraulic Systems Control 3-Speed Travel When the system pressure in the travel motor falls below 259 bar the swash plate returns to its minimum angle and the motor changes to the fast travel mode.

When the travel button A is pressed the signal at the MECU connector J1 pin 14 connects to earth. The MECU responds by sending a CAN message to the DECU which displays the applicable travel mode symbol.

Wires and Connectors K Fig 158. Circuit ( T C-229) K 8 Station Solenoid Valve ( T C-223) – Boost solenoid (C052), Maximum flow solenoid (C047), Travel speed solenoid (C048). K Pressure Switches ( T C-225) – Travel pressure switch (C037).

When the operator uses the controls to select travel the travel pressure switch closes. The signal at the MECU connector J2 pin 26 connects to earth. The MECU responds by energising or de-energising the travel speed solenoid, and maximum flow solenoid to select the applicable travel mode. The MECU also energises the boost solenoid in all travel modes. This ensures maximum hydraulic pressure is available. The solenoid and switch states for each travel mode are given in the table.

Travel Travel pressure Mode switch (C037)

Table 14. Travel speed MECU Maximum flow solenoid (C048) output solenoid (C047)

Slow

Closed

De-energised(1)

Fast

Closed

Creep

Closed

(1) (2) (3) (4)

Energised

-

De-energised(2)

J1 pin 24 De-energised

(3) (1)

De-energised

-

(2)

(4)

Energised

MECU output

Boost Solenoid (C052)

MECU output

-

Energised

J2 pin 5

-

Energised

J2 pin 5

J2 pin 23 Energised

J2 pin 5

The travel motor swash plate moves to its maximum angle (low speed high torque). Pump delivers maximum flow. The travel motor swash plate moves to its minimum angle (high speed low torque). Limits pump to 60% of its maximum flow for creep speed travel. Table 15. Harness Connector C123 - Mode switches Pins Details 1

Not used

2

Switch illumination power

3

H+ power mode switch (low side output). Refer to Engine and Power Distribution in this section

4

Travel speed mode select switch (low side output)

5

Common earth (0V)

6

Auto idle switch (low side output). Refer to Engine and Power Distribution in this section

C128400-C1

Fig 157. Harness connector C123

C-228

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C015 MECU (J1)

C048

C-229 REVOLVER EARTH STUD (EP03)

C047

Fig 158. Circuit

C052

C016 MECU (J2)

C016 MECU (J2)

C015 MECU (J1)

C037

A

REVOLVER EARTH STUD (EP03)

C123

C129110

Section C - Electrics

Hydraulic Systems Control 3-Speed Travel

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C-229


Section C - Electrics Hydraulic Systems Control Controls Enable (Lever Lock)

Controls Enable (Lever Lock) Overview

Wires and Connectors

The machine is equipped with a hydraulic controls lock lever lock 1, lever switch 2, controls enable switch 3 and controls enable solenoid valve.

K Fig 161. Circuit ( T C-231)

The controls enable solenoid valve is part of the 8 station solenoid valve. K 8 Station Solenoid Valve ( T C-223) The lever lock has to be raised to enter and exit the cab. When the lever is raised the controls automatically isolate by means of the controls enable solenoid valve. When the lever lock is lowered the controls enable switch must be pressed before hydraulic operation of the machine is possible.

K 8 Station Solenoid Valve ( T C-223) – Controls enable solenoid (C051). When the lever lock is in the up position the lever switch (C063) changes state and the controls enable solenoid (C051) de-energises. At the same time the input at MECU connector J2 pin 34 connects to earth. The MECU responds by switching off the output to the controls enable solenoid at connector J2 pin 6. When the lever lock is in the lowered position the lever switch changes state and the earth connection at MECU is switched off. At the same time the controls enable solenoid is connected to earth. The MECU output at connector J2 pin 14 remains off and the controls enable solenoid does not energise. When the operator presses the controls enable switch (C122) there is a momentary earth connection at the MECU connector J2 pin 25. The MECU responds by switching on the output to the controls enable solenoid at connector J2 pin 6. The controls enable solenoid energises and the hydraulic controls are active.

1 2

If the operator presses the controls enable switch again the MECU responds by switching off the output to the controls enable solenoid at connector J2 pin 6. The controls enable solenoid de-energises and the hydraulic controls isolate.

C122

C063

3 C129470

Fig 159.

C-230

C129480

Fig 160. Harness connectors C063, C122

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C-230


Section C - Electrics Hydraulic Systems Control

C016

MECU (J2)

C016

C-231

MECU (J2)

Fig 161. Circuit

CAB BASE EARTH POINT (INT) (EP07)

C016

MECU (J2)

C129120

Controls Enable (Lever Lock)

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C-231


Section C - Electrics Hydraulic Systems Control Controls Enable (Lever Lock ISO)

Controls Enable (Lever Lock ISO) Overview The ISO standard 13998 requires a lever lock circuit which consists of: – Two Lever Lock Switches located below the lever lock lever – A Control Enable switch – A Control Enable solenoid

If the operator presses the controls enable switch again the MECU responds by switching off the output to the controls enable solenoid at connector J2 pin 6. The controls enable solenoid de-energises and the hydraulic controls isolate. The system has Error codes which can be generated to display a fault in the system: – C1316: Pilot pressure is above 20 bar with the lever lock up. The solenoid may be stuck open.

– A Hydraulic Pilot Pressure Sensor

Wires and Connectors

– C1317: Pilot pressure is below 20 bar with the lever lock down. The solenoid may be stuck closed or the pilot pressure is low.

K Fig 163. ( T C-233)

– C1318: Control Enable solenoid is stuck.

K 8 Station Solenoid Valve ( T C-223)

– C131A: Only 1 Lever Lock Switch is signalling that the lever lock is down.

– Controls enable solenoid (C051).

C122

K Pressure Switches ( T C-225) – Hydraulic Pilot Pressure Sensor (C090) When the lever lock is in the up position the lever lock switches (C063 and C225) change state and the controls enable solenoid (C051) de-energises. At the same time the input at MECU connector J2 pin 34 connects to earth. The MECU responds by switching off the output to the controls enable solenoid at connector J2 pin 6. When the lever lock is in the lowered position the lever switches change state and the earth connection at MECU is switched off. Lever Lock Switch 1 (C063) connects the controls enable solenoid to earth. The MECU output at connector J2 pin 14 remains off and the controls enable solenoid does not energise. The lever lock switch 2 (C225) sends a signal to the DECU.

C063, C225 C090

C129480-C17.eps

Fig 162. Harness connectors C063, C225, C090 and C122

When the operator presses the controls enable switch (C122) there is a momentary earth connection at the MECU connector J2 pin 25. The MECU responds by switching on the output to the controls enable solenoid at connector J2 pin 6. The controls enable solenoid energises and the hydraulic controls are active. The pilot pressure sensor (C090) measures the pilot pressure at the cab manifold to verify that the control enable solenoid is working correctly.

C-232

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Section C - Electrics Hydraulic Systems Control

C016 C016

MECU (J2)

C016

MECU (J2)

C016

C-233

MECU (J2)

Fig 163.

C015

MECU (J1)

MECU (J2)

C134550.eps

Controls Enable (Lever Lock ISO)

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C-233


Section C - Electrics Hydraulic Systems Control Slew Brake and Slew Lock

Slew Brake and Slew Lock Overview Slew Brake The slew brake is part of the slew motor. Springs apply pressure to friction pads to prevent rotation of the slew motor. The brake is held in the OFF position by hydraulic pressure. For details of the slew brake hydraulic operation refer to Section E. The function of the slew brake is to operate as a slew park brake. When the operator de-selects the slew function the slew motor cross line relief valves operate to bring the slew motion to a stop. The swing brake does not operate until the slew motion stops. The slew brake releases automatically when the operator selects the slew function.

Slew Lock Operation of the slew lock function is selected by the slew lock switch in the cab console. The slew lock mode prevents operation of the slew function, even if the controls operate to select slew. The slew lock mode selects 100% slew brake and locks the slew hydraulic service spool in it’s neutral position. For details of the slew lock hydraulic operation refer to Section E. Note: The controls isolate mode also enables the slew lock.

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Section C - Electrics Hydraulic Systems Control Slew Brake and Slew Lock

Wires and Connectors

Locked

Closed - red LED ON

Energised(1)

Unlocked

Open - red LED OFF

De-energised De-energised

K Fig 165. Circuit ( T C-236) K 8 Station Solenoid Valve ( T C-223) – Slew brake solenoid (C051), Slew shut off solenoid (C050), Slew lock solenoid (C049).

Energised after five seconds

(1) Only when the engine is running When the slew lock switch (C120) is set to LOCK the MECU responds with an output from connector J2 pin 11, energising the slew shut off solenoid (C050). Hydraulic servo pressure is applied to both sides of the slew service spool in the main valve block, locking it in its neutral position. This prevents operation of the slew function.

K Pressure Switches ( T C-225) – Slew pressure switch (C080).

The MECU energises the slew lock solenoid (C049) after 5 seconds, sufficient time for the slew motion to stop before the slew brake is applied.

C129480-C1

Fig 164. Harness connector C120

Slew Brake Slew Brake Mode

Slew pressure switch (C080)

Slew brake solenoid (C053)

Brake OFF

Closed

Energised

Brake ON

Open

De-energised after five seconds

When the slew function is de-selected the slew pressure switch (C080) opens. The MECU keeps the slew brake solenoid (C053) energised for a further 5 seconds, sufficient time for the slew motion to stop. The MECU then de-energises the slew brake solenoid. Hydraulic pressure in the slew brake is released and the slew brake is applied. When the operator selects the slew function the slew pressure switch closes. The input at connector J2, pin 14 on the MECU connects to earth. The MECU responds with a 24V output at connector J2 pin 13 energising the slew brake solenoid. The solenoid connects the slew brake to hydraulic pressure and the slew brake releases.

Slew Lock Slew Lock Mode

C-235

Slew lock switch (C120)

Slew shut off Slew lock solenoid solenoid (C049) (C050)

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C-235


C-236

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REVOLVER EARTH STUD (EP03)

C050

C053

C015

MECU (J1)

Fig 165. Circuit

MECU (J2)

C016

SENSOR: PRESSURE SWING PILOT

C080

CAB BASE EARTH POINT (INT)

SWING LOCK SWITCH

C120

C049

C129100

Section C - Electrics

Hydraulic Systems Control Slew Brake and Slew Lock

C-236


Section C - Electrics Hydraulic Systems Control Pump Proportional Control Solenoid

Pump Proportional Control Solenoid Operation

Wires and Connectors

The pump power control proportion solenoid 1 is located on the hydraulic pump regulator assembly. The solenoid controls the hydraulic horsepower available from the main hydraulic pump.

K Fig 167. Circuit ( T C-238)

The MECU controls the current to the proportional solenoid depending on the machine status. The MECU uses inputs from the operator, engine rpm and available engine torque (sent by the engine ECU) to calculate the correct current to maintain the necessary pump power output. When there is no hydraulic service operation the MECU sends the maximum current to the pump proportional solenoid. This enables the engine to increase the available torque for initial operation of a hydraulic service and prevents the engine rpm falling too low.

1

The pump proportional solenoid is part of the machine power mode control system. For more details refer to the applicable topic in this section. C132220

Fig 166. Harness connector C045 The MECU controls the power from the pump by means of a PWM output from connector J1, pin 12. to the proportional solenoid (C045). When the PWM output supplies the highest current (300 mA) the pump output is at maximum power.

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Section C - Electrics Hydraulic Systems Control Pump Proportional Control Solenoid MECU (J2)

C045

C015

MECU (J1)

C129080

Fig 167. Circuit

C-238

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C-238


Section C - Electrics Hydraulic Systems Control Cushion Control

Cushion Control Overview The cushion control switch enables the operator to set the control response of the boom and dipper hydraulic service to one of two modes: 1

Cushion ON. Slow acceleration and deceleration of the boom and dipper services when selected and deselected. This mode enables maximum precision. When cushion is ON the cushion solenoid valve deenergises.

2

Cushion OFF. Fast acceleration and deceleration of the boom and dipper services when selected and deselected. This mode enables maximum operating productivity. When cushion is OFF the cushion solenoid valve energises.

Wires and Connectors K Fig 169. Circuit ( T C-240) K 8 Station Solenoid Valve ( T C-223) – Cushion control solenoid (C054).

C129480-C1

Fig 168. Harness connector C128 The cushion control switch (C128) is connected to + 24V at pin 2 via fuse F3 located on the main PCB in the cab. When the switch is set to Cushion OFF the cushion control solenoid (C054) energises via pin 3 of the switch. The red LED in the switch illuminates.

C-239

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C-239


C065 CONNECTOR: VEHICLE DIAGNOSTIC

C-240

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Fig 169. Circuit

CAB BASE EARTH POINT (INT) (EP07)

C128 CUSHION MODE SWITCH

8018

REVOLVER EARTH STUD (EP03)

8018

C054 SOLENOID CUSHION

C129130

Section C - Electrics

Hydraulic Systems Control Cushion Control

C-240


Section C - Electrics Hydraulic Systems Control Overload Caution (option)

Overload Caution (option) Overview A hydraulic pressure switch 1 is fitted to the boom HBCV manifold 2. When the overload threshold is reached a warning is displayed on the DECU monitor.

1

2

C130030

Fig 170.

Wires and Connectors K Fig 172. Circuit ( T C-242) The boom overload pressure switch (C023) pin A is supplied with power from the main fuse board (C100 X4) via fuse 13. The boom overload pressure switch earths via pin B to the revolver earth point (EP03). When the pressure exceeds the threshold of the switch a 24V signal is sent via pin C to the MECU J2 pin 22. As a result of this input a CANbus message will be sent to the DECU and the DECU will inform the operator that there is a boom overload situation.

C129530

Fig 171. Harness connector C023

C-241

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C-241


C065 CONNECTOR: VEHICLE DIAGNOSTIC

C-242

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C015 MECU (J1)

Fig 172. Circuit

1001 1001D

C

4010

1

2

6030

B

6012

REVOLVER EARTH STUD (EP03)

C036 SENSOR: PRESSURE UPPER PILOT

A

C023 SENSOR: PRESSURE BOOM OVERLOAD

C129340.eps

C016 MECU (J2)

Section C - Electrics

Hydraulic Systems Control Overload Caution (option)

C-242


Section C - Electrics Hydraulic Systems Control Boost Pressure

Boost Pressure Overview The boost function is used to increase the relief pressure setting of the main relief valve.

Wires and Connectors K Fig 174. Circuit ( T C-244) K 8 Station Solenoid Valve ( T C-223) – Boost solenoid (C052). The MRV boost solenoid (C052) is energised by the MECU (C016) from connector J2. When the MECU inputs require the solenoid to be energised it will output 24V from pin 5 to energise the MRV boost solenoid pin 1. The MRV boost solenoid earths through pin 2 to the revolver earth point (EP03). The inputs to inform the MECU to energise the boost solenoid are: – Power selection on the DECU at levels L1, L2, L3. – Travel pressure switch signal. – Boost button pressed on the RH joystick. When the travel pressure switch closed (machine travelling) the boost solenoid will be energised. When in lift mode power settings (L1, L2 or L3) the boost solenoid will be energised. When the boost button on the RH joystick (C095-X3) is operated, the boost solenoid will be energised for three seconds, then de-energised for nine seconds. When the boost button is released the boost function will remain off for nine seconds before it can be selected again.

C129540

Fig 173. Harness connector C095-X3 (blue)

C-243

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C-243


Section C - Electrics Hydraulic Systems Control Boost Pressure C016 MECU (J2)

C095-X3 JOYSTICK: RH HANDLE

C052 SOLENOID: MRV BOOST

A CAB BASE EARTH POINT (INT) (EP07)

REVOLVER EARTH STUD (EP03)

REVOLVER EARTH STUD (EP03)

C129370.eps

Fig 174. Circuit

C-244

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C-244


Section C - Electrics Hydraulic Systems Control Maximum Flow Cut Solenoid

Maximum Flow Cut Solenoid Overview When the maximum flow cut solenoid energises, a signal is sent to the main hydraulic pump to reduce the oil flow to 60% of maximum. For operation of the hydraulic pump refer to Section E - Hydraulic Pump/Regulator.

The maximum flow cut solenoid (C047) is energised by the MECU. The MECU outputs 24V from pin 23 to the maximum flow cut solenoid pin 2. – Power selection on the DECU at levels L1, L2, L3. – Creep travel mode selected and travel pressure switch signal.

Wires and Connectors The inputs to inform the MECU to energise the maximum flow cut solenoid are:

K Fig 174. Circuit ( T C-244)

The maximum flow cut solenoid earths through pin 1 to the revolver earth point (EP03).

K 8 Station Solenoid Valve ( T C-223) – Maximum flow cut solenoid (C047).

C015 MECU (J1) C048 SOLENOID: TRAVEL SPEED

C052 SOLENOID: MRV BOOST

C016 MECU (J2)

C047 SOLENOID: MAX FLOW

REVOLVER EARTH STUD (EP03)

C037 SENSOR: PRESSURE TRAVEL PILOT

REVOLVER EARTH STUD (EP03) C129360.eps

Fig 175. Circuit

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C-245


Section C - Electrics Hydraulic Systems Control Hydraulic Oil Temperature Sensor

Hydraulic Oil Temperature Sensor Overview The hydraulic oil temperature sensor 1 is located in the suction pipe assembly below the main hydraulic pump.

1 C132240

Fig 176.

Wires and Connectors The hydraulic oil temperature sensor (C046) pin 1 supplies a signal to MECU J1 (C015) pin 31. The resistance of the sensor varies according the temperature. The sensor earths through pin 2 which is connected to the MECU J1 pin 14.

C129450-C2

Fig 177. Harness connector C046

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C-246


Section C - Electrics Hydraulic Systems Control Hydraulic Oil Temperature Sensor C046 C015 MECU (J1) SENSOR: HYDRAULIC OIL TEMPERATURE 4000

4002

J1 C129390.eps

Fig 178. Circuit

C-247

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C-247


Section C - Electrics Hydraulic Systems Control Quickhitch (option)

Quickhitch (option) Overview

inside the hydraulic compartment above the hydraulic pump.

The quickhitch latch electrical control system allows operation of the quickhitch hydraulic latch when the boom and arm are in the correct position. Enclosures 1 and 2 mounted on the boom and dipper, each house a position sensing switch 4. Solenoid valve 5 diverts oil pressure to the quickhitch latch ram. The solenoid valve is located

A pressure switch is located in the bucket crowd pilot line. This allows operation of the quickhitch only when the crowd service is selected. LED indicator 3 flashes when the quickhitch latch operates.

3

1 2

4

5

C130050

Fig 179.

C-248

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C-248


Section C - Electrics Hydraulic Systems Control Quickhitch (option)

Wires and Connectors K Fig 183. ( T C-250) and K Fig 184. ( T C-251) The quickhitch latch control system is controlled by the HECU.

C129450-C2

Fig 180. Harness connectors C158, C157, C156

There are three ground switches to the HECU: – When the arm position sensor (C158) recognises that the arm is in a safe position (perpendicular or closer to the cab) and sends a ground signal to the HECU J2 pin 29 (C154). – When the boom position sensor (C157) recognises that the boom is in a safe position (parallel to the ground or lower) and sends a ground signal to HECU J2 pin 34.

C129480-C14

Fig 181. Harness connector C121

– When the bucket crowd service operates the quickhitch pressure switch (C156) sends a ground signal to J2 pin 35. C129540

When the quickhitch momentary switch (C121) is pressed a ground signal is inputted into J2 pin 3, if the operator has pressed the switch by mistake the switch can be selected in the opposite direction and an input will be sent to pin 15 to cancel the request.

Fig 182. Harness connector C095-X2 (green)

When the HECU receives the input from the switch (C121) it will inform the DECU via canbus of a quickhitch unlock request. The DECU will then display the Boom/Arm/ Padlock symbol. As the boom and arm switches connect the HECU to ground, the applicable symbol will change to green to show that either boom or arm are in the correct position to allow operation of the quickhitch. The LED lights on the boom will also flash to act as a warning to others that the attachment can release from the arm. With the arm and boom now in a safe position and bucket crowd pilot switch closed the operator can select the quickhitch button (C095 - X2) on the RH controller. This will send a ground signal to HECU J2 pin 16 (C154) and the HECU energises the quickhitch solenoid. When the quickhitch is in the unlock position the DECU will display the padlock unlocked symbol and activate the warning buzzer. The button on the RH controller must remained pressed throughout the operation. If the button is released before the procedure is complete the unlock procedure must be repeated from the start.

C-249

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C-249


C-250

CAB BASE EARTH POINT (INT) (EP07)

C121 SWITCH: QUICK HITCH

Q/H SWITCH PRESSED

Fig 183. Circuit - Sheet 1 of 2

REVOLVER EARTH STUD (EP03)

C154

ECU: HYDRAULIC CONTROL ECU (J2)

C129730.eps

REVOLVER EARTH STUD (EP03)

C156 SENSOR: PRESSURE - QUICK HITCH

C157 SENSOR: ALIGNMENT - BOOM

C158 SENSOR: ALIGNMENT - ARM

BUCKET CROWD SELECTED

Section C - Electrics

Hydraulic Systems Control Quickhitch (option)

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C-250


C-251

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C153

ECU: HYDRAULIC CONTROL ECU (J1)

CAB BASE EARTH POINT (INT) (EP07)

Fig 184. Circuit - Sheet 2 of 2

REVOLVER EARTH STUD (EP03)

C085 LIGHT: QUICK HITCH BOOM STATUS

C155 SOLENOID: QUICK HITCH

REVOLVER EARTH STUD (EP03)

C095 JOYSTICK RH HANDLE

C154

ECU: HYDRAULIC CONTROL ECU (J2)

Q/H BUTTON PRESSED

C129730-C1.eps

Section C - Electrics

Hydraulic Systems Control Quickhitch (option)

C-251


Section C - Electrics Hydraulic Systems Control Quickhitch (option)

Page left intentionally blank

C-252

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Section C - Electrics

Cab Systems and Lighting Camera System Component Location

C110

C068/C069

C066

The typical camera locations are as follows: – Camera 1 - is fitted to the counterweight to view from the rear of the machine. – Camera 2 - is fitted to the right hand side of the machine to view the right hand side of the machine.

Overview

C129480-C13.eps

If the optional 7” display is fitted then up to 2 cameras can be fitted and viewed on the DECU LCD.

Fig 185. Harness connectors C110, C068, C069 and C066

The cameras can be displayed simultaneously or individually on the DECU.

Wires and Connectors K Fig 186. Circuit ( T C-254) Table 16. C068/C069 Camera Units Pin 1

24V supply

2

Ground to cab base earth point

3

Signal wires to monitor

4

Shield Wire

5

Not Used

The cameras are connected to a 24V supply from fuse 9 of the main fuse board (C100 X3) to pin 1 of each camera unit. Pins 2 of the camera units (C068 and C069) are both connected to the cab base earth point (EP07). The images from the cameras are sent to the DECU (C110 J2) via a coaxial cable. Pins 3 on the cameras are the signal wires which connect to the DECU at pins 7 and 8. Pins 4 on the cameras are the shield wires which connect to pins 6 and 9 on the DECU.

C-253

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C-253


C-254

B+

IGN+

C109/C110 ECU: DISPLAY (J1) ECU: DISPLAY (J2)

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Fig 186. Circuit

C069 CONNECTOR: CAMERA 2 OFFSIDE

C068 CONNECTOR: CAMERA 1 COUNTERWEIGHT

C069 CAMERA: OFFSIDE

C068 CAMERA: COUNTERWEIGHT

CAB BASE EARTH POINT (INT) (EP07)

0.75 1023

C129170.eps

MODULE: CAB FUSES, REL AND DIAGNOSTICS

Section C - Electrics

Cab Systems and Lighting Camera System

C-254


Section C - Electrics Cab Systems and Lighting Standard Work Lights

Standard Work Lights Component Location Work lights are mounted on the boom, toolbox and counterweight to provide additional light when required.

Overview The work lights are operated from a three position rocker switch in the right hand console.

Wires and Connectors K Fig 188. Circuits ( T C-256) When the switch (C113) is in position 1 power supply to the work lights is isolated (work lights OFF). 24V is supplied by Fuse 24 on the main fuse module (C100 X4) to pin 2 of the switch (C113). When the switch is in position 2 - a 24V supply exits via pin 3 where is it is distributed to the boom working lights (C124, C162), the toolbox light (C018) and the DECU (C109 J1, pin 1) The DECU activates warnings if the work lights are ON after 15 seconds if the engine is not running. Power is also connected (via splice S039) to the LED (C147) to allow back lighting and illumination of the console. Position 3 of the switch provides power to the same circuits as position 2 plus supplies 24V to pin 5. Pin 5 is the supply to the counterweight light (C125).

C113

C018/C125

C129480-C3.eps

Fig 187. Harness connectors C018,C125 and C113

C-255

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C-255


C-256

C065 CONNECTOR: VEHICLE DIAGNOSTIC

Fig 188. Circuits

C113 WORKLIGHTS STANDARD

CAB BASE EARTH POINT (INT) (EP07)

C125 COUNTERWEIGHT

C100 MODULE: CAB FUSES, RELAY AND DIAGNOSTICS

8002A

9813/5550-1

REVOLVER EARTH STUD (EP03)

BOOM RH

C162

C124 BOOM LH

6015

C018 REVOLVER RH

C109/C110 ECU: DISPLAY (J1) ECU: DISPLAY (J2)

C147 LIGHT: CONSOLE ILLUMINATION

C129190.eps

6148

Section C - Electrics

Cab Systems and Lighting Standard Work Lights

C-256


Section C - Electrics Cab Systems and Lighting Cab Work Lights

Cab Work Lights Component Location Additional work lights (optional) are mounted on the roof of the cab pointing forward for increased lighting.

Overview The work lights are operated from a 2 position rocker switch in the right hand console.

Wires and Connectors K Fig 190. ( T C-258) The 2 position rocker switch (C114) receives a feed on pin 2 from i fuse 16 of the main fuse box module (C100 X4). Position 1 is the OFF position for the lights. Position 2 connects power across the switch to pin 3 which feeds 24V to the cab work lights (C055, C056) through the cab roof connector (IC07). The cab work lights switch ON.

C055-1, C055-2 C056-1, C056-2

C114

C129480-C2.eps

Fig 189. Harness connectors C055, C056 and C114

C-257

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C-257


C-258

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C065 CONNECTOR: VEHICLE DIAGNOSTIC

Fig 190. Circuit

CAB LH C056

CAB RH C055

8004B

8004A

8004

6093

ICO7 1

ICO7 7

8004

6093

8004

1009K

CAB BASE EARTH POINT (INT) (EP07)

IC07 - ROOF HARNESS CONNECTOR

3005

6087

C114 WORKLIGHTS CAB

C129210.eps

Section C - Electrics

Cab Systems and Lighting Cab Work Lights

C-258


Section C - Electrics Cab Systems and Lighting Beacon

Beacon Component Location

C115

The machine is fitted with three separate beacon sockets. – Socket 1 - is situated in the centre section of the machine on the front edge of the top plate for powering a cab mounted beacon which can be selected to operate alone. – Socket 2 - is located in the battery bay on the side of the fuse / 24 – 12V converter cover – Socket 3 - is located in the pump bay situated on the upright of the door frame. Sockets 2 and 3 are for counterweight mounted beacons if required. These can only be selected together with the cab beacon.

C025, C138, C139 C129480-C4.eps

Fig 191. Harness connectors C025, C138, C139 and C115

Overview The beacon is operated from a three position rocker switch in the right hand console.

Wires and Connectors K Fig 192. Circuit ( T C-260) 24V is supplied to the 3 position beacon switch (C115) from fuse 1 in the main fuse board (C100 X3). Position 1 - is the OFF position Position 2 - power is connected to the main cab roof beacon (C025) via pin 3 of the switch through the interconnector IC01. Position 3 - power is connected to the rear beacons (C139, C138) via pin 8 of the beacon switch through the interconnector IC01.

C-259

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C-259


Section C - Electrics Cab Systems and Lighting Beacon 3000

3019

3017 3004

1024

3011

CAB BASE EARTH POINT (INT) (EP07)

C115 SWITCH: BEACON

3005

BACKLIGHTING 1009D

C065 CONNECTOR: VEHICLE DIAGNOSTIC C025 1 SOCKET: BEACON - MAIN C025 2 C139 1 SOCKET: RH REAR BEACON C139 2 C138 1 SOCKET: LH REAR BEACON C138 2

REVOLVER EARTH STUD (EP03) C129220.eps

Fig 192. Circuit

C-260

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C-260


Section C - Electrics Cab Systems and Lighting Horn

Horn Overview The horn is operated from a switch located on the LH joystick handle.

Wires and Connectors K Fig 194. ( T C-262) The LH joystick horn button (C060) is supplied with 24V from the ignition splice S032 via pin 3 (C060 X4). When the horn button is pressed power is connected to pin 4 (C060 X4) to the horn relay (R2) pin 88 via the cab fuse/ relay board pin 1(C100 X4). The relay has an ignition supply from fuse 25. When the relay energises it provides a feed to the horn at pin 1(C022). The horn earths through pin 2 to the revolver earth point (EP03).

C060-X4

C022

C129480-C5.eps

Fig 193. Harness connectors C060 and C022

C-261

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C-261


C-262

C065 CONNECTOR: VEHICLE DIAGNOSTIC

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Fig 194. Circuit

CAB BASE EARTH POINT (INT) (EP07)

8000

6009

REVOLVER EARTH STUD (EP03)

8001

HORN C022

1010F

C060 JOYSTICK: LH HANDLE

C129230.eps

Section C - Electrics

Cab Systems and Lighting Horn

C-262


Section C - Electrics Cab Systems and Lighting Wipers and Washers

Wipers and Washers Overview The wiper and washer circuits are operated from three rocker switches in the right hand console.

1

– Lower Wiper Switch (if fitted) – Upper Wiper Switch – Screenwash Switch There is an upper wiper motor 2 and (if fitted) a lower wiper motor. The lower wiper is an option but shares the same washer pump as the upper wiper. The upper screen must be closed to enable operation of the washer/wiper circuits. A micro switch 1 closes when the upper screen is closed.

2

C130090

Fig 195.

C-263

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Section C - Electrics Cab Systems and Lighting Wipers and Washers

Wires and Connectors

C116

C058

K Fig 199. ( T C-266)

C142-1, C142-2

Upper/Main Wiper Switch and Motor 24V connects to the upper wiper switch (C116) via fuses 26 and 3 in the main fuse board (C100 X4). The upper wiper switch has three positions: – Position 1 - is the ON position for intermittent wiper

C129480-C6.eps

Fig 196. Harness connectors

– Position 2 - is the ON position for continuous wiper – Position 3 - is the OFF position.

Lower Wiper Switch and Motor

To energise the washer and wiper relay (R3) and so supply the wipers/washer with power the upper screen must be closed. Fuse 3 supplies 24V to the upper screen micro switch (C142). When the screen is closed the contacts on the switch (C142) close. Power connects to the wash/wipe relay (R3), closing the contacts and connecting power via fuse 26 to the wash/wipe circuit. Fuse 26 connects power via the relay and wire 8100 to the lower wiper switch, screen wash switch, upper wiper motor and main wiper switch. Intermittent wipe - When the switch (C116) is set to intermittent, 24V connects via wire 8007 to the wiper motor park/intermittent controller A at pin 1(C058). The controller connects power from wire 8100A at pin3 through its contact to pin 2 and wire 8009 to the wiper switch at pin 4 (C116). The switch connects power to pin 5 and to the wiper motor, via wire 8006, the wiper motor operates. The park/intermittent controller will control the delay between each wipe by opening and closing its internal contact. Continuous wipe - for continuous wipe, 24V connects to the wiper motor at pin 5 (C058) via wire 8100D from pin 6 pin 5 wire 8006 direct to the wiper motor bypassing the Park/Intermittent controller. When the wiper switch is set to OFF, power is restored from pin 4 to pin 5 of the switch until the park position is achieved which opens the internal contact between pins 3 and 2 of the wiper motor.

C-264

24V is supplied to the lower wiper switch (C118) via fuses 26 and 3 in the main fuse board (C100 X3). The lower wiper switch has two positions: – Position 1 - is the OFF position – Position 2 - is the ON position for wipers When the lower wiper switch is set to ON, a 24V supply from pin 2 of the switch energises the lower wiper motor (C125) via wire 8033 at pin 3. When the switch is set to OFF and the wiper arm is not in the park position the wiper motor operates until the park position is achieved. The wiper motor assembly has a switch B connected to the motor cam that opens when the park position is reached. When the wiper motor is not in the park position the switch B contacts are closed, allowing the 24V from pin 2 to connect to pin 1 of the wiper motor. Power is connected to pin 1 at the lower wiper switch (C118) via wire 8034. When the switch is set to OFF the switch contacts connect from pin 1 to 2 and the wiper motor continues to operate until the park position is achieved.

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C-264


Section C - Electrics Cab Systems and Lighting Wipers and Washers

C118 C126

C129480-C7.eps

Fig 197. Harness connectors C126 and C118

Washer Switch When the momentary washer switch (C117) is pressed 24V connects from pin 1 to wire 8008 which sends a signal to the park/intermittent controller on both wiper motors (C125, C058) to start three wipes. 24V also connects to wire 8008A to energise the washer pump (C026).

C117 C026

C129480-C8.eps

Fig 198. Harness connectors C117 and C026

C-265

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C-265


C-266

C100 X3

8006

8100J

6076

8100D

8009

8007

1009A

C116 SWITCH: MAIN WIPER

8100

8071

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Fig 199. Circuit

8033

6089

8008A

REVOLVER EARTH STUD (EP03)

8010

C026 SCREENWASH PUMP

CAB BASE EARTH POINT (INT) (EP07)

C125 MOTOR - WIPER - LOWER 8100B B 8034

C142-2-1 C142-1-1

C142 SENSOR: SCREEN OPEN

C100 X4

1010E

EARTH SPLICE (ROOF)

8007

8009

6098

8008

8100A

8006

8100F

1009M

8008C

8100G

SWITCH: WIPER - LOWER C118 8034

8008

8008C

6078

C117 SWITCH: SCREENWASH

A

C058 MOTOR: WIPER - UPPER

1009C

C129240.eps

Section C - Electrics

Cab Systems and Lighting Wipers and Washers

C-266


Section C - Electrics Cab Systems and Lighting Cab Interior Lamp

Cab Interior Lamp Overview The interior light can be operated automatically to illuminate the cab.

manually

C059-1, C059-2, C059-3, C148-1, C148-2

or

There are three settings for the interior light: – Off – Automatic - light illuminates when the cab door is opened – Manual - light is switched on manually. C129480-C12.eps

Fig 200. Harness connectors C059-1, C059-2, C059-3, C148-1 and C148-2

Wires and Connectors K Fig 201. ( T C-268) Automatic operation - With the ignition off, the automatic mode will operate when the cab door is opened. The door sensor (C148) detects the door movement and initiates the auto mode. 24V connects via fuse 22 on the main fuse board (C100 X4) to the light (C059) and the door sensor (C148). When the door sensor closes 24V connects to the wake up diode (C127). 24V connects via the wake up diode to the MECU J1 (C015) pin 22 to wake up the system. 24V connects to the MECU J2 (C016) at pin 30 to signal the door has been opened. The MECU J1 pin 26 will now energise the interior light (C059) and the console illumination (C147). Once the ignition is turned on the wake up function will turn off along with the interior light. Manual mode - With the ignition on the interior light (C059) can pressed in either direction to turn the light on via its internal switch.

C-267

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C-267


C-268

C065 CONNECTOR: VEHICLE DIAGNOSTIC

CAB BASE EARTH POINT (INT) (EP07)

C148 SENSOR: DOOR OPEN

C059 LIGHT: INTERIOR ILLUMINATION

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Fig 201. Circuit

C147 LIGHT: CONSOLE ILLUMINATION

C100 X4

IC07 - ROOF HARNESS CONNECTOR

C127 DIODE: WAKE-UP REFUEL/DOOR OPEN

C015 MECU (J1)

C016 MECU (J2)

C129260.eps

Section C - Electrics

Cab Systems and Lighting Cab Interior Lamp

C-268


Section C - Electrics Cab Systems and Lighting 24 to 12 Volt Converter

24 to 12 Volt Converter Component Location

C067

The 24 to 12V converter module is located in the back of the cab next to the main fuse and relay board.

C111

Overview The 24 to 12V voltage converter module provides 12V power for operation of the radio, auxiliary power sockets and HVAC unit.

C151, C163

Wires and Connectors C129480-C9.eps

– 24 to 12V - Radio K Fig 203. ( T C-270) – 24 to 12V Auxiliary K Fig 204. ( T C-271)

Power

Sockets

Fig 202. Harness Connectors C067, C111, C151 and C163

The voltage is reduced by the voltage converter module (C067) and gives out a permanent 12V supply on pin 4 and a switched 12V supply on pin 5. Pin 3 is the earth wire for the unit. The converter has both a 24V battery and an ignition supply to the module and a 12V battery and ignition supply from the module. The24V battery supply connected via fuse 23 on the cab fuse and relay board (C100 X4) to pin 1 on the converter connector. A permanent 12V battery supply is then output on pin 4. This 12V supply enables the radio memory function (C057). A second 24V ignition supply is fed from fuse 4 of the fuse and relay board (C100 X4) to pin 2 of the converter connector. A 12V ignition feed supply is then output on pin 5 to the radio ignition supply via the radio mute button (C111). If the mute button is set to ON power connects to the radio. The converter also has 2 grounds on pins 3 and 6. There is also a 12V ignition supply to the two auxiliary sockets (C163, C151) and HVAC unit (C072).

C-269

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C-269


C-270

C100 X3

1006

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EARTH SPLICE (ROOF)

C065 CONNECTOR: VEHICLE DIAGNOSTIC

Ignition On

3000

CAB BASE EARTH POINT (INT) (EP07)

S044 1CO8 6

1CO8 S024

Fig 203. Circuit, 12V radio

C111 SWITCH: RADIO MUTE

C141 SPEAKER: LH

C140 SPEAKER: RH

CAB BASE EARTH POINT (INT) (EP07)

C067 VOLTAGE 24/12 V

C057/C143/C195 CONNECTOR: RADIO POWER CONNECTOR: RADIO SPEAKERS CONNECTOR: FM ANTENNA

C100 X4

S033

C129270.eps

Section C - Electrics

Cab Systems and Lighting 24 to 12 Volt Converter

C-270


C-271

C100 X3

Ignition On

3000

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C100 X4

S033

S044 1CO8 6

S024

CAB BASE EARTH POINT (INT) (EP07)

C163 SOCKET: AUXILIARY 12 V (2)

CAB BASE EARTH POINT (INT) (EP07)

CAB BASE EARTH POINT (INT) (EP07)

C151 SOCKET: AUXILIARY 12 V (1)

C067 VOLTAGE 24/12 V

Fig 204. Circuit, 12V auxiliary sockets and HVAC

C072 10

C072 11

C072 HEATER/ATC OPTION CONNECTOR

C065 CONNECTOR: VEHICLE DIAGNOSTIC

1006

C129280.eps

Section C - Electrics

Cab Systems and Lighting 24 to 12 Volt Converter

C-271


Section C - Electrics Cab Systems and Lighting HVAC Control

HVAC Control Component Location

Temperature Switch

Refer to Section B - Basic Operation for details of the HVAC Components.

The temperature switch (C076) is a potentiometer which changes resistance according to the position of the switch.

Overview

A 12V ignition supply from pin 5 of the 24 to 12V convertor module (C067) connects to the switch at pin 2. K 24 to 12 Volt Converter ( T C-269)

Refer to Section B - Basic Operation for details of the HVAC controls and operation.

The switch connects to earth via pin 1 to the cab base earth point - internal (EP07).

Wires and Connectors Machines without Air Conditioning

The switch position signal is sent from the switch at pin 3 to the heater unit (C082) at pin 7.

K Fig 206. ( T C-273)

Re-circulation Switch

Fan Speed Switch

The re-circulation switch (C075) pin 1 is connected to 24V via the fan speed switch (C074) pin C when positions L, M or H are selected.

The heater fan speed switch (C074)is a four position switch:

When the switch is closed (set to re circulation), 24V connects to the heater unit (C082) at pin 9.

– Off Position – Position L - Low fan speed. – Position M - Medium fan Speed.

C077

– Position H - High fan speed.

C075X1, X2

C074

C076

The switch is connected to 24V via fuse F10 in the main fuse board (C100 X1). When the switch is in position L - the power connects to the blower low terminal at pin 6 of the heater unit (C082).

C082

When the switch is in position M - the power connects to the blower medium terminal at pin 5 of the heater unit. When the switch is in position H - the power connects to the blower high terminal at pin 4 of the heater unit. Heater Unit

C129480-C10.eps

A 12V ignition supply from pin 5 of the 24 to 12V convertor module (C067) connects to the heater unit at pin 11 (C082). K 24 to 12 Volt Converter ( T C-269)

Fig 205. Harness connectors C077, C075-X1, C075-X2, C074, C076 and C082

The heater unit connects to earth via pin 10 to the cab base earth point - internal (EP07)

C-272

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Section C - Electrics Cab Systems and Lighting

C-273

C074

C076

C077

C075

C082

Fig 206. Circuit, heater unit

C072

C129320.eps

HVAC Control

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C-273


Section C - Electrics Cab Systems and Lighting HVAC Control Machines with Air Conditioning

Compressor Clutch Relay

K Machines with Air Conditioning ( T C-274)

The compressor clutch relay (C072-15) energises via a power supply on pin 86 from the ATC control module (C072-5).

The heater fan speed controls operate as described in the machines without air conditioning description. K Machines without Air Conditioning ( T C-272) The air conditioning is controlled by additional devices as follows: ATC Control Module The ATC control module (C072-5) processes the inputs and outputs of the air conditioning components. The ATC control module receives and transmits CANbus data via the pins 1 and 2. These are connected to the HVAC CANbus connector (C071). The HVAC CANbus connector connects to the machine CANbus via splices (CANHS2, CANLS2).

When energised the relay coil connects to earth via pin 85 to the cab base earth point - internal (EP07). The relay switch contacts connect the main power supply from fuse F10 in the main fuse board (C100 X1) from pin 30 to pin 87 which connects to the AC Compressor Clutch Solenoid (C040) at pin 1. Compressor Clutch Solenoid The compressor clutch solenoid pin 1 (C040) energises via a power supply from the compressor clutch relay at pin 87 (C072-15). When energised the compressor clutch solenoid connects to earth via pin 2 to the revolver earth point (EP03).

The ATC control module connects to 24V via fuse F10 in the main fuse board (C100 X1).

Low Pressure Switch

The ATC control module connects to earth via pin 18 to the cab base earth point - internal (EP07).

The low pressure switch (C072-17) is connected to the ATC control module (C072-5).

HVAC Display

When the low pressure switch contacts close the switch pin A sends an output to ATC control module on pin 35.

The HVAC display unit (C072-2) displays data from air conditioning devices. The HVAC display unit pin C2 connects to 24V via fuse F10 in the main fuse board (C100 X1). The unit connects to earth via pin 5 to the cab base earth point - internal (EP07). PWM Unit The PWM unit (C072-11) connects to 24V at pins 1 and 2 via fuse F10 in the main fuse board (C100 X1). The unit connects to earth via pin 5 to the cab base earth point - internal (EP07). An input at pin 3 from the ATC control module (C072-5) changes depending on the fan speed selected. The unit converts the input signal to a PWM signal. An output on pin 4 to provides a PWM earth for the blower motor (C072-13).

C-274

When the low pressure switch contacts open there is no output to ATC control module on pin 35. The switch connects to power via the pressure sensor at pin 1 (C039). Re-circulation Actuator A 12V ignition supply from pin 5 of the 24 to 12V convertor module (C067) connects to the re-circulation actuator at pin A (C072-4). K 24 to 12 Volt Converter ( T C-269) The actuator connects to earth via pin C to the cab base earth point - internal (EP07). The ATC control module (C072-5) supplies an output via pin 11 to the actuator at pin D.

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C-274


Section C - Electrics Cab Systems and Lighting HVAC Control Water Valve Actuator

When the switch is open the there is no output to ATC control module on pin 33.

A 12V ignition supply from pin 5 of the 24 to 12V convertor module (C067) connects to the water valve actuator at pin A (C072-10). K 24 to 12 Volt Converter ( T C-269)

C071

C039, C040

C072

The actuator connects to earth via pin C to the cab base earth point - internal (EP07). The ATC control module (C072-5) supplies an output through pin 3 to the actuator at pin D. Blower Motor The blower motor (C072-13) pin 1 connects to 24V via fuse F10 in the main fuse board (C100 X1).

C129480-C11.eps

Fig 207. Harness connectors C071, C039 and C040

The PWM unit (C072-11) Pin 4 connects to a PWM earth for the blower motor at pin 2. Evaporator Temperature Sensor The evaporator temperature sensor (C072-8) pin 1 outputs an earth signal to the ATC control module (C072-5) at pin 23. The sensor connects to earth via pin 2 to the cab base earth point - internal (EP07). Outlet Temperature Sensor The outlet temperature sensor (C072-6) pin 1 outputs an earth signal to the ATC control module (C072-5) pin 22. The sensor connects to earth via pin 2 to the cab base earth point - internal (EP07). Cab Temperature Sensor The cab temperature sensor (C072-7) pin 1 outputs an earth signal to the ATC control module (C072-5) pin 21. The sensor connects to earth via pin 2 to the cab base earth point - internal (EP07). Air Conditioning Pressure Sensor The pressure sensor (C039) supplies an output to the ATC control module (C072-5). When the switch is closes the switch pin 2 sends an output to ATC control module on pin 33.

C-275

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C-275


C-276

C072-15

C072-2

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C072-13

C072-11

C071 C072-5

Fig 208. Circuit

C072-17

C040

C072-6

C072-18

C072-4

C072-7

C072-8

C072-10

C072

C129310.eps

C039

Section C - Electrics

Cab Systems and Lighting HVAC Control

C-276


Section 1 - 1

Machine Diagnostic Modes Overview The machine electronic control system features three machine diagnostic modes as follows: – Test Run Mode automatically sets the power control to H power band engine rpm and the pump control solenoid current to a fixed value. This mode is intended to enable hydraulic test results, such as cycle times, to be compared against normal values. K Test Run Mode ( T 1-3) – Pressure Switch Status Mode enables live monitoring of all the hydraulic pressure switches on the machine. The pressure switch status is shown graphically on the DECU LCD monitor. Use this mode when fault finding systems that use inputs from pressure switches. K Pressure Switch Status Mode ( T 1-3) – Fan Test Mode automatically selects the H+ power band and drives the cooling fan at 70% of its maximum speed. Use this mode to confirm correct operation of the cooling fan. In addition to the diagnostic modes the DECU LCD can be set to display the machine status of the following parameters: – Battery voltage – Alternator voltage – Coolant temperature – Hydraulic oil temperature – Barometric pressure – Hydraulic pump proportional solenoid current – Engine speed – Brake system accumulator pressure – Servo hydraulic pressure For information about how to set the DECU to display the machine status screens refer to Section 2, About the Machine.

1-1

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1-1


Section 1 - 1 Machine Diagnostic Modes Selecting the Diagnostic Mode Screen

Selecting the Diagnostic Mode Screen 1

Use the controls on the DECU 4 to select the machine status information screen. Turn the select rotary control to display the first status information screen. Refer to Section 2, About the Machine.

1

2

4

3 C130420

Fig 3.

C140510

Fig 1. Machine status information screen

1 2 3

C131030

Fig 4. Diagnostic mode screen

C140510-C1

Fig 2. First status information screen 2

Press and hold the buttons 1 and 2 at the same time for a period of five seconds. The diagnostic mode screen is displayed.

1

Test run mode symbol

2

Pressure switch status mode symbol

3

Fan test mode symbol

3

Use the select rotary control 3 to enter and use a diagnostic mode, refer to the applicable procedure: K Test Run Mode ( T 1-3) K Pressure Switch Status Mode ( T 1-3) K Fan Test Mode ( T 1-4)

1-2

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1-2


Section 1 - 1 Machine Diagnostic Modes Selecting the Diagnostic Mode Screen

Test Run Mode

Pressure Switch Status Mode

To use the test run mode, proceed as follows:

To select the pressure switch status mode, proceed as follows:

1

Start the engine and enable the hydraulic controls. If necessary operate the machine until the hydraulic oil temperature is between 50 ยบC and 85 ยบC.

1

Start the engine and enable the hydraulic controls.

2

Select the diagnostic mode screen and turn the select rotary control to highlight the pressure switch status mode symbol. K Selecting the Diagnostic Mode Screen ( T 1-2)

3

Press the select rotary control.

The test run mode will not enable unless the hydraulic oil temperature is within the correct range, and the hydraulic controls are enabled. 2

Select the diagnostic mode screen and turn the select rotary control to highlight the test run mode symbol. K Selecting the Diagnostic Mode Screen ( T 1-2)

3

Press the select rotary control to start the test run mode. The engine automatically goes to the H power band.

1 2

5

2

6

3

7

4

8 C130390

Fig 6. Pressure switch status screen

3

C130400

Fig 5. Test run status screen

1

Engine rpm (actual)

2

Pump solenoid current (actual)

3

Hydraulic oil temperature (actual)(1)

(1) If the symbol is grey, the oil temperature is out of range. The test run mode is not enabled.

1

High flow auxiliary pressure switch(1)

2

Overload caution pressure switch(1)

3

Travel pressure switch

4

Slew pressure switch

5

Excavator pressure switch

6

Crowd pressure switch (quickhitch)(1)

7

Boom up pressure switch(1)

8

Dozer / stabiliser pressure switch(1)

(1) The symbol is only shown if the applicable option is fitted.

For information about carring out machine cycle time test procedures, refer to Secion E, Fault Finding, Fault Finding Tests. To exit the test run mode press the back button or home button. Disabling the hydraulic controls or switching off the engine will also exit the test run mode.

1-3

1

When a symbol on the status screen is grey, the applicable pressure switch is not active. When a symbol on the status screen is green, the applicable pressure switch is active. To exit the pressure switch status mode press the back button or home button. Disabling the hydraulic controls or switching off the engine will also exit the pressure switch status mode.

9813-5550-1

1-3


Section 1 - 1 Machine Diagnostic Modes Selecting the Diagnostic Mode Screen

Fan Test Mode

To exit the fan test mode press the back button or home button. Disabling the hydraulic controls or switching off the engine will also exit the fan test mode.

To select the fan test mode, proceed as follows: 1

Start the engine and enable the hydraulic controls.

2

Select the diagnostic mode screen and turn the select rotary control to highlight the fan test mode symbol. K Selecting the Diagnostic Mode Screen ( T 1-2)

3

Press the select rotary control to start the fan test mode. The engine automatically goes to the H+ power band.

1 2 3 4 C131040

Fig 7. Fan test status screen

1

Engine rpm (actual)

2

Cooling fan rpm (actual)

3

Engine coolant temperature (actual)

4

Hydraulic oil temperature (actual)

The 70% fan speeds for different engine speeds are given in the table. When the fan test mode is selected the electronic control system sets the fan speed to 70% of the maximum (100%) speed. Compare the values in the table with the status screen to see if the fan speed is close to the expected value. A tolerance of +/- 5% is acceptable. Engine rpm

70% fan speed rpm

2050

1295

1900

1225

1700

1100

1500

973

1200

777

1-4

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1-4


Section C - Electrics

Fault Code SYSTEM Operation Overview Fault Code Display A fault codes will be displayed on the display monitor LCD. For details about navigating the display screens refer to Section 2. The colour of the display will change according to the severity of the fault displayed. – K Service/Operator Fault ( T C-5) – K Critical Fault ( T C-6)

Service/Operator Fault The display is Amber, the buzzer will sound for 1 second, an Icon representing area of machine affected and a fault code is displayed. This indicates faults that may result in reduced machine performance but are not dangerous. They are unlikely to damage the machine. These are known as ‘SERVICE’ or ‘OPERATOR’ faults. Warnings remain active until the operator acknowledges the warning with the info key. If multiple fault codes are active the screen will alternate between the active faults.

C128810.jpg

Fig 1. Service/Operator fault warning display

C-5

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C-5


Section C - Electrics Fault Code SYSTEM Operation Overview Critical Fault Critical Fault : The display is Red, the buzzer will sound, an Icon representing area of machine affected and a fault code will display to indicate faults that may result in serious damage to the machine or make the machine dangerous to operate. This is known as a ‘Critical’ fault. The operator must stop the machine. Critical faults remain active until the critical fault is no longer there, otherwise it cannot be cancelled or acknowledged. The active fault screen is shown at A. After 2 seconds screen B is displayed. Screens A and B will display alternately every 2 seconds. Press the control wheel to display the fault code log screen C.

C128820.jpg

Fig 2. Critical fault warning displays

C-6

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C-6


Section C - Electrics Fault Code SYSTEM Operation Overview Fault Code Log The Display Electronic Control Unit (DECU) incorporates a ‘data logging’ feature for recording fault codes. The log enters the fault code together with the current time and date. The fault code log can be read on the DECU LCD. Alternatively use the JCB diagnostics tool. Reading the Fault Code Log with Servicemaster Error codes logged can be accessed via a suitable laptop computer running the applicable diagnostics software. The computer must be connected to the machine CANbus socket using a data link adaptor (DLA). Once connected all recorded codes can be displayed. The engineer also has a facility to erase the fault code log. Reading the Fault Code Log on the LCD 1

C-7

Operate the rotary wheel to view the fault codes logged in the display monitor ECU.

C127760-C6.jpg

Fig 3. Display fault code log Key

K Fig 3. ( T C-7)

A

Fault Code

B

Time of Fault Occurrence

C

Date of Fault Occurrence

D

Engine Hours at which Fault Occurred

E

How Many Times Fault Was Recorded.

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C-7


Section C - Electrics Fault Code SYSTEM Engine ‘P’ Codes

Engine ‘P’ Codes Should faults occur related to the Engine ECU or the electrical devices connected to it, the ECU generates fault codes and stores them in its memory. By using the JCB Servicemaster Diagnostics Tool these codes can be read using a laptop computer connected to the ECU. The system will also display ‘real time’ data for faults active with the engine running.

The ‘P’ fault code will display a 5 digit code followed by a suffix of 2 digits: ‘P1234-56’ The third digit of the code (in the above example = 2) refers to which system is affected. K Table 1. P Code Definitions ( T C-8)

Depending on the machine installation fault codes may be displayed using one or more display systems. K Operation Overview ( T C-5). Table 1. P Code Definitions Third Digit

System

Powertrain Component Affected

1

Fuel and Air Metering

Engine

2

Fuel and Air Metering (Injector Circuit Malfunction Only )

Engine

3

Ignition System or Misfire

Engine

4

Auxiliary Emission Control System

Engine

5

Vehicle Speed Control and Idle Control System

Engine/Transmission

6

Computer Output Circuit

Engine/Transmission

7

Transmission

Transmission

8

Transmission

Transmission

For details of ‘P’ fault codes refer to the applicable service manual: – 9806/4300 T4i Engine Service Manual.

C-8

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C-8


Section C - Electrics Fault Code SYSTEM Cab Area ‘B’ Codes

Cab Area ‘B’ Codes Fault Code

Description

Symptom

B0300

HECU - Low Flow Thumbwheel High Fault Condition Low flow proportional hydraulics system does not operate

B0301

HECU - High Flow Thumbwheel Low Fault Condition Low flow proportional hydraulics system does not operate

B0302

HECU - High Flow Thumbwheel High Fault Condition Low flow proportional hydraulics system does not operate

B0303

HECU - High Flow Thumbwheel Low Fault Condition Low flow proportional hydraulics system does not operate

B1002

Alternator Not Charging

-

B1002

Alternator Excitation Open Circuit

-

B105A

MECU ECU 5V Supply Voltage High Fault Condition

Loss of throttle / power control

B105B

MECU ECU 5V Supply Voltage Low Fault Condition

Loss of throttle / power control

B105C

HECU ECU 5V Supply Voltage High Fault Condition

Loss of auxiliary hydraulic system control

B105D

HECU ECU 5V Supply Voltage Low Fault Condition

Loss of auxiliary hydraulic system control

B1300

Power Mode Selector - Voltage Above Normal

Idle speed only (reset with key OFF / ON cycle)

B1301

Power Mode Selector - Voltage Below Normal

Idle speed only (reset with key OFF / ON cycle)

B1302

Controls Isolate Switch Fault

Machine controls isolated

B1307

Interior Light Short Circuit

-

B1308

Interior Light Open Circuit

-

B1309

Service interval due or elapsed

-

B130A

Supplementary service interval due / elapsed

-

B1543

Coolant temperature high (critical)

Engine power restriction (de-rate)

B1546

Coolant temperature high

-

C-9

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C-9


Section C - Electrics Fault Code SYSTEM Chassis ‘C’ Codes

Chassis ‘C’ Codes Fault Code

Description

Symptom

C0300

HECU - low flow solenoid A short circuit

Low flow proportional hydraulics system does not operate

C0301

HECU - low flow solenoid A open circuit

Low flow proportional hydraulics system does not operate

C0302

HECU - low flow solenoid B short circuit

Low flow proportional hydraulics system does not operate

C0303

HECU - low flow solenoid B open circuit

Low flow proportional hydraulics system does not operate

C0304

HECU - high flow solenoid A short circuit

High flow proportional hydraulics system does not operate

C0305

HECU - high flow solenoid A open circuit

High flow proportional hydraulics system does not operate

C0306

HECU - high flow solenoid B short circuit

High flow proportional hydraulics system does not operate

C0307

HECU - high flow solenoid B open circuit

High flow proportional hydraulics system does not operate

C0308

HECU - quickhitch solenoid short circuit

Quickhitch does not operate

C0309

HECU - quickhitch solenoid open circuit

Quickhitch does not operate

C030A

HECU - quickhitch boom warning lamp short circuit

Quickhitch does not operate

C030B

HECU - quickhitch boom warning lamp open circuit

Quickhitch does not operate

C030C

HECU - merged flow solenoid A short circuit

Merged flow function does not operate

C030D

HECU - merged flow solenoid A open circuit

Merged flow function does not operate

C030E

HECU - merged flow solenoid B short circuit

Merged flow function does not operate

C030F

HECU - merged flow solenoid B open circuit

Merged flow function does not operate

C0310

HECU - tool select ARV proportional solenoid A short Tool select function does not operate circuit

C0311

HECU - tool select ARV proportional solenoid A open Tool select function does not operate circuit

C0312

HECU - tool select ARV proportional solenoid B short Tool select function does not operate circuit

C0313

HECU - tool select ARV proportional solenoid B open Tool select function does not operate circuit

C0314

MECU - auxiliary mode changeover solenoid short circuit

Bi-direction high flow auxiliary circuit does not operate

C0315

MECU - auxiliary mode changeover solenoid open circuit

Bi-direction high flow auxiliary circuit does not operate

C0316

HECU - ISO controls changeover input short circuit

Machine controls only operate in ISO pattern

C0317

HECU - ISO controls changeover input open circuit

Machine controls only operate in ISO pattern

C-10

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C-10


Section C - Electrics Fault Code SYSTEM Chassis ‘C’ Codes Fault Code

Description

Symptom

C0318

HECU - arm limiter solenoid short circuit

Arm limiter function does not operate

C0319

HECU - arm limiter solenoid open circuit

Arm limiter function does not operate

C031A

HECU - low flow proportion solenoid A current not correct

Low flow proportional auxiliary hydraulic system does not operate

C031B

HECU - low flow proportion solenoid B current not correct

Low flow proportional auxiliary hydraulic system does not operate

C031C

HECU - high flow proportion solenoid A current not correct

High flow proportional auxiliary hydraulic system does not operate

C031D

HECU - high flow proportion solenoid B current not correct

High flow proportional auxiliary hydraulic system does not operate

C031E

Low Flow Pilot Pressure Transducer Output is Out of Advance tool select does not operate Range

C031F

High Flow Pilot Pressure Transducer Output is Out of Advance tool select does not operate Range

C0320

Low Flow ARV Pressure Transducer Output is Out of Advance tool select does not operate Range

C0321

High Flow ARV Pressure Transducer Output is Out of Advance tool select does not operate Range

C101D

Fuel Level Low Alarm

-

C101E

Fuel Level Empty Alarm

-

C101F

Fuel Level Sensor Short Circuit

-

C1020

Fuel Level Sensor Open Circuit

-

C1021

Engine Coolant Level Low

-

C1022

Engine Coolant Temperature Sensor Open Circuit

-

C1023

Hydraulic Oil Temperature High Alarm

Engine power restriction (de-rate)

C1024

Hydraulic Oil Temperature Sensor Open Circuit

-

C1025

Battery Voltage High Fault Condition

-

C1026

Battery Voltage Low Fault Condition

-

C1027

Alternator Voltage High Fault Condition

-

C1028

Alternator Voltage Low Fault Condition

-

C1029

Ambient Air Temperature Sensor Short Circuit

-

C102A

Ambient Air Temperature Sensor Open Circuit

-

C102B

Cooling Fan Solenoid Fault Condition

Cooling fan runs at maximum speed

C102C

Cooling Fan Solenoid Short Circuit

Cooling fan runs at maximum speed

C102D

Cooling Fan Solenoid Open Circuit

Cooling fan runs at maximum speed

C1032

Hydraulic Oil Temperature Critical Alarm

Engine power restriction (de-rate)

C1035

Hydraulic Oil Temperature Sensor Short Circuit

-

C1300

Boost (2-Stage Relief) Solenoid Short Circuit

Boost function does not operate correctly

C1301

Boost (2-Stage Relief) Solenoid Open Circuit

Boost function does not operate correctly

C-11

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Section C - Electrics Fault Code SYSTEM Chassis ‘C’ Codes Fault Code

Description

Symptom

C1303

Travel Speed Change Solenoid Short Circuit

Machine travel only operates in one speed

C1304

Travel Speed Change Solenoid Open Circuit

Machine travel only operates in one speed

C1305

Max Flow Solenoid Short Circuit

Maximum flow function does not operate correctly

C1306

Max Flow Solenoid Open Circuit

Maximum flow function does not operate correctly

C1307

Controls Enable Solenoid Open Circuit

Machine controls isolated

C1308

Controls Enable Solenoid Short Circuit

Machine controls isolated

C1309

Slew Lock Solenoid Short Circuit

Slew lock engages continuously

C130A

Slew Lock Solenoid Open Circuit

Slew lock engages continuously

C130B

Slew Brake Solenoid Short Circuit

Slew lock engages continuously

C130C

Slew Brake Solenoid Open Circuit

Slew lock engages continuously

C130D

Slew Shut Off Solenoid Short Circuit

Slew lock engages continuously

C130E

Slew Shut Off Solenoid Open Circuit

Slew lock engages continuously

C130F

Boom Priority Solenoid Short Circuit

Boom priority function does not operate correctly

C1310

Boom Priority Solenoid Open Circuit

Boom priority function does not operate correctly

C1311

Travel Alarm Solenoid Short Circuit

Travel alarm function does not operate correctly

C1312

Travel Alarm Solenoid Open Circuit

Travel alarm function does not operate correctly

C1313

Refuel Pump Relay Short Circuit

Refuel function does not operate correctly

C1314

Refuel Pump Relay Open Circuit

Refuel function does not operate correctly

C1316

Pilot Pressure Transducer - Voltage Above Normal

Machine controls isolated

C1317

Pilot Pressure Transducer - Voltage Below Normal

Machine controls isolated

C1318

Controls Enable Pressure - Out of Range

Warning Only

C131A

Lever Lock Switch Plausibility Error

Machine controls isolated

C1321

Brake Accumulator Pressure Low

Foot brake does not operate correctly

C1322

Forward And Reverse Inputs Active At The Same Time

Transmission drive isolated

C1323

Vref Shorted To Battery

-

C1324

Vref Shorted To Ground

-

C1325

Brake Accumulator Sensor Shorted To Battery

Brake accumulator low warning permanently on

C1326

Brake Accumulator Sensor Shorted To Ground

Brake accumulator low warning permanently on

C1327

Swing Rotation Sensor Shorted To Battery

Highway mode not available

C1328

Swing Rotation Sensor Shorted To Ground

Highway mode not available

C1329

Forward Drive Output Open Circuit

Only reverse direction available

C132A

Forward Drive Output Short Circuit

Only reverse direction available

C132B

Reverse Drive Output Open Circuit

Only forward direction available

C132C

Reverse Drive Output Short Circuit

Only forward direction available

C132D

Left Turn Indicator Output Open Circuit

No LH turn signals

C132E

Left Turn Indicator Output Short Circuit

No LH turn signals

C-12

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Section C - Electrics Fault Code SYSTEM Chassis ‘C’ Codes Fault Code

Description

Symptom

C132F

Right Turn Indicator Output Open Circuit

No RH turn signals

C1330

Left Turn Indicator Output Short Circuit

No RH turn signals

C1331

Rear Fog Lights Output Open Circuit

No rear fog lights

C1332

Rear Fog Lights Output Short Circuit

No rear fog lights

C1333

Reverse Lights Output Open Circuit

No reverse lights

C1334

Reverse Lights Output Short Circuit

No reverse lights

C1335

Pump 1 Output Open Circuit

Creep speed unavailable

C1336

Pump 1 Output Short Circuit

Creep speed unavailable

C1339

Front LH Stabilizer/dozer Output Open Circuit

Front LH stabilizer/dozer will stay in current position

C133A

Front LH Stabilizer/dozer Output Open Circuit

Front LH stabilizer/dozer will stay in current position

C133B

Front RH Stabilizer Output Open Circuit

Front RH stabilizer will stay in current position

C133C

Front RH Stabilizer Output Open Circuit

Front RH stabilizer will stay in current position

C133D

Rear LH Stabilizer/dozer Output Open Circuit

Rear LH stabilizer/dozer will stay in current position

C133E

Rear LH Stabilizer/dozer Output Open Circuit

Rear LH stabilizer/dozer will stay in current position

C133F

Rear RH Stabilizer Output Open Circuit

Rear RH stabilizer will stay in current position

C1340

Rear RH Stabilizer Output Open Circuit

Rear RH stabilizer will stay in current position

C1341

Hazard Led Output Open Circuit

No switch warning for hazard switch

C1342

Hazard Led Output Short Circuit

No switch warning for hazard switch

C1343

M1 Output Open Circuit

High speed not available

C1344

M1 Output Short Circuit

High speed not available

C1345

M2 Output Open Circuit

Creep and mid speed not available

C1346

M2 Output Short Circuit

Creep and mid speed not available

C1347

Brake Light Output Open Circuit

No brake lights

C1348

Brake Light Output Short Circuit

No brake lights

C1349

Axle Lock Output Open Circuit

Axle will remain in place

C134A

Axle Lock Output Short Circuit

Axle will remain in place

C134B

Dig End Enable Output Open Circuit

Dig end isolated

C134C

Dig End Enable Output Short Circuit

Dig end isolated

C134D

Drive Enable Output Open Circuit

Machine will not drive

C134E

Drive Enable Output Short Circuit

Machine will not drive

C134F

Revolver Not Aligned When In Travel Mode

Warning only

C1350

Creep Speed Disabled Due To Transmission Output Fault

Creep speed disabled

C1351

Slow Speed Disabled Due To Transmission Output Fault

Slow speed disabled

C1352

Fast Speed Disabled Due To Transmission Output Fault

Fast speed disabled

C-13

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Section C - Electrics Fault Code SYSTEM Chassis ‘C’ Codes Fault Code

Description

Symptom

C1353

Travel Speed Disabled Due To Transmission Output Fault

Travel speed disabled

C1354

Brake Accumulator Pressure Low At Key On

Brake system charging before drive

C1355

Door Open While Cab Raised

-

C-14

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Section C - Electrics Fault Code SYSTEM CANbus ‘U’ Codes

CANbus ‘U’ Codes Fault Code

Description

Symptom

U010A

Engine ECU lost communication with EGR

-

U010C

Engine ECU lost communication with VGT

-

U040B

Exhaust Gas Recirculation Control Module A - Invalid Torque Reduced Data

U040D

Turbocharger/Supercharger Control Module A - Invalid Torque Reduced Data

U1100

Internal Data logger Memory Full

-

U1300

ECU Binding - Module mismatch or missing

Machine immobilised

U1308

DECU has lost CAN communication with MECU

-

U1800

ECU Binding Fault

Machine immobilised

U1900

LiveLink ECU - vehicle battery voltage below normal

-

U1901

LiveLink ECU - internal battery voltage below normal

-

U1904

LIveLink ECU temperature high

-

U1905

LIveLink ECU temperature low

-

U1906

LIveLink ECU - accelerometer internal failure

-

U1907

LiveLink ECU - Modem fault

-

U1908

LiveLink ECU - GPS antenna fault

-

U1909

LiveLink ECU - no communication with GPS module

-

U190A

LiveLink ECU - SIM card fault

-

U190B

LiveLink ECU - no communication with GSM module

-

U190C

LiveLink ECU - GSM network registration failure

-

C-15

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Section C - Electrics Fault Code SYSTEM CANbus ‘U’ Codes

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Section 1 - 1

Servicemaster SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Why Use ServiceMaster? ( T 1-2) K Fault Finding ( T 1-2) K Identify Poor Maintenance ( T 1-2) K Access Machine Set-up Data ( T 1-2) K Re-Programming ECUs ( T 1-2) K Summary ( T 1-2) K What is Servicemaster? ( T 1-3) K Introduction ( T 1-3) K CANbus Communications System ( T 1-3) K Servicemaster Structure ( T 1-3) K How to Set-up Servicemaster ( T 1-5) K New Installation of JCB ServiceMaster DVD ( T 1-6) K New Installation of JCB ServiceMaster WebUpdate ( T 1-9) K Authorising JCB WebUpdate Downloads ( T 1-12) K Using JCB WebUpdate to Download Updates ( T 1-13) K JCB ServiceMaster ( T 1-14) K ServiceMaster Front End ( T 1-14) K Selecting Service Tool Applications ( T 1-15) K Start Servicemaster ( T 1-16) K Load the DLA Laptop Driver Software ( T 1-17) K Configure the DLA Type and Communications Port ( T 1-18) K Check the DLA Firmware File ( T 1-19) K Connect Servicemaster to the Machine CANbus ( T 1-21)

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Section 1 - 1 Servicemaster SYSTEM Why Use ServiceMaster?

Why Use ServiceMaster? JCB machines use the latest developments in electronic management of machine systems. This means that machine systems such as service hydraulics, engine, transmission and steering are controlled using electronic control units (ECUs). The ECUs process inputs from electrical sensors and then output signals to electrical actuators on the applicable devices. The ECUs are also connected to the machine CANbus electronic communication system.

Re-Programming ECUs The ECU's use pre-loaded data to compute responses to inputs from sensors. If an ECU is replaced the correct data files must be programmed (`flashed') into the ECU memory. New data files may also be issued by JCB Service to improve machine operation. This will also require the ECU to be re-programmed.

Fault Finding

This can only be done with ServiceMaster.

Faults with ECU controlled systems can be difficult or impossible to trace using traditional methods.

Summary

In addition to the primary function of machine control the ECUs are also able to detect possible faults with sensors and actuators. The faults are `logged' using a code system. Use ServiceMaster to see and understand these codes.

With the latest ServiceMaster software loaded on your laptop and you can: – Fault find – For fast, effective fault finding. – Check maintenance standards – See if the machine has been abused.

In addition ServiceMaster has direct links to relevant onscreen help information about relevant devices. This information is designed to help you identify, test, and if applicable, remove and replace devices.

– View and change machine set-up data – This can only be done with ServiceMaster. – Flash ECUs with the correct data files – This can only be done with ServiceMaster.

Identify Poor Maintenance System faults that are present, or have happened in the past can be seen. This is not only useful when fault finding but can also identify poor standards of maintenance. For example a log showing a history of water in fuel detected. Use ServiceMaster to see and understand these logs.

Access Machine Set-up Data Machine parameters such as tyre sizes, gear shift points and engine injector calibration codes are all stored and used by the relevant control ECU's. During the life of the machine it will be necessary to change some of these parameters. Without the correct data the machine will not operate correctly. This can only be done with ServiceMaster.

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Section 1 - 1 Servicemaster SYSTEM What is Servicemaster?

What is Servicemaster? Introduction JCB Servicemaster is software for use with Microsoft Windows and a laptop personal computer. The laptop computer is connected to the machine ‘diagnostic socket' using special cables and an adaptor. Use ServiceMaster software to: – Display data from machine ECUs – Change data stored in ECUs

CANbus Communications System C

Controller

A

Area

N

Network C140910.jpg

Servicemaster software communicates with the machine ECUs using the CAN. CAN is an electronic communications system that connects compatible machine ECUs to one pair of data wires called the CANbus. Coded data is sent to and from the ECUs on the CANbus. By connecting Servicemaster software to the CANbus this data is seen and decoded for use by an engineer.

Fig 1.

Tool Sets Tool sets are different for each machine range. A typical tool set includes:

Servicemaster Structure Servicemaster software is supplied via DVD and updated via internet. Vehicle Set-up tool

Diagnostics tool

Flash Programmer tool

Data Logger tool

A selector window is used to choose the correct software tool set for each machine range.

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Section 1 - 1 Servicemaster SYSTEM What is Servicemaster?

Service History Each tool is specific to the chosen machine range. The tool icons are `shortcuts' to the tool software files. Detailed information about how to use the tools is given in the applicable machine documentation.

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Section 1 - 1 Servicemaster SYSTEM How to Set-up Servicemaster

How to Set-up Servicemaster Note: The procedures that follow describe how to set-up Servicemaster for USB compatible equipment. There are other procedures and options. These are described in detail in the Servicemaster help files contained on the JCB Service Information DVD.

2

Run the service master WebUpdate.

3

Start Servicemaster.

4

Load the DLA laptop driver software.

Before you set-up Servicemaster make sure you have:

5

Configure the DLA type and communications port.

– A Microsoft Windows compatible laptop computer with a DVD drive and/or a USB port A

6

Make sure that the DLA flash memory contains the latest firmware file.

Note: Servicemaster is compatible with Windows 98, 2000, ME, XP, Vista, and 7 (32 bit and 64bit).

7

Connect Servicemaster to the machine CANbus.

– The latest Servicemaster software B (DVD and internet connection for web updates). – A JCB compatible data link adaptor (DLA) C. – The correct connection cables D.

K New Installation of JCB ServiceMaster DVD ( T 1-6) K New Installation of JCB ServiceMaster WebUpdate ( T 1-9) K Start Servicemaster ( T 1-16)

Important: DO NOT connect any cables at the laptop, DLA or machine now.

K Load the DLA Laptop Driver Software ( T 1-17) K Configure the DLA Type and Communications Port ( T 1-18) K Check the DLA Firmware File ( T 1-19) K Connect Servicemaster to the Machine CANbus ( T 1-21)

T063421

Fig 2. To set-up Servicemaster for the first time: 1

1-5

Install Servicemaster from the DVD.

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Section 1 - 1 Servicemaster SYSTEM How to Set-up Servicemaster

New Installation of JCB ServiceMaster DVD This topic covers the new installation ServiceMaster on a new laptop / PC.

of

JCB

1

Once you have put the CD into your computer, open “My Computer” and select the CD Drive (D:).

2

Double clicking on this will explore the contents of the CD. Please double click on the “Set-up.exe” application. T0640010-1

Fig 4. Note: The version number will depend on when the CD was obtained. 4

A popup box will now appear to allow you to select a language. Once selected, click “OK”

T040010-2

Fig 5.

T0640010-11

Fig 3.

T040010-3

Fig 6. 3

1-6

This will start the set-up application, click on “Install V10.0.3”.

5

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On the next screen, click “Next”.

1-6


Section 1 - 1 Servicemaster SYSTEM How to Set-up Servicemaster

T040010-5

T040010-7

Fig 7. 6

Fig 9.

The next screen requires you to put in your username and organization. Once inserted, click next.

8

The next screen shows you where ServiceMaster will be installed to on your computer. Click next to begin the install.

T040010-6

Fig 8.

T040010-7

Fig 10. 7

1-7

On the next screen, please choose “Complete� to do the full install to your laptop.

9

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During the install you may get a number of errors indicating language files for TransLink haven't been found. Please click Ignore, these files will be installed later via WebUpdate.

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Section 1 - 1 Servicemaster SYSTEM How to Set-up Servicemaster

T040010-9

Fig 13. To6020-10

12

The two shortcuts will be placed on the desktop

Fig 11. 10

Once the install has finished, you will get the following popup box.

T040010-10

Fig 14. T040010-8

Fig 12. 11

1-8

Once you have clicked OK, the following screen will appear. Clicking Finish on this will take you to the JCB portal, please see Fresh Installation of JCB WebUpdate for the next steps.

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Section 1 - 1 Servicemaster SYSTEM How to Set-up Servicemaster

New Installation of JCB ServiceMaster WebUpdate This topic covers the fresh installation of JCB WebUpdate on a new laptop / PC. 1

Once you have ServiceMaster installed on your laptop you will need to keep it updated. This is done via JCB Webupdate. The following steps are a guide to downloading and installing JCB WebUpdate.

2

JCB WebUpdate is installed using the following web address: www.business.jcb.com.

3

This link brings up the following page:

T064000-3

Fig 15.

T064000-2

Fig 16. 4

5

If you do not already have a User ID and Password then please click Get Support and apply for an account with access to JDS and Serviceparts Pro.

6

Clicking this will bring up a popup with the following screen:

Once logged in you will find a link on the left hand tool bar called “JDS�, click this.

T064000-4

Fig 17. 7

1-9

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From this screen, click on the SM WebUpdate link on the left hand tool bar. This will bring up the following screen:

1-9


Section 1 - 1 Servicemaster SYSTEM How to Set-up Servicemaster

T064000-1

Fig 20. T064000-11

Fig 18. 8

10

The download will now begin. When the download is finished, the installer will automatically run.

Within the orange text there is a “click here” link. Click this to begin the download of JCB WebUpdate.

T064000-8

Fig 21. T064000-9

Fig 19. 9

11

JCB WebUpdate has now finished installing and the following icon should appear on your desktop:

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1-10

Please click “Run” when the above popup appears. This will begin the download. Due to the firewall on the computer you may get the following popup, if this occurs, click “Run”.

1-10


Section 1 - 1 Servicemaster SYSTEM How to Set-up Servicemaster

T064000-10

Fig 22. 12

Please follow the instruction in the Authorising JCB WebUpdate downloads to authorise your downloads.

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Section 1 - 1 Servicemaster SYSTEM How to Set-up Servicemaster

Authorising JCB WebUpdate Downloads This topic covers the authorisation process needed to access downloads via JCB WebUpdate on a laptop / PC. 1

After the installation you will need to authorise the download to ensure that you get future updates.

2

This is accessed from the webupdate section of JDS (see instruction within Fresh Installation of JCB WebUpdate to get to the following page).

T04000-6

Fig 25. 6

This now completes the authorisation step of JCB WebUpdate.

7

To perform a ServiceMaster Update, please run WebUpdate either by using your desktop icon or from within the help menu within ServiceMaster.

8

The program will check for updates and inform you if you have any to download.

T064000-11

Fig 23. 3

4

On this page you will either have a red or orange box dependant on the download privileges attached to your name (red for pre release, orange for full release only).

T064000-7

Fig 26. 9

From here you can either click “Details” to see which files have been changed, added or removed.

10

Clicking on the “Download” button will start the download of the updates.

11

Once downloaded, WebUpdate will ask you if you want to install the updates. You can either choose to install the updates immediately or at a later date.

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1-12

Clicking on this box will begin the authorisation process.

T039990

Fig 24. 5

After the system has authorised the download it will ask you if you wish to perform the download. Please click “Download”

1-12


Section 1 - 1 Servicemaster SYSTEM How to Set-up Servicemaster

Using JCB WebUpdate to Download Updates This topic covers the download of ServiceMaster updates via JCB WebUpdate on a laptop / PC. 1

To perform a ServiceMaster Update, please run WebUpdate either by using your desktop icon or from within the help menu within ServiceMaster.

2

The program will check for updates and inform you if you have any to download.

Fig 27.

T064020-1

Fig 28. 3

From here you can either click “Details” to see which files have been changed, added or removed.

4

Clicking on the “Download” button will start the download of the updates.

T064020-2

Fig 29. 5

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Once downloaded, WebUpdate will ask you if you want to install the updates. You can either choose to install the updates immediately or at a later date.

1-13


Section 1 - 1 Servicemaster SYSTEM How to Set-up Servicemaster

JCB ServiceMaster JCB ServiceMaster is an application allowing engineers to diagnose/set-up the various electronic control units within the JCB product range. The tools comprises of a Front End GUI allowing the user to select the machine which they wish to work on as well as a number of various tools which allow: programming of electronic control units, the diagnosing of electronic issues, the set-up of various options and checking the service history of the machine.

Once the user has clicked on the applicable machine type they will be able to select the tool they require from a list of the tools available for that machine range. Below are screen-shots showing the difference between 2 machine types tool set.

JCB ServiceMaster is updated on a monthly basis by incorporating WebUpdate. This is a program which works alongside ServiceMaster to let the user know and allow them to download an update as and when it becomes available to them

ServiceMaster Front End The start-up page of ServiceMaster is known as the front end. This is a GUI allowing the user to easily and quickly navigate to the machine they are working on to ensure that they have the applicable tools for that machine.

C140910.jpg

Fig 30. The front end is split into 3 main sections (denoted by the tabs in the black bar), Construction machines, Agricultural machines and other applications. Within the construction and agricultural tabs are the applicable machine ranges, i.e. Backhoe Loaders in construction and Fastrac in agricultural.

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Section 1 - 1 Servicemaster SYSTEM How to Set-up Servicemaster

Selecting Service Tool Applications When you have navigated to the correct machine type via the front end, you will be greeted with the relevant tools for that particular machine. These tools are accessed by a single click on the icon of the tool you require. There are 5 main tools within ServiceMaster, these are: Set-up

Parameter settings, Option/ Attachment control Alternative Language Support Model/Serial Number Identification

Vehicle Set-up

As well as the tools stated above there are also 3rd party tools for some of the machine range which will need to be installed. These tools are denoted by the following symbol:

To install these applications you need to take the following steps: – On the front end, click the other tab – Click on general – Click onto “extra applications”

Data Logging

Running Data Collection, Operating Data, Statistics, Device Error Log Recording.

– Choose the relevant tool which you require to be installed and run the installer. Once the installer has been run, the icon should have changed within the machine tool page. e.g. the above icon has now become:

Data Logger Service History Engine Hour records, Service Dealership Codes.

Service History Flashloader

Reprogramming and Software update/Revision capability.

Diagnostics

ECU I/O testing and diagnostics.

Flashloader

Diagnostics

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Section 1 - 1 Servicemaster SYSTEM How to Set-up Servicemaster

Start Servicemaster 1

Double click on the Servicemaster icon. (The icon is found on the desktop or in the `Start' menu `Programs' - 'JCB'.)

Fig 31. 2

The Servicemaster window will open. T064020-

Fig 33.

T063980

Fig 32. 3

Double click the desired machine group.

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Section 1 - 1 Servicemaster SYSTEM How to Set-up Servicemaster

Load the DLA Laptop Driver Software To use Servicemaster for the first time you must load the DLA driver software. You will not have to do the procedure again. Important: DO NOT connect the DLA or cables at the laptop or machine now. 1

Start the Servicemaster software on your laptop computer. K Start Servicemaster ( T 1-16).

2

Click the ‘Other’ tab.

3

Click on the ‘General’ icon.

4

Click on the ‘DLA' icon. K Fig 34. ( T 1-17).

Fig 35.

T064020-11

Fig 36. Note: Drivers are also available for computers with serial ports (no USB) and other versions of Microsoft Windows. If your laptop does not have a USB port, double click on the correct driver icon. 6

The driver installer window will open. Follow the onscreen installation instructions to complete the installation.

T06020-5

Fig 34. 5

Double click on K Fig 36. ( T 1-17)

1-17

the

USB

driver

icon.

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Section 1 - 1 Servicemaster SYSTEM How to Set-up Servicemaster

Configure the DLA Type and Communications Port To use Servicemaster for the first time you must make sure that the correct DLA and laptop port is selected to communicate with the DLA. You will not have to do the procedure again. 1

Start the Servicemaster software on your laptop computer.

2

Click the ‘Other’ tab.

3

Click on the ‘General’ icon.

4

Click on the ‘DLA' icon.

5

Double click the COM Port icon.

Co47220-C1

Fig 38. Note: Older DLAs and laptop computers may not be compatible with USB ports. Choose the `Parallel/Serial DLA' device in the DLA screen.

T06020-8

Fig 37. 6

The DLA window will open. Select the `USB/Serial DLA' device and then click `Apply'.

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Section 1 - 1 Servicemaster SYSTEM How to Set-up Servicemaster

Check the DLA Firmware File The DLA has software embedded in its own flash memory. This file must be replaced with a new one when new firmware is released. You will only have to Check the DLA firmware file version if you receive a new Servicemaster version or use a different DLA. 1

Make sure that the DLA is connected to the laptop computer. K Connect the 'USB PC Cable' A to the DLA and a free port on your laptop computer. ( T 1-21)

C048070.jpg

Fig 40. 2

Start the Servicemaster software on your laptop computer. K Start Servicemaster ( T 1-16)

3

Click the ‘Other’ tab.

4

Click on the ‘General’ icon.

5

Click on the ‘DLA' icon.

6

Double click on the USB DLA Flash Loader icon. K Fig 39. ( T 1-19)

8

Check for a new firmware file: Click on the browse button A and locate the file stored within the JCB_Servicemaster directory on your laptop hard drive. a

Click the `Open' button. The selected file appears in the `Firmware File Name' field together with its release date and application version, for example 2.01.K Fig 42. ( T 1-20)

T06020-9

Fig 39. Note: Older DLAs and laptop computers may not be compatible with USB ports. Double click the `Flash loader for Serial/Parallel DLA' icon. 7

The device flash update tool window opens. The details of the firmware in the DLA are displayed including the application version, for example 1.04.

1-19

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Fig 41.

1-19


Section 1 - 1 Servicemaster SYSTEM How to Set-up Servicemaster

C048070-C3.jpg

Fig 42. 9

Load a new firmware file: If the firmware in the DLA is not up to date, load the new file. Click the `Start' button A and follow the on-screen instructions.

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Section 1 - 1 Servicemaster SYSTEM How to Set-up Servicemaster

Connect Servicemaster to the Machine CANbus To use Servicemaster connect your laptop computer to the machine CANbus. Connection is made using Data Link Adaptor (DLA) C and the applicable cables.

1

Make sure the machine ignition system is OFF.

2

Connect the 'USB PC Cable' A to the DLA and a free port on your laptop computer.

Note: Connect the USB cable directly to the laptop computer. DO NOT connect the cable via a USB hub. Note: Older DLAs and laptop computers may not be compatible with USB ports. Use the serial PC cable B to connect the DLA to the laptop serial port.

D

C

A405350-C4.jpg

Fig 44.

A

B

3

Connect the 'Machine Cable' D to the DLA. The 'Machine Cable' has a 15-way D-type connector on one end and a 9-way CAN connector on the other. Plug the 15-way connector into the DLA and tighten the thumb-screws.

4

Connect the 9-way CAN connector into the machines' Diagnostics Connector A as follows:

C032140-C1.eps

Fig 43.

A

Table 1. Component Key USB PC Cable 718/20235

B

Serial PC Cable

C

USB DLA

728/26500

D

Machine Cable

718/20237

a

Position the CAN connector B to align the centre pin location tab C with the diagnostics connector A.

b Couple the connectors. Turn the locking ring D clockwise to secure the connectors.

718/20236

Kit 892/01174 (includes items A,B,C and D)

1-21

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1-21


Section 1 - 1 Servicemaster SYSTEM How to Set-up Servicemaster

Page left intentionally blank

1-22

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Section C - Electrics

Servicemaster Tools Set Introduction

K Tools Suites ( T C-24) K Machine Tools ( T C-24) K Engine Tools ( T C-26) K Diagnostics Connectors ( T C-28) K Servicemaster Machine Selection ( T C-29) K Servicemaster Engine Selection ( T C-30)

C-23

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Section C - Electrics Servicemaster Tools Set Tools Suites

Tools Suites Machine Tools Tool

Icon

Description Set-up the control systems for the applicable vehicle options such as a quickhitch Unlock ECU binding and bind ECU’s on the CANbus.

Vehicle Set-up

T063900

Set-up applicable immobiliser variant. Manage immobiliser keys and codes. Lock immobiliser binding on the CANbus

Immobiliser Set-up

T063900

Vehicle Diagnostics

View machine operating parameters in real time. View machine ECU input / output status in real time. Enable diagnostics of machine switches, sensors and actuators for systems such as power, hydraulic and travel controls. View or save the machine ECU fault code logs.

T063930

Datalogger

Records and displays machine operating history. Data includes operating hours, engine speeds, oil and coolant overheating. Fault code log.

T063920

Enables upload and download of machine service history. Includes a help file.

Service History

T063950

Flashloader

Enables upload and download of machine ECU program files stored on the ECU flash memory, to and from a suitable laptop PC.

T063940

Reference file listing all possible fault codes.

Fault Codes

T063940-C1

C-24

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Section C - Electrics Servicemaster Tools Set Tools Suites Tool

Icon

Description

7 DECU

Current DECU flash file for loading via the DECU USB port.

C142190

Flash Loading the DECU

Procedures for uploading the DECU flash file via the DECU USB port.

T063940-C1

C-25

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Section C - Electrics Servicemaster Tools Set Tools Suites

Engine Tools Tool

Icon

Description View engine operating parameters in real time. Perform engine electrical actuator tests. View, save or clear engine ECU fault code log. Includes help files with comprehensive information about engine related sensors, actuators and ECU fault codes.

JCB Ecomax Engine Diagnostics

T063930

JCB Dieselmax Engine Diagnostics

View engine operating parameters in real time. Perform engine electrical actuator tests. View, save or clear engine ECU fault code log. Includes help files with comprehensive information about engine related sensors, actuators and ECU fault codes.

T063930

Comprehensive interactive help file enables efficient diagnostics of electrical engine related faults.

Help File - JCB Ecomax

T063940-C1

Comprehensive interactive help file enables efficient diagnostics of electrical engine related faults.

Help File - JCB Dieselmax

T063940-C1

JCB Ecomax Engine Set-up

Set-up the control systems for the applicable JCB Ecomax engine options such as a cold start inlet manifold heater. Set the injector codes for replacement injectors. Record the specifications of replacement actuators. Unset and set the engine immobiliser

T063900

Set-up the control systems for the applicable JCB Dieselmax engine options such as a cold start inlet manifold heater. Set the injector codes for replacement injectors.

JCB Dieselmax Engine Set-up

T063900

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Section C - Electrics Servicemaster Tools Set Tools Suites Tool

Icon

Description

JCB Ecomax Engine Flashloader

Enables upload and download of engine ECU program files stored on the ECU flash memory, to and from a suitable laptop PC.

T063940

JCB Dieselmax Engine Flashloader

Enables upload and download of engine ECU program files stored on the ECU flash memory, to and from a suitable laptop PC.

T063940

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Section C - Electrics Servicemaster Tools Set Diagnostics Connectors

Diagnostics Connectors Connect the diagnostics plug from the DLA to the diagnostics socket on the machine. For details about the DLA refer to Servicemaster SYSTEM. Diagnostics Socket Location The diagnostics socket 2 is located on the cab fuse and relay board. To get access, open cover 1.

1

2

C129890

Fig 1.

Flash Loading the DECU It is not possible to upload a flash file o the Display ECU (DECU) via the normal diagnostics connector. Loading of a flash file is enabled via a dedicated USB port located inside the rear DECU housing. For the correct procedures refer to the applicable file contained in JCB Servicemaster. K Tools Suites ( T C-24)

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Section C - Electrics Servicemaster Tools Set Servicemaster Machine Selection

Servicemaster Machine Selection 1

Open Servicemaster, SYSTEM.

refer

to

Servicemaster

2

Click on the construction tab. Click on the tracked excavators icon.

C131180

Fig 2. 3

Click on the DECU machines icon, Icons for the diagnostic tool suite for all DECU control system machines are displayed.

C131180-C2

Fig 4.

C131180-C1

Fig 3. 4

Click on the icon to open the applicable diagnostics tool. For applicable diagnostics tools refer to the table. K Machine Tools ( T C-24)

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Section C - Electrics Servicemaster Tools Set Servicemaster Engine Selection

Servicemaster Engine Selection 1

Open Servicemaster, SYSTEM.

refer

to

Servicemaster

2

Click on the ‘Other’ tab. Click on the Engines icon.

C131190-C3

Fig 8. JCB Ecomax

C131190-C1

Fig 5. 3

Click on the applicable engine icon:

C131190-C2

Fig 6. JCB Ecomax

C131190-C5

Fig 9. JCB Dieselmax

C131190-C4

Fig 7. JCB Dieselmax 4

Click on the icon to open the applicable diagnostics tool. For applicable diagnostics tools refer to the table. K Engine Tools ( T C-26)

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Section 1 - 1

Routine Maintenance Procedures Scheduled Tasks The table below lists the Electrical related Scheduled tasks. The procedures are in addition to the Daily/Weekly tasks. For details of all applicable maintenance schedules refer to Section 2.

Note: Maintenance schedules can vary according to machine operating conditions and environments. Refer to Section 2.

Table 1. Item

Task

Refer to

Starter motor

Check (Condition)

K Check (Condition) ( T 1-2)

Alternator

Check (Condition)

K Check (Condition) ( T 1-3)

Alternator - output

Check (Condition)

K Check (Condition) ( T 1-3)

Overload Warning System

Check (Operation)

K Check (Operation) ( T 1-4)

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1-1


Section 1 - 1 Routine Maintenance Procedures Starter Motor

Starter Motor Check (Condition) Inspect the starter motor installation as follows: – Check the security of the starter motor to engine fixing bolts. Make sure that they are tightened to the correct torque. – Check that the electrical connections at the starter motor are clean and secure. – Repair or replace related electrical cables, wiring and connectors if they are defective. – Check the operation of the starter motor. If it fails to operate normally or makes excessive noise repair or replace as necessary.

1-2

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Section 1 - 1 Routine Maintenance Procedures Alternator

Alternator Check (Condition) Inspect the alternator installation as follows: – Check the security of the alternator to engine fixing. – Check that the electrical connections at the alternator are clean and secure. – Repair or replace related electrical cables, wiring and connectors if they are defective. – Check the alternator drive pulley security. – Start the engine and check the machine instrumentation for electrical charging fault warnings. Check the fault log for electrical charging related faults. Refer to Section 2. If there are related warnings or fault codes fault find the electrical charging system.

1-3

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Section 1 - 1 Routine Maintenance Procedures Overload Warning System

Overload Warning System Check (Operation) Test the overload warning system as follows: – Switch on the overload warning system. Refer to Section 2, Operation, Working With the Excavator Arm. – Make sure that the machine instrumentation activates the applicable overload warning system active indicators. Refer to Section 2, Operation, Lifting and Loading, Overload Warning System. – Attach suitable test load with suitable lifting equipment. Lift the load 25 -50 mm off the ground. Refer to Section 2, Operation, Working With the Excavator Arm. – Make sure that the overload system warning indicators operate correctly. Refer to Section 2, Operation, Lifting and Loading, Overload Warning System. – Lower the test load and make sure that the overload warning system indicators re-set correctly. If the overload warning system does not operate correctly carry out the necessary procedures to repair it. Important: DO NOT operate the machine if the overload warning system is defective.

1-4

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Section E Hydraulics Service Manual - JS 200 Series Tracked Excavators Section 1 - General Information Section 2 - Operator’s Manual Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track & Running Gear Section K - Engine

Publication No.

9813/5550-1

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


Section E - Hydraulics

Notes:

E-0

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Section E - Hydraulics

Technical Data General Data Main Hydraulic Pump Type

Twin variable displacement piston pump

Displacement Volume

117 cm3/rev (7.01 in3/rev ) x 2

Operating Pressure RATED

343 bar (350 kgf/cm2, 4977 lb/in2)

Maximum Output (JS200/210/220)

215 l/min x 2 (47.3 UK gal/min, 56.4 US gal)

Maximum Output (JS240/260)

226 l/min x 2 (49.7 UK gal/min, 59.3 US gal)

Working Pressure

39.2 bar (40 kgf/cm2, 569 lb/in2)

Minimum Output

30 l/min (6.6 UK gal, 7.9 US gal)

Dry weight

141 kg (311 lb)(1)

(1) Includes mounting flange.

Servo Pump Type

Fixed Displacement Gear Pump

Displacement Volume

10 cm3/rev (0.61 in3/rev)

Working Pressure

37-43 bar (37.7-49 kgf/cm2, 536.5-623.5 lb/in2)

Proportional Pressure Reducing Valve Max. primary pressure

39 bar (40 kgf/cm2, 529 Ib in2)

Max, back pressure (allowable pressure) 9.8 bar (10 kgf/cm2, 142 Ib in2) Secondary pressure setting range

0- 39 bar (0 - 40 kgf/cm, 0 - 468 Ib in2)

Max. flow rate

10 l/min (2.2 UK gal/min, 2.6 US gal/min)

Electrical specifications

E-1

1 Rated current

700 mA

2 Coil resistance (at 20°C)

17.5 ohm

3 Recommended fluctuation of proportional solenoid current

80 Hz, 200 mApp

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Section E - Hydraulics Technical Data General Data

Slew Motor Type

Fixed displacement piston motor

Suction Capacity

151 cm3/rev (9.21 in3/rev)

Working Pressure Max.

289 bar (294.7 kgf/cm2 ,4191.6 lbf/in2)

Work Flow

198.7 l/min (43.6 gal/min)

Set Pressure Relief

289 bar (294.6 kgf/cm2, 4191 Ib in2) at 155 litre/ min (34 UK gal, 41 US gal)

Reduction Gear Ratio

16.757:1

Brake Torque

More than 739 Nm (75 kgf m, 545 lbf ft) (not including reduction gear)

Brake Pressure Release

Min 29 bar (29.5 kgf/cm2, 420 Ib in2)

Dry Weight

197 kg (434 lb)

Main Control Valve JS200/210/220 Type

Hydraulic Pilot System

Operating System

Set pressure relief

Main Relief Pressure Standard

343 bar (350 kgf/cm2 , 4975 lb/in2) at 138 litre/min (30.3 Uk gal, 36.4 US gal)

Pressure Raising

373 bar (380.5 kgf/cm2 , 5410 lb/in2) at 155 litre/min (34 Uk gal, 41 US gal)

Overload Relief Pressure Bucket Open/closed

392 bar (400 kg cm2, 5685 lb/in2) at 20 litre/min (4.4 Uk gal, 5.3 US gal)

Dipper

392 bar (400 kg cm2, 5685 lb/in2) at 20 litre/min (4.4 Uk gal, 5.3 US gal)

Boom Raising

392 bar (400 kg cm2, 5685 lb/in2) at 20 litre/min (4.4 Uk gal, 5.3 US gal)

Boom Lowering Pressure

264 bar (269 kg cm2, 3828 lb/in2) at 20 litre/min (4.4 Uk gal, 5.3 US gal)

Function

Travel priority, Slew priority, Boom and Dipper holding valves, Boom and Dipper 2-Speed internal confluence

Dry weight

165 kg (364 lb)

Main Control Valve JS240/260 Type

Hydraulic Pilot System

Operating System

Set pressure relief

Main Relief Pressure Standard

343 bar (350 kgf/cm2 , 4975 lb/in2) at 138 litre/min (30.3 Uk gal, 36.4 US gal)

Pressure Raising

373 bar (380.5 kgf/cm2 , 5410 lb/in2) at 155 litre/min (34 Uk gal, 41 US gal)

Overload Relief Pressure Bucket Open/closed

392 bar (400 kg cm2, 5685 lb/in2) at 20 litre/min (4.4 Uk gal, 5.3 US gal)

Dipper

392 bar (400 kg cm2, 5685 lb/in2) at 20 litre/min (4.4 Uk gal, 5.3 US gal)

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Section E - Hydraulics Technical Data General Data Boom Raising

392 bar (400 kg cm2, 5685 lb/in2) at 20 litre/min (4.4 Uk gal, 5.3 US gal)

Boom Lowering Pressure

264 bar (269 kg cm2, 3828 lb/in2) at 20 litre/min (4.4 Uk gal, 5.3 US gal)

Function

Travel priority, Slew priority, Boom and Dipper holding valves, Boom and Dipper 2-Speed internal confluence

Dry weight

193 kg (425 lb)

Spool Stroke versus Pilot Pressure

SPOOL STROKE (mm)

10 9 8 SLEW/DIPPER PRIORITY SPOOL & MERGE SPOOL

6 STRAIGHT TRAVEL & BOOM 2

4

OTHER

2 2.5

1.1 0

3

10

12

20

26

SERVO PRESSURE (bar)

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27 A709320

E-3


Section E - Hydraulics Technical Data General Data

Boom Ram JS200/210/220

JS240/260

Cylinder Inside Diameter

125 mm (4.9 in)

130 mm (5.1 in)

Rod Diameter

85 mm (3.4 in)

90 mm (3.54 in)

Max Contracted Length

1790 mm +/-3 (70.5 in)

1843 mm +/-3 (72.6 in)

Stroke

1259 mm +/-2 (49.6 in)

1278 mm +/-2 (50.3 in)

Dry Weight

176 kg (388 lb)

219 kg (483 lb)

JS200/210/220

JS240/260

130 mm (5.1in)

140 mm (5.51 in)

Dipper Ram

Cylinder Inside Diameter Rod Diameter

95 mm (3.7 in)

100 mm (3.9 in)

Max Contracted Length

2150 mm +/-3 (84.6 in)

2234 mm +/-3 (88 in)

Stroke

1578 mm +/-2 (62 in)

1632 mm +/-2 (64.25 in)

Dry Weight

275 kg (606 lb)

316 kg (697 lb)

JS200/210/220

JS240/260

Cylinder Inside Diameter

115 mm (4.5 in)

130 mm (5.1 in)

Rod Diameter

85 mm (3.3 in)

95 mm (3.74 in)

Bucket Ram

Max Contracted Length

1583 mm +/-3 (62.3 in)

1687 mm +/-3 (66.4 in)

Stroke

1012 mm +/-2 (34.8 in)

1073 mm +/-2 (42.24 in)

Dry Weight

146 kg (322 lb)

222 kg (489 lb)

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Section E - Hydraulics

Basic System Operation Introduction to Hydraulic Schematic Symbols TE-001

General (Basic and Functional Symbols) Complex hydraulic components and circuits can be described to the engineer by using graphical symbols. The following pages illustrate and give a brief description for some of the more common symbols used.

Table 2. Rams Single acting

Double acting There are many symbols in use and it would be impossible to include them all here. However it should be noted that most are only variations or refinements on the basic principles explained here. If more detailed information is required you are recommended to obtain a copy of BS2917 or IS01219. Once familiar with the symbols, the engineer can use hydraulic circuit diagrams as an aid to fault finding. It will be possible to see the complete hydraulic circuit and decipher the relationship between hydraulic components. Table 1. General

Double ended

Double acting with damping at rod area end

Table 3. Pumps and Motors Variable capacity pump two directions of flow

Spring Flow restriction affected by viscosity

Fixed capacity motor one direction of flow

Direction of flow Fixed capacity motor two directions of flow

Indication of rotation

Variable capacity motor one direction of flow

Indication of direction and paths of flow

Variable capacity motor two directions of flow

Variable control

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Section E - Hydraulics Basic System Operation Introduction to Hydraulic Schematic Symbols Table 4. Control Valves Used to enclose several valves indicating they are supplied as one unit

Throttling orifice - normally closed

3-Position, 4-port spring centered pilot operated valve

Throttling orifice - normally open

3-position, 6-port spring centered pilot operated valve Relief valve

3-Position, 4-port spring centered solenoid & pilot pressure operated valve 3-Position, 4-port spring centered detent hand operated valve

Variable restrictor

Non-return valve

Non-return valve with back pressure spring

Pilot operated non-return valve

One way restrictor

High pressure selector (shuttle valve)

E-6

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Section E - Hydraulics Basic System Operation Introduction to Hydraulic Schematic Symbols Table 5. Energy Transmissions and Conditioning Working line, return or feed

Reservoir - return line below fluid level

Pilot control Drain lines Header tank Flexible pipe

Pressure sealed tank Line junction

Accumulator

Crossing lines

Filter or strainer

Water trap Air bleed

Line plugged, also pressure test point Line plugged with take off line

Cooler - with no indication of coolant flow

Cooler - indicating direction of coolant flow

Quick release couplings connected Heater Quick release couplings disconnected

Reservoir - return line above fluid level

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Section E - Hydraulics Basic System Operation Introduction to Hydraulic Schematic Symbols Table 6. Control Mechanisms Solenoid one winding

Rotating shaft - one direction

Solenoid two windings

Rotating shaft - two directions

Detent

M

Locking device

Electric motor operated

Internal pressure pilot operated

Over centre device External pressure pilot operated Simple linkage Pressure operated spring release General control Pilot operated by solenoid pilot valve Push button operated Pilot operated by a solenoid or seperate pilot valve Lever operated Pressure guage Pedal operated Pressure switch Stem operated

Spring operated

Roller operated

Roller trip operated (one directional)

E-8

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Section E - Hydraulics Basic System Operation Introduction to Hydraulic Schematic Symbols

Control Valves Control valves are usually represented by one or more square boxes. K Fig 1. ( T E-9) shows a control valve represented by three boxes. The number of boxes indicates the number of possible valve operating positions, (3 boxes - 3 positions etc).

Fig 4. Fig 1. K Fig 2. ( T E-9) - In circuit diagrams the pipework is usually shown connected to the box which represents the unoperated condition. (Hydraulic circuit diagrams are usually shown in the unoperated condition).

It must be noted that not all spools are of the same type. Their operating designs can be seen by following the path the flow arrows take in their respective operating squares. Three typical JCB style spools are known as 'D' spools, 'F' spools and 'N' spools. The 'D' spools generally control rams because when in the neutral position the outlet ports are blocked, preventing ram movement. K Fig 4. ( T E-9) shows a 'D' type spool.

Fig 2. K Fig 4. ( T E-9) shows a valve described as a 3-position, 4-port control valve. Port describes the openings to and from the valve by which the hydraulic fluid enters or leaves. In the fig shown, Position 2 indicates that in an unoperated condition all 4 ports are blocked.

K Fig 5. ( T E-9) - 'F' spools are often shown as four position spools with the three normal positions for neutral and service control; and the forth position, which has a detent, connects both sides of the ram together to allow the service to 'float'.

Fig 5. K Fig 6. ( T E-9) - 'N' spools are sometimes used to control hydraulic motors, and it can be seen from the flow arrows, that in neutral position both service ports are connected to the exhaust oil port

Fig 3. If the valve spool was moved to Position 1, movement of the spool would connect Port P1 to Port P2, and Port P3 to Port P4. K Fig 4. ( T E-9). If the valve spool was moved to Position 3, movement of the spool would connect Port P1 to Port P4, and Port P3 to Port P2. K Fig 4. ( T E-9).

E-9

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Fig 6.

E-9


Section E - Hydraulics Basic System Operation Introduction to Hydraulic Schematic Symbols

Example of Schematic Circuit

A

B

C

D

E

G

F

Fig 7. Simple Schematic Circuit Some of the symbols described on the preceding pages have been arranged into a simple schematic circuit. K Fig 7. ( T E-10). Hydraulic tank 7-A is a pressurised tank with an internally mounted strainer 7-B on the suction line to the fixed displacement pump 7-C. System pressure is limited to the setting of relief valve 7-D. Valve spool 7-E is an open-centre spool that is in neutral position; flow from the pump passes through the spool and returns to the hydraulic tank.

Example Circuit Key 7-A

Hydraulic Tank

7-B

Strainer

7-C

Fixed Displacement Pump

7-D

Relief Valve

7-E

Spool

7-F

One Way Valve

7-G

Double Acting Hydraulic Ram

If the lever operated spool is moved away from neutral position hydraulic fluid is directed to either head side or rod side of hydraulic ram 7-G. Notice that the fluid must first open one way valve 7-F before flowing to the ram.

E-10

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Section E - Hydraulics

Circuit Descriptions Hydraulic Schematic JS200, JS210, JS220

Main hydraulic systems

The hydraulic schematic diagrams are shown on sheets as follows:

Item

Description

1

Motor - Swing

2

Rotary Coupling

3

Trackmotor

4

Cyl - Arm

5

HBCV - Arm

6

Boom Cylinder

7

HBCV Boom

8

Bucket Cylinder

10

Coupling Male 1/2”

13

Main Control Valve

15

Coupling Male 1 1/4”

16

Coupling Male 1”

17

Hammer Aux Valve

18

Return Line Filter

19

Cooling Pack

20

Check Valve 1 bar

21

Return Manifold

22

Drain Filter

23

Air Breather

24

In Line Filter

26

Hydraulic Tank

27

Strainer

28

Relief Valve

29

Main Return Filter

30

Shuttle Valve - Pilot

31

Merged Valve

32

Valve - LH Joystick

E-11

K 333/K1613 Sheet 1 issue 5 ( T E-13) The item numbers in the following table are identified on the hydraulic schematic diagrams. K Fig 1. ( T E-13) Grid Reference

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Sheet

E-11


Section E - Hydraulics Circuit Descriptions Hydraulic Schematic Item

Description

33

Valve - LH Joystick

34

Cushion Valve

36

Pilot Valve - Travel

37

Hammer/Auxiliary Valve

38

Pilot Manifold - Cab

39

Pilot Filter

40

Priority Valve - 25 litre / min

41

Priority Valve - 50 litre / min

42

Main Pump

43

Accumulator

Grid Reference

Sheet

44 45

Shuttle Valve

46

Pressure Switch

47

Pressure Switch

49

Pressure Switch

50

Pressure Switch

51

Pressure Switch

52

Test Point - Bulkhead

53

Slew Gearbox

54

Gear Pump - Low Flow

55

Solenoid Valve - Closed Centre

56

Solenoid Valve - Open Centre

57

Manifold Block

59

Test Point (tee)

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Section E - Hydraulics Circuit Descriptions

Fig 1. 333/K1613 Sheet 1 issue 5

333-k1613-5-sheet1.eps

Hydraulic Schematic

E-13

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E-13


HRC Schematic

E-14

D

CAB DOWN

CAB UP

9813/5550-1

B

C

B

A

P

T

90

CT5

CT3

V1

CT4

C5

CT2

BYPASS

PRIORITY

C2

3 8 "HOSES

C3

V2

P

C4

Fig 2. 332/J3436 issue 1

a

b

CT1

C1

ST

3 8 "BSP

3 8 "BSP

CAB DOWN

ST

ST

3 8 "BSP

ST

CAB UP

3 8 "BSP

E

T

TO TANK MANIFOLD

G

A

A2

P2

G

F

Section E - Hydraulics Circuit Descriptions Hydraulic Schematic

E-14


Section E - Hydraulics Circuit Descriptions Hydraulic Schematic Table 1. Component identification Remark

Item Part number

Description

A

JRJ0050

Priority Valve

24 V DC Relief Valve 100-180 Bar. Max. Working Pressure 338 Bar. Flow 36 l/min Adjustable +/-30% i.e. 25 To 47 l/min. Nominal Pressure 150 Bar

B

JRJ0344

Spool - Open Centre

DCV + X Line Relief

C

25/221537

Cab Lowering Hic Integrated Hydraulics

All Ports 3/8" Bsp. Max Pressure 350 Bar. Max Flow 30 L/Min

D

TBA

Valve. "Fijtech" 500 Bar Lock.

Normally Closed. Located On Rh Face Of Rh Cab Control Arm Fab.

E

557/60109

Lift Rams

(706 Stroke) Actual Stroke = 631

F

TBA

Hydraulic Pump

G

TBA

Main Control Valve

Table 2. Calculated Flow Rates Total Flow (L/min) Time To Raise Cab 15

32

30

16

45

10

Calculated minimum pressure to raise cab = 40 bar (required time = 10-15 seconds)

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Section E - Hydraulics Circuit Descriptions Hydraulic Schematic

Page left intentionally blank

E-16

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Section E - Hydraulics Circuit Descriptions Servo/Pilot Line

Servo/Pilot Line Components

Hose Colour BL

Blue

BR

Brown

CI

Colourless

G

Green

1

Cab Manifold

2

Left hand Joystick

3

Right hand Joystick

GR

Grey

4

Shuttle Valve

LB

Light Blue

5

Cushion Valve

O

Orange

P

Pink

6

Main Control Valve

R

Red

a

Dipper 2

b Boom 1 c

Bucket

d Travel Right hand e

Dipper 1

f

Boom 2

V

Violet

W

White

Y

Yellow

LG

Light Green

DG

Dark Green

g Slew h Option i

Travel Left hand

j

Dipper Holding Valve

k

Boom Holding Valve

l

Slew over Dipper Priority Valve

m Boom over Bucket Priority Valve 7

Travel pedal

8

8 Station

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E-17


CL

W

P2

T2

1

P6

T6

9813/5550-1

P5

E-18

T5

Pb6

Pb7

Pb8

Pb9

CL

W

W

P

2

3

P

T

T

1

CL

4

3

2

1

4

3

2

T

P

4

1

BACK

3

2

Br

GR

7

Y/G

B

Pc3

Pb1

Pb2

Pb3

Pb4

Pb5

V

BL O

R

LG

P

Y

G

C1

C6

A5 B5

B1

B2

A2

A1

B3

B4

A3

A4

B6

C2

C9

A6

C3

S1

C7

C8

C10

B7

B8

C4

C5

S2

S3

C11

A7

A8

R/G

LG/V

P/V

O/O

O/G

G Y

V

O

BL

R

LG

P

LB/BL

P/G

Pa5

5

F

E

B

A

R

FRONT

A1

S

E1

T

H

G

D

C

BL/V

P

R

LG

BL

Pa6

Pa7

Pc2

Pa8

Pa9

Fig 3. Servo/Pilot Line Schematic - 215/13620-8

4

RIGHT

Pa1

Pa2

Pa3

Pa4

Pc1

6

LEFT

Pa9

a

Pb9

Pa8

b

Pb8

Pa7

c

Pb7

Pa6

d

Pb6

Pi1

Pa5

e

Pb5

8

A

Pa4

f

Pb4

Pa3

g

Pb3

Pa2

h

Pb2

Pa1

j

Pb1

Pc3

k n

Pc1

Pc2

Pi1

m p

Section E - Hydraulics Circuit Descriptions Servo/Pilot Line

E-18


Section E - Hydraulics Circuit Descriptions Servo/Pilot Pressure and Return Line

Servo/Pilot Pressure and Return Line Components 1

Shuttle Valve

2

Slew Motor

3

Rotary coupling

4

Boom Priority Valve

5

Cushion Valve

6

Cab Manifold

7

Tank Manifold

8

Servo Pump

9

Servo Filter

10

Main Control valve

11

Solenoid Valve (8 Spool)

12

Pump Assembly

E-19

9813/5550-1

E-19


Section E - Hydraulics Circuit Descriptions

Fig 4. Servo/Pilot Pressure and Return Line Schematic - 333/K1422-5

12

1

2

3

11

4

5

6

7

9

10

8

Servo/Pilot Pressure and Return Line

E-20

9813/5550-1

E-20


Section E - Hydraulics Circuit Descriptions Hydraulic Pump Regulation

Hydraulic Pump Regulation Hydraulic Pump Regulation For this description pump A2 has been used. For Schematic, K Fig 5. ( T E-22). On start up, the swash plate piston B is held in the maximum flow position by the spring A and also by servo pressure which enters via check valve H and is available to the small area side of swash plate piston B to hold the pump in the maximum flow position. Once oil as passed through the valve block a 40 bar (580 Ib/in2) negative control signal enters port Pi2 and is available to the negative control piston D. This acts against spring A to move the spool across allowing pump pressure to cross the spool and pressurise the large diameter side of the swash plate piston B. Pressure is now available to both sides of the swash piston B, but due to the difference in surface areas the piston moves to the minimum flow position. When a service is selected the negative control pressure drops. Piston D now moves back due to the spring pressure. This allows the oil in the larger area side of the swash plate piston B to vent to tank, but pump pressure oil is still available to the smaller diameter side so the pump moves over to the maximum flow position. As the pump pressure increases, the pressure seen at the small diameter end of the swash plate piston B is also seen at the piston E. At the same time any pressure generated at pump A1 is also seen at pump A2 at the piston. As the pressure increases at piston E via line F it starts to push against spring A. When the pressure has increased to approximately 200 bar (2900Ib/in2) the spool will start to select. This will now allow pump pressure to the large diameter side of the swash plate piston B which will proportionally start to select minimum flow. When P mode is selected a 40 bar (580 Ib/in2) secondary pressure is also seen at piston G. This signal will add to the force of the pump pressure at pistons E and G so that minimum flow is selected earlier. In A mode the secondary pressure drops to approximately 10 bar (145Ib/in2). This reduction in secondary pressure at piston G has to be made up for by higher pump pressure at pistons E and F before the sumater spool starts to select, hence more hydraulic horsepower. The regulator on pump A1 works the same as above.

E-21

9813/5550-1

E-21


E-22

For

9813/5550-1

description,

M

Lock Up

Cavitation

Exhaust

Servo Neutral

Pressure

Full Pressure

Dr

B1

Max

3

A2

A2

a2

B3

A3

a3

(REAR)

Regulation ( T E-21).

Fig 5. Hydraulic Pump

B

2

Pi

a

A

Pt 1

Psv

C

Pm 2

A1

a1

A1

H

Pm 1

Pump

(FRONT)

K Hydraulic

Key to Oil Flow & Pressure

D

G

E

F

Section E - Hydraulics Circuit Descriptions

Hydraulic Pump Regulation

E-22


Section E - Hydraulics Circuit Descriptions Neutral Circuit

Neutral Circuit For Schematic, K Fig 6. ( T E-24). With all the controls in the neutral position, flow from pump A1 enters the main control valve at port P1 and flow from pump A2 enters the main control valve at port P2. Oil is allowed to flow across all of the spools via the neutral gallery when all controls are in the neutral position. Oil from pump A1 exits port Ps1 and oil from pump A2, exits port Ps2 at the top of the main control valve. Both flows of oil meet a separate restrictor and relief valve. Some oil will pass through the restrictor and back to tank, creating back pressure in the line. Oil is exhausted across the relief valves at 40 bar (580 lb/in2). The back pressure is sensed at ports Ps1 and Ps2 and ports Pt1 and Pt2 of the pumps, holding the pumps on minimum flow. Flow from the servo pump enters the valve block at port Pp, where it meets 3 restrictors. These maintain the pressure on the input side at full servo pressure. Oil that crosses the restrictors, is allowed back to tank after passing over the neutral gallery of the spools. No pressure is created in this line whilst all controls are in neutral, allowing all pressure switches to remain in the open position. K Fig 6. ( T E-24) a

Dipper (1) spool

b

Boom (2) spool

c

Slew spool

d

Option spool

e

Travel (left) spool

f

Dipper (2) spool

g

Boom (1) spool

h

Bucket spool

i

Travel (right) spool

k

Linear Travel spool

E-23

9813/5550-1

E-23


E-24

9813/5550-1

1

Dr

A1

B1

A2

Lock Up

Cavitation

Exhaust

Servo Neutral

Pressure

Full Pressure

Keyto Oil Flow & Pressure

For description, K Neutral Circuit ( T E-23).

M

A2

a 2

B3

A3

a 4

(REAR)

2

Pt

3

Pt

1

a

Pm 2

a

Psv

Pm 1

(FRONT)

A1

SWING

BOOM(2)

ARM(1)

e

d

c

b

a

P1

Fig 6. Neutral Circuit

P a1

A 1 TRAVEL(L) P b1

B1

A2 OPTION P b2 P4 P a2

P P i2 Dr4 B2 a3

P b3

P a4

P b4

P c3

P a5

P b5

B5

A5

P C1

P S1

PT

T3

PP

PA

T1

PH

D3 D1 D2

ON 335 bar OFF 330 bar

T2

P3

P S2

P2

k

ARM(2)

i

P a7 P i1 B6

P b7

BUCKET A 7

P a8 B7

P b8

B8

A8

P c2

P a9

P b9

A405460

P a6

P b6

6 TRAVEL(R) A

h

g BOOM(1)

f

Section E - Hydraulics Circuit Descriptions Neutral Circuit

E-24


Section E - Hydraulics Circuit Descriptions Straight Line Travel

Straight Line Travel (Travel and excavator services selected) For schematic, K Fig 7. ( T E-26). For servo function of travel circuit and Boom Up for servo function of Boom up function, K Travel - Slow Speed ( T E-27). Servo pressure entering at port Pp on the main control valve is blocked from the tank port by the Travel spools and the Boom (2) spool, this causes back pressure which selects the travel and excavator pressure switches 50 and 49 and selects the Linear travel spool. Flow from pump A1 is available to the left hand Travel spool and the Linear travel spool which diverts the flow to the right hand Travel motor. Flow from pump A2 is available to all the functions on the left hand side of the Main control valve via the parallel working gallery. If any excavator function is selected at slow speed and does not require the full flow from pump A2, then the extra flow is used in the travel circuit via (as long as the travel circuit is at a lower pressure) the check valve at the right hand travel spool, a restrictor gives low priority to the travel circuit. If the Boom up is selected both Boom 1 and 2 spools are fed from the pump A2 through the left and right hand parallel working gallery. When both Travel spools are selected, the loss of pressure in the neutral gallery is sensed at the pumps through ports Ps1 and Ps2 on the main control valve. The pumps come into full flow. K Fig 7. ( T E-26) a

Dipper (1) spool

b

Boom (2) spool

c

Slew spool

d

Option spool

e

Travel (left) spool

f

Dipper (2) spool

g

Boom (1) spool

h

Bucket spool

i

Travel (right) spool

k

Linear Travel spool

E-25

9813/5550-1

E-25


E-26

For description, K Straight Line Travel ( T E-25)

TRAVEL(L)

P1

PT

Fig 7. Straight Line Travel Schematic

P a1

PP

A1

PA

PH

A2

P3

P2

LINEARTRAV

Section E - Hydraulics Circuit Descriptions Straight Line Travel

9813/5550-1

E-26


Section E - Hydraulics Circuit Descriptions Travel - Slow Speed

Travel - Slow Speed For schematic, K Fig 8. ( T E-28). When both tracks are selected, servo pressure from port 2 (LH travel lever), and port 4 (RH travel lever) enters the main control valve at Pa1 and Pa6 respectively, selecting the left and right hand travel spools. Flow from pump A1 is available at the LH travel spool and is directed to the LH travel motor via port A1 of the Main control valve, through the rotary coupling and in to port P1 on the LH travel motor. Exhaust oil from the motor enters the main control valve at port B1 and is directed by the LH travel spool to the tank port. Flow from pump A2 is available at the RH travel spool and is directed to the RH travel motor via port A6 of the main control valve, through the rotary coupling and in to port P2 on the RH travel motor. Exhaust oil from the motor enters the Main control valve at port B6 and is directed by the RH travel spool to the tank port. The servo oil flowing over restrictors R1 and R2 is available to tank causing the excavator pressure switch 49 to stay open and the straight line travel spool to remain un-selected. Pressure is lost on both negative control ports Ps1 and Ps2, which is sensed at the pumps which come into full flow. K Fig 8. ( T E-28) a

Dipper (1) spool

b

Boom (2) spool

c

Slew spool

d

Option spool

e

Travel (left) spool

f

Dipper (2) spool

g

Boom (1) spool

h

Bucket spool

i

Travel (right) spool

k

Linear Travel spool

E-27

9813/5550-1

E-27


E-28

For description, K Travel - Slow Speed ( T E-27).

TRAVEL(L)

P1

PT

R3

PA

A1

R1

R2

PP

PH

Fig 8. Travel Slow Speed Schematic

P a1

A2

P3

P2

1

2

T

P

4

Section E - Hydraulics Circuit Descriptions Travel - Slow Speed

9813/5550-1

E-28


Section E - Hydraulics Circuit Descriptions Boom Up

Boom Up For schematic, K Fig 9. ( T E-30).

K Fig 9. ( T E-30)

Servo pressure from the hand controller enters the servo shuttle valve 30 at port A3 and is distributed to: 1

Boom up pressure switch 48 at port S2

2

Port B3 to the Cushion control valve 34, the signal is divided between the Boom (1) spool valve at port Pa8 and Boom (2) spool at port Pb4 on the main control valve.

3

Port C1 to port Pi1 on the Main control valve to operate boom over bucket priority spool valve BBV.

a

Dipper (1) spool

b

Boom (2) spool

c

Slew spool

d

Option spool

e

Travel (left) spool

f

Dipper (2) spool

g

Boom (1) spool

h

Bucket spool

i

Travel (right) spool

k

Linear Travel spool

Flow from pump A2 is stopped by the Boom (1) spool and is diverted via the parallel working passage to the Boom (1) spool. The oil passes through the spool and merges with the flow from pump A1. Flow from pump A1 in the neutral gallery is stopped by the Boom (2) spool and is diverted via the parallel working passage to the Boom (2) spool. The oil passes through the spool and merges with the flow from pump A2. The pressure lifts the Boom holding valve BHV off it's seat allowing oil to leave the main control valve at port B8 to enter the Hose Burst Protection valve (HBPV) (if fitted) and the Boom rams 6. Exhaust oil enters the Main control valve at port B8 and crosses the Boom (1) spool to tank. Pressure is lost on both negative control ports Ps1 and Ps2, which is sensed at the pumps, which comes into full flow. The Excavator pressure switch 49 is closed by back pressure resulting from Boom (2) spool closing the servo route to tank. The travel pressure switch 50 remains open.

E-29

9813/5550-1

E-29


E-30

e

P1

PT

For description, K Boom Up ( T E-29).

Lock Up

Cavitation

Exhaust

Servo Neutral

Pressure

Full Pressure

Keyto Oil Flow & Pressure

P a1

A 1 TRAVEL(L) P b1

B1

PP

A1

PA

PH

A2

P3

1

BUCKET OPEN CLOSE

Fig 9. Boom Up Schematic

P2

k 3

2

UP

BOOM DOWN 4

A450540-C2

Section E - Hydraulics Circuit Descriptions Boom Up

9813/5550-1

E-30


Section E - Hydraulics Circuit Descriptions Boom Down

Boom Down For schematic, K Fig 10. ( T E-32).

K Fig 10. ( T E-32)

Servo pressure from the Hand controller enters the Servo Shuttle valve 30 at port A4 and is disributed to: 1

2

Port C2 to the Main control valve at port Pc2. The Boom holding spool valve is moved across allowing pressure at the top of the Boom Holding Valve BHV to exhaust to tank. Port B4 to port E of the Cushion control valve 34. The oil flows across the unrestricted part of the spool and out of port G to the main control valve at port Pb8, moving the spool to the down position.

a

Dipper (1) spool

b

Boom (2) spool

c

Slew spool

d

Option spool

e

Travel (left) spool

f

Dipper (2) spool

g

Boom (1) spool

h

Bucket spool

i

Travel (right) spool

k

Linear Travel spool

Note: If HBCV's are fitted a signal is also sent from port E1 of the Cushion control valve 34 to the P ports of the HBCV's to move the HBCV spool over and allow oil to return from the rams. Flow from pump A2 travels through the neutral gallery to the Boom (1) spool. The flow is restricted allowing a reduced pressure at port Ps2 which is sensed at Pm2 of the pump A2 which increases flow (less than full flow). Oil flow also passes through the parallel working gallery to the Boom (1) spool and is directed to the Boom rams 6 via port B8. Exhaust oil passes through the HBVC's (if fitted) to the Main control valve at port A8, lifts the Boom Holding Valve BHV off it's seat and passes through the Boom (1) spool and exhausts to tank. Exhaust oil passing through the spool can be regenerated into the feed side of the rams. A check valve in the spool allows oil to enter the pressure side of the spool, If the returning oil is at a higher pressure, due to the weight of the boom or load, Item A K Fig 10. ( T E-32). The restrictor creates back pressure, causing the check valve to open.

E-31

9813/5550-1

E-31


E-32

For description, K Boom Down ( T E-31).

Lock Up

Cavitation

Exhaust

A1

P2

A2

Pm2

1

Fig 10. Boom Down Schematic

P3

BUCKET OPEN CLOSE 3

2

UP

BOOM DOWN 4

A405510-C3

Section E - Hydraulics Circuit Descriptions Boom Down

9813/5550-1

E-32


Section E - Hydraulics Circuit Descriptions Dipper Out

Dipper Out For schematic, K Fig 11. ( T E-34) Servo pressure from the Hand controller 32 is sent to port A5 of the shuttle valve 30 and is disributed to: 1

Port C3 to port Pa9 of the Main control valve to activate the Dipper (2) spool.

2

Port B5 to port B of the Cushion valve 34, through the valve leaving at port D. The signal is sent to port Pa5 on the Main control valve activating the Dipper.(1) spool.

Flow from pump A1 is available at the Dipper (1) spool via the left hand neutral passage and the Linear travel spool via the parallel working passage. Flow from pump A2 is blocked at the Dipper (2) spool and joins the flow from pump A1 just after the Dipper (1) spool. Exhaust oil from the ram enters the Main control valve at port B5 and has a path to tank via the Dipper (1) and Dipper (2) spools. K Fig 11. ( T E-34) a

Dipper (1) spool

b

Boom (2) spool

c

Slew spool

d

Option spool

e

Travel (left) spool

f

Dipper (2) spool

g

Boom (1) spool

h

Bucket spool

i

Travel (right) spool

k

Linear Travel spool

E-33

9813/5550-1

E-33


For description, K Dipper Out ( T E-33)

SWING LEFT RIGHT 1 2 3

IN

ARM OUT 4

E-34

c

e

P1

Fig 11. Dipper Out Schematic

P a1

A 1 TRAVEL(L) P b1

B1

A2 OPTION d P b2 P4 P a2

a3

P P i2 Dr4 B2

P b3

PT

PP

A1

PA

PH

A2

P3

P2

k

LINEARTRAVEL

i TRAVEL(R)

h BUCKET

P a6

A6 P b6

B6

P a7

P b7

A405490-C3

Section E - Hydraulics Circuit Descriptions Dipper Out

9813/5550-1

E-34


Section E - Hydraulics Circuit Descriptions Dipper In

Dipper In For schematic, K Fig 12. ( T E-36) Servo pressure from the Hand controller 32 is sent to port A6 of the servo shuttle valve 30 and is distributed to: 1

Port C4 to port Pb9 on the Main control valve to the Dipper (2) spool (via a shuttle valve, if fitted with a merged auxiliary circuit).

2

Port C4 to port Pb9 on the Main control valve to the Dipper (2) spool (via a shuttle valve, if fitted with a merged auxiliary circuit).

3

across to the more restricted position. When the feed pressure is greater than the exhaust pressure the regeneration check valve will close. Servo pressure from the Dipper (1) spool travels over restrictors R2 and R3 and to tank via the unselected travel spools. Oil passing over R1 has no passage to tank, creating back pressure that selects the excavator pressure switch 50. K Fig 12. ( T E-36)

Port B6 to port A on the Cushion valve 34, through the valve leaving at port C (if machine is fitted with HBCV, pressure is also sent via port A1 to port P on the HBCV to allow trapped oil in the ram to exit). From port C to port Pb5 on the Main control valve to the Dipper (1) spool and the Dipper load hold check valve DHV.

Flow from pump A2 is available at the Dipper (1) spool via the left hand neutral gallery or after passing over the straight line travel spool via the parallel working passage. At the Dipper (1) spool the flow is diverted to the Dipper ram 2. Pressure is sensed at the regeneration spool RGS and moves it to the lesser restricted position (Fig 2).

a

Dipper (1) spool

b

Boom (2) spool

c

Slew spool

d

Option spool

e

Travel (left) spool

f

Dipper (2) spool

g

Boom (1) spool

h

Bucket spool

i

Travel (right) spool

k

Linear Travel spool

Flow from pump A2 is blocked at the Dipper (2) spool and joins the flow of pump A1 just after the Dipper (1) spool. The pressure from both pumps is now cut off from the negative control ports Ps1 and Ps2. This reduced pressure is sensed at both pumps which now come into full flow. Exhaust oil from the ram passes (through the HBCV if fitted) to the Main control valve at port A5 through the Dipper hold check valve DHV (that has been released by servo pressure) to the Dipper (1) Spool. Exhaust oil from the Dipper ram 4 can be at a higher pressure than the feed oil due to the effect of gravity on the dipper arm when first selected. This causes the regeneration check valve RG to open, feeding a proportion of exhaust oil into the feed side. The remaining exhaust oil returns to tank passing over the regeneration spool RGS. The regeneration spool has two restrictors, one more restricted than the other. The restrictors cause back pressure encouraging the regeneration check valve to open. As the pressure drops the regeneration spool moves

E-35

9813/5550-1

E-35


E-36

Fig 2

P b5

B5

A5

P C1

RG

ARM(1)

DHV

RGS

e

d

P1

Fig 12. Dipper In Schematic

P a1

A 1 TRAVEL(L) P b1

B1

A2 OPTION P b2 P4 P a2

P P i2 Dr4 B2

PT

R3

PP

R1

R2

A1

PA

PH

A2

P3

P2

k

i P a6

P b6

TRAVEL(R) A 6

B6

P a7

A405480-C3

Section E - Hydraulics Circuit Descriptions Dipper In

9813/5550-1

E-36


Section E - Hydraulics Circuit Descriptions Dipper In For Description, K Dipper In ( T E-35)

E-37

9813/5550-1

E-37


Section E - Hydraulics Circuit Descriptions Bucket Opening

Bucket Opening For schematic, K Fig 13. ( T E-39). Servo pressure from port 2 of the Hand controller 33 selects the bucket spool open position via port Pa7 of the Main control valve. Flow from pump A2 is available to the Bucket spool via the parallel working gallery and Boom over Bucket priority valve BBV. At the spool the flow is diverted to port B7 of the Main control valve to the Bucket ram 8. Returning oil enters the Main control valve at port A7 and is diverted by the Bucket spool to the tank port. Pressure in the neutral circuit drops after the selected Bucket spool, this is sensed at the port Ps2 and at the pump bringing it into full flow. Servo pressure entering the Main control valve at port Pp is blocked by the bucket spool causing back pressure to the restrictor which activates the Excavator pressure switch 49. K Fig 13. ( T E-39) a

Dipper (1) spool

b

Boom (2) spool

c

Slew spool

d

Option spool

e

Travel (left) spool

f

Dipper (2) spool

g

Boom (1) spool

h

Bucket spool

i

Travel (right) spool

k

Linear Travel spool

E-38

9813/5550-1

E-38


For description, K Bucket Opening ( T E-38)

PP

PT

E-39 P3

Fig 13. Bucket Opening Schematic

PH

A2

P2

k

i

P a6

P b6

TRAVEL(R) A 6

B6

P a7

1

BUCKET CLOSE OPEN 2

P

3

BOOM DOWN UP 4

T

A405500-C3

Section E - Hydraulics Circuit Descriptions Bucket Opening

9813/5550-1

E-39


Section E - Hydraulics Circuit Descriptions Bucket Close

Bucket Close For schematic, K Fig 14. ( T E-41). Servo pressure from the hand controller is sent from port 1 to port Pb7 of the Main control valve and moves the Bucket spool into the bucket close position. Flow from pump A2 is available at the Bucket spool via the parallel working gallery and Boom over Bucket priority valve BBV. Flow is diverted to port A7 of the Main control valve to the Bucket ram 8. Returning oil from the Bucket ram enters the Main control valve at port B7 and is diverted to tank by the Bucket spool. A regeneration valve is fitted in the Bucket spool. When returning oil from the Bucket ram enters the spool it crosses a restrictor which causes back pressure. If the pressure in the return line is greater than that of the feed line, the valve will open allowing return oil to be regenerated into the feed line. Servo pressure entering the main control valve at port Pp is blocked by the bucket spool causing back pressure to the restrictor which activates the Excavator pressure switch 49 K Fig 14. ( T E-41) a

Dipper (1) spool

b

Boom (2) spool

c

Slew spool

d

Option spool

e

Travel (left) spool

f

Dipper (2) spool

g

Boom (1) spool

h

Bucket spool

i

Travel (right) spool

k

Linear Travel spool

E-40

9813/5550-1

E-40


E-41

e

AVEL(L)

P1

PT

PP

A1

PA

PH

For description, K Bucket Close ( T E-40)

d

OPTION

c

A2

P3

P2

k

h

TRAVEL(R)

P a6

A6 P b6

B6

P a7

P b7

BUCKET CLOSE OPEN 1 2

P

Fig 14. Bucket Close Schematic

i

BUCKET

3

BOOM DOWN

T

UP 4

A406070

A406070-C2

Section E - Hydraulics Circuit Descriptions Bucket Close

9813/5550-1

E-41


Section E - Hydraulics Circuit Descriptions Priority Valves

Priority Valves For schematic, K Fig 16. ( T E-43).

When Slew is selected a signal is sent from the servo Shuttle valve 30 via port C8 to the Main control valve at port Pc3. This selects Slew over Dipper priority valve B and limits the flow to the Dipper from pump A1 only. This makes it possible to have maximum swing torque with high swing pressure when the Dipper is used at the same time.

Boom over Slew Priority (A) This is selected by the operator via the DECU. When operated the Boom priority solenoid 35 is energised sending a signal to the Main control valve at port Pi2. This selects the Boom over slew priority. Oil now being fed to the Slew spool is restricted to give priority to the boom.

Boom Priority over Bucket (C) This a non-selectable function automatically carried out within the Main control valve when Boom and Bucket are used together. When Boom up is selected a signal is sent from port C1 on the servo Shuttle valve 30 to the main control valve port Pi1. This selects the Boom over Bucket priority valve. Oil now flowing to the Bucket spool is restricted and gives priority to Boom up. K Fig 16. ( T E-43)

35

a

Dipper (1) spool

b

Boom (2) spool

c

Slew spool

d

Option spool

e

Travel (left) spool

f

Dipper (2) spool

g

Boom (1) spool

h

Bucket spool

i

Travel (right) spool

k

Linear Travel spool

C132280

Fig 15. Boom priority valve location

Slew over Dipper Priority (B) This is a non-selectable function automatically carried out within the Main control valve when Slew and Dipper are used together.

E-42

9813/5550-1

E-42


E-43

9813/5550-1

35

For description, K Priority Valves ( T E-42).

38

Lock Up

Cavitation

Exhaust

Servo Neutral

Pressure

Full Pressure

Key to Oil Flow & Pressure

SWING

BOOM(2)

ARM(1)

P a1

A 1 TRAVEL(L) P b1

B1

A2 OPTION P b2 P4 P a2

P a3 P i2 D r4 B2

P b3

P a4

P b4

P c3

P a5

P b5

B5

A5

P C1

e

d

c

b

a

PT

T3

PP

PA

T1

PH

D3 D1 D2

T2

P3

P S2

Fig 16. Priority Valve Schematic

P1

P S1

30

P2

k

B

b7

7

b6

6

P a6

i TRAVEL(R) AP

P a7 P i1 B6

h BUCKET AP

P a8 B7

b8

8

A8

P c2

P a9

P b9

g BOOM(1) P

f ARM(2)

30

C132040

Section E - Hydraulics Circuit Descriptions Priority Valves

E-43


Section E - Hydraulics Circuit Descriptions Slew Circuit

Slew Circuit Slew Motor Configuration Slew Unit

Planetary 2-stage Reduction Gear

Swash Plate Type Axial Piston Hydraulic Motor

Mechanical Brake

Relief Valve

By-pass Valve

Make-up Valve

E-44

9813/5550-1

E-44


Section E - Hydraulics Circuit Descriptions Slew Circuit

Slew Motor Reduction Gear

Fig 17. Key A

A Chamber

B

B Chamber

C

Torque path

Reduction Gear Structure and working principles Power transmitted by the hydraulic motor output shaft is transmitted to second sun gear 77 via first sun gear 66, planetary gear 69 and holder 65. Power is then transmitted to output shaft 53 via second sun gear 77, planetary gear 72 and holder 76. The output shaft is constructed with an integral pinion and is supported in gear case 58 by bearings 57 and 62.

E-45

Due to the severe conditions under which the output shaft operates, an oil seal 61 is provided in the centre of gear case 58 to protect the bearings from metal waste worn from the gears. The bearing in chamber A is lubricated with gear oil and the bearing in chamber B with grease.

9813/5550-1

E-45


Section E - Hydraulics Circuit Descriptions Slew Circuit

Slew Circuit For schematic, K Fig 18. ( T E-47). Servo pressure from the Hand controller 32 enters the Servo shuttle valve 30 at port A2 and is distributed to: 1

Port C7 to port A on valve 8 station 44.

2

Port C8 to Pc3 on Slew over Dipper priority spool SDV in the main control valve.

3

Slew pressure switch 48.

Flow from pump A1 is stopped in the neutral gallery by the Slew spool. The flow passes through the Linear travel spool into the parallel working passage over the unrestricted side of the Boom priority spool BPV and to the Slew spool. the flow is then directed via port A3 to the Slew motor 1. Exhaust oil enters the Main control valve at B3 to the Slew spool to the tank line. K Fig 18. ( T E-47) a

Dipper (1) spool

b

Boom (2) spool

c

Slew spool

d

Option spool

e

Travel (left) spool

f

Dipper (2) spool

g

Boom (1) spool

h

Bucket spool

i

Travel (right) spool

k

Linear Travel spool

E-46

9813/5550-1

E-46


For description, K Slew Circuit ( T E-46)

LEFT

SWING RIGHT

P a4

E-47 SWING

Fig 18. Slew Circuit

P a1

1

A TRAVEL(L) P b1

B1

A2 OPTION P b2 P4 P a2

P a3 P i2 Dr4 B2

P b3

P1

PT

PP

A1

PA

PH

A2

P3

P2

TRAVEL(R)

BUCKET

P

A P

B

P

A P

P B

A405550a-C3

Section E - Hydraulics Circuit Descriptions Slew Circuit

9813/5550-1

E-47


Section E - Hydraulics Circuit Descriptions 100% Slew Lock

100% Slew Lock For schematic, K Fig 19. ( T E-49). When the slew lock button is operated in the cab, the MECU gives two outputs: 1

To the CT6 solenoid on the 8 spool solenoid valve 44, allowing servo pressure to enter the shuttle valve 46 at port C6 causing the slew spool in the main control valve 14 to be hydraulically locked in its neutral position.

2

To the CT3 solenoid on the 8 spool solenoid valve 44, allowing any pressure in the slew brake to drain to tank. The CT1 slew brake solenoid is de-energised as soon as the slew lock button is pressed.

Note: The CT3 solenoid is energised either, 5 seconds after the button is operated, or 5 seconds after the slew pressure switch 48 opens, depending on which is last to operate. This allows the slew to come to a standstill on the cross line relief valves, before the brake is applied.

E-48

9813/5550-1

E-48


E-49

9813/5550-1

C13

A

T2

1

CT2

CT3

T1

4

B2

C9

8

7

CT6

5

C12

C11

C10

C8

C7

C6

C5

B

C7 C8

C6

46

For description, K 100% Slew Lock ( T E-48).

P

C1

B

C4

44

RIGHT

Dr

A1

B1

A

S1

B2

LEFT

Mu

P

48

A2

1

A3

B3

S3

C2

A4

B4

A5

B5

S4

C3

C5

C4

A6

B6

Ts6

Ts3

pa1

pb1

B1 A1

pb2 P4 pa2

B2 A2

pa3

B3 A3 pa4

pa4

pb4

B4

pa5 pc3

pb5

B5

A5

pc1

ps1

TRAVEL

d

c

e

OPTION 1

SLEW

b

BOOM 2

a

DIPPER 1

Fig 19. 100% Slew Lock Schematic

S2

C1

14

P1

PT

R3

PP

R2

A2

R1

PA

T1

T2

PH

DR

pbu

Pm

A1

Lock Up

Cavitation

Exhaust

Servo Neutral

Pressure

Full Pressure

BHV

P3

Key to Oil Flow & Pressure

Tr4

P2

LINEAR TRAVEL

k

i

TRAVEL

h

BUCKET

g

BOOM 1

f

DIPPER 2

OPTION 2

pa6

pb6

pa7 B6 A6

A7 pb7

B7

pa8

pb8

B8

A8

pc2

pa9

pb9

pcc

ps2

715820-C4

prb1 BR1 AR1

pra1

Section E - Hydraulics Circuit Descriptions 100% Slew Lock

E-49


Section E - Hydraulics Circuit Descriptions Auxiliary Flow

Auxiliary Flow For schematic, K Fig 20. ( T E-51). An auxiliary circuit gives a bi-directional flow to the equipment being used: The Option pedal 37 can be selected back or forward depending on the direction the operator wants the equipment to move. Servo pressure from the pedal, enters the main control valve at either port Pa2 or Pb2 depending on the direction the pedal is selected. This in turn moves the spool in the selected direction. Oil from pump A1 is blocked at the option spool and is diverted to the parallel-working gallery via the linear travel spool, where it is available to the now selected option spool. Depending on the direction selected, the oil will exit the valve block through ports A2 or B2. Returning oil again goes across to the option spool via port B2 were it is diverted to the tank port. In Auxiliary the oil from pump A2 is in a neutral state, K Neutral Circuit ( T E-23). K Fig 20. ( T E-51) a

Dipper (1) spool

b

Boom (2) spool

c

Slew spool

d

Option spool

e

Travel (left) spool

f

Dipper (2) spool

g

Boom (1) spool

h

Bucket spool

i

Travel (right) spool

k

Linear Travel spool

E-50

9813/5550-1

E-50


9813/5550-1

2

T

ON 5 Bar OFF 3 Bar

3

OPTION HAM/AUX

P

1

3.5 Bar

VENTS TO ATMOSPHERE

For Description, K Auxiliary Flow ( T E-50).

48

37

Lock Up

Cavitation

Exhaust

Servo Neutral

Pressure

10

T

B

VENTS TO ATMOSPHERE

P

31

A

SWING

BOOM(2)

ARM(1)

P a1

A 1 TRAVEL(L) P b1

B1

A 2 OPTION P b2 d P4 P a2

P a3 P i2 Dr4 B2

P b3

P a4

P b4

P c3

P a5

P b5

B5

A5

P C1

e

c

b

a

P1

P S1

PT

Fig 20. Auxiliary and Merged Schematic

P

For Description, K 100% Slew Lock ( T E-48).

18

A2

Full Pressure

B2

A1

E-51 B1

Key to Oil Flow & Pressure

T3

PP

A1

PA

T1

PH

D3 D1 D2

T2

A2

P3

P S2

P2

k

f

BUCKET

BOOM(1)

i TRAVEL(R)

h

g

ARM(2)

P a6

A6 P b6

P a7 P i1 B6

A7 P b7

P a8 B7

P b8

B8

A8

P c2

P a9

P b9

A405471-C3

Section E - Hydraulics Circuit Descriptions Auxiliary Flow

E-51


Section E - Hydraulics Circuit Descriptions Super High Flow (Merge) Auxiliary

Super High Flow (Merge) Auxiliary Some machine variants have a Super High Flow (SHF) auxiliary function. When the operator selects SHF the oil flow from the two main pumps A1 and A2 combines for operation of the auxiliary hydraulic circuit. For schematic. K Fig 22. ( T E-54) When SHF mode is selected via the DECU, and the operator operates the auxiliary pedal 37, the auxiliary service spool 2 operates in the normal way. At the same time merge flow solenoid valves 35A and 35B energise. Oil at pilot pressure flows from merge flow solenoid valve 35A to shuttle valve 45. The shuttle valve moves and oil at pilot pressure flows to pilot port pb9 of the main control valve 13. The dipper spool 9 moves to close the flow to tank from pump A2. Since the dipper service is not selected dipper spool 5 remains in its neutral position. At the same time oil at pilot pressure from merge flow solenoid valve 35B flows to the merge valve 31. The merge valve opens and connects the flow from pump A2 to the pressure port of the auxiliary spool, combining with the flow from pump A1.

E-52

9813/5550-1

E-52


Section E - Hydraulics Circuit Descriptions Super High Flow (Merge) Auxiliary

13 45

35A 35B

31 37

35

38 C131440

Fig 21.

E-53

9813/5550-1

E-53


Section E - Hydraulics Circuit Descriptions Super High Flow (Merge) Auxiliary

45

14

9

5

2

31

35B

35A

37

A1

A2

C131430

Fig 22. Super high flow operation

E-54

9813/5550-1

E-54


Section E - Hydraulics Circuit Descriptions Hammer Circuit

Hammer Circuit For schematic, K Fig 23. ( T E-56) The hammer function only works when the hammer pedal 37 is pressed in a forward direction. In this position pressure from the foot pedal is available to the hammer pressure switch 48, to reduce engine RPM to supply the required oil flow for the hammer. Servo pressure from the foot pedal enters the main control valve at port Pa2 and selects the option spool. Oil from pump A1 is then blocked at the option spool and is diverted through the linear travel spool and into the parallel working gallery, where it is able to cross the now selected option spool and exit the valve block at port A2. The pressure required to drive the hammer is set at the option spool ARV on the main valve block. Oil returning from the hammer flows through the hammer filter 18 and direct to tank. Note: When the machine is equipped for hammer only (not auxiliary) the hose from Port2 of the hammer pedal will be connected to the tank port of the cab manifold and the hose from Port Pb2 of the main control valve will be connected to the tank manifold. When a machine that is fitted with a hammer/auxiliary combined option the ARV's in the valve block are set to the pressure required for the auxiliary system and not the hammer. K Fig 23. ( T E-56) a

Dipper (1) spool

b

Boom (2) spool

c

Slew spool

d

Option spool

e

Travel (left) spool

f

Dipper (2) spool

g

Boom (1) spool

h

Bucket spool

i

Travel (right) spool

k

Linear Travel spool

E-55

9813/5550-1

E-55


9813/5550-1

2

T

ON 5 Bar OFF 3 Bar

3

OPTION HAM/AUX

P

1

3.5 Bar

VENTS TO ATMOSPHERE

For Description, K Hammer Circuit ( T E-55).

48

37

Lock Up

Cavitation

Exhaust

Servo Neutral

Pressure

10

T

18

B

A2

Full Pressure

B2

A1

E-56 B1

Key to Oil Flow & Pressure

A

P a1

A 1 TRAVEL(L) P b1

B1

e

c

b

a

P1

Fig 23. Hammer Schematic

VENTS TO ATMOSPHERE

P

31

SWING

BOOM(2)

ARM(1)

A 2 OPTION P b2 d P4 P a2

P a3 P i2 Dr4 B2

P b3

P a4

P b4

P c3

P a5

P b5

B5

A5

P C1

P S1

PT

T3

PP

A1

PA

T1

PH

D3 D1 D2

T2

A2

P3

P S2

P2

k

f

BUCKET

BOOM(1)

i TRAVEL(R)

h

g

ARM(2)

P a6

A6 P b6

P a7 P i1 B6

A7 P b7

P a8 B7

P b8

B8

A8

P c2

P a9

P b9

Section E - Hydraulics Circuit Descriptions Hammer Circuit

E-56

P


Section E - Hydraulics

Main Control Valve Description For location diagram K Fig 1. ( T E-58).

For Schematic K Fig 2. ( T E-59).

Key A

Negative Control Valve Ps1

B

Restrictor Orifice

C

Negative Control Valve Ps2

D

Shuttle Valve

E

Load Hold Check Valves (x7)

F

Priority Valve F1 Boom over Bucket, F2 Boom over Slew

G

Blank

H

Pressure Switch H2 Travel, H3 Excavator

I

Main Relief Valve (MRV)

J

Restrictors , J1 Travel, J2 Linear Travel, J3 Excavator Pressure Switch

K

Auxiliary Relief Valves (ARV) K1 Dipper out, K2 Option, K3 Boom Up, K4 Bucket Open, K5 Boom Down, K6 Bucket Close, K7 Dipper In, K8 Option

L

Load Holding Valve L1 Dipper, L2 Boom

M

Regeneration Valves

N

Spool (x 10)

O

Shuttle Valve

P

P1 - Pump 1pressure in, P2 - Pump 2 pressure in

Q1, Q2

Blank (For option spool only when not used, to centralise the option spool)

R

Slew over Dipper Priority Valve

S

End Cap

V

V1 Merge Out, V2 Merge In

W

MRV Shuttle Valve ( x2 )

E-57

9813/5550-1

E-57


E-58

9813/5550-1

Q2

K6

K5

N10

N9

N8

N7

N6

Q1

N5

N4

N3

N2

N1

R

K7

K8

O

For description, K Main Control Valve ( T E-57).

S

K

P1

E7

E6

F2

E5

E4

H3

H2

F

V2

E

H1

K

L

Q

N

K2

K1

L

Fig 1. Main Control Valve

J1 J2 J3

N

I

N5

N4

N3

N2

N1

M

N10

N9

N8

N7

N6

K4

L1

K3

A C

B D

P2

G

E3

F1

E2

E1

V1

F

E

Section E - Hydraulics Main Control Valve Description

E-58


Section E - Hydraulics Main Control Valve Description T1

T3

P s1

D3 D1 D2

T2

P s2

C

A L1

P C1

L1

A5

K7

B5 P b5

Dipper

N6

D

K1 N

DIPPER 2

E1

P a9

M R

E4

P a5

L2P c2

L2

B

A8

P c3 P b4

K3

O

N2

BOOM(2)

BOOM(1)

K6 N8 F1 N4 K8

A2 OPTION P b2 P4 P a2

BUCKET

F2 N9

K2 E3

B1

N5

A 1 TRAVEL(L) P b1

E7

A7 P b7 P a7 P i1 B6

TRAVEL(R)

E6

P b8 P a8 B7

K4

SWING

P a3 P i2 D r4 B2

V2

K5 N7

N3 P b3

B8

E5

P a4

P b9

A6 P b6 P a6

N10

P a1

J2

J1 P1

J3

PT

H2

I

PP PA

PH

P3

P2

V1

H3

A406671-C1

Fig 2. Main Control Valve Schematic

E-59

9813/5550-1

E-59


Section E - Hydraulics Main Control Valve Description

10

9

11

8

12

7

6

pb9

pb5

pb8

pb4

13

14 pb7

pb3

pb6

pb2

15

5 16

4 pb1

3 2

17

1

18 A405940 Fig 3. Main Control Valve viewed from rear of machine

For port identification, K Table 1. ( T E-61).

E-60

9813/5550-1

E-60


Section E - Hydraulics Main Control Valve Description Table 1. Port Identification Item Port Function 1 2

pba

Linear Travel Spool

3

pb6

Travel (R) Backwards spool

4

pb7

Bucket Close Spool

5

ARV Bucket Close

6

ARV Bucket Down

7

pb8

Boom Down Spool

8

pb9

Dipper (1) In Spool

pc3

Slew over Dipper Priority Valve

pb5

Dipper (1) In Spool

9 10 11 12

Shuttle Valve

13

ARV Dipper In

14

pb4

15

pb3

16

Boom 2 Up Spool Slew Right Spool ARV Option

17

pb2

Option Spool

18

pb1

Travel (L) backwards Spool

For port location, K Fig 3. ( T E-60).

E-61

9813/5550-1

E-61


Section E - Hydraulics Main Control Valve Description

25

26

27

28

29 30

T1

ps1

31 24

B5

A5

32

B4

23 22

33

A3

B3

Pi2

21 B2

20

A2

P4

A1

B1

PT

34

PA P1

19 1

A405950

40

39

38

37

36

35

Fig 4. Main Control Valve viewed from right hand side of machine For port location, K Table 2. ( T E-63).

E-62

9813/5550-1

E-62


Section E - Hydraulics Main Control Valve Description Table 2. Port Identification Item Port Function 19

B1

Travel (L) Backwards

20

B2

Option

21

B3

Slew Left

22

B4

Not Used

23

B5

Dipper In

24

Pc3

Swing over Dipper Priority

25

T1

Tank

26 27

Load Hold Check Valve ps1

28 29

Negative Control Port Load Hold Check Valve

A5

Dipper out

A3

Slew Right

33

A2

Option

34

PT

Travel Pressure Switch

35

PA

Excavator Pressure Switch

36

A1

Travel Left

37

Pi2

Boom Priority

38

P1

Pump 1

30 31 32

39 40

Load Hold Check Valve (Travel) P4

Merge In (if fitted)

For port location, K Fig 4. ( T E-62).

E-63

9813/5550-1

E-63


Section E - Hydraulics Main Control Valve Description

52

51 50

53 T3

54 49

DR1 pa9

pa5

48

55 56

pc1

47 46 45

pa4

pa8

pa3

pa7

pa2

pa6

57

pc2

58

44 43

59 pa1 PA PORT

60

PP

61

1

pr

42 PH

62

41 A405960

64

63

Fig 5. Main Control Valve Viewed from front of machine For port location, K Table 3. ( T E-65)

E-64

9813/5550-1

E-64


Section E - Hydraulics Main Control Valve Description Table 3. Port Identification Item Port Function 41

pa1

Travel (L) Forward Spool

42

pp

Servo Pressure In (Pressure switches only)

43

pa2

Option Spool

44

ARV Option

45

pa3

46

DR2 Drain (Slew over Dipper Priority)

47

Swing Left Spool AVR Dipper Out

48

pa4

Tank

49

pc1

Dipper Holding Valve

50

pa5

Dipper out Spool

51

Blank

52

T3

53

DR1 Boom Hold Drain

54

pa9

55

Tank Dipper In Spool ARV Boom Up

56

pa8

Boom Up Spool

57

pc2

Boom Holding Valve

58

ARV Bucket Open

59

DR3 Drain (Boom Bucket)

60

pa7

Bucket Open Spool

61

pa6

Travel (R) Forward Spool

62

Linear Travel Spool

63

pr

Auto Power Boost Pressure Switch

64

PH

MRV

For port location, K Fig 5. ( T E-64).

E-65

9813/5550-1

E-65


Section E - Hydraulics Main Control Valve Description

70

72

71

73

69

74 ps2

pc3

T2

75

68 67

A8

pc2

76

B8

A7

B7

Pi1

77 B6

A6

78

79

P3 P2

66

80 81

65 82 A405970 Fig 6. Main Control Valve viewed from left of machine For port location, K Table 4. ( T E-67)

E-66

9813/5550-1

E-66


Section E - Hydraulics Main Control Valve Description Table 4. Port Identification Item Port Function 65

Blank

66

A6

Travel (R) Forwards

67

A7

Bucket Close

68

Blank

69

A8

Boom Up

70

T2

Tank

71

ps2

Negative control port

72

Dipper 2 Check Valve

73

Boom1 Check Valve

74

pc3

Slew over Bucket Priority

75

B8

Boom Down

76

Pi1

Boom over Bucket Priority

77

B7

Bucket Open

78 79

Drain (Boom over Bucket) B6

80

Travel (R) Backwards Travel (R) load hold valve

81

P3

Merge Port Out

82

P2

Pump 2

For port location, K Fig 6. ( T E-66).

E-67

9813/5550-1

E-67


Section E - Hydraulics Main Control Valve Description

86

86

85 84 pc3 PORT

DR2

83

DR4

88

Fig 7. Main Control Valve viewed from above machine Table 5. Port Identification Item Port Function 83 84

Blank Ps1

85 86 87 88

Negative control Valve Restrictor

Ps2

Negative control Valve Shuttle Valve

DR4 Drain (Slew over Dipper Priority

For port location, K Fig 7. ( T E-68).

E-68

9813/5550-1

E-68


Section E - Hydraulics Main Control Valve Description

1

DR3

89

A405980

Fig 8. Main Control Valve viewed from below machine Table 6. Port Identification Item Port Function 89

Dr3

Drain (Boom, Bucket)

For port location, K Fig 8. ( T E-69).

E-69

9813/5550-1

E-69


Section E - Hydraulics Main Control Valve Description

Page left intentionally blank

E-70

9813/5550-1

E-70


Section E - Hydraulics

Hydraulic Pump/Regulator Hydraulic Pump Operation Main Pumps (P1 and P2) The rotary group consists of the drive shaft 7, cylinder rod 19, piston shoe 4, 5, press plate 11, spherical bush 12, spacer 13 and cylinder spring 14. The drive shaft is supported on both sides by the bearings 8, 16. The shoe is caulked on the piston and forms the spherical coupler, and because it slides slightly on the shoe plate 6, it has a pocket to balance the oil pressure. The subgroup, which is made up of the piston and shoe is held down on the shoe plate by the cylinder spring through the press plate and spherical bush. In the same way, the cylinder block is held down on the valve plate 15 by the cylinder spring. The swash plate group consists of the swash plate 10, shoe plate 6, swash plate support 9 bush 2 pin 3 and servo piston 1. The swash plate is supported by the swash plate support at the cylindrical part formed by the side opposite to the shoe sliding surface. The oil pressure controlled by the regulator is guided to the hydraulic cavities on both sides of the servo piston which moves the servo piston to the left and right, causing the swash plate, through the spherical portion of the pin, to press on the swash plate support and changes the angle of the swash plate. The valve cover group comprises of the valve block 17, valve plate 13 and valve plate pin 18. The valve plate, which has two oval shaped ports, is on the valve block and delivers oil to and recovers oil from the cylinder block. The oil directed by the valve plate flows through the valve block and is connected to the outer piping. When the drive shaft is driven by the engine, the cylinder block rotates simultaneously with the spline coupling. When the swash plate is leaning, the piston in the cylinder block rotates simultaneously with the cylinder block and causes reciprocal motion relative to the cylinder.

6 5 18 4 17 16 15 14 12 2

11

1

10 9

Therefore, during one rotation, the piston moves away from the valve plate for 180° (enough for oil suction) and approaches the valve plate for the remaining 180°. When the swash plate leaning angle is at the minimum 5° the piston does not stroke and does not deliver oil.

E-71

13

3

9803/5550-1

8 7 A406500-1

Fig 1.

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Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Operation

Pump Hydraulic Circuit Diagram A2

A1 a1

a2

Pi1

Pi2

Pm1

Pm2

a4

M Psv A3 Dr

B1

B3

a3

C077790

Fig 2.

A1,2

Table 1. Key Delivery port

B1

Suction port

Dr

Drain port

Pi1,2

Pilot port

P1

Proportional pressure reducing valve

Pm1,2

Q max cut port

a1-3

Gauge port

a4

Gauge port

A3

Gear pump delivery port

B3

Gear pump suction port

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9803/5550-1

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Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Operation

Hydraulic Pump/Regulator Exploded View

3

4 2

24 26 27 25 31

22

16

5

21

15 14

17

14

16 30

32

20 X

8

32A 16 17A

29 28

22A

9

5A

12 31

10

19

1 23 13 11 18 803230

Fig 3.

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9803/5550-1

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E-74

A1

9803/5550-1

a1

CLOCKWISE

Hydraulic Pump/Regulator Plan View

Dr

Pi1

A1

Pm1

Fig 4.

A2

Pm2

P1

Pi2

P1

a3

A3

B3

Pi2

a2

A2 A357730-C2

Section E - Hydraulics

Hydraulic Pump/Regulator Hydraulic Pump Operation

E-74


Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Removal and Replacement

Hydraulic Pump Removal and Replacement Removal

with a suitable cleaning agent and apply a lubricant to the shaft being careful not to get either on to the oil seal of the pump.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device.

– Install the pump coupling 7 onto the splined pump shaft 6 so that the end of the shaft is flush with the circlip 5.

BF-4-1_1

– Torque tighten grub screws 8.

1

Make the machine safe, refer to Section E, Service procedures.

– Apply Locking Fluid - High Strength and torque tighten bolts 4, 2 and 10.

2

Drain the hydraulic fluid from the hydraulic tank.

3

Disconnect all hydraulic hoses and pipes from the hydraulic pump and plug all orifices to prevent ingress of dirt. Label each hose before disconnecting, this will ensure correct position when refitting.

4

Disconnect electrical connection solenoid on hydraulic pump.

5

Attach lifting eyes to the pump. Support weight of the pump with suitable lifting apparatus, refer to Section E, Technical Data.

6

Remove engine exhaust muffler bracket 1 from pump flange 9 by removing four bolts 2. Remove the remaining bolts 10 and washers from pump flange.

7

to

– Before tightening pump flange 9 to the engine, make sure the mating surfaces are fully together.

proportion

– Fill the pump casing inside fully with oil and operate at low engine revs with no services selected for 3 minutes. – If there is any air left in the circuit or pump, this may cause faulty operation or damage so be sure to bleed the air completely. – It is not desirable to leave the pump motor unused for a long period of time (more than one year.) At intervals, start the engine even if for short periods of time. When left unused by itself, rotating the shaft end by hand can be effective. If left unused for an extended period of time, inspection for overhaul will become necessary.

Withdraw the pump clear of the engine.

8

Loosen the two grub screws on the pump coupling 7. Withdraw pump coupling from the pump's splined shaft.

9

If necessary remove bolts 4 and remove the drive plate 3 from the engine.

10

If necessary support the weight of the pump flange 9, remove four cap screws 11 and remove the pump flange from pump.

Item

Table 2. Torque Settings Nm Kgf m

lbf ft

8

120

12.2

88

3

53

5.4

39

2, 10

60

6.2

44

11

435

44.4

321

Replacement Replacement is the reversal of removal procedure but note the following: – When fitting a new pump, the shaft end spline may be coated with a anti-rust coating. Remove this coating

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9803/5550-1

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Section E - Hydraulics Hydraulic Pump/Regulator Hydraulic Pump Removal and Replacement

1 2 11

3 4 10 9 8

8

5

7

6

C132130

Fig 5.

E-76

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