Service Manual

JS200 Asia Pacific

Service Manual - JS200 Asia Pacific
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body & Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section J - Track and Running Gear
Section K - Engine

Publication No.
9813/0400-1

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
Technical Data
Static Dimensions

Technical Data
Static Dimensions

JS200

Fig 1.

Table 1.
Dimensions in millimetres (ft. in)
A Track length on ground 3370 (11 ft 1 in)
B Undercarriage overall length 4170 (13 ft 8 in)
C Track gauge 2200 (7 ft 3 in)
D Width over tracks (500 shoes) 2700 (8 ft 10 in)
D Width over tracks (600 shoes) 2800 (9 ft 2 in)

Table 2.
Dipper lengths 1.9m 2.4m 3.0m
E Transport length 9570 (31 ft 5 in) 9560 (31 ft 4 in) 9440 (31 ft 0 in)
F Transport height 3055 (10 ft 0 in) 3060 (10 ft 0 in) 3025 (9 ft 11 in)

Table 3.
Dimensions in millimetres (ft. in)
I Counterweight clearance 1066 (3 ft 6 in)
J Tailswing radius 2825 (9 ft 3 in)
K Width of superstructure 2549 (8 ft 4 in)
L Height over cab 2946 (9 ft 8 in)
M Height over grab rail 3025 (9 ft 11 in)
N Ground clearance 486 (1 ft 7 in)
P Track height 885 (2 ft 11 in)

B-1 9813/0400-1 B-1

 Section B - Body and Framework
Technical Data
Dig Depth Chart

Dig Depth Chart

JS200

Fig 2.

Table 4.
5.7 m
Dipper 1.91 2.4 3.0
m (ft in) m (ft in) m (ft in)
A Maximum digging reach 8.89 (29 2) 9.34 (30 8) 9.87 (32 5)
B Maximum digging reach (on ground) 8.70 (28 7) 9.16 (30 1) 9.70 (31 10)
C Maximum digging depth 5.53 (18 2) 6.02 (19 9) 6.60 (21 8)
D Maximum digging height 8.95 (29 4) 9.20 (30 2) 9.40 (30 10)
E Maximum dumping height 6.31 (20 8) 6.53 (21 5) 6.75 (22 2)
F Maximum vertical wall cut depth 4.9 (16 1) 5.47 (17 11) 6.07 (19 11)
G Maximum swing radius 3.76 (12 4) 3.71 (12 2) 3.60 (1110)

B-2 9813/0400-1 B-2

 Section B - Body and Framework
Technical Data
Shipping Weight

Shipping Weight

Approximate weight when equipped with monoboom,

medium length dipper, bucket, operator and full fuel tank
except where indicated otherwise.

Table 5.
Model Track shoe width Weight
JS200 500mm 19850 kg
JS200 600mm 20100 kg

B-3 9813/0400-1 B-3

 Section B - Body and Framework

Service Procedures
Cab Structure

Direct Glazing
TB-002_5
!MWARNING
The following procedures explain how to correctly remove Laminated glass must be handled with extra care to
and install panes of glass that are directly bonded to the prevent breakage. Wherever possible, store and
cab frame apertures. When carrying out the procedures, handle it in a vertical attitude. When placing or lifting
relevant safety precautions must be taken. the glass in a horizontal attitude it must be supported
over its whole area, not just at the edges.
1 Always wear safety glasses during both removal and BF-1-8_1
replacement.
Removing the Broken Glass and Old Sealant
2 Use protective gloves - heavy duty leather gauntlet
type gloves when cutting out the broken glass; 'non-
slip' type gloves when handling/moving panes of
!MWARNING
glass; surgical type gloves when using the Always wear safety glasses when removing or
polyurethane adhesives. installing screen glass. Never use a power operated
knife when removing the sealant around a toughened
3 Wear protective overalls. glass screen. The action of the knife could cause
particles of glass to be thrown with sufficient force to
4 Do not smoke - the activators and primers used in the cause serious injury, even when safety glasses are
procedures are highly flammable. being worn. Use only hand operated tools when
working with toughened glass.
5 Do not attempt to handle or move panes of glass BF-2-3_1
unless you are using glass lifters.
1 Position the machine on level ground and apply the
Several special tools are required to successfully complete park brake. Stop the engine. Put protective covers
the removal and replacement procedures. Reference is over the cab seat and control pedestals.
made to the tools in the text. The majority of these tools
can be obtained locally and the remainder from JCB 2 If a laminated pane breaks it will stay in one piece
Service (see Service Tools). even though the glass is cracked. A toughened pane
will shatter and fall apart. The method of removal of
The work must only be carried out in a dry, frost free the glass depends upon which type it is.
environment. A protective canopy may be required or the
machine/frame must be moved to a sheltered area. In a Laminated glass - leave installed until the old
damp or wet conditions, hinged doors and window frames sealant has been cut away, after which it will be
can be removed from the machine and taken to a more possible to lift the broken screen away from its
suitable (dry) environment. frame housing in one piece.

Glass should not be replaced at temperatures below 5°C b Toughened glass - remove as much of the
(41°F). 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:

B-5 9813/0400-1 B-5

 Section B - Body and Framework
Service Procedures
Cab Structure
a Pneumatic Knife. K Fig 1. ( T B-6). This provides
one of the easiest methods of removing the
sealant around laminated glass. The tool,
powered by compressed air, should be sourced
locally.

Fig 1. Pneumatic Knife

i Press the handle to start the knife blade

oscillating.

Important: This tool must not be used on toughened

glass.
Fig 2. Braided Cutting Wire and Handles
ii Insert the knife blade into the sealant.
ii Insert the braided cutting wire B down the
centre of the steel tube. If necessary, from the
iii Slowly move the knife along the sealant with
outside, cut out local sealant at the point of the
the blade positioned as close to the glass as
tube to gain access to the wire.
possible. Do not allow the knife blade to
overheat or the sealant will melt.
iii Using suitable pliers, pull the cutting wire
through the sealant to the outer side of the
b Braided Cutting Wire and Handles.
glass.
K Fig 2. ( T B-6). This method uses a 3-core
wire, a wire starter tube and two handles.
iv Secure each end of the braided cutting wire in
the special handles C.
i Insert the steel tube A into the old sealant on
the inside of the glass.
v 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.

c Cut-out Knife. K Fig 3. ( T B-7). The cut-out knife

can be used as a left handed or right handed tool.

B-6 9813/0400-1 B-6

 Section B - Body and Framework
Service Procedures
Cab Structure
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 5. ( T B-7).

1-2 mm

Fig 3. Cut-out Knife

Fig 5.
i Insert the knife blade into the sealant.
6 Apply a coat of 'Black Primer 206J' to the paintwork if:
ii Make sure that the blade of the knife is against
the glass A. K Fig 3. ( T B-7). a Paintwork was damaged or scratched during the
glass/sealant removal procedures.
iii Use the 'pull-handle' to pull the knife along and
cut out the old sealant. b The old sealant was inadvertently cut back to the
cab frame during the glass/sealant removal
d Craft Knife. K Fig 4. ( T B-7). The blades A are procedures.
replaceable.
Preparing the Cab Frame Aperture
i Insert the knife blade into the sealant.
1 If damp or wet, dry the aperture area using a hot air
ii Pull the knife along and cut out the old sealant. gun (sourced locally).

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

Fig 4. Craft Knife

!MWARNING
4 Laminated glass - lift out the broken pane using glass Laminated glass must be handled with extra care to
lifters. prevent breakage. Wherever possible, store and
handle it in a vertical attitude. When placing or lifting
Toughened glass - remove the cut off sealant and all the glass in a horizontal attitude it must be supported
remaining particles of shattered glass. over its whole area, not just at the edges.
BF-1-8_1

B-7 9813/0400-1 B-7

 Section B - Body and Framework
Service Procedures
Cab Structure
1 Make sure that the new glass correctly fits the frame
aperture A. K Fig 6. ( T B-8).

a Put two spacer blocks B onto the bottom part of

the frame aperture.

b Install the new glass on the spacer blocks -

Always use glass lifters 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 7. Glass Stand

Important: The glass edges must not touch the frame, Small panes of glass will need locating on a 600 x 700
otherwise movement of the frame will chip and eventually mm x 15 to 19 mm thick plywood board, sourced
break the newly installed glass. locally to fit the glass stand. K Fig 8. ( T B-8). 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.

Fig 6.
Fig 8.
2 After checking for size, remove the new glass and
place it on a purpose made glass stand. 3 Make sure the glass is positioned on the stand the
K Fig 7. ( T B-8). correct way up (i.e. with the black ceramic ink band
upwards) ready for application of primer etc.

4 Clean the glass

a 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.

B-8 9813/0400-1 B-8

 Section B - Body and Framework
Service Procedures
Cab Structure
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 9. ( T B-9).

Fig 10.

6 Apply the pre-heated adhesive to the glass (do not

start in a corner). Keep the nozzle guide A against the
edge of the glass and make sure that the adhesive
forms a continuous 'pyramid' shape.
K Fig 11. ( T B-9)

Fig 9.

5 Install the Ultra Fast Adhesive cartridge (see Sealing

and Retaining Compounds, Section 1 and Note)
into a suitable applicator gun:

a Remove the aluminium disc cover from the base

of the cartridge and discard the 'dessicant
capsule'.
Fig 11.
b Make sure that the rolled edge of the cartridge is
not damaged - if necessary, the edges should be Note: Once the pre-heated adhesive has been applied to
pressed flat, otherwise it will be difficult to remove the glass, install the glass in the aperture as soon as
the cartridge from the applicator gun. possible. After approximately 10 minutes the sealant will
form a 'skin', this will prevent the glass from bonding.
c Pierce the front 'nozzle' end of the cartridge to its
maximum diameter. 7 After applying the adhesive, leave a small amount of
sealant protruding from the nozzle. This will prevent
d Fit the pre-cut nozzle. K Fig 10. ( T B-9). any adhesive left in the cartridge from 'curing'.

e Install the cartridge in the applicator gun. Installing the New Glass
Note: Cold material will be very difficult to extrude. The
1 If the internal trim strip is damaged, renew it (cut to
cartridges must be pre-heated in a special oven for 1 hour
length as required) before fitting the new glass. Make
to a temperature of 80°C (176°F). Pre-heating the
sure the two spacer blocks are in position.
cartridges makes the adhesive more workable and also
K Preparing the New Glass ( T B-7) - step 1.
brings the 'curing' time down to 30 minutes.
2 Install the glass in the frame aperture:

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 12. ( T B-10).

B-9 9813/0400-1 B-9

 Section B - Body and Framework
Service Procedures
Cab Structure
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'.
Fig 12. Typical M/c. Installation
b Large amounts of excess sealant should be left to
b Sit the bottom edge of the glass on the spacer
'cure' and then cut off with a sharp knife.
blocks. K Fig 13. ( T B-10)
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
minutes, but it must not be used during the curing period of
30 minutes.

c Clean the glass using a purpose made glass

cleaner

6 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 safety and instructional labels so that

the new installation conforms with the original cab
installation.
Fig 13.

c 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.

3 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.

B-10 9813/0400-1 B-10

 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. Table 1. Torque Settings
Item Nm Kgf m lbf ft
Check the structure for damage. Check that the six A 132 14 97
mounting bolts A are installed and undamaged. Check the

Fig 14.

B-11 9813/0400-1 B-11

Section C

Electrics
Service Manual - JS200 Asia Pacific
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body & Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section J - Track and Running Gear
Section K - Engine

Publication No.
9813/0400-1

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
Contents

Contents Page No.

Basic System Operation
Schematic Diagram .................................................................................. C-1
Ignition Circuit ........................................................................................... C-4
Hydraulic Lock Circuit ............................................................................... C-5
Power and Economy Mode Charge Circuit .............................................. C-6
Mode Change ....................................................................................... C-6
Swing Brake Circuit .................................................................................. C-7
Work Lamp ............................................................................................... C-8
ECU .......................................................................................................... C-9
ECU 4 functions ................................................................................. C-10

Service Procedure
Using a Multimeter .................................................................................. C-17
Measuring DC Voltage ....................................................................... C-18
Measuring Resistance ........................................................................ C-18
Measuring Continuity .......................................................................... C-19
Measuring Frequency ......................................................................... C-19
Testing a Diode or a Diode Wire ......................................................... C-20
Battery .................................................................................................... C-21
Maintenance ....................................................................................... C-21
Testing ................................................................................................ C-21
Specific Gravity Testing ...................................................................... C-23
Wiring Harness Repair ........................................................................... C-24
Introduction ......................................................................................... C-24
Repair Procedure ............................................................................... C-24

Harness Data
Main Harness ......................................................................................... C-27
Connector Identification ...................................................................... C-27
Facia Harness ........................................................................................ C-29
Connector Identification ...................................................................... C-29
Cab Harness ........................................................................................... C-30
Connector Identification ...................................................................... C-30

C-i C-i
 Section C - Electrics

Basic System Operation

Schematic Diagram

K Fig 1. ( T C-3) Item Description

32 Start Motor
Item Description
33 Engine Shut Off Solenoid
1 Face Fan
34 Battery Relay
2 Cabin Lamp
35 Fuse Box
3 Cab Work Lamp (option)
A1 Lever Lock Solenoid (5A)
4 Cab Work Lamp (option)
A2 Swing Lock (5A)
5 Radio 12v (option)
A3 Relays Coil Feed (5A)
6 Water Temp Gauge
A4 Wiper Motor (10A)
7 Fuel Gauge
A5 -
8 Hour Meter
B1 Face Fan (5A)
9 Warning Cluster
B2 Battery Feed (20A)
10 Timer Relay
B3 Refuel Pump (15A)
11 ECU4
B4 Cabin Lamp (5A)
12 PWM Port
B5 Horn (5A)
13 Refuel Pump (option)
C1 Panel Lights (5A)
14 Power Mode Solenoid
C2 ESOS (Hold) (15A)
15 Swing Lock Solenoid
C3 Work Lamp (standard) (10A)
16 Lever Lock Solenoid
C4 Work Lamp (option) (10A)
17 Hyd Pressure Sensor
C5 Alternator Signal (5A)
18 Travel Pressure Sensor
D1 ESOS (Pull) (5A)
19 Solenoid
35 Horn Switch
20 Horn
36 Lock Lever Switch
21 Tool Box Lamp
37 Servo Isolator Switch
22 Boom Lamp
38 Work Lamp Switch
23 Counter Weight Lamp (option)
39 Swing Lock Switch
24 Fuel Sensor
40 Power Mode Priority Switch
25 Hydraulic Temp Switch
41 Rock Breaker Pressure Switch
26 Air Filter Switch
42 Auto Idle Relay
27 Reserve Tank LSW
43 Horn Relay
28 Water Temp Sensor
44 Radio Switch
29 Water Temp Switch
45 Start Relay
30 Engine Oil Pressure Switch
46 ESOS Relay
31 Alternator
47 Ignition Switch

C-1 9813/0400-1 C-1

 Section C - Electrics
Basic System Operation
Schematic Diagram

Item Description
48 Battery
49 Battery
50 Fuse
51 E Mode
52 P Mode
53 Servo Isolator
54 Slew Lock
55 Master Warning
56 Alternator
57 Air Filter
58 Coolant Pressure
59 Engine Oil Pressure
60 Hyd Oil Temp
61 Water Temp
62 Master Warning

C-2 9813/0400-1 C-2

C-3

36 35 35
38 37 50
34

49
48 33
39 41
40
32
31
30
1 29
28
2
47 27
3 26
4 25
9813/0400-1

24
5 44 23
43 45 46
42
6 22
7 21
8 20 19
51 18
52
53
17
54 16
55 15

Basic System Operation

Section C - Electrics
9
56
57
14
58
13
59
60
61 11

Schematic Diagram
62 12
10
T056750
Fig 1. 331/67706 issue 4
C-3
 Section C - Electrics
Basic System Operation
Ignition Circuit

Ignition Circuit

B
A

s
C

B
- +
s 15A s
24V 40A

B F
B
C D
D
G

5A

s
E
Fig 2.

Current from the battery is always available at the battery Table 1.

relay, B port of the ignition switch and the start relay. It is Item Description
also available through a resistor of 40A at the ESOS relay.
A Battery Relay
When the ignition is ON the battery relay is energized; it B Ignition Switch
gives a feed to the starter motor port B. C Starter Motor
D ESOS Hold Relay
When the ignition switch is turned to crank, it energizes the
start relay and gives current to the ESOS relay and E ECU 4
energizes it. This in turn gives the feed from the battery F ESOS
relay (already available) to the PULL of ESOS. ECU 4 now
gives a current to the HOLD of the ESOS and the solenoid G Start Relay
of the starter motor. This way the ESOS and starter motor
solenoid are actuated. The ESOS enables the fuel supply
and the starter motor solenoid engages the gear of the
motor with the flywheel.

C-4 9813/0400-1 C-4

 Section C - Electrics
Basic System Operation
Hydraulic Lock Circuit

Hydraulic Lock Circuit

s
s
- +
s A
24V

s s D
com

B
E
C

F
Fig 3.

When the ignition is ON, current goes to the battery relay

to energize it and current is given to the com port of the
lock lever. If the hydraulic lever is lowered the current is
given to the hydraulic lock rocker switch. If the hydraulic
lever lock is raised the current goes to the warning cluster
to illuminate the warning light.

If the rocker switch is in the OFF position then the current

is given to the hydraulic lock solenoid to energize it. If the
rocker switch is in the ON position then the current goes to
the warning cluster to illuminate the warning light.

Item Description
A Battery Relay
B Ignition Switch
C Warning Cluster
D Lock Lever
E Rocker Switch
F Hydraulic Lock Solenoid

C-5 9813/0400-1 C-5

 Section C - Electrics
Basic System Operation
Power and Economy Mode Charge Circuit

Power and Economy Mode Charge Circuit

K Fig 4. ( T C-6)

A
B

Fig 4.

Mode Change
Idle RPM is set at the engine and the max RPM is set to
2200RPM using the cable. At the throttle lever position
where RPM reaches 1800RPM the power mode proximity
switch is set to make contact and current is given by the
ECU 4 to the power mode solenoid to energize it.

So the modes are changed by the Throttle Lever position.

Below 1800RPM it is “E” economy mode and above
1800RPM it is “P” power mode.

Item Description
A ECU 4
B Power Mode Proximity Switch
C Power Mode Solenoid
D Warning Cluster

C-6 9813/0400-1 C-6

 Section C - Electrics
Basic System Operation
Swing Brake Circuit

Swing Brake Circuit

s
- +
s A D
24V

s s

B
C

E
Fig 5.

When the ignition is ON the battery relay is energized and

current is given to the rocker switch. Item Description
A Battery Relay
If the rocker switch is OFF (which means the swing
function is unlocked) then the current goes to the swing B Ignition Switch
solenoid and energizes it. This enables 40 bar pressure to C Warning Cluster
the swing brake and releases the brakes. When the
D Rocker Switch
ignition is ON, the swing brakes are released but the
machine is locked hydraulically. E Swing Solenoid

If the rocker switch is ON, (which means the swing function

is locked). the swing solenoid is de-energized and the
current goes to the warning cluster to illuminate the
warning light. The 40 bar pressure to the swing brake and
brakes is removed and the brakes are applied by spring
action.

C-7 9813/0400-1 C-7

 Section C - Electrics
Basic System Operation
Work Lamp

Work Lamp

s
s E
s s

A D s
s
s

B
C

C
Fig 6.

Current is available at the ignition switch, battery relay and

work lamp relays. When the ignition switch is ON, the
battery relay is energized and current is given to the work
lamp switch. When switch is pressed ON, this energizes
the work lamp relays and current is given to the work
lamps.

Item Description
A Ignition Switch
B Boom and Tool Box W/L
C Relay
D Ignition Switch
E Battery Relay
F Work Lamp Switch

C-8 9813/0400-1 C-8

 Section C - Electrics
Basic System Operation
ECU

ECU

The ECU does not have any user interface port so it is not This ECU will take the signal from the drive line and engine
possible to communicate with the ECU using a computer. and clock the actual hours, which could be retrieved from
PWM port by measuring the value with multi-meter.

12/24V M L
Ignition feed Ground
12/24V
K
Alternator Supply to
A Frequency ESOS
Engine Oil Pr.
B Signal (Digital)
Engine water
C temperature ECU - 4 Hour counter supply feed
(when engine is running.) J
Hydraulic oil
D temperature Hour s checking port (PWM)
Alternator
(when engine is not running H
E Charging (Digital)
and ignition is ON

Start switch
F
Supply to pump regulator G
solenoid valve.

Fig 7.
Item Description
A Alternator Frequency
B Engine Oil Pressure Signal (digital)
C Engine Water Temp
D Hydraulic Oil Temp
E Alternator Charging (digital)
F Start Switch
G Supply to pump regulator solenoid valve
H Hours checking port (PWM) (When
engine is not running and ignition is ON)
J Hour counter supply feed (when engine
running)
K Supply to ESOS
L Ground
M Ignition Feed

C-9 9813/0400-1 C-9

 Section C - Electrics
Basic System Operation
ECU

ECU 4 functions
ECU4 performs following functions:

– Engine start and shut off control. K Engine Start and

Shut off control ( T C-11).
– Engine monitoring for temperature rise.
K Temperature Rise ( T C-13)
– Hour meter running. K Hourmeter ( T C-14)
– Hour monitoring. K Hour Monitoring ( T C-15).

C-10 9813/0400-1 C-10

 Section C - Electrics
Basic System Operation
ECU
Engine Start and Shut off control

– ECU4 lets the engine start (24V current to ESOS hold

coil) in the following conditions.
– Ignition switch current signal (pin 12) (24V)
– Crank switch current signal (pin 5) (24V)

Table 2.
S. No. Ignition Feed Crank Feed ESOS hold Coil
1 24V 0V
2 24V 24V 24V Crank and hold the current till the engine shuts off
3 0V 0V 0V
4 0V 24V 0V
5 24V 0V 0V Some problem at ESOS
6 24V 24V 0V - do -
7 0V 0V 0V
8 0V 24V 0V

ECU4 shuts OFF the engine in following conditions:

– Ignition switch current signal (pin 12) is 0V (i.e.

ignition switch is switched off).K Table 3. ( T C-12)
– There is no signal coming from engine sensors. (Pin
no. 6,7 and 8) after 10 sec of engine crank.
– There is a temperature warning (pin 9) “ON” since last
5 minutes (T1). K Fig 8. ( T C-11)

T=10sec
Fig 8.
_________ Ignition
---------------- Crank

C-11 9813/0400-1 C-11

 Section C - Electrics
Basic System Operation
ECU
Table 3.
S.No. Ignition Feed Engine Sensor Feed Time (Sec) Time (Sec) (Figure 1) T2 ESO hold
(Figure 1) (mm) coll
1 24V NO T<=10 T1<=1 24V
2 24V YES T<=10 T1<=1 24V
3 0V NO T<=10 T1<=1 0V
4 0V YES T<=10 T1<=1 0V
5 24V NO T<10 T1<=1 0V
6 24V YES T<10 T1<=1 24V
7 0V NO T<10 T1<=1 0V
8 0V YES T<10 T1<=1 0V
9 24V NO T<=10 T1<=1 0V
10 24V YES T<=10 T1<=1 0V
11 0V NO T<=10 T1<=1 0V
12 0V YES T<=10 T1<=1 0V
13 24V NO T<10 T1<=1 0V
14 24V YES T<10 T1<=1 0V
15 0V NO T<10 T1<=1 0V
16 0V YES T<10 T1<=1 0V

C-12 9813/0400-1 C-12

 Section C - Electrics
Basic System Operation
ECU
Temperature Rise change (0V to 24V) from any of these points it changes the
pump mode from high to low mode by cutting off the
ECU4 monitors the system for a rise in temperature above current to the pump mode solenoid. If the warning persists
specified limits by checking the signals from the hydraulic for 1 minute it shuts off the engine by cutting off the ESOS
and coolant temperatures (pin 9). If there is a signal current. K Table 4. ( T C-13).

Table 4.
S. No. Temp Warning Pump mode (P) Temp warning time T1 (min) ESOS hold Coil
1 24V 0V T1<=1 24V
2 0V 24V T1<=1 24V
3 24V 0V T1<=1 0V
4 0V 24V T1<=1 24V

C-13 9813/0400-1 C-13

 Section C - Electrics
Basic System Operation
ECU
Hourmeter meter. The ECU runs the hour meter when the ignition feed
is ON and the engine sensors are ON
The ECU provides the feed to the hour meter on the basis K Table 5. ( T C-14)
of signals from the engine sensors and runs the hour

Table 5.
S. No. Ignition feed Alternator Alternator Feed Engine oil Hour meter
feed WL W frequency pressure ground
1 24V 0V 24V 24V YES Engine Warning
2 24V 24V 24V 24V YES EOP Warning
3 24V 0V 0V 24V YES EOP Warning alternator
disconnected
4 24V 24V 0V 24V YES Warnings disconnected
5 24V 0V 24V 0V YES Battery no charge warning
6 24V 24V 24V 0V YES Engine running
7 24V 0V 0V 0V YES Alternator connector unplugged
8 24V 0V 0V 0V YES No frequency output
9 0V 0V 24V 24V NO No frequency output
10 0V 24V 24V 24V NO No ignition feed
11 0V 0V 0V 24V NO No ignition feed
12 0V 24V 0V 24V NO No ignition feed
13 0V 0V 24V 0V NO No ignition feed
14 0V 24V 24V 0V NO System is off
15 0V 0V 0V 0V NO No ignition feed
16 0V 24V 0V 0V NO No ignition feed

C-14 9813/0400-1 C-14

 Section C - Electrics
Basic System Operation
ECU
Hour Monitoring

The ECU also monitors the hours by recording the hours in

the hidden counter in side. This can only be accessed
through the PWM from pin no. 10 when the engine is OFF
and the ignition switch is turned ON. This has been done
to cross check the hour meter reading and could be
retrieved with the help of a multi-meter. The hours could be
retrieved in the following conditions on pin 10. Every time
the ignition switch is turned OFF or the ECU cuts off the
current of ESOS, the engine will reset its timer
K Table 6. ( T C-15).

Table 6.
S. No. Ignition Engine running PIN 10 out put
feed
1 24V Yes Power mode
2 24V No PWM out put
3 0V Yes No output
4 0V No No output.

Pulse Width Modulation

As mentioned earlier this ECU doesn’t have any user

interface port and does not have memory so there is no
real time clock which could give the accurate information
about date and hours clocked. So, the pulse width
modulation port (pin10) has been configured to give the
value of hours.

The ECU 4 has 8 bit microprocessor, which is one time

programmable with 2K ROM and 128 byte RAM. We need
minimum 0.5% duty cycle for 5000 hours.

So for example K Table 7. ( T C-15)

Table 7.
0-25 hours 0% duty cycle
25-50 hours 0.5% duty cycle
50-75 hours 1.0% duty cycle —— as so on

From above it is evident the PWM port could give the

reading in the accuracy of 25 hours

Higher resolution would be acceptable to increase the

accuracy of hours in terms of no. of hours

C-15 9813/0400-1 C-15

 Section C - Electrics

Service Procedure
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 2. AVO 2003

Fig 1. FLUKE 85

Fig 3. A Typical Analogue Meter

C-17 9813/0400-1 C-17

 Section C - Electrics
Service Procedure
Using a Multimeter
1 Make sure that the test leads are plugged into the Measuring Resistance
correct sockets. The black test lead should be
plugged into the black socket (sometimes, this socket 1 Make sure there is no power to the part of the circuit
is also marked by a "-", or "E" or marked as you are about to measure.
"COMMON" or "COM"). The red test lead should be
plugged into the red socket marked with "+", "V" or 2 Connect one probe at one end of the component or
"Ω". wire to be checked and the other probe at the other
end. It does not matter which way round the two
2 When making measurements ensure that the test probes are placed.
probes have a good clean contact with bare metal,
free from grease, dirt, and corrosion as these can 3 Select the correct range on the multimeter.
cause a false reading.
a On the FLUKE 85.
3 When measuring voltage: Make sure that the correct
range is selected, that is set the selector to a value i Turn the switch to position 1-C and check that
equal to or greater than that you are about to the W sign at the right hand side of the display
measure. e.g. If asked to measure 12 Volts, set the window is on. If the F sign is on instead, press
selector to the 12V range. If there is no 12V range, set the blue button 1-G to change the reading to
the selector to the next range higher, 20V for Ω. Touch the meter lead probes together and
instance. If the meter is set to a range that is too low, press the REL3 key on the meter to eliminate
it may be damaged. e.g. setting to the 2V range to the lead resistance from the meter reading.
measure 12V.
b On the AV0 2003.
Measuring DC Voltage
i Move the right hand slider switch to position 2-
1 Select the correct range on the multimeter. B, and the left hand slider switch to the
appropriate Ohms (Ω) range.
a On the FLUKE 85.
c On an analogue meter.
Turn the switch to position 1-B.
i Move the dial to the appropriate Ohms (Ω)
b On the AV0 2003.
range.
Move the right slider switch to position 2-A, and
the left hand slider switch to the appropriate
range.

c On an analogue meter.

Turn the dial to the appropriate DC Volts range.

2 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.

C-18 9813/0400-1 C-18

 Section C - Electrics
Service Procedure
Using a Multimeter

Measuring Continuity Measuring Frequency

1 Make sure there is no power to the part of the circuit The AVO 2003 and the analogue meter are not capable of
you are checking for continuity. 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 1 Insert the black plug into the COM socket on the
end. It does not matter which way round the two meter and attach the probe to the nearest suitable
probes are placed. earth point on the chassis, for example, the battery
negative terminal.
3 Select the correct range on the multimeter.
2 Insert the red probe into socket 1-J.
a On the FLUKE 85.
3 Turn the selector switch to position 1-A and depress
Turn the switch to position 1-C and check that the 1-G repeatedly until 1-F is highlighted on the top row
beeper symbol appears at the left hand side of the of the display.
display window. If the F sign is on instead, press
the button labelled 1-F in the meter drawing. 4 Press button 1-H once.

If there is continuity in the circuit, the beeper will 5 Touch or connect the red probe to the frequency
sound. If there is no continuity (open circuit), the source to be measured. Press and hold button if an
beeper will not sound. average reading is required.

b On the AV0 2003.

Move the right hand slider switch to position 2-B,

and the left hand slider switch to position 2-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 (Ω) 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.

C-19 9813/0400-1 C-19

 Section C - Electrics
Service Procedure
Using a Multimeter

Testing a Diode or a Diode Wire c On an analogue meter.

A diode wire is a diode with male connector fitted on one i Select the Ohms 1000s (1k) range.
end and a female connector fitted on the other end. The
diode is sealed in heatshrink sleeving. Connect the black probe to the end of the
diode marked with a band, or to the male
1 To test a Diode or a Diode Wire connector of the diode wire, the red probe
should be connected to the other end of the
a On the FLUKE 85. diode or diode wire. The meter should read
20-400 kΩ, if it reads more than this the diode
i Turn the switch to position 1-D. is faulty.

ii Press the HOLD button and check that the H ii Select the Ohms 100s range.
sign appears at the top right hand side of the
display window. Connect the red probe to the end of the diode
marked with a band, or to the male connector
iii Connect the black probe to the end of the of the diode wire, the black probe should be
diode with a band or to the male connector of connected to the other end of the diode or
the diode wire. Connect the red probe to the diode wire. The meter should read 300-400Ω,
other end of the diode or diode wire. If the if it reads less than this the diode is faulty.
beeper does not sound the diode or diode wire
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 2-A, and

the left hand slider switch to position 2-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.

C-20 9813/0400-1 C-20

 Section C - Electrics
Service Procedure
Battery

Battery
TC-001_4

Maintenance !MWARNING
To ensure that the battery provides optimum performance Batteries give off an explosive gas. Do not smoke
the following steps should be observed: when handling or working on the battery. Keep the
battery away from sparks and flames.
1 Make sure that the electrical connections are clean
and tight. Smear petroleum jelly on connectors to Battery electrolyte contains sulphuric acid. It can burn
prevent corrosion. you if it touches your skin or eyes. Wear goggles.
Handle the battery carefully to prevent spillage. Keep
2 When applicable - never allow the electrolyte level to metallic items (watches, rings, zips etc) away from the
fall below the recommended level - 6 mm (1/4 in) battery terminals. Such items could short the
above the plates. Use only distilled water for topping terminals and burn you.
up.
Set all switches to OFF before disconnecting and
3 Keep the battery at least three quarters charged, connecting the battery. When disconnecting the
otherwise the plates may become sulphated battery, take off the earth (-) lead first.
(hardened) - this condition makes recharging the
battery very difficult. Re-charge the battery away from the machine, in a well
ventilated area. Switch the charging circuit off before
Extra precautions must be taken when bench charging connecting or disconnecting the battery. When you
maintenance free batteries, they are more prone to have installed the battery in the machine, wait five
damage by overcharging than the standard type of battery: minutes before connecting it up.

– Never boost-charge a maintenance free battery. When reconnecting, fit the positive (+) lead first.
5-3-4-12
– Never charge a maintenance free battery at a voltage
in excess of 15.8 Volts.
Testing
– Never continue to charge a maintenance free battery
after it begins to gas.
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).

Ensure that the battery is completely disconnected from

the vehicle.

Connect up the battery tester as follows:

1 Set the CHECK/LOAD switch 4-A to OFF.

2 Set rocker switch 4-B to the battery voltage (12V).

3 Connect the red flying lead to the battery positive (+)

terminal and the black flying lead to the battery
negative (-) terminal.

C-21 9813/0400-1 C-21

 Section C - Electrics
Service Procedure
Battery
4 Set the CHECK/LOAD switch 4-A to CHECK to read
the battery no-load voltage which should be at least
12.4 volts.

5 Set the CHECK/LOAD switch 4-A to LOAD and hold

down for 5-10 seconds until the meter reading
stabilises. The reading should be at least 9 volts.

Note: Do not hold the switch in the LOAD position for more
than 10 seconds.

6 K Table 1. Fault Diagnosis ( T C-22), if the

foregoing tests are unsatisfactory. Fig 4. Battery Tester

Table 1. Fault Diagnosis

Battery Tester Readings Remedy
1 CHECK: 0 - 12.6 Volts Renew battery

LOAD: less than 6 Volts

2 CHECK: 6 - 12.4 Volts Recharge and re-test. If tests still unsatisfactory renew
battery.
LOAD: less than 9 Volts and falls steadily but remains
in yellow zone.
3 CHECK: less than 10 Volts Indicates battery has been over-discharged and unlikely to
recover. Renew battery.
LOAD: less than 3 Volts
4 CHECK: more than 11 Volts Charge battery which will probably recover.

LOAD: 6 - 10 Volts steady

C-22 9813/0400-1 C-22

 Section C - Electrics
Service Procedure
Battery

Specific Gravity Testing Readings should be as tabulated and should not vary
between cells by more than 0.04. A greater variation
The specific gravity of the electrolyte gives an idea of the indicates an internal fault on that particular cell.
state of charge of the battery. Readings should be taken
using a hydrometer, when the electrolyte temperature is If the electrolyte temperature is other than 15°C (60°F) a
15°C (60°F). If the battery has recently been on charge, 'correction factor' must be applied to the reading obtained.
wait approximately one hour (or slightly discharge the Add 0.07 per 10°C (18°F) if the temperature is higher than
battery) to dissipate the surface charge before testing. 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-23 9813/0400-1 C-23

 Section C - Electrics
Service Procedure
Wiring Harness Repair

Wiring Harness Repair

TC-004

Introduction !MCAUTION
Instances do occur where it is necessary to incorporate When the heater is in use, the reflector and the air
auxiliary electrical components into existing electrical coming out are extremely hot. Keep away to avoid
circuits and, although unlikely with present wiring accidental burns. Do not touch the reflector until it has
harnesses, repair or replace specific individual wires within had time to cool down after switching off. If flame
a harness. This will also apply to other machines in reappears at the reflector when the heater is in use, the
addition to those of manufacture. catalytic element is damaged or used up. Stop work
immediately and replace the heater.
To ensure that either the inclusion of an auxiliary electrical ELEC-2-3
component or a repair within a harness is completed to an
acceptable standard it is strongly recommended that the Repair Procedure
following tools, equipment and procedures are always
used. Note that JCB harnesses have an International Table 3. Tools Required
Protection rating of 67 (I.P.67). Part No. Description Qty
892/00350 Butane Heater assembly 1
The sheath covering of the recommended splice is heat
shrunk onto the original wire insulation. This results in a 892/00349 Crimp tool 1
seal and corresponding joint to IP 67 specifications. 892/00351 Splice 0.5-1.5 mm (Red) 50
892/00352 Splice 1.5-2.5 mm (Blue) 50
!MCAUTION 892/00353 Splice 3.0-6.0 mm (Yellow) 50
When installing Auxiliary Electrical Components
always ensure that the additional load rating is 1 Cut the wire and remove the protective insulation for
suitable for that particular circuit. It is unacceptable to a suitable distance dependent upon the size of wire
simply increase the fuse rating as this can cause and splice to be used. For the splices detailed in
overloading and consequential failure of wiring, along K Table 3. ( T C-24), the dimension is 7mm.
with failure of integral circuit components, which the
fuse is protecting.
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 5.
ELEC-2-2
2 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 5. ( T C-24). Note that each of the splices
detailed is colour-coded to make size and range

C-24 9813/0400-1 C-24

 Section C - Electrics
Service Procedure
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, seal the

connection. K Fig 6. ( T C-25).

a Remove the cap 7-A from the end of the

disposable gas cartridge 7-B.

Fig 8.

d Turn the small ring 9-E so that the air holes at 9-F
are completely closed.
Fig 6.

b Before assembling the gas cartridge to the

reflector element 8-C, turn the red ring 8-D to the
left, (in the direction of the minus sign marked on
the ring).

Fig 9.

e Turn the red ring 10-D to the right (in the direction
of the plus sign) in order to turn on the gas.
Fig 7.
Important: Before turning the heater on, make sure that
c Position the tube hanging down from inside the
the cartridge is not hotter than the reflector element. This
reflector assembly into the hole at the top of the
may occur if the cartridge is held in the hand for a long
gas cartridge. Then press the gas cartridge up
time. The temperature difference between the cartridge
into the reflector assembly as far as possible until
and the reflector element may cause long yellow flames to
the two elements are clasped firmly together.
appear on ignition.
K Fig 8. ( T C-25). A click will be heard.

C-25 9813/0400-1 C-25

 Section C - Electrics
Service Procedure
Wiring Harness Repair
i Side wings 12-G down, reflector head
completely open. In this mode the infra-red
heat waves are dominant (recommended for
the light coloured plastic splices).

Fig 10.

f Hold the heater vertically and, using a match or

cigarette lighter, light the gas as shown.
Fig 12.
Hold the heater vertically for 1 to 2 minutes until
the catalytic reaction occurs. This is indicated ii Side wings 13-G up, reflector head opening
when the blue flame fades and the ceramic reduced. In this mode the heating is done only
element glows red. Then turn the small ring 11-E by the hot gas (use for dark coloured plastic
until the air holes at 11-F are completely open. splices).
The tool is ready for use.

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 13.

h To switch off the heater, turn the red ring 13-D to

the left (in the direction of the minus sign).
Fig 11.

g The heater can be used in two modes:

C-26 9813/0400-1 C-26

 Section C - Electrics
Harness Data
Main Harness

Harness Data
Main Harness

Note: All wires are yellow colour

Connector Identification

T056760
Fig 1. 332/P1386-3 sheet 1

C-27 9813/0400-1 C-27

 Section C - Electrics
Harness Data
Main Harness

T056760-2
Fig 2. 332/P1386-3 sheet 2

C-28 9813/0400-1 C-28

 Section C - Electrics
Harness Data
Cab Harness

Cab Harness

Note: All wires are yellow colour

Connector Identification

2
T056770
Fig 4. 333/P6340-1 sheet 1

C-30 9813/0400-1 C-30

 Section C - Electrics
Harness Data
Cab Harness

1
3

T056770-1
Fig 5. 333/P6340-1 sheet 2

C-31 9813/0400-1 C-31

 Section C - Electrics
Harness Data
Cab Harness

T056770-2

Fig 6. 333/P6340-1 sheet 3

C-32 9813/0400-1 C-32

Section E

Hydraulics
Service Manual - JS200 Asia Pacific
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body & Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section J - Track and Running Gear
Section K - Engine

Publication No.
9813/0400-1

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

Contents Page No.

Technical Data
General Data ............................................................................................ E-1

Basic System Operation

Introduction to Hydraulic Schematic Symbols .......................................... E-3

Circuit Descriptions
Hydraulic Schematic ............................................................................... E-10
Servo/Pilot Line ...................................................................................... E-12
Servo/Pilot Pressure and Return Line .................................................... E-14
Component Location .............................................................................. E-16
Neutral Circuit ......................................................................................... E-18
Travel - Single Speed ............................................................................. E-20
Straight Line Travel ................................................................................. E-22
Boom Up ................................................................................................ E-24
Boom Down ............................................................................................ E-26
Dipper Out .............................................................................................. E-28
Dipper In ................................................................................................. E-30
Bucket Opening ...................................................................................... E-32
Bucket Closing ........................................................................................ E-34
Swing ...................................................................................................... E-36

Main Control Valve

Description .............................................................................................. E-38

Hydraulic Pump/Regulator
Hydraulic Pump Operation ..................................................................... E-52
Hydraulic Pump Removal and Replacement .......................................... E-56
Hydraulic Pump Dismantling and Assembly ........................................... E-58
Regulator Dismantling and Assembly ..................................................... E-64

Remote Control Valve (Hand Control)

Operation ................................................................................................ E-72
Removal and Replacement .................................................................... E-74
Dismantling and Assembly ..................................................................... E-76

Travel Pedal Valve

Dismantling and Assembly ..................................................................... E-82

Slew Motor
Motor Operating Principles ..................................................................... E-86
Slew Brake Operation ............................................................................. E-87
Fault Finding ........................................................................................... E-88
Removal and Replacement .................................................................... E-90
Slew Motor Configuration ....................................................................... E-92
Dismantling and Assembly ..................................................................... E-93

Slew Gearbox
Reduction Gear Structure and Working Principles ................................ E-110
Description ............................................................................................. E-111
Dismantling and Assembly .................................................................... E-113

Rotary Coupling
Description ............................................................................................. E-118
Removal and Replacement .................................................................. E-120

E-i E-i
 Section E - Hydraulics

Contents Page No.

Dismantling and Assembly ................................................................... E-122

Hydraulic Rams
Precautions During Use ........................................................................ E-126
Removal and Replacement .................................................................. E-128
Dismantling and Assembly ................................................................... E-146
Maintenance Specifications .................................................................. E-158

Service Procedure
Make the Machine Safe ........................................................................ E-160
Pressure Testing - General ................................................................... E-161
Pressure Relief Valve Location ............................................................. E-164
Main Relief Valve (MRV) Pressure ....................................................... E-166
Servo Relief Pressure ........................................................................... E-168
Auxiliary Relief Valves .......................................................................... E-169
Slew Motor Pressure Relief .................................................................. E-175
Travel Motor Relief Pressure ................................................................ E-177

Fault Finding
Hydraulic Contamination ...................................................................... E-178
Main Control Valve ............................................................................... E-180
Relief Valve ........................................................................................... E-181
Hydraulic System .................................................................................. E-182
Slew Motor ............................................................................................ E-183
Hydraulic Pump .................................................................................... E-185
Hydraulic Rams .................................................................................... E-186

E-ii E-ii
 Section E - Hydraulics
Technical Data
General Data

Technical Data
General Data

Slew Motor Main Control Valve

Table 1. A combined four and five spool control valve with auxiliary
Swing motor Axial piston type service spool as standard. When required twin pump flow
is combined to boom and dipper services for greater speed
Swing brake Automatic spring applied disc type
and efficiency K Table 3. ( T E-1).
parking brake
Final drive Planetary reduction Table 3.
Swing speed 12.9 ± 10% Rev/min ARV Setting
Swing gear Large diameter, internally toothed fully Boom/Arm/Bucket 343 bar
sealed oil bath lubricated Swing circuit 289 bar
Travel circuit 343 bar
Hydraulic Pump
Pilot control 40 bar
A variable flow negative control system with flow on Arm In 392 bar
demand, variable power output and servo operated, multi Arm Out 392 bar
functional. K Table 2. ( T E-1)
Bucket In 392 bar
Table 2. Bucket Out 392 bar
Main pumps 2 variable displacement axial piston Boom Up 392 bar
Max. Flow 2 x 110 l/min Boom Down 264 bar
Servo pump Gear type Track motor 353 bar
Swing speed 12.9 ± 10% Rev/min.
Max. Flow 21 l/min A separate restriction valve in the system provides smooth
operation of the boom and dipper spools selection.

Track Motor
Table 4.
Type Fully hydrostatic
Travel motors Axial piston type, fully guarded within
undercarriage frame
Final drive Planetary reduction, bolt-on
sprockets
Service brake Hydraulic counter balance valve to
prevent over-speeding on gradients
Park brake Disc type, spring applied, automatic
hydraulic release
Grade ability 70% (35 deg.) continuous
Tractive effort 164.7 KN
Travel speed Single, 4 Km/h

E-1 9813/0400-1 E-1

 Section E - Hydraulics
Technical Data
General Data

Filtration Controls
The hydraulic components are protected by the highest Table 6.
standard of filtration to ensure long hydraulic fluid and Excavator All servo lever operated.
component life K Table 5. ( T E-2).
Tracks Servo operated by foot pedal or hand
lever.
Table 5.
In tank 150 Micron, suction strainer Control Via gate lock lever at cab entrance or
isolation panel switch.
Main return line 10 Micron
Engine speed Easy Pull type with mode change
Plexus bypass line 1.5 Micron control.
Pilot line 10 Micron Engine stop Ignition key operated.
Horn Operated via servo lever mounted
Hydraulic Cylinders button.

Double acting type, with bolt-up end caps and hardened

steel bearing bushes. End cushioning is fitted as standard
on boom and dipper. EMS bushes at boom mtg. and
Dipper mtg. allows greasing at every 1000 hrs K Table 4.
( T E-1).

Cab
Pressed steel with high strength rolled section frame. All
tinted safety glass windows with fully opening two-piece
windscreen and in screen stowage. Gas strut assisted.
Opening door windows. Fan forced fresh air ventilation
Fully adjustable deluxe suspension seat with armrest and
back rest recline. Radio cassette player with digital tuning
as an optional.

ECU4 Control
2-Modes i.e. “E” Economy & “P” Power mode operational.

ECU4 allows the fool proofing of the hour meter recording,

at gauge and itself by ECU4 K Table 6. ( T E-2).

E-2 9813/0400-1 E-2

 Section E - Hydraulics

Basic System Operation

Introduction to Hydraulic Schematic Symbols
TE-001

General (Basic and Functional Symbols) Table 2. Rams

Complex hydraulic components and circuits can be Single acting

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.
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 Double ended
required you are recommended to obtain a copy of
BS2917 or IS01219.
Double acting with damping
Once familiar with the symbols, the engineer can use at rod area end
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 3. Pumps and Motors
Table 1. General
Variable capacity pump two
Spring directions of flow

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

Indication of direction and direction of flow
paths of flow

Variable capacity motor two

Variable control directions of flow

E-3 9813/0400-1 E-3

 Section E - Hydraulics
Basic System Operation
Introduction to Hydraulic Schematic Symbols
Table 4. Control Valves

Used to enclose several Throttling orifice - normally

valves indicating they are closed
supplied as one unit

3-Position, 4-port spring Throttling orifice - normally

centered pilot operated valve 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 Variable restrictor
operated valve

Non-return valve

Non-return valve with back

pressure spring

Pilot operated non-return

valve

One way restrictor

High pressure selector

(shuttle valve)

E-4 9813/0400-1 E-4

 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
Cooler - with no indication of
Line plugged, also pressure coolant flow
test point

Line plugged with take off line Cooler - indicating direction

of coolant flow

Quick release couplings -

connected
Heater
Quick release couplings -
disconnected

Reservoir - return line above

fluid level

E-5 9813/0400-1 E-5

 Section E - Hydraulics
Basic System Operation
Introduction to Hydraulic Schematic Symbols
Table 6. Control Mechanisms
Solenoid one winding
Rotating shaft - one direction

Rotating shaft - two directions Solenoid two windings

Detent Electric motor operated

M

Locking device 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-6 9813/0400-1 E-6

 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-7) 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.

It must be noted that not all spools are of the same type.
Fig 1.
Their operating designs can be seen by following the path
the flow arrows take in their respective operating squares.
K Fig 2. ( T E-7) - In circuit diagrams the pipework is
usually shown connected to the box which represents the
Three typical JCB style spools are known as 'D' spools, 'F'
unoperated condition. (Hydraulic circuit diagrams are
spools and 'N' spools.
usually shown in the unoperated condition).
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-7) shows a 'D' type spool.

K Fig 5. ( T E-7) - '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
Fig 2. detent, connects both sides of the ram together to allow the
service to 'float'.
K Fig 4. ( T E-7) 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.

Fig 5.

K Fig 6. ( T E-7) - '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-7).

If the valve spool was moved to Position 3, movement of

the spool would connect Port P1 to Port P4, and Port P3 to Fig 6.
Port P2. K Fig 4. ( T E-7).

E-7 9813/0400-1 E-7

 Section E - Hydraulics
Basic System Operation
Introduction to Hydraulic Schematic Symbols

Example of Schematic Circuit

A
B

C G
D E

Fig 7. Simple Schematic Circuit

Some of the symbols described on the preceding pages Example Circuit Key
have been arranged into a simple schematic circuit.
K Fig 7. ( T E-8).
7-A Hydraulic Tank
Hydraulic tank 7-A is a pressurised tank with an internally 7-B Strainer
mounted strainer 7-B on the suction line to the fixed 7-C Fixed Displacement Pump
displacement pump 7-C. System pressure is limited to the
setting of relief valve 7-D. 7-D Relief Valve
7-E Spool
Valve spool 7-E is an open-centre spool that is in neutral 7-F One Way Valve
position; flow from the pump passes through the spool and
returns to the hydraulic tank. 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-8 9813/0400-1 E-8

 Section E - Hydraulics

Circuit Descriptions
Hydraulic Schematic

JS200 Item Part number Description

29 229/01003 Solenoid Valve
The item numbers in the following table are identified on
the Hydraulic Schematic diagrams. K Fig 1. ( T E-11) 30
31 JHJ0050U-A Accumulator
Table 1. Component identification
32
Item Part number Description
33 32/925214 Line Filter
1 20/925315 Slew Motor
34 229/01000 Hyd Pump
2 229/00570 Arm Ram
35 KSJ2465 Remote Control Valve
3
36* 928/60209 Remote Control Valve
4 229/01002 Travel Motor
37 229/01004 Check Valve
5 45/920020 Centre Joint
38
6 229/00573 Bucket Ram
39 25/220836 Remote Valve
7 229/00484 Boom Ram
40
8 229/00484 Boom Ram
41
9
42* JLV0535 Quick Release Coupling
10 229/01001 Valve Control
43* JBJ0037 Valve C/over
11
44* JBJ0038 Relief Valve
12
45* JBJ0066Y-C Line Filter
13 KNJ0287U Main Control Valve
46
14 KRJ3823 Check Valve
47
15 KRJ3515U-A Check Valve
48 JHV0195 Quick Release Coupling
16 30/925515 Radiator
49
17 229/010006 Slew Gearbox
50
18 KRJ4235Y-A Air Breather
51 25/220837 Remote Valve RH
19 215/11191 Sump Tank
52
20
53
21 32/925359 Strainer
22 KRJ2246Y-A Relief Valve * Option
23 KRJ3836Y-A Return Filter
24 KHJ0897Y-A Stop Valve
25 JRJ0238 Plexus Filter
26
27
28

E-10 9813/0400-1 E-10

 Section E - Hydraulics
Circuit Descriptions
Hydraulic Schematic
Fig 1. 229/01100 issue 4
E-11 9813/0400-1 E-11
 Section E - Hydraulics
Circuit Descriptions
Servo/Pilot Line

Servo/Pilot Line

Components
1 Centre Joint

2 Slew Motor

3 Solenoid Valve

4 Main Pump

5 Cab Manifold

6 Tank Manifold

7 Main Control Valve

8 Pilot Pump

Hose Colour
BL Blue
BR Brown
CI Colourless
G Green
GR Grey
LB Light Blue
O Orange
P Pink
R Red
V Violet
W White
Y Yellow
LG Light Green
DG Dark Green

Oil from the servo pump is filtered and passes to the pilot
valve and Pp port of the main control valve. Oil is stopped
at the pilot valve if the hydraulic control is locked by the
Hydraulic Lever and Rocker Switch lock solenoid and P1
port of the cab Manifold. From the cab Manifold oil is
available to the P port of the LHS/RHS joysticks and Travel
valve. When any service selected, oil is supplied to the
respective spools of the main control valve.
K Fig 2. ( T E-13)

E-12 9813/0400-1 E-12

E-13

DR2
DR4 Ps1 Ps2
DR1

Pi2

Pp
BACK RIGHT
W/BL FRONT PH LEFT

5 T T7 T1 P1

6
T
T
T1 T2 T3 T4 T5 T6 T7 T8
2
P
-
-
- -
1 -
T
P
9813/0400-1

- - -
-
C2 C3

ACC
3 T2

P2

P1
-
- Ps1 Ps2 Pp Dr1 Dr2

Section E - Hydraulics
Pt Pa Pr
-
-

Circuit Descriptions
R
8
Pt2 Pt1 Pf

Servo/Pilot Line
Psv

Fig 2. Servo/Pilot Line Schematic 229/01272 issue 6

E-13
 Section E - Hydraulics
Circuit Descriptions
Servo/Pilot Pressure and Return Line

Servo/Pilot Pressure and Return Line

Components
1 Right joystick

2 Left joystick

3 Cab manifold

4 Pilot check valve

5 Main control Valve

Hose Colour
BL Blue
BR Brown
CL Colourless
G Green
GR Grey
LB Light Blue
O Orange
P Pink
R Red
V Violet
W White
Y Yellow
LG Light Green
DG Dark Green

E-14 9813/0400-1 E-14

E-15

Y O/W
CL

W G

O/W
1 4
R BL O/G
O BL
9813/0400-1

V BL/GR P
O/R
2
O BL/W
6
W O
P
CL

Servo/Pilot Pressure and Return Line

3

Section E - Hydraulics
CL LB

Y/G

Circuit Descriptions
W GR

Fig 3. Servo/Pilot Pressure and Return Line Schematic 229/01271 issue 5

E-15
 Section E - Hydraulics
Circuit Descriptions
Component Location

Component Location

Note: The illustration(s) show a typical machine model; 25 Engine Oil Pan
your machine may look different from the model shown.
26 Servo (Pilot Line) Filter
1 Bucket
27 Main Fuel Filter/Sedimenter
2 Bucket Link
28 Engine Oil Filter
3 Dipper Link
29 Return Filter
4 Bucket Ram
30 Suction Filter
5 Dipper
31 Drain Line Filter
6 Tipping Ram
32 Air Filter
7 Boom
33 Slew Ring
8 Boom Ram
34 Plexus Filter
9 Operators Cab
35 Breaker Filter
10 Hydraulic Tank Breather
36 Counterweight
11 Fuel tank
37 Primary Fuel Filter/Sedimenter
12 Hydraulic Oil Tank

13 Engine

14 Main Valve Block

15 Slew gearbox

16 Battery

17 Air Pre Cleaner (option)

18 Track Plate

19 Track Gearbox

20 Lower Roller

21 Upper Roller

22 Recoil Spring

23 Idler Wheel

24 Front Attachment Pin

E-16 9813/0400-1 E-16

 Section E - Hydraulics
Circuit Descriptions
Component Location

Fig 4.

Fig 5.

E-17 9813/0400-1 E-17

 Section E - Hydraulics
Circuit Descriptions
Neutral Circuit

Neutral Circuit

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-19)

E-18 9813/0400-1 E-18

E-19

P S1 T3 T1 D1 D2 T2 P S2

P C1

A5
B5
ARM(1) f ARM(2)
P b5 a P b9

P a9

a 3
P c2
A1 Psv A2
P a5 A8
P c3
B8
a 1 a 2

(FRONT) (REAR)
P b4
BOOM(2) b g BOOM(1) P b8

P a4 P a8
B7
SWING
P b3 c BUCKET A 7
h P b7
9813/0400-1

Pm 1 Pm 2 P a3

P i2 P a7
Pt 1 Pt 2 Dr4
B2 B6
A2 TRAVEL(R) A
6

A1 A2 P b2
OPTION d i P b6
M P4
P a2 P a6
B1
a 4

A 1 TRAVEL(L) k
P b1 e
Dr B1 B3 A3
P a1

P1 PT PP PA PH P3 P2

Section E - Hydraulics
Keyto Oil Flow & Pressure

Full Pressure
Pressure
Servo

Circuit Descriptions
Neutral
Exhaust
Cavitation
Lock Up

Fig 6. Neutral Circuit

Neutral Circuit
E-19
 Section E - Hydraulics
Circuit Descriptions
Travel - Single Speed

Travel - Single Speed

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 K Fig 7. ( T E-21).

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 into 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.

E-20 9813/0400-1 E-20

E-21

P S1 T3 T1 D1 D2 T2 P S2

P C1

Keyto Oil Flow & Pressure A5

B5
Full Pressure ARM(2)
P b5
ARM(1) a f P b9
Pressure
Servo
Neutral P a9

Exhaust P c2
Cavitation P a5 A8
Lock Up P c3
B8
BOOM(1)
P b4
BOOM(2)
b g P b8

P a4 P a8
B7
SWING A7
P b3 c BUCKET
h P b7
P a3

P i2 P a7
Dr4
B2 A6
A2 OPTION P b6
P b2 d i
P4
TRAVEL(R)
P a2 P a6
B1
A1 k
P b1 e
9813/0400-1

P a1 TRAVEL(L)

R2

R3 R1
P1 PT PP PA PH P3 P2

A1 A2

Section E - Hydraulics
Circuit Descriptions
1 2 T P 4 3

Travel - Single Speed

Fig 7. Travel Circuit
E-21
 Section E - Hydraulics
Circuit Descriptions
Straight Line Travel

Straight Line Travel

Refer to Travel speed for travel circuit servo function and

Boom Up for servo function of Boom up. Servo pressure
entering at port Pp on the main control valve 10 is blocked
by the Travel spool and Boom (2) spool, this causes back
pressure which selects the travel 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
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 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 onto full flow
K Fig 8. ( T E-23).

E-22 9813/0400-1 E-22

E-23

P S1 T3 T1 D1 D2 T2 P S2

Keyto Oil Flow & Pressure

P C1
Full Pressure
Pressure A5
Servo B5
Neutral P b5
ARM(1) a f ARM(2) P b9
Exhaust
Cavitation P a9
Lock Up
P c2
P a5 A8
P c3
B8
BOOM(2)
b g P b8
P b4
BOOM(1)
P a4 P a8
B7
SWING BUCKET A 7
P b3 c h P b7
P a3
P i2 P a7
Dr4
B2 B6
A2 A6
P b2
OPTION d i P b6
P4
TRAVEL(R)
P a2 P a6
B1
A1 k
P b1 e
9813/0400-1

P a1 TRAVEL(L) LINEARTRAVEL

P1 PT PP PA PH P3 P2

A1 A2

Section E - Hydraulics
Circuit Descriptions
Straight Line Travel
Fig 8. Straight Line Travel Schematic
E-23
 Section E - Hydraulics
Circuit Descriptions
Boom Up

Boom Up

For schematic, K Fig 9. ( T E-25).

Servo pressure from the hand controller enters the servo

restriction valve and is divided between the Boom (1) spool
valve port Pa8 and the boom (2) spool on the main control
valve 10. The servo restriction valve provides a smoothing
effect to the service circuits.

Flow from pump A2 is stopped by the Boom (1) spool and

diverted via the parallel gallery 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 diverted via the parallel
gallery 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 its seat
allowing oil to leave the main control valve at port B8 to
enter the Boom rams 7 and 8. Exhaust oil enters the Main
control PS1and P2 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 come onto full
flow.

E-24 9813/0400-1 E-24

E-25

6 6
P S1 T3 T1 D1 D2 T2 P S2

C2 C2
C2 C2

P C1

A5
B5
ARM(2)
P b5
ARM(1) a f P b9
V2 E BL P P BL E V2

P a9

P c2
P a5 A8
P c3
B8
BOOM(2)
P b4 b g P b8
BOOM(1)
P a4 P a8
B7
SWING c A7
P b3 h BUCKET P b7
P a3
P i2 P a7 P T
Dr4
B2 B6
A2
i TRAVEL(R) A 6
P b2
OPTION d P b6
P4
9813/0400-1

P a2
P a6
B1
A 1 TRAVEL(L) k BUCKET BOOM
P b1 e OPEN CLOSE UP DOWN
1 3 2 4
P a1

P1 PT PP PA PH P3 P2

A1 A2

Section E - Hydraulics
Keyto Oil Flow & Pressure

Full Pressure
Pressure
Servo

Circuit Descriptions
Neutral
Exhaust
Cavitation
Lock Up

Fig 9. Boom Up Schematic

Boom Up
E-25
 Section E - Hydraulics
Circuit Descriptions
Boom Down

Boom Down

Servo pressure from the Hand controller enters the Servo

Shuttle valve 30 at port A4 and is distributed to:

1 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.

2 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.

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 gallery to the Boom
(1) spool and is directed to the Boom rams 6 via port B8.
Exhaust oil passes through to the Main control valve at 10
port A8, lifts the Boom Holding Valve BHV off its 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. The restrictor creates back pressure,
causing the check valve to open K Fig 10. ( T E-27).

E-26 9813/0400-1 E-26

E-27

T2 P S2

ARM(2)
f P b9

P a9

P c2
A8

B8

g BOOM(1)
P b8

P a8
B7
A7
h BUCKET
P b7

P a7

B6

Keyto Oil Flow & Pressure i TRAVEL(R) AP 6

b6

Full Pressure P a6

Pressure
k
Servo
Neutral P T

Exhaust
9813/0400-1

Cavitation
Lock Up
P3 P2

BUCKET BOOM
OPEN CLOSE UP DOWN
1 3 2 4

A1 A2

Pm2

Section E - Hydraulics
Fig 10. Boom Down Schematic

Circuit Descriptions
Boom Down
E-27
 Section E - Hydraulics
Circuit Descriptions
Dipper Out

Dipper Out

Servo pressure from the Hand controller 39 is sent directly

to port C3 and port Pa 9 of the main control valve 10, to
activate the dipper spool, and through restriction valve to
port Pa5 on the main control valve 10, 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 gallery. 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-29).

E-28 9813/0400-1 E-28

E-29

Keyto Oil Flow & Pressure

T
Full Pressure
4
C2
C2
Pressure
Servo M
D D
Neutral
Exhaust
Cavitation
P BL E V2
Lock Up P S1 T3 T1 D1 D2 T2 P S2

P C1

A5
B5 ARM(2)
ARM(1)
P b5 a f P b9

P a9

P c2
P a5 A8
P c3
B8
BOOM(1)
P b4
BOOM(2) b g P b8
P T
P a4 P a8
B7
SWING c A7
h BUCKET
9813/0400-1

P b3
P b7

SWING ARM P a3
LEFT RIGHT IN OUT P i2 P a7
1 2 3 4
Dr4
B2 B6
A2 A6
P b2
OPTION
d i TRAVEL(R) P b6
P4
P a2 P a6
B1
LINEARTRAVEL
A 1 TRAVEL(L) k
P b1 e
P a1

P1 PT PP PA PH P3 P2

Section E - Hydraulics
Circuit Descriptions
A1 A2

Dipper Out
Fig 11. Dipper Out Schematic
E-29
 Section E - Hydraulics
Circuit Descriptions
Dipper In

Dipper In

Servo pressure from the Hand controller 39 is distributed

to C4 Port Pb9 on the Main control valve. From the out port
of the restriction valve, it flows to port Pb5 and port Pc1 on
the Main control valve 10 and to the Dipper (1) spool and
the dipper load hold check valve DHV respectively.

Flow from pump A1 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 gallery. At the
Dipper spool flow is diverted to the Dipper ram 2. Pressure
is sensed at the regeneration spool RGS and moves it to
the lesser restricted position.

Flow from pump A2 is blocked at the Dipper (2) spool and

joins the flow of pump A1 just after the Dipper (1) spool.

Exhaust oil from the ram passes to the Main control valve
10 at port A5 through Dipper hold check valve DHV (that
has been released by servo pressure) to the Dipper (1).
This 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 restrictive than the other. The
restrictors cause back pressure, encouraging the
regeneration check valve to open. As the pressure drops
the regeneration spool moves across to the more
restricted position. When the feed pressure is greater than
the exhaust pressure the regeneration check valve will
close.

Exhaust oil from the Dipper (1) spools travels over

restrictors R2 and R 3 and to tank via the unselect travel
spool K Fig 12. ( T E-31).

E-30 9813/0400-1 E-30

E-31

Keyto Oil Flow & Pressure

Full Pressure
Pressure
Servo
Neutral
Exhaust
P S1 T3 T1 D1 D2 T2 P S2
Cavitation
Lock Up

P C1

A5
B5

P b5
ARM(1) a f ARM(2)
P b9

P T P a9

P c2
P a5 A8
P c3
B8
BOOM(1)
b g P b8
P b4
SWING ARM
BOOM(2)
LEFT RIGHT IN OUT P a4 P a8
1 2 3 4 B7

P b3 c h BUCKET
A7
P b7
SWING
P a3
P i2 P a7
Dr4
9813/0400-1

B2 B6
A2 TRAVEL(R) A 6
P b2
OPTION d i P b6
P4
P a2 P a6
B1
A 1 TRAVEL(L) k
P b1 e
P a1

R2

R3 R1
P1 PT PP PA PH P3 P2

P C1
DHV

Section E - Hydraulics
A5
B5 A1 A2

ARM(1)
P b5

Circuit Descriptions
RG
RGS

Fig 2

Dipper In
Fig 12. Dipper In Schematic
E-31
 Section E - Hydraulics
Circuit Descriptions
Bucket Opening

Bucket Opening

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 gallery. At the spool the flow is diverted to port B7
of the Main control valve 10 to the Bucket ram 6. Returning
oil enters the Main control valve 10 at port A7 and is
diverted by the Bucket spool to the tank. Pressure in the
neutral circuit drops after the Bucket spool is selected. This
is sensed at the port Ps2 and at the pump, bringing it onto
full flow K Fig 13. ( T E-33).

E-32 9813/0400-1 E-32

E-33

D1 D2 T2 P S2
Keyto Oil Flow & Pressure

Full Pressure
Pressure
Servo
Neutral
Exhaust
Cavitation
Lock Up
f ARM(2) P b9

P a9

P c2
A8

B8
g BOOM(1)
P b8

P a8
B7
BUCKET A 7
h P b7
9813/0400-1

P a7 P T

B6
TRAVEL(R) A 6
i
P b6
BUCKET BOOM
CLOSE OPEN DOWN UP
1 2 3 4
P a6

Section E - Hydraulics
PT PH P3 P2
PP

Circuit Descriptions
A2

Bucket Opening
Fig 13. Bucket Opening Schematic
E-33
 Section E - Hydraulics
Circuit Descriptions
Bucket Closing

Bucket Closing

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 gallery. Flow is diverted to port A7 of the Main
control valve to the Bucket ram 6.

Returning oil from the Bucket ram enters the Main control
valve at port B7 and is diverted to tank by 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 K Fig 14. ( T E-35).

E-34 9813/0400-1 E-34

E-35

Fig 3
BUCKET
P S1 T3 T1 D1 D2 T2 P S2

P C1

A5
B5
Keyto Oil Flow & Pressure
P b5
ARM(1) a f ARM(2) P b9
Full Pressure
P a9 Pressure
Servo
P c2
Neutral
P a5 A8
Exhaust
P c3
B8 Cavitation
P b4
BOOM(2) b g BOOM(1) P b8 Lock Up

P a4 P a8
B7
SWING c A7
P b3 h BUCKET
P b7
P a3
P i2 P a7
D r4
9813/0400-1

B2 B6
A2 A6
P b2
OPTION d i TRAVEL(R)
P b6
P4
P a2 P a6
B1
A 1 TRAVEL(L) k
P b1 e
P a1

P1 PT PP PA PH P3 P2

P T

Section E - Hydraulics
BUCKET BOOM

Circuit Descriptions
CLOSE OPEN DOWN UP
A1 A2 1 2 3 4

Bucket Closing
A406070

Fig 14. Bucket Close Schematic

E-35
 Section E - Hydraulics
Circuit Descriptions
Swing

Swing

When Ignition is ON, the swing lock solenoid is energized

and allows 40 bar pressure to go to the swing brakes to
release them. The machine is still locked hydraulically.

Servo pressure from the Hand controller 51 enters port B2

to the slew spool at port Pa3 on the Main control valve 10
to move the spool across. Flow from the pump A1 is
stopped in the neutral gallery by the slew spool. The flow
passes through the linear travel into the parallel gallery to
the slew spool. The spool 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 and to tank through a restriction K Fig 15. ( T E-37).

E-36 9813/0400-1 E-36

E-37

Key to Oil Flow & Pressure

Full Pressure
Pressure
Servo
P
Neutral
Exhaust
Dr Cavitation
Lock Up

P S1 T3 T1 D1 D2 T2 P S2

P C1

Mu A5
B5
RIGHT B A LEFT
ARM(1) ARM(2)
P b5 P b9

P a9

P c2
SDV A8
oil servo pump P a5
P c3
B8
BOOM(2) BOOM(1)
P b4 P b8

P a4 P a8
9813/0400-1

B7
P b3 A7
BUCKET
P b7
SWING
P a3
P i2 P a7
Dr4
B2 B6
A2 A6
OPTION TRAVEL(R)
P b2 P b6
P4
P a2 P a6
B1
A 1 TRAVEL(L)
P b1
P a1

Section E - Hydraulics
P1 PT PP PA PH P3 P2

SWING

Circuit Descriptions
LEFT RIGHT A1 A2

Fig 15. Slew Circuit

Swing
E-37
 Section E - Hydraulics

Main Control Valve

Description

For location diagram K Fig 1. ( T E-39). For Schematic K Fig 2. ( T E-40).

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
F2 Boom over Slew
G Blank
H -
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-38 9813/0400-1 E-38

E-39

E
K

N6 R
O
K5 E4
N1 F
N7
K7
K6 E5
N2
N8

N3 F2
N9
H2
N4 E6
N10 H3
K8 B
N5 E7 A
S C D
V2
P1

Q2
9813/0400-1

M
N L

N1 E1
E
N6
K1 K3
N2 E2
L
N7
N3 L1 F1
K2
N8 F
K
N4 E3
K4
N9
N5 G
N V1
Q

Section E - Hydraulics
N10
J1 J2 J3
Q1 I
P2

Main Control Valve

H1

Description
Fig 1. Main Control Valve
E-39

For description, K Main Control Valve ( T E-38).

 Section E - Hydraulics
Main Control Valve
Description

P s1 T3 T1 D1 D2 T2 P s2

A C

P C1 L1
A5
L1
B5 K7 N6
DIPPE
R2
P b5
Dipper D P b9
K1
N E1
P a9
M L2
P c2
P a5
E4 R B L2 A8

P c3
B8
BOOM(2) N2 O K3 K5 BOOM(1)
P b4 P b8

P a4 E5 N7 P a8
N3 K4 B7
SWING A7
P b3 K6 BUCKET
P b7

P a3 F2 N8 P a7
P i2
D r4
B2 B6
N9
A2
P b2
OPTION N4 K8 TRAVEL(R)
A6
P b6
V2 P4 K2
P a2 E6 E3 P a6
B1
E7 N10
A 1 TRAVEL(L) N5
P b1
P a1

J2 I
J1 J3
P1 PT PP PA PH P3 P2

V1
Fig 2. Main Control Valve Schematic

E-40 9813/0400-1 E-40

 Section E - Hydraulics
Main Control Valve
Description

9 10

11
8
12

7
pb9 pb5 13

6 pb8 pb4
14

pb7 pb3 15
5

pb6 pb2
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-42).

E-41 9813/0400-1 E-41

 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
9
10 pc3 Slew over Dipper Priority Valve
11 Shuttle Valve
12 pb5 Dipper (1) In Spool
13 ARV Dipper In
14 pb4 Boom 2 Up Spool
15 pb3 Slew Right Spool
16 ARV Option
17 pb2 Option Spool
18 pb1 Travel (L) Backwards Spool

For port location, K Fig 3. ( T E-41).

E-42 9813/0400-1 E-42

 Section E - Hydraulics
Main Control Valve
Description

25 26 27 28
29

30
T1
ps1

31
24 B5
A5

B4 32
23

B3 A3
33
22 Pi2

21
B2 P4 A2

B1 A1 PT
20

PA 34
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-44).

E-43 9813/0400-1 E-43

 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 Load Hold Check Valve
27 ps1 Negative Control Port
28 Load Hold Check Valve
29 A5 Dipper out
30
31
32 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
39 Load Hold Check Valve (Travel)
40 P4 Merge In (if fitted)

For port location, K Fig 4. ( T E-43).

E-44 9813/0400-1 E-44

 Section E - Hydraulics
Main Control Valve
Description

51 52

50 53
T3

54

49 DR1
pa5 pa9
55
48
pc1 56
47
pa4 pa8
46 pc2 57

45 pa3 pa7 58

pa2 pa6

44 59
pa1
43 60
PA PORT
PP
1
pr 61
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-46)

E-45 9813/0400-1 E-45

 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 Swing Left Spool
46 DR2 Drain (Slew over Dipper Priority)
47 AVR Dipper Out
48 pa4 Tank
49 pc1 Dipper Holding Valve
50 pa5 Dipper Out Spool
51 Blank
52 T3 Tank
53 DR1 Boom Hold Drain
54 pa9 Dipper In Spool
55 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-45).

E-46 9813/0400-1 E-46

 Section E - Hydraulics
Main Control Valve
Description

70 71 72

73
69

74
ps2 pc3
T2

75
68

A8 B8 76
67 pc2

A7 Pi1 B7

77
A6 B6
78

P3
79
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-48)

E-47 9813/0400-1 E-47

 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 -
77 B7 Bucket Open
78 Drain (Boom over Bucket)
79 B6 Travel (R) Backwards
80 Travel (R) load hold valve
81 P3 Merge Port Out
82 P2 Pump 2

For port location, K Fig 6. ( T E-47).

E-48 9813/0400-1 E-48

 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 Blank
84 Ps1 Negative control Valve
85 Restrictor
86 Ps2 Negative control Valve
87 Shuttle Valve
88 DR4 Drain (Slew over Dipper Priority)

For port location, K Fig 7. ( T E-49).

E-49 9813/0400-1 E-49

 Section E - Hydraulics
Main Control Valve
Description

DR3

89 A405980

Fig 8. Main Control Valve viewed from below machine

Table 6. Port Identification

Item Port Function
88 Dr3 Drain (Boom, Bucket)

For port location, K Fig 8. ( T E-50).

E-50 9813/0400-1 E-50

 Section E - Hydraulics

Hydraulic Pump/Regulator
Hydraulic Pump Operation
TE-029_2

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 6
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
5
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. 18
4
The swash plate group consists of the swash plate 10,
shoe plate 6, swash plate support 9 bush 2 pin 3 and servo 17
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 16
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
15
spherical portion of the pin, to press on the swash plate
support and changes the angle of the swash plate.
14
The valve cover group comprises of the valve block 17, 13
valve plate 13 and valve plate pin 18. The valve plate, 3
which has two oval shaped ports, is on the valve block and
12
delivers oil to and recovers oil from the cylinder block. The
oil directed by the valve plate flows through the valve block 2 11
and is connected to the outer piping.

1 10
When the drive shaft is driven by the engine, the cylinder
block rotates simultaneously with the spline coupling. 9
When the swash plate is leaning, the piston in the cylinder
block rotates simultaneously with the cylinder block and 8
causes reciprocal motion relative to the cylinder.

Therefore, during one rotation, the piston moves away 7

from the valve plate for 180° (enough for oil suction) and
A406500-1
approaches the valve plate for the remaining 180°. When
Fig 1.
the swash plate leaning angle is at the minimum 5° the
piston does not stroke and does not deliver oil.

E-52 9813/0400-1 E-52

 Section E - Hydraulics
Hydraulic Pump/Regulator
Hydraulic Pump Operation

Pump Hydraulic Circuit Diagram

A1 A2
a1 a2

Pi1 Pi2

Pm1 Pm2

a4

M
Psv

A3

Dr B1 B3 a3

C077790
Fig 2.

Table 1. Key
A1,2 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

E-53 9813/0400-1 E-53

 Section E - Hydraulics
Hydraulic Pump/Regulator
Hydraulic Pump Operation

Hydraulic Pump/Regulator Exploded View

4 3

2
24
26
27

25
31

22 5

21
16 17 15 14
14 16
32 30
20

X 8 32A
16

29 17A
28 5A
9 22A
12
31 10

19 1
23
13
11
18
803230
Fig 3.

E-54 9813/0400-1 E-54

 Hydraulic Pump/Regulator Plan View
E-55

Pi1 Pm1 P1 P1

Dr Pm2 Pi2
9813/0400-1

Pi2

B3
CLOCKWISE

A3

Hydraulic Pump/Regulator
Section E - Hydraulics
Hydraulic Pump Operation
A1 a1 A1 A2 a3 a2 A2
A357730-C2
Fig 4.
E-55
 Section E - Hydraulics
Hydraulic Pump/Regulator
Hydraulic Pump Removal and Replacement

Hydraulic Pump Removal and Replacement

Removal
2
!MWARNING
Hydraulic Pressure 7
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.
INT-3-1-11_2
3
!MWARNING
This component is heavy. It must only be removed or
handled using a suitable lifting method and device.
BF-4-1_1

1 Make the machine safe, refer to Section E, Service

procedures.

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 C080180
ensure correct position when refitting. Fig 5.

4 Disconnect electrical connection to proportion 8 Remove rubber flange 5 from pump coupling 4 by
solenoid on hydraulic pump. removing the two retaining bolts 6.

5 Attach lifting eyes to the pump. Support weight of the 9 Loosen the two grub screws on the pump coupling 4.
pump with suitable lifting apparatus, refer to Section Withdraw pump coupling from the pump's splined
E, Technical Data. shaft.

6 Remove engine exhaust muffler bracket from pump 10 Support the weight of the pump flange 2. Remove
flange 2 by removing three set pins 3. Remove the four cap screws 7 from the flange and pump. Remove
remaining nine set pins 3 and washers from pump flange from pump.
flange 2.
11 Remove the four studs 8 from the engine.
7 Withdraw the pump clear of the engine. When clear of
engine, lift pump clear of machine.

E-56 9813/0400-1 E-56

 Section E - Hydraulics
Hydraulic Pump/Regulator
Hydraulic Pump Removal and Replacement

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
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.
– The bevelled edge of the pump coupling 4 must be
fitted facing the pump.
– To prevent the rubber flange 5 from twisting on
installation, apply a small amount of lubricant to the
under face axial and radial screws
– Locate the rubber flange 5 of the pump into the four
engine studs 8.
– Before fastening pump flange 2 to engine, make sure
the mating surfaces are fully together.
– Apply JCB Threadlocker to bolts 3 and 6.
– Fill the pump casing inside fully with oil and operate
at low engine revs with no services selected for 3
minutes.

!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses and gloves.
Hold a piece of cardboard close to suspected leaks
and then inspect the cardboard for signs of fluid. If
fluid penetrates your skin, get medical help
immediately.
INT-3-1-10_3

– 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.

E-57 9813/0400-1 E-57

 Section E - Hydraulics
Hydraulic Pump/Regulator
Hydraulic Pump Dismantling and Assembly

Hydraulic Pump Dismantling and Assembly

The working environment must be clean and the

workbench covered with a cloth or rubber sheet to prevent 3
damage to the components.

The illustration opposite shows both halves of the tandem 2

double axial piston pump, but the procedures refer mostly
to Pump 1. These procedures should also be applied to
Pump 2 except where indicated otherwise.

Note: The components from one pump section must not

be mixed up with the corresponding components from the 4
other section and should be returned to the section from
which they came.

The item numbers called up in the following procedures

correspond with those in the exploded view.
K Fig 3. ( T E-54).
5

Dismantling
Before dismantling, the pump ports should be plugged and
the external surfaces thoroughly cleaned to prevent the
ingress of dirt into the pump mechanism.

1 Remove drain plug 1 and let the oil drain into a 379380-C1
Fig 6.
suitable receptacle.
3 Remove the four socket head screws 7.
2 As an aid to re-assembly, match mark the mating
flanges of regulator 4 and pump casing 5. Remove
socket head screws 2 and 3 (2 off each) and lift off the
regulator. Put the regulator to one side in readiness
for dismantling if required. K Dismantling ( T E-64).
7

8 5
379540-C1
Fig 7.

E-58 9813/0400-1 E-58

 Section E - Hydraulics
Hydraulic Pump/Regulator
Hydraulic Pump Dismantling and Assembly
4 Place the pump on the workbench with its regulator
mounting face downwards. Match mark the mating
flanges of pump casing 5 and valve block 8. Separate
the pump casing from the valve block.

5 Remove the piston/cylinder assembly Z comprising

cylinder 9, piston assemblies 10, set plate 11,
spherical bush 12 and cylinder springs 13 from pump
casing 5. Take care not to damage the sliding
surfaces of the components.

379560-C2
Fig 9.

7 Match mark the mating flanges of swash plate

support 17 and pump casing 5. Separate the swash
plate support from the pump casing by lightly tapping
the support around its flange using a plastic hammer.
Z
379550-C1
Fig 8.

6 Remove screws 14 and then remove servo pump X

(Pump 1) or seal cover 15 (Pump 2), taking care not 5A (5)
to damage the oil seal 16. This task can be simplified
by inserting a pull-out bolt into the tapped hole in the
cover.

17A
(17)

379570-C1
Fig 10.

8 Remove shoe plate 18 and swash plate 19 from pump

casing 5.

E-59 9813/0400-1 E-59

 Section E - Hydraulics
Hydraulic Pump/Regulator
Hydraulic Pump Dismantling and Assembly

18 8
19

379580-C1
Fig 11.

9 Pump 1

Remove snap ring 20 and bearing spacer 21. Using a

plastic hammer, gently tap shaft 22 out of its support 23
bearing 32 to remove it from swash plate support 17. 379600-C2
Fig 13.
Pump 2
11 If necessary, remove plugs 24 and 25, servo piston 26
Gently tap shaft 22A, at the end nearest the mating and tilting pin 27 from pump casing 5.
flange of valve block 8, to separate it from swash
plate support bearing 32A. Note: When removing the tilting pin use a protector to
prevent damage to the pin head. Also take care not to
damage the servo piston as a result of the JCB
Threadlocker used to secure it.

32A 12 Remove needle bearings 28 and splined coupling 29

from valve block 8. K Fig 3. ( T E-54).

Note: Do not remove the needle bearing assembly unless

22A it needs renewing.

Note: To avoid the risk of changing the flow settings, do

not loosen nut 30 in valve block 8 or nut 31 in swash plate
support 17. K Fig 3. ( T E-54).
17A

379590-C1
Fig 12.

10 Remove valve plate 23 from valve block 8.

E-60 9813/0400-1 E-60

 Section E - Hydraulics
Hydraulic Pump/Regulator
Hydraulic Pump Dismantling and Assembly

Assembly
Before assembling:
17
a Thoroughly clean all components with clean 5
hydraulic oil and dry with compressed air.

b Apply clean hydraulic oil to all sliding surfaces,

bearings, etc. 19

1 If previously removed from pump casing 5, install

tilting pin 27 and servo piston 26. Use a protector to
prevent damage to the tilting pin head and feedback
pin.

2 Take care to align the flange match marks and then fit
swash plate support 17 to pump casing 5 by gently
tapping it with a plastic hammer.
379620-C1
Fig 15.

4 Pump 1
5
17A From inside pump casing 5 install shaft 22 through its
(17) support bearing 32 and secure with bearing spacer 21
and snap ring 20.

Pump 2 (right)

From outside pump casing 5A, install shaft 22A, small

splined end first, through its support bearing 32A as
far as it will go.

379610-C1
Fig 14.

3 Place the pump casing on the workbench with its

regulator mounting face downwards. Attach swash
plate tilting bush 31 to tilting pin 27. Smear the sliding
surfaces of swash plate support 17 and swash plate
19 with grease. Install the swash plate against the
support and manually check that the swash plate
slides smoothly.

E-61 9813/0400-1 E-61

 Section E - Hydraulics
Hydraulic Pump/Regulator
Hydraulic Pump Dismantling and Assembly
sure the internal splines of the cylinder and the
spherical bearing are aligned.

5A Insert the piston/cylinder sub-assembly into pump

casing 5.

32A 11 9
12
10

13

22A
379630-C1
Fig 16.

5 Grease oil seal 16 and fit seal cover 15 to swash plate Z

support 17. Secure it with socket head screws 14 379650-C1
tightened to a torque of 11.5 Nm (8.5 lbf ft). Fig 18.

7 Attach valve plate 23 to valve block 8, engaging the

location pin in the process. Check that the suction and
delivery ports of the plate are not transposed.
5A (5)
8 Insert splined coupling 29 into valve block 8.
17A K Fig 13. ( T E-60). Fit the valve block to pump
(17) casing 5, taking care to align the match marks.
Engage the spline on shaft 22 with the splined
15 coupling. Secure with the four socket head screws 7,
tightened to a torque of 130 Nm (94 lbf ft).

9 Refit regulator 4 to pump casing 5 taking care to

14 locate the feedback pin of tilting lever 27 with the lever
of the regulator. Secure the regulator with socket
head screws 2 and 3, tightened to a torque of 29.4
Nm (25.8 lbf ft).

379640-C2
Fig 17.

6 Assemble the piston/cylinder sub-assembly Z

comprising cylinder 9, piston assemblies 10, set plate
11, spherical bush 12 and cylinder springer 13. Make

E-62 9813/0400-1 E-62

 Section E - Hydraulics
Hydraulic Pump/Regulator
Hydraulic Pump Dismantling and Assembly

379680-C1
Fig 19.

10 Refit servo pump assembly X, tighten the securing

screws to a torque of 6.9 Nm (5 lbf ft).
K Fig 13. ( T E-60).

11 Refit drain plug 1. K Fig 13. ( T E-60).

E-63 9813/0400-1 E-63

 Section E - Hydraulics
Hydraulic Pump/Regulator
Regulator Dismantling and Assembly

Regulator Dismantling and Assembly

The working environment must be clean and the ring 12. Do not interfere with the settings of any of
workbench covered with a cloth or rubber sheet to prevent these components as this could alter the pre-set flow
damage to the components. settings.

The item numbers called up in the following procedures

correspond with those in the exploded view. 5
K Fig 29. ( T E-67). 6

Dismantling
Before dismantling, remove dust, rust, etc. using clean
hydraulic oil.

Retain all washers, snap rings etc. for later re-use. O-rings
should be renewed.

1 If not already done, separate the regulator 1 from the

pump casing by removing socket head screws 2 and
3 (2 off each). Do not lose the large O-ring 4.
379390-C1
Fig 21.

3 3 From regulator body 1, withdraw outer spring 13,

inner spring 14 and spring seat 15. Also withdraw
adjusting ring 16 (refer to Note 1), pilot spring 17 and
2 spring seat 18.

Note: 1 Use an M4 screw Z attached to the end of

adjusting ring 16 to facilitate its easy removal.

13
14
15
1 16
1

17
379380-C2 18 Z
Fig 20.
379400-C1
2 Remove the four socket head screws 5 and lift off Fig 22.
cover 6 complete with adjusters 7/8, adjusting screw
9, two locking nuts 10, mounting nut 11 and adjusting

E-64 9813/0400-1 E-64

 Section E - Hydraulics
Hydraulic Pump/Regulator
Regulator Dismantling and Assembly
4 Remove socket head screws 19 and 20 and lift off
pilot cover 21. Take out set spring 22. 1

33

29
28
22

31
30 Y
379430-C1
20 Fig 25.

21 7 Remove lever 32 leaving pin 33A in position on the

19 lever.
379410-C1
Fig 23.
1
5 Remove snap ring 23 taking care not to allow the
components behind it to spring out. Take out spring
seat 24, return spring 25 and sleeve 26 (complete
with snap ring 27).

25
23 32

26 1 33A
379440-C1
Fig 26.
24
379420-C1
8 Knock out pin 34 (4 mm dia.) using a suitable metal
Fig 24. rod X and a plastic hammer.

6 Remove snap ring 28 and take out fulcrum plug 29,

complete with pin 33. Remove snap ring 30 and take
out adjusting plug 31.

Note: 2 Use an M6 screw Y attached to the ends of

fulcrum plug 29 and adjusting plug 31 to facilitate their
easy removal.

E-65 9813/0400-1 E-65

 Section E - Hydraulics
Hydraulic Pump/Regulator
Regulator Dismantling and Assembly
Note: 3 Piston case 40 can be removed by pressing
compensating rod 42 from the opposite side of regulator
body 1.

379450-C1
Fig 27.

9 Withdraw feedback lever 35.

35

379460-C1
Fig 28.

10 Remove lever 36 from pin 37 (in the regulator body)

leaving pin 37A in position on the lever.

11 Draw out pilot piston 38 and spool 39.

12 Withdraw piston case 40, compensating piston 41

and compensating rod 42.

E-66 9813/0400-1 E-66

E-67

14
13

15

12

42
D
41 B 36
40
35
F
34 16
32 17 5
37A 18
39 11
A
26 G
10
22 E
6
24 C
25 33A
23 10
7
8
9813/0400-1

38 3 2
9

Regulator Dismantling and Assembly

Hydraulic Pump/Regulator
Section E - Hydraulics
37

3
F 29
G 28A
20 A
B 28
C

31
19
4 30A
21 30
379670-C1
E-67

Fig 29.
 Section E - Hydraulics
Hydraulic Pump/Regulator
Regulator Dismantling and Assembly

Assembly
Before assembling:

– Thoroughly clean all components with clean hydraulic

oil and dry with compressed air. 36 32
– Apply clean hydraulic oil to all sliding surfaces,
bearings, etc.
– Renew any damaged components.
– Renew all O-rings and other seals.

The item numbers called up in the following procedures

correspond with those in the exploded view 35
K Fig 29. ( T E-67).

1 Insert compensating rod 42 into hole B of regulator 379480-C1

body 1. Fig 31.

2 Locate pin 37A in lever 36 in the groove of 5 Insert pilot piston 38 into hole C of regulator body 1.
compensating rod 42. Locate lever 36 on pin 37 in Check that the piston slides freely without binding.
regulator body 1.
6 Locate pin 33A in lever 32 in the groove of pilot piston
3 Fit spool 39 and sleeve 26 into hole A of regulator 38. Position lever 32 in regulator body 1.
body 1. Check that the spool and the sleeve slide
smoothly in the body without binding. Check the 7 Fit fulcrum plug 29 so that integral pin 33 locates with
orientation of the spool with respect to feedback lever lever 32. Fit a new seal 28A and install snap ring 28.
35. K Fig 30. ( T E-68).

39 35
29
379470-C1
Fig 30.

4 Install feedback lever 35, orientating it as shown 1

below and aligning its pin hole with that of spool 39.
Insert pin 34.

379490-C1
Fig 32.

E-68 9813/0400-1 E-68

 Section E - Hydraulics
Hydraulic Pump/Regulator
Regulator Dismantling and Assembly
8 Insert adjusting plug 31. Fit a new seal 30A and install
snap ring 30.
1
Check that feedback lever 35 moves freely but does
not have excessive play. 22
9 Insert return spring 25 and spring seat 24 into hole A
of regulator body 1. Compress the spring and secure
with snap ring 23.

41
40

23 Fig 34.
379510-C1

24 11 Insert spring seat 18 (flat face first), pilot spring 17

and adjusting ring 16 into hole E of regulator body 1.
25 Insert spring seat 15 (flat face first) inner spring 14
and outer spring 13 into hole D of regulator body 1.
1

13
14
1 15
379500-C1
Fig 33.

10 Insert set spring 22 into hole A of regulator body. 16

17
Insert compensating piston 41 and piston case 40
into hole B of regulator body 1. 18

Fit pilot cover 21 and secure with socket head screws

19 and 20 tightened to a torque of 11.8 Nm (10.3 lbf
ft). 379520-C1
Fig 35.

12 Install the cover 6 assembly comprising adjusting

screws 7/8, adjusting ring 12, mounting nut 11, two
locking nuts 10 and adjusting screw 9.

Secure the cover using socket head screws 5

tightened to a torque of 11.8 Nm (10.3 lbf/ft).

E-69 9813/0400-1 E-69

 Section E - Hydraulics
Hydraulic Pump/Regulator
Regulator Dismantling and Assembly

7
379530-C1
Fig 36.

E-70 9813/0400-1 E-70

 Section E - Hydraulics
Hydraulic Pump/Regulator
Regulator Dismantling and Assembly

Page left intentionally blank

E-71 9813/0400-1 E-71

 Section E - Hydraulics

Remote Control Valve (Hand Control)

Operation
TE-008

The remote control valve is a pressure reduction valve springs also provide a resistive force, giving the operator a
used to control the servo pressure operated system. Four `tactile feel' of the controls.
pressure reduction valves used to control the servo
pressure are located in the main housing. Direction of the The control handles contain electrical push button and
output servo pressure is controlled by selective movement rocker switches which are used to operate auxiliary
of the control lever. The valves and control levers are services.
mounted in the arm rests on both sides of the operator's
seat.

The pressure reduction unit is comprised of spools 17,

pressure control springs, return springs and spring seats
13. The spools 17 are held against the plungers 11 by the
return springs 15. When the control handle is tilted, the
plungers 11 move down, depressing the return spring
seats 13, simultaneously compressing the pressure
control springs moving the spool, allowing hydraulic oil to
flow to the designated pilot port.

The lower end of the main body contains the main inlet port
P, outlet port T to tank and the servo pressure outlet ports
1, 2, 3 and 4.

The servo pressure controls the stroke and direction of the

main control valve spools. This is achieved by providing a
spring at one end of the main control valve spools and
applying pilot pressure to the opposite end. (In some
cases, pilot pressure is applied to both ends of the control
valve spool.)

Function
Oil supplied by the hydraulic servo pump enters at port P
and the function of the spools 17 is to direct oil from the
inlet port P to the output ports 1, 2, 3 and 4 or alternatively,
to the exhaust port T to tank. The pressure control springs
act on the spools 17 to determine pressure at each port.
Plungers 11 slide in the guides to vary the compression in
the springs. The control handle, fixed to the adjusting nut
24 and circular rocker plate 25 is operated to move the
plungers 11. The control handle is able to rotate 360°
around the knuckle joint 26.

The return springs operate between the casing and the

seats 13, regardless of the outlet pilot pressure, returning
the plungers 11 to their outer positions, ensuring the
spools 17 return to their neutral (closed) positions. The

E-72 9813/0400-1 E-72

 Section E - Hydraulics
Remote Control Valve (Hand Control)
Operation

24

26
25
11
11

13
13

T 17

2,4 1,3
A409170-C1
Fig 1.

T P

1 2 3 4

JS03240-C1
Fig 2.

E-73 9813/0400-1 E-73

 Section E - Hydraulics
Remote Control Valve (Hand Control)
Removal and Replacement

Removal and Replacement

!MWARNING 9 Lift the remote control valve clear of the arm rest.

Hydraulic Pressure Note: Care should be taken when removing right arm rest,
Hydraulic fluid at system pressure can injure you. remove switches, using a thin flat bladed screw driver and
Before connecting or removing any hydraulic hose, disconnect electrical connections.
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service Replacement
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while Replacement is the reversal of the removal sequence.
the hoses are open.
INT-3-1-11_2 Note: All hydraulic adapters that are installed together with
a bonded sealing washer must also have JCB Threadseal
!MWARNING applied to the threads of the adapter.

Fluid Under Pressure

Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses and gloves.
Hold a piece of cardboard close to suspected leaks
and then inspect the cardboard for signs of fluid. If
fluid penetrates your skin, get medical help
immediately.
INT-3-1-10_3

Removal
1 Lower dipper and place bucket on the ground

2 Turn off engine.

3 Operate both control joysticks back and forth and side

to side to vent residual pressure.

4 Remove the two screws A from each side, and loosen

screws B (one either side of the arm rest). Remove
front panel C.

5 Disconnect electrical connection to remote control

valve.

6 Disconnect all hydraulic hoses and pipes from the

remote control valve and plug all orifices to prevent
ingress of dirt. Label each hose before disconnecting,
this will ensure correct position when refitting.

7 Remove the two screws D, two screws E and loosen

the two screws F. Remove panel G.

8 Lift up gaiter H and remove the fours bolts holding the

valve to the arm rest.

E-74 9813/0400-1 E-74

 Section E - Hydraulics
Remote Control Valve (Hand Control)
Removal and Replacement

G F

D B

A
C
A407780-C1
Fig 3.

Table 1.
Left hand Control Valve Right hand Control Valve
Port Hose Colour Port Hose Colour
1 Orange 1 Green
2 Green 2 Blue
3 Violet 3 Yellow
4 Pink 4 Red
P White P White
T - T -

E-75 9813/0400-1 E-75

 Section E - Hydraulics
Remote Control Valve (Hand Control)
Dismantling and Assembly

Dismantling and Assembly

Dismantling Note: Ensure retaining plate moves freely to prevent

sudden release due to spring pressure beneath.
Note: All parts are precision made and require the utmost
care when being handled. 7 Clean the valve exterior using approved solvent and
using soft metal pads for protection, clamp the valve
Note: During dismantling, do not use excessive force to body into a vice.
separate components which could cause scratches or
burrs on bearing surfaces. Failure to observe this 8 If the return springs 15 are weak, the sliding
instruction will cause oil leaks leading to poor resistance of the seal 9 will cause the guides 8 to stick
performance. in the casing. Using a screw driver, carefully ease out
the guides 8 and plungers 11.
Note: Label all parts during dismantling, to ensure correct
assembly. Note: Care must be taken to prevent damage to the guides
when removing. Ensure the guides do not fly out due to the
Note: Storing the valve when dismantled could cause force of the return springs.
rusting of parts. Ensure they are suitably protected by anti-
rust treatment. 9 Remove spring seats13, split washers 12, return
springs 15, pressure control springs 14 and spools
Note: Refer to the illustration for part number identification 17.
K Fig 4. ( T E-78).
Note: Identify each set of parts and their locations for
1 Push down upper section of gaiter 19 and remove roll assembly.
pin 20.
10 Loosen the two hex bolts 27 on the base of the valve.
2 Remove control handle from mounting knuckle 3. Remove the base plate and `O'-ring 30 from the valve
casing.
Note: Take care when removing handle to avoid damage
to wiring loom and switches. These should be removed by 11 Slacken and remove body assembly screw 6.
separating the line connectors in the control handle and Remove and discard `O'-ring 7.
below the valve body.
12 Separate upper and lower body sections 1 and 2 and
3 Remove gaiter 19 from valve housing. remove dowel pins 5.

4 Slacken locknut 22 and remove mounting knuckle 23. 13 Remove and discard `O'-rings 3 and 4.

5 Slacken and remove joint nut 24 and rocker plate 25. Note: The surface of spool 17 and spring 13 can be
damaged by mis-handling. Take care not to damage the

!MWARNING surface of the spool during removal and do not push the
spring seat down more than 6mm (0.24 in).
Always wear safety glasses when dismantling
assemblies containing components under pressure 14 Hold spools 17 firmly on the work bench and depress
from springs. This will protect against eye injury from spring seat 13 and remove split washers 12.
components accidentally flying out.
Note: Avoid scratching the surface of the spools. Do not
GEN-6-2
depress the spring seats more than 6 mm (0.24 in).
Note: The return spring 15, retaining plate 18 and plunger
11 will rise when knuckle joint 26 is loosened. 15 Separate spools 17, spring seats 13, springs 14 and
15 and shims 16.
6 Using a jig, slacken and unscrew knuckle joint 26,
releasing retaining plate 18. 16 Remove plungers 11 from guides8.

E-76 9813/0400-1 E-76

 Section E - Hydraulics
Remote Control Valve (Hand Control)
Dismantling and Assembly
17 Remove seals 9 and 10 from guide 8 and discard.

Note: Leave all parts to soak in suitable solvent until dirt is

loosened. Using clean solvent wash all parts and allow to
air dry. Apply rust inhibitor to all parts.

E-77 9813/0400-1 E-77

 Section E - Hydraulics
Remote Control Valve (Hand Control)
Dismantling and Assembly

21

26

18
8
19

9
10
2 11

20 12
23 3
4 13
5
14
22 1
15
24
16
25 7
17
6

30

29

28

27
A408130-C1
Fig 4.

E-78 9813/0400-1 E-78

 Section E - Hydraulics
Remote Control Valve (Hand Control)
Dismantling and Assembly
Table 2.
Item Description Qty. Item Description Qty. Item Description Qty.
1 Lower body 1 11 Plunger 4 21 Control handle 1
2 Upper body 1 12 Split Washer 4 22 Locknut 1
3 `O'-ring 1 13 Spring seat 4 23 Mounting knuckle 1
4 `O'-ring 1 14 Compression spring 4 24 Joint nut 1
5 Dowel pin 2 15 Return spring 4 25 Rocker plate 1
6 Body assembly screw 1 16 Shims - 26 Knuckle joint 1
7 `O'-ring 1 17 Spool 4 27 Hex Bolt 2
8 Plunger guide 4 18 Retaining plate 1 28 Washer 2
9 Seal 4 19 Gaiter 1 29 Base plate 1
10 Seal 4 20 Roll pin 1 30 `O'- ring 1

E-79 9813/0400-1 E-79

 Section E - Hydraulics
Remote Control Valve (Hand Control)
Dismantling and Assembly

Inspection
Note: Before assembling the remote control valve make
sure that a thorough inspection of all the components is
carried out. Remember that although a failed component
may be easy to identify, the cause may be less easy to
trace. It is also possible that a failed component may have
caused damage to other areas of the valve.

1 Carefully clean all components using a suitable

degreasing agent.
24
2 Carefully inspect all components for signs of
excessive wear or damage. If wear or damage is
evident, components must be renewed. 25
Note: `O'-rings and other sealing materials should
preferably be replaced each time the valve is
disassembled but they may be re-used provided a careful
check is made that they are un-damaged. 26

Assembly
18
Note: During assembly, ensure all parts are clean and free
from burrs and scratches. Remove minor damage by
lapping.

Note: Renew all `O'-rings, seals and back-up rings. Take 1

care to install seals the correct way around.

Note: During assembly apply hydraulic oil to `O'-rings and

seals.

Note: Ensure all screws and bolts are tightened to the

torque settings given.

The numerical sequence given previously is a guide to

dismantling. For assembly the sequence should be P
reversed noting the following details:

1 Locate retaining plate 18 onto plunger guides 8 and

using the jig, screw knuckle joint into position. 6,7
JS03250-C1
2 Locate rocker plate 25 and tighten until it makes Fig 5.
contact with the plungers 11. Ensure the plungers are
Item Nm Kgf m lbf ft
not depressed at this stage.
6 40 4 29.5
3 Holding the rocker plate 25 in its position, screw down 24 68 7 50
joint nut 24.
25 30 3 22
4 Ensure the switch cable is free from obstruction and 26 30 3 22
the line connectors are securely fastened. 27 20 2 14.7

E-80 9813/0400-1 E-80

 Section E - Hydraulics
Remote Control Valve (Hand Control)
Dismantling and Assembly

Fault Finding

Symptom Possible cause Remedy

Low secondary pressure. Primary pressure is low. Apply the correct primary pressure.
Spring 4 is damaged. Renew the spring.
Clearance between the spool and Renew the remote control valve
seating is too large. assembly.
The handle unit is loose. Dismantle, reassemble or renew the
handle unit.
Unstable secondary pressure. Sliding parts are sticking. Release the sticking part.
Fluctuations in the tank line pressure. Check return line and filter for
blockage.
Air is trapped in the piping. Operate the valve several times to
remove the air.
High secondary pressure. The tank line pressure is too high. Check return line and filter for
blockage.
Release the sticking part.

E-81 9813/0400-1 E-81

 Section E - Hydraulics

Travel Pedal Valve

Dismantling and Assembly
TE-007

Note: Parts can be damaged by use of excessive force. 8 Remove plug 7 with the grease cap 12, packer 13 and
Parts can be damaged by corrosion caused by humidity `O'-ring attached.
and dust if left in un-assembled.
9 Remove piston 14 and damping spring 8 from the
Note: For part number identification for the Travel Pedal casing.
Valve, K Fig 2. ( T E-83).
10 Remove spring washer 16 from the casing 10 using
Dismantling tweezers etc.

1 Clean the valve exterior using an de-greasing agent 11 Remove steel balls 17 using a magnet.
and using soft metal pads for protection, clamp the
valve body into a vice. 12 Fix the lower casing assembly in a vice and remove
the `O'-rings 18, 19 from casing 20.
2 Remove the gaiter 1 from the cover 2.
13 Remove pressure reduction valve assembly and
3 Loosen the 5mm hex screw 3. return spring 21 from casing 20.

!MWARNING 14 Place cover 2 flat on a flat bench, apply special jig,

K Fig 1. ( T E-82) to bush 23 and tap with a hammer
Always wear safety glasses when dismantling to remove the bush
assemblies containing components under pressure
from springs. This will protect against eye injury from (A = 2 mm)
components accidentally flying out.
10mm -0.3
-0.4

GEN-6-2

8mm-0.2
-0.3
Note: Take care that push rod 4 does not fly out under
spring tension.

30
4 Remove pin 5 using a 7mm punch and remove cam
and steel balls 6.
20 mm 2
Note: Take care that push rod 4 and plug 7 are not thrown
30mm
out by damping spring 8 pressure.
A406320-1
5 Loosen hex bolt 9 and remove cover. Making a note Fig 1.
of the relative positions of the cover 2 and the
casing 10. The plug 7 will remain in casing 10 due to A Central Hole (2mm maximum)
friction of the `O'-ring 11.
15 For disassembly of the pressure reduction valve,
6 Remove casing 10 and fix in vice using soft metal
press in spring washer 24, slide the spring washer
pads for protection.
sideways, bending secondary pressure spring 25,
then remove spool 26 from the larger hole.
7 Pull push rod 4 from plug 7 noting the relative
positions of plugs and push rods to the casing 10.
16 Separate spool 26, secondary pressure setting spring
25, shim 27 and washer 28.

E-82 9813/0400-1 E-82

 Section E - Hydraulics
Travel Pedal Valve
Dismantling and Assembly
17 Remove grease cap 12 from plug 7. c Wipe clean de-greasing agent from all parts using
a lint-free cloth.
Remove packing 13 from plug 7 using a small flat
screw driver being careful not to scratch the plug. Note: Adhered dirt and grease may cause damage during
Remove `O'-ring 11 from plug 7. the first washing; soak well to loosen and float these off.
Dirty de-greasing agent may cause damage to the parts.
18 Wash all parts: Monitor the cleanness of the de-greasing agent up to re-
assembly. Do not dry with compressed air as the dust and
a Place all parts in container with clean de-greasing moisture carried by the air may damage the parts or cause
agent (first washing). corrosion

b Place all parts in a finishing wash container with

clean de-greasing agent and rotate slowly to
ensure complete washing. (finish wash).

24 24
4
4 25 25
1 27 27
9 14 28 28
3
6 14 8 26 26
23
5 8
9 16 21 21
16 17
18 18
23 2 17 19
20
12 10
13 12
7 13 30
29
7
11
11

A406310-C4
Fig 2.

E-83 9813/0400-1 E-83

 Section E - Hydraulics
Travel Pedal Valve
Dismantling and Assembly

Inspection 3 Fix casing 20 in a vice. Fit return spring 21 into

casing.
Before assembling the Directional control valve make sure
that a thorough inspection of all the components is carried 4 Fit the pressure reduction valve sub-assembly,
out. Remember that although a failed component may be assembled in 1 and 2 above, into casing 20. When
easy to identify, the cause may be less easy to trace. It is fitting the pressure reduction valve sub assembly,
also possible that a failed component may have caused take care not to hit the lower end of the spool against
damage to other areas of the valve. the edge of the casing, K Fig 3. ( T E-84).

1 Carefully clean all components using a suitable de-

greasing agent.

2 Carefully inspect all components for signs of

excessive wear or damage. If wear or damage is
evident, components must be renewed.

Note: `O'-rings and other sealing materials should

preferably be replaced each time the valve is
disassembled but they may be re-used provided a careful A
check is made that they are undamaged.

Assembly
Note: `O'-rings and other sealing materials should A406350-1
preferably be replaced each time the valve is Fig 3.
disassembled but they may be re-used provided a careful
check is made that they are undamaged. Note: Be careful of the casing edge A.

Note: When hexagonal socket (hex) bolts 29 are loosened 5 Fit `O'-rings 18, 19 into the casing.
the seal washers 30 must be replaced.
6 Fix upper casing 10 in a vice and fit steel balls 17.
Note: Fit all components in the same positions as before
disassembly 7 Fit spring washer 16 into casing 10 using tweezers
etc.
!MWARNING 8 Fit damping spring 8 into casing 10.
Always wear safety glasses when dismantling
assemblies containing components under pressure 9 Fit piston 14 into casing 10.
from springs. This will protect against eye injury from
components accidentally flying out. 10 Fit `O'-ring 11 to plug 7.
GEN-6-2
11 Fit packing 13 to plug 7. Be careful of the direction
1 Assemble washer 28, shim 27, secondary pressure when fitting the packing, K Fig 4. ( T E-85). Apply a
setting spring 25 and spring washer, in that order, light coating of grease before fitting packing.
onto spool 26

2 Push spool 26 through the larger hole of spring

washer 24 and assemble by sliding the spring washer
sideways while bending the secondary pressure
spring

E-84 9813/0400-1 E-84

 Section E - Hydraulics
Travel Pedal Valve
Dismantling and Assembly
16 Fix the lower cover assembly, as assembled step 1-5,
in a vice and attach upper assembly, as assembled in
A steps 6-14

17 Fit cover 2 to casing 10.

18 Tighten the hexagonal socket bolt 9 to the specified

torque.
A406370-2
Fig 4. 19 Fit cam and steel balls 6 to cover 2. Press down cam
6 and insert cam shaft 5 from the outside.
A Packing
20 Apply JCB Threadlock or equivalent to the surfaces of
12 Fit grease cap 12 to plug 7. hexagonal socket screws 3.

13 Fit push-rod 4 to plug 7 Apply working oil to surfaces 21 Tighten hexagonal socket screw 3 to specified torque.
before fitting push-rod.There is a risk of damage to
the rib part of packing 13 do not use excessive force 22 Tilt cam 6, apply grease to the top of push-rod 4 and
when fitting. inject grease into grease cap 12 of plug 7. Grease is
to be applied and injected using a spatula made of
14 Fit the push-rod sub assembly, assembled in step 10, soft material and care it to be taken that the surfaces
11, 12 and 13, into casing 10. of the push-rod and plug are not damaged.

23 Fit the top of bellows 1 into cam 6 and then the bottom
Item Nm Kgf m lbf ft into the groove in cover 2.
125 21 2 15
24 Before fitting the bottom edge of the bellows into the
312 69 7 51
groove in the cover, apply anti corrosion oil inside the
301 47 5 35 bellows.Please note that if the bellows do not fit
precisely into the groove and are loose, resistance to
15 Place cover 2 flat on a flat bench, push on bush 23 dust and water will deteriorate.
using the special Jig K Fig 5. ( T E-85) and insert by
tapping with a hammer.

(A = 2 mm)
10mm -0.3
-0.4

8mm-0.2
-0.3
30

20 mm 2

30mm

A406320-1
Fig 5.

A Central Hole (2mm maximum)

E-85 9813/0400-1 E-85

 Section E - Hydraulics

Slew Motor
Motor Operating Principles

The following detailed description explains the operating piston expels low pressure hydraulic fluid T via the output
cycle of an individual piston. side A (b) of the control plate, port b and back to tank.
Driving force F2 varies according to the flow rate of the
High pressure hydraulic fluid P from the pump flows via high pressure hydraulic fluid input.
input port a and control valve A into cylinder B when it is
aligned with the input side A (a) of the control plate. The There are nine pistons equally spaced around the cylinder
force F against piston C generates a force F2 (shown block. As each one in turn goes through the cycle
vectorally) which acts on piston shoe D. The piston shoe described, a continuous even rotation of the output shaft is
moves against stationary swash plate E, causing cylinder produced.
block F and hence drive shaft G to rotate. This situation
exists for 180° of rotation of the cylinder block i.e. until the By reversing the hydraulic fluid flow direction i.e. high
cylinder aligns with the output side A (b) of the control pressure feed into port b, the motor rotation is reversed.
plate. For the next 180° of rotation of the cylinder block the

E D C F B P T P

G
F2 b a
F1
F

A(b) A(a)

C075110
Fig 1.

E-86 9813/0400-1 E-86

 Section E - Hydraulics
Slew Motor
Slew Brake Operation

Slew Brake Operation

Cylinder block F is splined to output shaft G. Two friction locking cylinder block F and casing E and preventing
plates A are splined to the outer edge of the cylinder block rotation.
and are interleaved between three counter plates B which
are fixed to the slew motor casing E. The brakes are released when hydraulic pressure is
applied to port X. Oil enters chamber Y and pushes brake
The brakes are applied when the hydraulic pressure at port piston D up, against the pressure of spring C, to release
X is zero. Spring C pressure forces piston D down to press the previously locked friction plates A and counter plates
the friction plates and the counter plates together, thereby B. Cylinder block F is now free to rotate within casing E.

C
E D
F

A B Y
X
C075120
Fig 2.

E-87 9813/0400-1 E-87

 Section E - Hydraulics
Slew Motor
Fault Finding

Fault Finding

Motor Does Not Rotate

Symptom Cause Remedy

The pressure is low. The relief valve is not set correctly. Set to the correct value.
The relief valve does not work properly.
Plunger sticking. Repair or renew the plunger.
Plunger orifice contaminated. Dismantle and clean.
Plunger not seating correctly. Renew the plunger seat.
The pressure is correct but no Overload protection operating. Remove the cause of overload.
rotation. The moving part is burnt. Check and repair the piston/shoe,
cylinder/valve plate, etc.
No release pressure acting on the brake. Check and repair the circuit.
The brake piston is sticking. Dismantle and clean/repair.
The brake friction plate is burnt and Dismantle and renew the damaged parts.
sticking to counter plate.

Motor Rotates in the Reverse Direction

Symptom Cause Remedy

Reverse rotation. The motor has been incorrectly Check step 16 of the Assembly procedure
assembled. to verify that the valve housing 303 and
main housing 301 are in their correct
relative positions. Rectify if necessary.
Inlet/outlet hoses reversed. Re-locate hoses.

Motor Speed is Low

Symptom Cause Remedy

Slow rotation. The oil flow volume is low. Check the pump output and the circuit to
the motor.
The temperature is high and leakage is Check the oil cooling circuit.
serious.
The sliding parts are worn out or broken. Renew suspect parts.

E-88 9813/0400-1 E-88

 Section E - Hydraulics
Slew Motor
Fault Finding

Motor Brake Working Poorly

Symptom Cause Remedy

Low brake torque. The friction plate is worn out. Dismantle and renew worn parts.
The brake piston is sticking. Dismantle and clean.
The brake releasing pressure is low. Check and repair the supply circuit.
The spline of the friction plate is broken. Dismantle and renew the broken parts.

Motor is Driven by Exterior Torque

Symptom Cause Remedy

Slip volume is high. The relief valve is not set correctly. Set to correct value or renew.
Relief valve plunger not seating cleanly. Renew.
The reversal protecting valve does not Renew.
work properly.
Drain volume exceeds 500 cc/mm. Dismantle and check for signs of wear.
Renew suspect parts.

Oil Leakage

Symptom Cause Remedy

Oil leaking from around the drive Oil seal lip damaged. Renew the oil seal.
shaft oil seal. The shaft is damaged or worn. Repair or renew the shaft.
High pressure in casing, causing the lip of Clear the drain pipes.
the oil seal to become rolled.
The drive shaft is corroded. Dismantle and repair.
Oil leaking from mating surfaces of O-ring not fitted or damaged. Fit or renew the O-ring.
main housing and valve housing. The seal surface is damaged. Dismantle and repair.
The securing bolts are damaged or loose. Renew and/or tighten to the required
torque.

E-89 9813/0400-1 E-89

 Section E - Hydraulics
Slew Motor
Removal and Replacement

Removal and Replacement

TE-027

C078320
Fig 3.

Removal 3 Make an alignment line across the gearbox and motor

mounting flanges, to provide a reference during

!MWARNING
assembly.

Hydraulic Pressure 4 Remove bolts X.

Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose, 5 Using suitable lifting equipment carefully lift slew
residual hydraulic pressure trapped in the service motor until clear of machine, refer to Section E,
hose line must be vented. Make sure the hose service Technical Data.
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2

1 Make the machine safe, refer to Section E, Service

Procedures.

2 Disconnect all hydraulic hoses from the slew motor

and plug all orifices to prevent ingress of dirt. Label
each hose before disconnection.

E-90 9813/0400-1 E-90

 Section E - Hydraulics
Slew Motor
Removal and Replacement

Replacement
Replacement is a reversal of the removal sequence.

!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses and gloves.
Hold a piece of cardboard close to suspected leaks
and then inspect the cardboard for signs of fluid. If
fluid penetrates your skin, get medical help
immediately.
INT-3-1-10_3

1 Check slew gearbox oil level, refer to Section 3,

Routine Maintenance

2 After replacement check the main relief valve

(M.R.V.) and auxiliary relief valve (A.R.V.) pressure
settings.

E-91 9813/0400-1 E-91

 Section E - Hydraulics
Slew Motor
Slew Motor Configuration

Slew Motor Configuration

Slew Unit

Planetary 2-stage Reduction Gear Swash Plate Type Axial Piston Hydraulic Motor

Mechanical Brake

By-pass Valve Relief Valve

Make-up Valve

Fig 4.

E-92 9813/0400-1 E-92

 Section E - Hydraulics
Slew Motor
Dismantling and Assembly

Dismantling and Assembly

Fig 5.

E-93 9813/0400-1 E-93

 Section E - Hydraulics
Slew Motor
Dismantling and Assembly

Key
a Drain port g Flow paths N A side seat
a1 Pilot port h Flow paths P B side seat
b1 Pilot port i Flow paths R Anti-pendulum valve
a2 Pilot hole j By pass valve S Anti-pendulum valve
a3 Pilot hole A Inlet port T Pilot hole
b Flow paths B Outlet port U Spring chamber
c Flow paths C Anti-cavitation check valve V Make-up port
d Flow paths D Mechanical brake W Piston
e Flow paths J Cross-line relief valve X Mechanical brake release port
f Piston bore K A side cavity Y Motor output shaft
L B side seat Z Slipper foot
M Intermediate cavity

E-94 9813/0400-1 E-94

 Section E - Hydraulics
Slew Motor
Dismantling and Assembly

Dismantling
As a guide to dismantling and assembly, Refer to the
sectional drawing K Fig 5. ( T E-93).
26
Before attempting to dismantle the slew motor assembly,
the inlet and outlet ports should be blanked and the outer
surfaces washed down with a suitable solvent to remove
all dirt and dust. Dry using compressed air.

1 Remove the level gauge with a pipe wrench.

JS06110-C1

Fig 7.

3 Remove screws B with a 19 mm socket wrench and

remove the motor.

Note: Before removing the motor from the reduction gear,

it is advisable to make an alignment mark on the mating
faces to facilitate reassembly.

JS06100

Fig 6.

2 Remove plug 26 with an 8 mm allen key and drain the JS06120-C1

gear oil. Fig 8.

4 Remove the caps 37 with 14 mm A/F hexagonal key

and remove relief valves 34 from the motor.

Note: Record the position of relief valves 34 to ensure

correct reassembly.

5 Remove the caps 30 with a 14 mm A/F hexagonal key

and take out the springs 31 and check valves 29.
Remove by-pass valve assembly by unscrewing cap
28 using a 10 mm A/F hexagonal key.

E-95 9813/0400-1 E-95

 Section E - Hydraulics
Slew Motor
Dismantling and Assembly
Note: Record the relative positions of the parts to ensure
correct reassembly.
27
6 It is advisable to make alignment marks on cover 17
and housing 25 with white paint, etc. to facilitate
reassembly.
17
30
31 25
17 29
28
JS05670-C1
29
34 Fig 10.

9 Remove snap ring 23 and remove the inner ring of

needle bearing 22.

10 Remove 'O'-ring 13.

31 37 11 Remove balance plate 21. Remove the pins 15 from

30 the balance plate.
34
25
Note: The balance plate 21 must be reinstalled correctly
on cover 17. (The alignment of the hair groove and round
groove which select high and low pressure is very
important. Before removing the balance plate, note the
JS06130-C1 correct relationship with cover 17.)
Fig 9.
12 Remove the bushings 20 with Teflon rings 19 and the
7 Remove screws 27 attaching cover 17 to housing 25 plate springs 18.
with a 12 mm hexagonal key.

8 Place the motor with the main shaft downwards and

lift off cover 17.

E-96 9813/0400-1 E-96

 Section E - Hydraulics
Slew Motor
Dismantling and Assembly

23 14

13
22
12
13
11
21 15 25
15 20
19
25
18
X

12
17

JS05680-C1

Fig 11.
JS05700-C1

13 Remove the springs 14 from brake piston 12. Fig 12.

Note: Keep the springs in the order in which they are to be 16 Remove friction plate 9 and mating plate 10.
re-inserted.
17 Hold the end of cylinder 24 by hand and pull out the
14 It may be difficult to remove brake piston 12 from cylinder assembly from housing 25.
housing 25 due to resistance caused by `O'-rings 11
and 13. Therefore remove brake piston 12 using the Note: The oil seal 2 and the outer ring of taper roller
tapped M6 holes X as shown in the illustration. bearing 3 remain in the housing.

15 Remove `O'-ring 11 from housing 25 and `O'-ring 13 The end face of the cylinder should be protected by
from brake piston 12. clean cloth to prevent it from being damaged.

Make alignment marks or write numbers on the piston

bores and the piston assemblies so that the piston
assemblies can be replaced in the same bores during
reassembly.

18 Remove the outer ring of taper roller bearing 3 from

the housing.

E-97 9813/0400-1 E-97

 Section E - Hydraulics
Slew Motor
Dismantling and Assembly

10 9
10
9
10

24

JS06170-C1

Fig 14.

20 Attach a puller to the inner ring of taper roller bearing

25 3 at two places and on the end of cylinder 24 spline,
3 then extract bearing inner ring 1. Take out collar 53.

21 Remove swash plate 6, piston assemblies 8 and

retainer plate 7 together from cylinder 24.

JS05710-C1

Fig 13.

19 Tap oil seal 2 with a screwdriver and hammer to

remove it from housing 25.

Note: The oil seal cannot be reused.

E-98 9813/0400-1 E-98

 Section E - Hydraulics
Slew Motor
Dismantling and Assembly

1 5

53
6

7 24

8
5
JS06140-C1

Fig 17.

24

JS06160-C1

Fig 15.

22 Slide swash plate 6 from the sliding faces of the

piston assemblies.

Note: Take care not to damage the swash plate during

handling.

JS06150-C1

Fig 16.

23 Remove spring 5 from cylinder 24.

E-99 9813/0400-1 E-99

 Section E - Hydraulics
Slew Motor
Dismantling and Assembly

Inspection
1 Clean each part in a suitable solvent and dry using
compressed air.

2 Inspect all parts and act in accordance with the

following table.

3 Discard all used seals and `O' rings and fit new ones
during assembly.

!MCAUTION
If the machine is operated at full load before its initial
run-in procedure is complete it may cause scuffing
and seizing which can adversely effect the life of the
machine.
8-3-1-5

!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses and gloves.
Hold a piece of cardboard close to suspected leaks
and then inspect the cardboard for signs of fluid. If
fluid penetrates your skin, get medical help
immediately.
INT-3-1-10_3

!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2

E-100 9813/0400-1 E-100

 Section E - Hydraulics
Slew Motor
Dismantling and Assembly

Item Inspection and Maintenance Standards

The crescent-shaped ports in the balance plate, which are in sliding contact with the
end face of the cylinder assembly shaft, act to switch between high and low oil
pressure. Any damage to the sliding contact face will increase leakage, causing a
decrease in volumetric efficiency and an increase in slip. Any seizure of the sliding
Balance Plate 21
contact face causes a reduction in mechanical efficiency and can lead to further
damage. If the grooves or marks depths are less than 0.03 mm (.001 in), the plate can
be corrected using fine emery cloth. If the wear is greater than 0.03 mm (.001 in), the
plate should be renewed. The plate should be renewed if it shows any sign of seizure.
Correct any damage to the sliding contact face of the slipper feet by using fine emery
Piston assembly 8 slipper feet cloth. Renew the motor if the depth of any slipper foot oil groove is less than 0.45 mm
(.018 in) or if the slipper foot surfaces are seriously damaged.
The external surfaces of the piston assemblies should be practically unworn. The motor
Piston assembly 8 pistons
should be renewed if a piston assembly shows any sign of seizure.
Cylinder assembly 24 piston The piston bores should be practically unworn. The motor should be renewed if the
bores bores show any sign of seizure or are badly damaged.
HYDRAULIC MOTOR
Taper roller bearing 3 The bearings should be renewed if any slight damage is noticed on the contact
surfaces of the rollers or needles.It is recommended that all bearings be renewed on
Needle bearing 22
reassembly of the motor because bearings can be damaged when the motor is
Self-aligning roller bearing 57 dismantled.
Roller Bearing 62
HYDRAULIC MOTOR
Oil seal 2 Renew any oil seal if damage to the lip is apparent. New seals must be used when
REDUCTION GEAR reassembling the motor.
Oil seal 61
HYDRAULIC MOTOR Renew any 'O'-ring that appears to be damaged. New 'O'-rings must be used when
O-rings 11, 13, 33, 36, 41, 45, 52 reassembling the motor.
HYDRAULIC MOTOR
The back-up rings must be renewed when reassembling the motor.
Back-up ring 32, 35, 46

E-101 9813/0400-1 E-101

 Section E - Hydraulics
Slew Motor
Dismantling and Assembly

Assembly
As a guide to dismantling and assembly, Refer to the
sectional drawing K Fig 5. ( T E-93).

Check all parts before assembly and remove any

scratches with a fine oil stone or carborundum paper.
Wash with a suitable solvent and blow dry.

Replace all seals with new ones.

Apply clean hydraulic oil to all sliding faces during

assembly.
JS06190-C1

!MCAUTION Fig 19.

Cleaning
Cleaning metal parts with incorrect solvents can cause
corrosion. Use only recommended cleaning agents
and solvents.
INT-3-2-11

!MCAUTION
'O' rings, Seals and Gaskets
Badly fitted, 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. JS06200-C1

INT-3-2-12 Fig 20.

1 Lap the sliding contact faces of piston assemblies 8, 2 Apply grease to the curved part of cylinder 24 (contact
balance plate 21 and swash plate 6 with very fine face with spring 5) and mount spring 5.
paste on a flat surface.
3 Position the piston assemblies 8 into the holes of
retainer plate 7.

4 Mount the piston assemblies 8 together with retainer

plate 7 into cylinder 24.

Note: Insert the piston assemblies into the same bores

from which they were removed.

Apply clean hydraulic oil to all cylinder 24 bores

before reassembling.

5 Apply clean hydraulic oil to piston assembly 8 shoe

sliding surface and mount the swash plate 6.
JS06180-C1

Fig 18. 6 Mount collar 53 and inner ring of taper roller bearing
1 on motor output shaft.

E-102 9813/0400-1 E-102

 Section E - Hydraulics
Slew Motor
Dismantling and Assembly
7 Apply a thin coat of JCB Retainer where the inner ring
is mounted on motor output shaft.

1
1
53
6
24

8 JS05730-C1

Fig 22.
7
9 Apply grease to the lip of seal 2 and use a press and
5 jig (see Special Tools, Section 1) to force fit the seal
into position.

24 2

JS05720-C1
JS05740-C1
Fig 21.
Fig 23.
8 Using a jig, (see Special Tools, Section 1) press
inner ring 1 on output shaft. 10 Mount the outer ring of the taper roller bearing into
housing 25.

11 Hold the end of cylinder 24 by hand and carefully

insert the cylinder assembly into housing 25. Use the
seal protector on the splines.

Note: The splines of the cylinder assembly protrude

beyond the housing, so use a guide of 30-50 mm (1.2-1.9
in) on the lower part of the housing. Verify that spring 5 is
inserted correctly into the back face of retainer plate 7.

12 Mount friction plate 9 and mating plate 10.

E-103 9813/0400-1 E-103

 Section E - Hydraulics
Slew Motor
Dismantling and Assembly
Note: Apply hydraulic oil to both faces before mounting the
plates.
14
13 Mount 'O'-ring 11 in housing 25 and 'O'-ring 13 on
piston 12. 13
Note: Grease the 'O'-rings before mounting. 12
14 Apply hydraulic oil to the sliding surface around piston
12 and slide it into housing 25. 9
9
10 10
Note: It is difficult to insert piston 12 into the housing due
to O'-rings 11 and 13. Hold the piston horizontally and push 9
it into the housing with one movement.
10
11
15 Insert the brake unit springs 14 back into brake piston
12.

Note: Insert the springs 14 in the same order as they were

found during dismantling. 24 7, 5

25

JS05690-C1

Fig 24.

16 Mount the bushings 20 with Teflon rings 19 and the

plate springs 18 into the bushing holes in cover 17.

Note: Apply a coating of grease to the end faces and

peripheries of the bushings 20 and to the Teflon rings 19
before mounting them, as this helps prevent them from
falling out when the cover is mounted onto the housing.

E-104 9813/0400-1 E-104

 Section E - Hydraulics
Slew Motor
Dismantling and Assembly
17 Generously grease the pins 15 and insert into cover
17.

18 Mount balance plate 21 onto cover 17.

19 Press needle bearing 22 inner ring into cover 17 and

attach snap ring 23.

20 Apply grease to the 'O'-ring and install 'O'-ring 13 to

cover 17.

23

JS05650-C1

Fig 26.
22
22 Lift cover 17 and balance plate 21 by hand and mount
them carefully on housing 25.
13
Take care that balance plate 21 and bushings 20 do
21 15 not fall out while mounting cover 17. Align housing 25
15 20 and cover 17 alignment marks which were made
before dismantling.
19
23 Tighten the cap screws 27 (with a 12 mm A/F
18 hexagonal key) which attach cover 17 to housing 25
to a torque of 157 Nm (116 lbf ft).

17
27

JS05680-C1

Fig 25. 17

21 To prevent oil leakage from the cover bolt holes apply

JCB Multi-gasket to the surface. 25

JS05660-C1

Fig 27.

E-105 9813/0400-1 E-105

 Section E - Hydraulics
Slew Motor
Dismantling and Assembly
24 Assembling the Make-up and by-pass valves. Note: If the shaft does not turn, the unit has not been
assembled correctly so dismantle again and inspect.
Assemble the check valves 29 and springs 31 in
cover 17 and tighten the caps 30 (14 mm A/F 27 Degrease the mating faces of the gear unit ring gear
hexagonal sockets) to a torque of 137 Nm (101 lbf ft). 64 and motor housing 25 and apply Multi-gasket to
the ring gear.
Assemble by-pass valve assembly 28 to cover 17 and
tighten the caps (10 mm A/F hexagonal sockets) to a
torque of 79 Nm (58 lbf ft).

25 Insert the relief valve assemblies 34 into cover 17 and

tighten the caps 37 (14 mm A/F hexagonal sockets) 25
to a torque of 79 Nm (58 lbf ft).

Note: Ensure that the relief valves are replaced in their

original positions.
64

30
31 JS06220-C1
17 29 Fig 29.
28
28 Attach the motor with hexagonal bolts and spring
washers.
29
34
Size: 19 mm, Tightening torque: 103 Nm (76 lbf ft).

B
31 37
30 34
25

JS06130-C1
Fig 28.

26 Final checks after assembling. JS06120-C1

Fig 30.
Open the inlet and outlet ports and apply 30 kgf/cm2
(427 lbf/in2) pilot pressure to the brake release port. 29 Attach the level gauge A with a pipe wrench, setting
(Take care as oil will be discharged from the drain the height as shown.
port). Check that the drive shaft can be rotated
smoothly for at least one full revolution by applying a
torque of approx. 39 Nm (29 lbf ft).

E-106 9813/0400-1 E-106

 Section E - Hydraulics
Slew Motor
Dismantling and Assembly

26

JS06110-C1
JS06210-C1
Fig 33.
Fig 31.
31 Apply grease (type and capacity is given in Fluids
and Lubricants).

Note: Bleed air in the chamber from the air bleed port
before filling with grease, as a build-up of internal pressure
can damage the oil seal.

After the unit is filled, run it for around 10-15 minutes

at zero load, and at low speed and verify that there is
no abnormal noise or vibration. Gradually bring the
system into high speed and loaded operation.

Item Nm Kgf m lbf ft

Fig 32. B 103 16 76

30 Fill with gear oil through the filler port. 26 39 4 29

27 157 16 116
Insert plug 26 with an 8 mm Allen key and tighten to 28 78.5 8 58
torque of 39 Nm (29 lbf ft).
30 137 14 101
Note: Fill the hydraulic motor case with hydraulic oil
before connecting the piping to the drain port.

See Fluids and Lubricants, Section 3, for type and

quantity of oil.

E-107 9813/0400-1 E-107

 Section E - Hydraulics
Slew Motor
Dismantling and Assembly

Relief Valves
Dismantling 39

Refer to the sectional drawing as a guide to dismantling 44

and assembling.

Take steps during dismantling to ensure that all the parts

are returned to their original positions.
JS06240-C1
Clean the parts with a suitable solvent and blow them dry.
Fig 35.
Replace all used 'O'-rings

1 If not already done, remove cap 37 (with a 14 mm A/

F hexagonal socket) from the relief assemblies 34
and remove piston 38, liner 51, shim 40, poppet 43
and spring 42.

34

40
43 38

42
51

37 JS06230-C1

Fig 34.

2 The seat 44 is press-fitted into sleeve 39. Remove it

using a soft object, taking care not to scratch the seat
face.

E-108 9813/0400-1 E-108

 Section E - Hydraulics
Slew Motor
Dismantling and Assembly
Assembly

1 Press fit seat 44 into sleeve 39 which has an 'O'-ring

41.

2 Mount poppet 43, spring 42, shim 40, piston 38, liner
51 onto sleeve 39.

3 Screw cap 37 (with a 14 mm A/F hexagonal socket)

with 'O'-ring 36 and back-up 35 mounted, on to sleeve
39 and tighten to a torque of 157 Nm (116 lbf ft).

Check the relief set pressure.

The correlation between the set pressure of the relief

valve and the adjusting shims is shown below.
However, adjustment must not be attempted if the
pressure cannot be checked.

A 0.1 mm (0.003 in) shim equals 5 kgf/cm2 (71 lbf/in2)

approximately.

41
39
44
40
43 38
35
42
51
36
37
JS06250-C1

Fig 36.

E-109 9813/0400-1 E-109

 Section E - Hydraulics

Slew Gearbox
Reduction Gear Structure and Working Principles

Fig 1.

Table 1. Key Due to the severe conditions under which the output shaft
A A Chamber operates, an oil seal 61 is provided in the centre of gear
case 58 to protect the bearings from metal waste worn
B B Chamber
from the gears. The bearing in chamber A is lubricated with
C Torque path gear oil and the bearing in chamber B with grease.

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-110 9813/0400-1 E-110

 Section E - Hydraulics
Slew Gearbox
Description

Description

K Fig 3. ( T E-113)

3 10

11

12
4
13

7 14

8 15

16
9

17

C041470
Fig 2.

E-111 9813/0400-1 E-111

 Section E - Hydraulics
Slew Gearbox
Description

Component Identification
Table 2.
1 1st Reduction Sun Gear
2 1st Reduction Planet gear assembly
3 Bolt
4 Cover
5 2nd Reduction Sun Gear
6 O- ring Seal
7 Ring Gear
8 O- ring Seal
9 2nd Reduction planet gear assembly
10 Ring nut
11 Bearing
12 Seal
13 Gearbox housing
14 Bearing
15 Nylon ring
16 Spacer
17 Pinion Shaft

E-112 9813/0400-1 E-112

 Section E - Hydraulics
Slew Gearbox
Dismantling and Assembly

Dismantling and Assembly

Dismantling
Cleanliness is of the utmost importance when servicing the
gearbox. All precautions to prevent any ingress of dirt, grit
etc. must be taken K Fig 3. ( T E-113).

Note: For the details of service tool referred to see

Service Tools, Section 1.

1 Remove the bolts 3 which hold the cover 4 to the ring

gear and gear box cover 13.

a Lift out 1st Reduction Sun Gear 1

K Fig 4. ( T E-113).
Fig 4.
b Lift out 1st Reduction Planet gear assembly 2

c Lift out 2nd Reduction Sun gear 5

d Remove cover 4.

e Remove O- ring 6 from the ring gear

f Lift out 2nd Reduction Planet gear assembly 9.

g Remove ring gear 7

h Remove O-ring 89 from the ring.

2 Assemble the socket Box wrench and nut Adaptor

(see Service Tools, Section1) on the ring nut 10. By Fig 5.
using torque multiplier (1:25) loosen the ring nut 10.
Removing the nut K Fig 5. ( T E-113). 3 Using a 3 leg puller release gear box housing 13 from
pinion shaft 17 and bearing. Using suitable lifting
equipment, remove gearbox housing 13
K Fig 6. ( T E-114).

Fig 3.

E-113 9813/0400-1 E-113

 Section E - Hydraulics
Slew Gearbox
Dismantling and Assembly

Fig 8.

Fig 6. Inspection

4 Assemble the bearing Rig section 1) between the Before assembling the gear box make sure that a thorough
pinion shaft 17 and the bearing 14. Using suitable inspection of all the components is carried out. Remember
lifting equipment, place the unit in the tube provided that although a failed component may be easy to identify,
with the service tool. Using a press, push on the the cause may be less easy to trace. It is also possible that
pinion shaft 17 to separate it from the bearing 14. a failed component may have caused damage to other
Remove the bearing 14 nylon ring 15 from pinion areas of the gearbox.
shaft K Fig 7. ( T E-114)
Components that are subject to general wear and tear are
the following:

Gears 1,2,5,7,9

Pinion shaft 17

Bearings 11,14

Seals 10

1 Carefully clean all components using a suitable

degreasing agent.

2 Carefully inspect all gears, bearings and shafts for

Fig 7. signs of excessive wear or damage. If wear or
damage is evident, components must be renewed.
5 Turn gear box housing 13 upside down. Place seal
Ring tool on the seal 12 and, using a soft faced 3 In the case of damaged gears, for example a
hammer, tap service tool to remove seal 12. Remove planetary gear, do not proceed to replace the
bearing 11 from gear box housing 13 individual gears but the entire assembly.
K Fig 8. ( T E-114).

E-114 9813/0400-1 E-114

 Section E - Hydraulics
Slew Gearbox
Dismantling and Assembly

Assembly
Note: Apply clean hydraulic fluid to all sliding contact faces
during assembly. New seal must be use on assembly.

1 Place seal 12 on its seat in the gearbox housing 13.

2 Use the Ring Seal Tool A, see Service Tools and a

soft faced hammer to push the seal 12 against its
seat.

3 Turn the gearbox housing 13 upside down and apply

with grease K Fig 9. ( T E-115). Fig 10.

4 Place nylon ring 15 on the pinion shaft 17.

5 Place the bearing 14 on the pinion shaft

K Fig 10. ( T E-115).

6 Use tool, see Service Tools and a press to push the

bearing onto the pinion shaft and seated against the
shoulder.

7 Apply a coat of grease, on the bearing 14.

Fig 11.

8 Using suitable lifting equipment, lift the pinion shaft 17

into the tube of the bearing Rig.

9 Using suitable lifting equipment, place the gearbox

housing 13 into the pinion shaft 17.

Using the stopper Tool and a press push the gear

housing 13 against the pinion shaft and shoulder 17.

10 Insert the bearing 11 into the pinion 17 and using the

Fig 9. stopper Tool and press, assemble the output unit
K Fig 11. ( T E-115)

11 Apply JCB Threadlocked to the thread of a new ring

nut 10.

Assemble the socket box wrench and nut adapter

tools 18-B, see Service Tools on the ring nut 10.
tighten the ring nut 10 K Fig 12. ( T E-116).

E-115 9813/0400-1 E-115

 Section E - Hydraulics
Slew Gearbox
Dismantling and Assembly

Fig 12.

12 Place 2nd Reduction planetary gear assembly 9 over

the pinion shaft 17.

13 Replace O- Ring 8 into its seat in the ring gear 7.

14 Place ring gear 7 into the gear box housing, 13

making sure bolt holes are aligned.

15 Replace O ring 6 into its seat in the ring gear 7.

16 Insert the 2nd reduction sun gear 5 in the 2nd

reduction planetary gear assembly 9.

17 Assemble the cover 4 into the gear ring. Insert bolts

3 and tighten to 205 Nm torque.

18 Insert the 1st Reduction planet gear assembly 2.

19 Insert 1st reduction sun gear 1.

Torque Settings

Table 3.
Item Nm kgf m lbf ft
10 1400 1032 143
3 205 21 151

E-116 9813/0400-1 E-116

 Section E - Hydraulics
Slew Gearbox
Dismantling and Assembly

Page left intentionally blank

E-117 9813/0400-1 E-117

 Section E - Hydraulics

Rotary Coupling
Description

Fig 1.
Item Part no.
11 Axle
12 V- ring
13 Motor
14 O -ring
15 Packing ring
16 Thrust plate
17 Hexagonal Socket head
18 O-ring
19 Cover
20 Plug
21 Plug

K Fig 2. ( T E-119)

E-118 9813/0400-1 E-118

 Section E - Hydraulics
Rotary Coupling
Description

Fig 2.
Item Part no.
1 High strength bolt
2 High strength washer
3 JCB Threadlocker & Sealer high strength
4 Lock bar
5 Seal washer
6 Seal cap
7 Rubber Packing
8 Seal ring
9 Rotating joint assembly

E-119 9813/0400-1 E-119

 Section E - Hydraulics
Rotary Coupling
Removal and Replacement

Removal and Replacement

Removal !MWARNING
Refer to the sectional illustration on the previous page as Hydraulic Pressure
a guide to the dismantling and assembly procedures. Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
Using the excavator, raise the machine as shown and residual hydraulic pressure trapped in the service
block the undercarriage K Fig 3. ( T E-120). 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.
INT-3-1-11_2

!MWARNING
Take care when disconnecting hydraulic hoses and
fittings as the oil will be HOT.
TRANS-1-2

3 Attach identification tags to the rotary coupling hoses

for reconnection purposes. Remove the hoses and
install blind plugs and caps to prevent contamination
K Fig 5. ( T E-120).
Fig 3.

1 Prepare the machine.

a Stop the machine and release the hydraulic

pressure, (See Releasing Tank Pressure).

2 Remove the access panel K Fig 4. ( T E-120).

Fig 5.

4 Remove the Coupling.

Remove the two bolts B and remove lock bar A.

Remove the three mounting bolts C and carefully lift
the rotary coupling out of the machine
K Fig 6. ( T E-121).
Fig 4.

E-120 9813/0400-1 E-120

 Section E - Hydraulics
Rotary Coupling
Removal and Replacement

!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses and gloves.
Hold a piece of cardboard close to suspected leaks
and then inspect the cardboard for signs of fluid. If
fluid penetrates your skin, get medical help
immediately.
INT-3-1-10_3

Fig 6.

Replacement
1 Align the coupling (9) to the lower frame and tighten
the rotating joint installation bolt (1)
K Fig 7. ( T E-121).

Tighten the lock bar installation bolt (1) and washer

(2) to the specified torque, 109-127 Nm (11.1-2.9 kgf
m, 80.28-93.28 and install the lock bar.

Fig 7.

2 Reconnect the hoses and install the access cover.

Remove the wooden block and lower the machine to
the ground.

Start the machine and check for leaks.

E-121 9813/0400-1 E-121

 Section E - Hydraulics
Rotary Coupling
Dismantling and Assembly

Dismantling and Assembly

Dismantling
1 Remove the bolt 19 and cover 17
K Fig 8. ( T E-122).

Fig 10.

4 Remove seal F.

5 Using a jig push off the axle G from the rotor H

K Fig 11. ( T E-122).
Fig 8.
Do not hit with a hammer.
2 Remove the 'O'-ring C.

Do not reuse the 'O'-ring 18 K Fig 9. ( T E-122).

Fig 11.

6 Remove the V-ring J and nylon ring K from the axle H.

Note: Do not reuse the V-ring J and nylon ring K

Fig 9. K Fig 12. ( T E-122).

3 Remove bolts 16 and the thrust plate 17

K Fig 10. ( T E-122).

Fig 12.

E-122 9813/0400-1 E-122

 Section E - Hydraulics
Rotary Coupling
Dismantling and Assembly

Fig 16.
Fig 18.
4 Install the V-ring 12 and nylon ring on the axle 11and
grease adequately. Take care to prevent 6 Install a new seal K Fig 19. ( T E-124)
contamination of the grease by water or dirt
K Fig 17. ( T E-124).

Fig 19.
Fig 17.
7 Install a new 'O'-ring K Fig 20. ( T E-124).
5 Install the axle 11 to the rotor 13
K Fig 18. ( T E-124).

Note: Set the V-ring 12 so that it will not be cut or

scratched.

Fig 20.

8 Install the cover and bolts K Fig 21. ( T E-125).

E-124 9813/0400-1 E-124

 Section E - Hydraulics
Rotary Coupling
Dismantling and Assembly

Fig 21.

E-125 9813/0400-1 E-125

 Section E - Hydraulics

Hydraulic Rams
Precautions During Use
TE-006

Installation Special seal materials are necessary so check to

see if the ram that you are using is suitable or not.
1 Precautions when installing the ram on the machine.
c The number one cause of ram oil leakage is rod
a When installing and removing from the machine, damage. Be careful not to damage the rod.
suspend the ram safely.
2 Warm up sufficiently before beginning work.
b Suspending the ram by the piping is not only
dangerous, but can also cause damage to the a In cold conditions the rod seals may be frozen, so
cylinder. if the ram is operated at maximum pressure and
maximum speed, the seals will be damaged.
c Secure the piston rod with a band. It is very
dangerous if the rod extends unexpectedly. Also, b There is a large amount of air in a new ram or one
the rod can be damaged and become unusable. which has been left for a long time, so the ram will
not operate smoothly. Also, if pressure is applied
2 Welding after installing the ram may result in damage. suddenly without bleeding the air, high
temperatures will be generated due to adiabatic
a If electric welding is done even at a point away compression and the seals may burn.
from the ram, there may be sparking inside the
ram and it will become necessary to replace the c Before beginning work, always move the ram at
ram with a new one. full stroke with no load and expel air from the
cylinder.
3 When painting the machine, mask the ram.
3 When stopping or storing, do it at a safe and fixed
a If paint adheres to the rod surface or to the wiper position.
ring and the ram is operated, the wiper ring will not
function properly and foreign matter and paint can a The installed ram cannot maintain the same
easily enter the ram. This will cause damage to position for a long period of time, because the oil
the seals, drastically shortening the life of the ram. inside the ram may leak and the hydraulic oil
volume decreases as it cools. Stop or store the
4 Install the ram only when it is clean. machine in a safe and fixed position.

Caution During Use Maintenance, Inspection Points

1 Use only under designated conditions. 1 Carry out daily maintenance and inspection.

a If hydraulic oil other than the designated oil is a The key point for correct long-term ram function is
used, the seals quickly degenerate and become daily maintenance and inspection. Carry out
damaged. If the relief valve is set at a value higher maintenance and inspection so that the ram
than specified, it may cause ram damage and is functions fully at all times. Always remove any
dangerous. mud, water, dust or oil film adhering to the rod and
keep it in normal condition. However, when
b In high temperature environments (approx. 90°C cleaning the wiper ring and seals, do not get them
and above) or low temperature environments wet with water but wipe clean with a rag. To
(below -20°C), seals quickly become damaged. prevent rust forming during storage, the amount of
exposed ram piston rod should be kept to a

E-126 9813/0400-1 E-126

 Section E - Hydraulics
Hydraulic Rams
Precautions During Use
minimum. If leaving for more than one week,
apply a light coating of suitable grease or
petroleum jelly to the exposed part of the ram
piston rod.

2 Use genuine JCB parts when replacing parts.

a If parts other than genuine JCB parts are used,

the desired results may not be obtained. Use only
genuine JCB parts.

3 Caution during dismantling and reassembly.

a Dismantling the ram while it is still installed on the

machine can be dangerous as unexpected
movements of the machine can occur. Remove
the ram from the machine and then dismantle.

b If reassembled with dirty hands, foreign matter

can enter the ram causing a shorter life span and
also the other hydraulic equipment may be
damaged. Reassemble in a clean state.

c Follow the instructions in the diagrams regarding

torque tightening for screwed parts. If the torque is
too high or too low, it can cause damage.

E-127 9813/0400-1 E-127

 Section E - Hydraulics
Hydraulic Rams
Removal and Replacement

Removal and Replacement

Typical Bucket Ram

P11-E001_2

Removal

!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service 803090
line has been vented before connecting or removing Fig 2.
hoses. Make sure the engine cannot be started while
the hoses are open. 3 Stop the engine, remove the key.
INT-3-1-11_2
Release the tank pressure, see Releasing the Tank
!MWARNING Pressure.

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.
INT-1-3-7_2

1 Lower the attachment to the ground.

709600
Fig 3.

4 Remove the nuts and bolts from the rod end of the
ram.

709670
Fig 1.

2 Place a wooden block under the bucket ram.

E-128 9813/0400-1 E-128

 Section E - Hydraulics
Hydraulic Rams
Removal and Replacement

803091

803140
Fig 6.
Fig 4.
7 Remove the ram hoses and install plugs or caps to
5 Push the pin out using a bar and hammer. prevent contamination.

!MWARNING 8 Attach slings to support the ram.

Metal Splinters
You can be injured by flying metal splinters when
driving metal pins in or out. Use a soft faced hammer
or copper pin to remove and fit metal pins. Always
wear safety glasses.
INT-3-1-3_2

803095-1
Fig 7.

9 Remove the nuts and bolts from the cylinder end of

the ram. Push out the pin using a bar and hammer.
Lift the ram clear.

!MWARNING
Metal Splinters
You can be injured by flying metal splinters when
803141
Fig 5. driving metal pins in or out. Use a soft faced hammer
or copper pin to remove and fit metal pins. Always
6 Restrain the eye end of the ram piston rod to the ram wear safety glasses.
cylinder to prevent the piston rod from extending. INT-3-1-3_2

E-129 9813/0400-1 E-129

 Section E - Hydraulics
Hydraulic Rams
Removal and Replacement
2 Install the pin, bolt and nuts to the cylinder end of the
ram.

803093
Fig 10.

803092
Fig 8.

Replacement

1 Attach slings to the ram and lift it into position on the

dipper.

Fig 11.

Note: When checking or refitting JS machine pivot pins,

the retaining nuts and bolts should not be fastened up tight
to the pivot boss but must have approximately 3mm of play
so that the pin is free from tension.

3 Connect the hoses.

803096-1
Fig 9.

E-130 9813/0400-1 E-130

 Section E - Hydraulics
Hydraulic Rams
Removal and Replacement

A409820-C2
Fig 14.
803094
Fig 12. Note: When checking or refitting JS machine pivot pins,
the retaining nuts and bolts should not be fastened up tight
to the pivot boss but must have approximately 3mm of play
so that the pin is free from tension.

803142
Fig 13.

4 Hoist the ram to align with the link.

Install the pin, bolt and nuts.

Note: Stroke the ram to release entrapped air. After

releasing the air, check for oil leakage.

E-131 9813/0400-1 E-131

 Section E - Hydraulics
Hydraulic Rams
Removal and Replacement

Typical Dipper Ram

P11-E003_1

Removal

!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
803190
INT-3-1-11_2 Fig 16.

!MWARNING 3 Stop the engine, remove the key.

Lifting Equipment Release the tank pressure, see Releasing the Tank
You can be injured if you use incorrect or faulty lifting Pressure
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.
INT-1-3-7_2

1 Lower the attachment to the ground, as shown.

709600
Fig 17.

4 Remove the nuts and bolts from the rod end of the
709670
ram.
Fig 15.

2 Place a wooden block under the dipper ram.

E-132 9813/0400-1 E-132

 Section E - Hydraulics
Hydraulic Rams
Removal and Replacement

803151
Fig 18.
803150

!MWARNING Fig 19.

Metal Splinters 6 Restrain the eye end of the ram piston rod to the ram
You can be injured by flying metal splinters when cylinder to prevent the piston rod from extending.
driving metal pins in or out. Use a soft faced hammer
or copper pin to remove and fit metal pins. Always
wear safety glasses.
INT-3-1-3_2

5 Push out the pin, using a bar and hammer.

803160
Fig 20.

7 Remove the ram hoses, and install plugs or caps to

prevent contamination.

Remove the grease tube.

E-133 9813/0400-1 E-133

 Section E - Hydraulics
Hydraulic Rams
Removal and Replacement

!MWARNING
Metal Splinters
You can be injured by flying metal splinters when
driving metal pins in or out. Use a soft faced hammer
or copper pin to remove and fit metal pins. Always
wear safety glasses.
INT-3-1-3_2

803170
Fig 21.

8 Attach slings to support the ram.

803200-1
Fig 23.

Replacement

1 Attach slings and lift the ram onto the boom.

803180-1
Fig 22.

9 Remove the nuts and bolts from the cylinder end of

the ram, push out the pin using a bar and hammer. Lift
the ram clear.

E-134 9813/0400-1 E-134

 Section E - Hydraulics
Hydraulic Rams
Removal and Replacement

803201
Fig 25.
803181-1
Fig 24.

2 Install the pin, bolts and nuts.

!MWARNING
Metal Splinters
You can be injured by flying metal splinters when
driving metal pins in or out. Use a soft faced hammer
or copper pin to remove and fit metal pins. Always
wear safety glasses.
INT-3-1-3_2 A409820-C2
Fig 26.

Note: When checking or refitting JS machine pivot pins,

the retaining nuts and bolts should not be fastened up tight
to the pivot boss but must have approximately 3mm of play
so that the pin is free from tension.

3 Install the grease tube and connect the hoses.

E-135 9813/0400-1 E-135

 Section E - Hydraulics
Hydraulic Rams
Removal and Replacement

A409820-C2
803171
Fig 29.
Fig 27.
Note: When checking or refitting JS machine pivot pins,
4 Hoist the ram to align the piston rod eye end with the
the retaining nuts and bolts should not be fastened up tight
dipper pin position.
to the pivot boss but must have approximately 3mm of play
so that the pin is free from tension.
5 Install the pin, bolt and nuts.

Note: Stroke the ram to release entrapped air. After

releasing the air, check for oil leakage.

!MWARNING
Metal Splinters
You can be injured by flying metal splinters when
driving metal pins in or out. Use a soft faced hammer
or copper pin to remove and fit metal pins. Always
wear safety glasses.
INT-3-1-3_2

803152
Fig 28.

E-136 9813/0400-1 E-136

 Section E - Hydraulics
Hydraulic Rams
Removal and Replacement

Typical Boom Ram

P11-E002_2

Removal

!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
803210

!MWARNING
Fig 31.

3 Remove the nuts, bolt and collar.

Lifting Equipment
You can be injured if you use incorrect or faulty lifting
equipment. You must identify the weight of the item to !MWARNING
be lifted then choose lifting equipment that is strong
enough and suitable for the job. Make sure that lifting Metal Splinters
equipment is in good condition and complies with all You can be injured by flying metal splinters when
local regulations. driving metal pins in or out. Use a soft faced hammer
or copper pin to remove and fit metal pins. Always
INT-1-3-7_2
wear safety glasses.
1 Lower the attachment to the ground, as shown. INT-3-1-3_2

Push out the pin, using a bar and hammer.

709670
Fig 30.

Stop the engine, remove the key.

2 Remove the grease tube and attach slings to the

boom ram.

803211
Fig 32.

4 Lower the ram and place it on a stand.

E-137 9813/0400-1 E-137

 Section E - Hydraulics
Hydraulic Rams
Removal and Replacement
6 Release the tank pressure, see Releasing the Tank
Pressure.

709600
Fig 35.

7 Remove the hoses, and install plugs or caps to

prevent contamination.

803222-1
Fig 33.

5 Restrain the eye end of the piston rod to the ram

cylinder, to prevent movement of the rod.

803220-1
Fig 36.

8 Remove the nut and bolt and push out the pin with a
hammer and bar.

!MWARNING
Metal Splinters
You can be injured by flying metal splinters when
driving metal pins in or out. Use a soft faced hammer
or copper pin to remove and fit metal pins. Always
wear safety glasses.
INT-3-1-3_2

803221-1
Fig 34.

E-138 9813/0400-1 E-138

 Section E - Hydraulics
Hydraulic Rams
Removal and Replacement
Replacement

1 Attach slings to the ram.

Align the ram to its installation position.

803223-1
Fig 37.

9 Lift the ram away from the unit.

803224-1
Fig 38.

2 Install the pin and then the bolt and nuts.

!MWARNING
Metal Splinters
You can be injured by flying metal splinters when
driving metal pins in or out. Use a soft faced hammer
or copper pin to remove and fit metal pins. Always
wear safety glasses.
INT-3-1-3_2

E-139 9813/0400-1 E-139

 Section E - Hydraulics
Hydraulic Rams
Removal and Replacement

803226-1
Fig 41.

803225-1 4 Lift the ram and align the rod eye end with the pin
Fig 39. position.

A409820-C2
Fig 40.
803213-1
Fig 42.
Note: When checking or refitting JS machine pivot pins,
the retaining nuts and bolts should not be fastened up tight 5 Install the pin with a bar and hammer.
to the pivot boss but must have approximately 3mm of play

!MWARNING
so that the pin is free from tension.

3 Install the hoses. Metal Splinters

You can be injured by flying metal splinters when
driving metal pins in or out. Use a soft faced hammer
or copper pin to remove and fit metal pins. Always
wear safety glasses.
INT-3-1-3_2

E-140 9813/0400-1 E-140

 Section E - Hydraulics
Hydraulic Rams
Removal and Replacement
Note: When checking or refitting JS machine pivot pins,
the retaining nuts and bolts should not be fastened up tight
to the pivot boss but must have approximately 3mm of play
so that the pin is free from tension.

7 Connect the grease tube.

Note: Stroke the ram and release entrapped air. After

releasing the air, check for oil leakage.

803212-1
Fig 43.

6 Install the collar and then the bolt and nuts.

803214-1
Fig 44.

A409820-C2
Fig 45.

E-141 9813/0400-1 E-141

 Section E - Hydraulics
Hydraulic Rams
Removal and Replacement

Typical Triple Articulated Boom (TAB)

Ram
P11-E004

Removal

!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while JS07240-C1
the hoses are open. Fig 47.
INT-3-1-11_2
3 Release the tank pressure, see Releasing the Tank
!MWARNING Pressure.

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.
INT-1-3-7_2

1 Park the machine on level ground and, with the

bucket and dipper rams fully retracted and the TAB
ram partially extended, lower the attachment to the Fig 48.
ground.
4 Remove the pivot pin retaining nuts and bolt from the
rod end of the ram.

Fig 46.

Stop the engine and remove the key.

2 Attach suitable lifting gear to the TAB ram and just

take up the slack.

JS07250-C1

Fig 49.

E-142 9813/0400-1 E-142

 Section E - Hydraulics
Hydraulic Rams
Removal and Replacement
5 Knock out the pivot pin using a bar and hammer.

!MWARNING
Metal Splinters
You can be injured by flying metal splinters when
driving metal pins in or out. Use a soft faced hammer
or copper pin to remove and fit metal pins. Always
wear safety glasses.
INT-3-1-3_2

JS07280-C1

Fig 52.

8 Remove the pivot pin retaining nuts and bolt from the
cylinder end of the ram. Knock out the pin using a bar
and hammer. Lower the ram clear.

!MWARNING
Metal Splinters
You can be injured by flying metal splinters when
JS07260-C1 driving metal pins in or out. Use a soft faced hammer
or copper pin to remove and fit metal pins. Always
Fig 50.
wear safety glasses.
INT-3-1-3_2
6 Fully retract the ram and secure the eye end of the
ram piston rod to the ram cylinder to prevent the
piston rod from extending.

JS07290-C1

Fig 53.

JS07270-C1

Fig 51.

7 Disconnect the hoses and install plugs and caps to

prevent contamination. Discard the `O' ring seal.

E-143 9813/0400-1 E-143

 Section E - Hydraulics
Hydraulic Rams
Removal and Replacement
Replacement

1 Attach suitable lifting gear and manoeuvre the TAB

ram to locate the cylinder end eye with its mounting.

Fig 56.

Note: When checking or refitting JS machine pivot pins,

the retaining nuts and bolts should not be fastened up tight
to the pivot boss but must have approximately 3mm of play
so that the pin is free from tension.
JS07300-C1
3 Fit new `O' ring seal to the connection flange.
Fig 54. Connect the hoses.
2 Install the cylinder eye retaining pin, bolt and nuts.

!MWARNING
Metal Splinters
You can be injured by flying metal splinters when
driving metal pins in or out. Use a soft faced hammer
or copper pin to remove and fit metal pins. Always
wear safety glasses.
INT-3-1-3_2

JS07280-C1

Fig 57.

4 Hoist the ram and extend the piston rod to align the
piston rod eye end with the boom mounting.

JS07290-C1

Fig 55.

E-144 9813/0400-1 E-144

 Section E - Hydraulics
Hydraulic Rams
Removal and Replacement

Fig 60.

JS07310-C1
Note: When checking or refitting JS machine pivot pins,
the retaining nuts and bolts should not be fastened up tight
Fig 58. to the pivot boss but must have approximately 3mm of play
so that the pin is free from tension.
5 Install the pivot pin and retaining bolt and nuts.
6 Once the installation is complete, start the engine and
!MWARNING raise the boom fully. Under no load conditions, expel
any trapped air by operating the ram to full stroke in
Metal Splinters both directions several times. Check for oil leaks.
You can be injured by flying metal splinters when
driving metal pins in or out. Use a soft faced hammer
or copper pin to remove and fit metal pins. Always
wear safety glasses.
INT-3-1-3_2

JS07320-C1

Fig 59.

E-145 9813/0400-1 E-145

 Section E - Hydraulics
Hydraulic Rams
Dismantling and Assembly

Dismantling and Assembly

TE-023

Dismantling the Piston Rod from the

Cylinder Tube
Refer to Section 1, Service Tools.

Before starting work, clean all surfaces with a suitable

solvent and dry with compressed air.

Each part is precision made, so handle with care. Do not

force any part as this may cause damage.

Protect the dismantled parts if they are to be left for a

period of time.

1 Drain the oil.

2 Disconnect the external piping.

3 Secure the ram.

Note: Fix the ram in a vertical or horizontal position. The

vertical position is more favourable for dismantling/re-
assembly work. Use the bottom pin hole for preventing the
ram from turning on its axis and for fixing the ram in the
axial position.

Remove the cylinder head cap screws (14 off) with an

Allen wrench. Use an extension pipe such as shown in the
figure below to facilitate bolt loosening.

1.5 m

C027430
Fig 62.

C027380
Fig 61.

E-146 9813/0400-1 E-146

 Section E - Hydraulics
Hydraulic Rams
Dismantling and Assembly

Dismantling the Piston Rod

Note: protect all the parts from dirt.

1 Secure the piston rod pack on the bench, brace the

piston rod head K Fig 63. ( T E-147).

373460a-V1
Fig 63.

2 Un-fasten and remove the stop screw X.

C030720
Fig 66.

5 Remove cushion ring A.

A
C030710-C1
Fig 64.

3 Un-fasten the nut K Fig 65. ( T E-147).

C030730-C1
Fig 67.

373460B-V1
6 Remove cylinder head
Fig 65.
Note: Protect the threads.
4 Fit Jig to piston K Fig 66. ( T E-147). Un-fasten
piston and then remove from piston rod.

E-147 9813/0400-1 E-147

 Section E - Hydraulics
Hydraulic Rams
Dismantling and Assembly

Removing the Piston Seals

Note: Never reuse seals.

While dismantling, handle the piston very carefully.

1 Remove the two slide ring A, two wear rings B, two

backup rings C, slipper seal D and slipper seal back
up ring E from the piston.

A B C D B A

C030740-C1
Fig 68.

2 Remove the o-ring A and backup ring B from the

inside of the piston.

Take care not to damage the surface.

A
B

C030780-C1
Fig 69.

E-148 9813/0400-1 E-148

 Section E - Hydraulics
Hydraulic Rams
Dismantling and Assembly

Removing the Cylinder Head Seals

1 remove the o-ring A and back up ring from the
cylinder head.

C030810
Fig 72.

A 4 Using a special pull out tool, remove the U-packing

ring. Using the pull out tool then remove the backup
ring and buffer seal K Fig 73. ( T E-149).
C030790-C1
Fig 70.

2 Insert tool into gap of retaining ring and remove from

its seat in the housing K Fig 71. ( T E-149).

C030860
Fig 73.

5 Repeat step 2 for the bush retaining ring

C030800 K Fig 74. ( T E-150).
Fig 71.

3 With the use of a take out tool, carefully extract the

dust wiper ensuring not to damage the surface of the
housing K Fig 72. ( T E-149).

E-149 9813/0400-1 E-149

 Section E - Hydraulics
Hydraulic Rams
Dismantling and Assembly
7 Remove the du-bush K Fig 76. ( T E-150).

C030900
Fig 76.

C030880
Fig 74.

6 Using a suitable tool, split the du-bush

K Fig 75. ( T E-150).

C030890
Fig 75.

E-150 9813/0400-1 E-150

 Section E - Hydraulics
Hydraulic Rams
Dismantling and Assembly

Assembly of Piston Seals

Before Assembly

1 Ensure that piton surface is clean and free from

damage. Ensure that slipper seal insertion tool is free
from defects. Burrs or marks may damage the seals
and cause leakage. Check the outside of the tool
carefully.

2 Fit the back up ring B into it seat on the inside of the

piston. Instal the o-ring A using the same method as
the backup ring.
C030910
Make sure the O-ring is not twisted after assembly. Fig 78.

4 Fit the first back up ring K Fig 79. ( T E-151).

A
B

C030920
C030780-C1
Fig 79.
Fig 77.
5 Carefully locate the slipper seal insertion jig onto the
3 Fit the slipper back up ring by inserting it in one side
piston K Fig 80. ( T E-151).
of its seat and stretching it to the other side by using
a screwdriver. ensure it sits in its seat and is not
twisted K Fig 78. ( T E-151)

C030930
Fig 80.

E-151 9813/0400-1 E-151

 Section E - Hydraulics
Hydraulic Rams
Dismantling and Assembly
6 Fit the heated slipper seal A (approximately 200°C)
into its installation grove B using the insertion jig.

Damage to the surface of the slipper seal cap will

affect its sealing performance. Be careful not to
scratch the surfaces of the seal when installing.

A
C030960
Fig 83.

Note: Wear and slide ring slits must not be aligned

K Fig 84. ( T E-152).
B

C030940-C1
Fig 81.

7 Fit the second back up ring.

8 Install the two wear rings into their installation

grooves K Fig 82. ( T E-152).

C030970
Fig 84.

C030950
Fig 82.

9 First twist and then fit the two slide rings into their
installation groves K Fig 83. ( T E-152).

E-152 9813/0400-1 E-152

 Section E - Hydraulics
Hydraulic Rams
Dismantling and Assembly

Assembling the Cylinder Head Seals

Before Assembly

Check that the assembly tools are free from defect. Clean
tools before starting. Clean cylinder head before assembly.
Check that grooves are clean and not damaged.

1 locate du-bush to cylinder and push into place using

a press K Fig 85. ( T E-153). Fit the bush retaining
ring.

373600-V1
Fig 87.

4 Fit the buffer ring into its seat in the cylinder head
K Fig 88. ( T E-153). Fit back up ring after putting
the buffer ring in place ensuring correct orientation. A
is correct B is incorrect.K Fig 89. ( T E-154).

C030980
Fig 85.

2 Fit the back up ring in its seat on the cylinder head

K Fig 86. ( T E-153).

C031020
Fig 88.

C031000
Fig 86.

3 Bend the buffer ring to a loose curve before fitting,

K Fig 87. ( T E-153).

E-153 9813/0400-1 E-153

 Section E - Hydraulics
Hydraulic Rams
Dismantling and Assembly

A B

C031040-C1
Fig 89. C031060
Fig 91.
5 Deform the u-packing ring into a loose curve with the
u-packing holder and insert it into its fitting groove 7 Install the retaining ring into it groove
K Fig 90. ( T E-154). Fit the back up ring after fitting K Fig 92. ( T E-154).
the u-packing ring.

C031070
Fig 92.

C031050
Fig 90.

6 Place the Wiper ring into the cylinder head

horizontally. Using the insertion tool, carefully press
the wiper into position making sure not to deform the
wiper lip K Fig 91. ( T E-154).

E-154 9813/0400-1 E-154

 Section E - Hydraulics
Hydraulic Rams
Dismantling and Assembly

Assembly of the Piston Rod

The cylinder components must be cleaned before
assembly. The piston and cylinder head must be cleaned
before seal assembly and be kept clean up until this stage.
Do not clean piston or cylinder head with seals fitted.

1 Secure the piston rod pack on the bench, brace the

piston rod head.

2 Carefully fit the cylinder head onto the piston rod

ensuring that the threads are not damaged.

3 Fit the cushion ring A

C030720
Fig 94.

5 Assemble the nut onto the piston rod and torque

tighten to stated torque value. K Table 2. ( T E-155).
C030730-C1
Fig 93.
Table 2.
Ram Piston Rod Nut
4 Assemble the piston head onto the piston rod. Fit the
Jig to piston and torque tighten the piston to stated Boom 1860 Nm +/- 186 Nm (1374 lbf ft +/- 137
torque value.K Table 1. ( T E-155). lbf ft) (190 kgf m +/- 19 kgf m)
Bucket 1860 Nm +/- 186 Nm (1374 lbf ft +/- 137
Table 1. lbf ft) (190 kgf m +/- 19 kgf m)
Ram Piston
Dipper 1860 Nm +/- 186 Nm (1374 lbf ft +/- 137
Boom 981 Nm +/- 98 Nm (723 lbf ft +/- 72 lbf ft) lbf ft) (190 kgf m +/- 19 kgf m)
(100 kgf m +/- 10 kgf m)
Bucket 981 Nm +/- 98 Nm (723 lbf ft +/- 72 lbf ft)
(100 kgf m +/- 10 kgf m)
Dipper 981 Nm +/- 98 Nm (723 lbf ft +/- 72 lbf ft)
(100 kgf m +/- 10 kgf m)

373460B-V2
Fig 95.

6 Locate and fasten the stop screw X and torque tighten

to stated torque value.K Table 3. ( T E-156).

E-155 9813/0400-1 E-155

 Section E - Hydraulics
Hydraulic Rams
Dismantling and Assembly

Assembly of Piston Rod in Cylinder Tube

X
1 Make sure that assembly tools and cylinder tube are
clean before assembly. The piston rod pack must be
protected from dirt up until this stage. Assembly
should be made vertically.

Secure the cylinder tube K Fig 97. ( T E-156) and

bring the end of the piston rod to the cylinder tube
opening.

C030710-C1
Fig 96.

Table 3.
Ram Stop Screw(1)
Boom 15 Nm (11 lbf ft) (1.5 kgf m)
Bucket 15 Nm (11 lbf ft) (1.5 kgf m)
Dipper 15 Nm (11 lbf ft) (1.5 kgf m)

(1) Apply Loctite #242 on the threaded portion (caulking

after tightening).

373740A-V1
Fig 97.

Release the end-flange cover on the cylinder tube in

order to let air out from the tube during assembly.

Make sure the piston rod head is turned in the right

position in relation to the bottom of the cylinder.

2 Before assembly, make sure that guiding slits on the

piston are not aligned K Fig 98. ( T E-157).

E-156 9813/0400-1 E-156

 Section E - Hydraulics
Hydraulic Rams
Dismantling and Assembly
4 Tighten in order according to K Fig 100. ( T E-157).

Note: Be careful not to damage the piston rod!

8 1
4 9
11 5
14 13

6 12
373740b-V1
Fig 98. 10 3
3 Put the piston rod pack into the cylinder tube. Make
2 7
C031080
sure that the piston guiding ring does not get jammed
Fig 100.
during assembly.
Table 4.
Clean hydraulic oil will help, but do not use a brush as
Ram Gland Housing(1)
hairs may come off.
Boom 383~412 Nm (282~304 lbf ft) (39~42 kgf.m)
When running the piston rod in, turn the cylinder head Bucket 383~412 Nm (282~304 lbf ft) (39~42 kgf.m)
into the right position. Finish doing this before the
cylinder head O-ring has reached the cylinder tube Dipper 628~687 Nm (463~507 lbf ft) (64~70 kgf.m)
K Fig 99. ( T E-157). Do not use assembly grease.
(1) Apply Loctite #242 on the threaded portion.
Fasten the cover.

Fasten cylinder head screws and torque tighten to

stated torque valve. K Table 4. ( T E-157)

373770A-V1
Fig 99.

E-157 9813/0400-1 E-157

 Section E - Hydraulics
Hydraulic Rams
Maintenance Specifications

Maintenance Specifications

In order to ensure long life of the hydraulic ram, carry out is found, repair as soon as possible referring to the
inspection and maintenance regularly. If an abnormal point troubleshooting chart.

Table 5.
Inspection, Inspection, Maintenance Contents Daily Monthly Annually Note
Maintenance Point
Is the ram kept clean (especially the rod sliding
O
part)?
Is there oil leakage from piping installation and fixing
Appearance O
points?
Is there any peeling paint, separation or rust? O

Are the movements smooth and are there any

O
abnormal sounds?
Is the response good? O
Is there oil leakage from the sliding parts? O
Operation Is there internal leakage? O
Is the working pressure normal? O
Is the set pressure for the overload relief valve
O
normal?

Is the hydraulic oil dirty or deteriorated? O

Is the hydraulic oil replaced periodically? O
Hydraulic Oil
Are the filters inspected periodically? O

Is the pin greasing sufficient? O

Is the pin greasing sufficient? O
Is there backlash or wear in the pins? O
Installation with
Is the pin seal normal? O
Main Body
Are the installation screws loose or missing? O
Tightening of the installation screws? O

Are the sliding parts worn? O When the rod

Are there scratches or dents on the sliding parts? O sliding part is
exposed for a
Is there coating separation on the sliding parts? O long period of
Piston Rod
Are the sliding parts bent? O time apply
anti-rust oil to
Are there cracks in the welding or other damage? O
the rod.

E-158 9813/0400-1 E-158

 Section E - Hydraulics
Hydraulic Rams
Maintenance Specifications

Inspection, Inspection, Maintenance Contents Daily Monthly Annually Note

Maintenance Point
Are the bolts, nuts loose? O
Are the bolts, nuts tightened? O
Ram Cylinder
Are there cracks in the welding or other damage? O
(Including Piping)
Are there big depressions or dents in the cylinder? O

Use Limit
Table 6. Piston Rod Outer Diameter Wear Limit
Nominal diameter (mm) Minimum outer diameter (mm) Treatment
55~80 -0.023 Replace or replate
85~120 -0.027 Replace or replate

Table 7. Rod Bushing Inner Diameter Wear Limit

Nominal diameter (mm) Standard inner diameter (mm) Maximum inner diameter (mm) Treatment
55~75 +0.06~+0.19 +0.30 Bushing replacement
80~120 +0.06~+0.195 +0.30 Bushing replacement

Table 8. Piston Slide Ring Thickness Wear Limit Section

Nominal diameter (mm) Standard thickness (mm) Maximum thickness (mm) Treatment
95~160 2.42~2.48 2.37 Replace slide ring
165~250 2.92~2.98 2.87 Replace slide ring

E-159 9813/0400-1 E-159

 Section E - Hydraulics

Service Procedure
Make the Machine Safe
TE-009

Note: You can complete most of the maintenance

procedures with the boom lowered. Unless a maintenance
procedure instructs you differently, you must lower the
boom.

You must make the machine safe before you complete any
service procedures.

1 Park the machine on firm level ground.

2 Apply the parking brake (if fitted).

3 Lower the equipment or, raise and fit the applicable

safety strut.

4 Stop the engine.

5 Turn the ignition to the `ON' position.

6 Operate the hand controllers to release pressure in

the hydraulic system.

7 Turn the ignition to the `OFF' position.

8 Remove the starter key

9 Disconnect the battery (if necessary).

10 Release the hydraulic oil tank pressure.

11 Chock the wheels/tracks as applicable.

12 If the machine is raised from the ground make sure it

is securely chocked. NEVER WORK UNDER A
MACHINE RAISED ON STABILISERS OR JACKS.

13 If you wish to arc weld the machine disconnect the

alternator and electronic control units (if fitted).

E-160 9813/0400-1 E-160

 Section E - Hydraulics
Service Procedure
Pressure Testing - General

Pressure Testing - General

Confirmation of the Oil Temperature

Confirm the oil temperature is between 45°C - 55°C using
the self check function. If the temperature is low use the
following warm-up procedure.

Warming-up Procedure
1 Turn the throttle control to mid-range and make sure
the work mode is set to E.

2 Run the engine until the coolant temperature gauge

reads within the normal (green) range.

3 Set the servo isolator switch to ON to enable the

hydraulic servo controls to be operated.

4 Operate the bucket control slowly until it reaches one

end of its travel and leave it there for 10 seconds.

5 Operate the bucket control slowly to the other end of

its travel and leave it there for 10 seconds.

6 Repeat steps 4 and 5 for 10 minutes to warm up the

hydraulic circuit.

7 Operate the excavating controls three to five times in

each direction to distribute warm hydraulic oil around
the system.

Note: All pressure testing to be carried out with the engine

set at minimum engine revs unless otherwise stated.

E-161 9813/0400-1 E-161

 Section E - Hydraulics
Service Procedure
Pressure Testing - General

Pressure Testing Points

TP3

TP1

TP2

C068440-C1
Fig 1.
TP1 Main Pump P1
TP2 Main Pump P2
TP3 Servo Pressure

K Table 1. ( T E-163)

E-162 9813/0400-1 E-162

 Section E - Hydraulics
Service Procedure
Pressure Testing - General
Table 1.
Part Name Pressure bar (lb/in2) Measurement Method Measurement Port
K Fig 1. ( T E-162)
Main Relief Standard: 343 bar (4975 lb/in2) Dipper Relief K Main TP1 or TP2
Power Boost: 373 bar (5395 lb/in2) Relief Valve (MRV)
Pressure ( T E-166)
Pilot Relief 37 - 43 bar (537 - 624 lb/in2) Lever Neutral K Servo TP3
Relief
Pressure ( T E-168)
Slew Port Relief Left/Right 289 bar (4192 lb/in2) Slew Relief K Slew TP2
Motor Pressure
Relief ( T E-175)
Boom Port Relief Raise 392 bar (5685 lb/in2) Boom Up Relief TP1(1)
K Auxiliary Relief
Valves ( T E-169)
Lower 264 bar (3829 lb/in2) Boom down Relief TP1
K Auxiliary Relief
Valves ( T E-169)
Bucket Port Relief Open/Close 392 bar (5685 lb/in2) Bucket Relief TP1(1)
K Auxiliary Relief
Valves ( T E-169)
Dipper Port Relief Out/In 392 bar (5685 lb/in2) Dipper Relief TP2(1)
K Auxiliary Relief
Valves ( T E-169)
Track Motor Relief 353bar (5112 lb/in2) Track Relief K Travel TP1 or TP2(1)
Motor Relief
Pressure ( T E-177)

(1) The main relief setting must be increased during testing.

E-163 9813/0400-1 E-163

 Section E - Hydraulics
Service Procedure
Pressure Relief Valve Location

Pressure Relief Valve Location

TE-011

1 4

9
8

10

11
C047240-C1>
Fig 2.

K Table 2. ( T E-165)

E-164 9813/0400-1 E-164

 Section E - Hydraulics
Service Procedure
Pressure Relief Valve Location
Table 2.
1 Main Relief Valve (MRV)
2 Tab/Dozer Relief Valve
3 Arm Out Relief Valve
4 Option Relief Valve
5 Boom Up Relief Valve
6 Bucket Close Relief Valve
7 Option Relief Valve
8 Arm In Relief Valve
9 T.A.B./Dozer Relief Valve
10 Boom Down Relief Valve
11 Bucket Open Relief Valve
K Fig 2. ( T E-164).

E-165 9813/0400-1 E-165

 Section E - Hydraulics
Service Procedure
Main Relief Valve (MRV) Pressure

Main Relief Valve (MRV) Pressure

TE-012

1 Prepare the Machine

a Operate the dipper out and lower the boom to set

the bucket on the ground.

C030150-1
Fig 3. C
b Make the machine safe, refer to Section E, A
Service Procedures.

c Install a 0 - 400 bar (0 - 6000 lb/in2) pressure

gauge in TP1 or TP2.
D
d Start the engine, and confirm that the engine is at B
its maximum no-load speed and it is in the E mode E
to test standard pressure and L mode to test
power boost pressure.
A406580-C1
e Raise the boom and then operate the dipper out Fig 4.
control. Read the pressure gauge with the dipper
ram stalled at the end of its stroke. a Make the machine safe, refer to Section E,
Service Procedures.
f If it is outside the limits, stop the engine and adjust
the MRV as below. b Remove servo hose E and plug hose.

Note: For accurate setting, the pressure should be c Start the engine, and confirm that the engine is at
adjusted up to the required level. its maximum no-load speed and it is in the E
mode.
2 High Pressure Setting (Power Boost)
d Stall the dipper.

e Hold nut C and release lock nut B and screw the

low pressure setting nut A clockwise all the way
in.

f Hold nut C and slacken nut D. Screw nut C in, to

increase pressure or out to decrease pressure.

g Once required pressure is achieved on the

pressure gauge, hold nut C and lock nut D back
up.

3 Low Pressure Setting (Standard)

E-166 9813/0400-1 E-166

 Section E - Hydraulics
Service Procedure
Main Relief Valve (MRV) Pressure
a confirm that the engine is at its maximum no-load
speed and it is in the L mode.

b Stall the dipper.

c Hold nut C and slacken locknut B. Screw nut A out

to reduce pressure or in to increase pressure.

d Once required pressure is achieved on the

pressure gauge, lock nut B against nut C.

e Make the machine safe, refer to Section E,

Service Procedures.

f Re-attach the servo hose to MRV.

4 Check the pressures.

E-167 9813/0400-1 E-167

 Section E - Hydraulics
Service Procedure
Servo Relief Pressure

Servo Relief Pressure

TE-013

1 Prepare the Machine 3 Start the engine and confirm that the engine is at its
minimum no-load speed and it is in the E mode. The
a Operate the dipper out and lower the boom to set pressure gauge reading should be compared to the
the bucket on the ground. technical data at the start of this section. If it is outside
the limits adjust the pilot relief valve as below.

4 Loosen the lock nut B of the pilot Relief Valve.

5 The valve is adjusted by turning relief valve adjusting

screw A (one turn of the adjustment screw equals
39.2 bar, (568.5 lb in2).
C030150-1
Fig 5. 6 Tighten lock nut B to 17 Nm (12. Ibf ft), check the
relief pressure again.
b Make the machine safe, refer to Section E,
Service Procedures.

2 Before testing the Pilot Relief valve C

K Fig 6. ( T E-168), connect a 0-100 bar (0-1500 lb/
in2) pressure gauge to test point TP3.

TP3

C
B

A405800-C3
Fig 6.

Note: For accurate setting, the pressure should be

adjusted up to the required level.

E-168 9813/0400-1 E-168

 Section E - Hydraulics
Service Procedure
Auxiliary Relief Valves

Auxiliary Relief Valves

TE-014_2

General
1 Prepare the machine

a Operate the dipper out and lower the boom to set

the bucket on the ground.

C030150-1
Fig 7.

b Make the machine safe, refer to Section E,

Service Procedures.

2 Increase MRV Pressure, refer to Section E, Service

Procedures.

3 Test the ARVs with the engine at idle using the

appropriate test points.

4 Restore Original MRV Pressure, refer to Section E,

Service Procedures.

E-169 9813/0400-1 E-169

 Section E - Hydraulics
Service Procedure
Auxiliary Relief Valves

Boom Ram
Boom Up

1 Prepare the machine

a Operate the dipper out and lower the boom to set

the bucket on the ground.

C030150-1
Fig 8.

b Make the machine safe, refer to Section E,

C002690-C1
Service Procedures. Fig 9.

c Connect a 0 - 400 bar (0 - 6000 lb/in2) pressure b The pressure gauge reading should be compared
gauge and adaptor to port TP1 on the hydraulic to the technical data at the start of the section. If it
pump. is outside the limits, adjust the ARV.

2 Increase MRV Pressure, refer to Section E, Service Note: For accurate pressure setting, the pressure should
Procedures. be adjusted up to the required level. Release lock nut X.
Adjust setting screw Y to a pressure below the required
3 Start the engine, lower the gate lock lever and run the level and then bring the pressure back up for final setting.
engine at minimum no-load speed in the E mode. Tighten lock nut X.

a Fully raise the boom and then continue to operate

the right control lever as at A.

312460-C1
Fig 10.

4 Restore Original MRV Pressure, refer to Section E,

Service Procedures.

E-170 9813/0400-1 E-170

 Section E - Hydraulics
Service Procedure
Auxiliary Relief Valves
Boom Down b The pressure gauge reading (Boom down) should
be compared to the technical data at the start of
1 Prepare the machine the section. If it is outside the limits, adjust the
ARV.
a Operate the dipper out and lower the boom to set
the bucket on the ground. Note: For accurate pressure setting, the pressure should
be adjusted up to the required level. Release lock nut X.
Adjust setting screw Y to a pressure below the required
level and then bring the pressure back up for final setting.
Tighten lock nut X.

C030150-1
Fig 11.

b Make the machine safe, refer to Section E,

Service Procedures.

c Connect a 0 - 400 bar (0 - 6000 lb/in2) pressure

312460-C1
gauge and adaptor to port TP1 on the hydraulic
Fig 13.
pump.
3 The relief valves for boom up and boom down must
2 It is not physically possible to fully close the boom
be swapped and returned to the correct ports.
ram, without lifting the undercarriage of the ground.
Therefore the ARV's must be swapped over.
4 Restore Original MRV Pressure, refer to Section E,
Service Procedures.
a Fully raise the boom and then continue to operate
the right control lever as at A at minimum no-load
speed in the E mode.

C002690-C1
Fig 12.

E-171 9813/0400-1 E-171

 Section E - Hydraulics
Service Procedure
Auxiliary Relief Valves

Dipper Ram
1 Prepare the Machine

a Operate the dipper out and lower the boom to set A

the bucket on the ground.
B

C030150-1
Fig 14.

b Make the machine safe, refer to Section E,

Service Procedures.
C002700-C1

c Connect a 0 - 400 bar (0 - 6000 lb/in2) pressure Fig 15.

gauge and adaptor to port TP2 on the hydraulic
pump. c The pressure gauge reading (Dipper Out) should
be compared to the technical data at the start of
2 Increase MRV Pressure, refer to Section E, Service the section. If it is outside the limits, adjust the
Procedures. ARV.

3 Start the engine, lower the gate lock lever and run the d Move the dipper fully in and then continue to
engine at minimum no-load speed in the E mode. operate the control lever, as at B.

4 Pressure Adjustment e Compare the pressure gauge reading (Dipper In)

to that stated in the technical data section at the
a Raise the boom enough to allow the Dipper to start of the section. If it is outside the limits, adjust
move freely. ARV.

b Move the dipper fully out and then continue to Note: For accurate setting, the pressure should be
operate the control lever, as at A. adjusted up to the required level. Release lock nut X.
Adjust setting screw Y to indicate a pressure below the
required level and then bring the pressure back up for final
setting. Tighten lock nut X.

312460-C1
Fig 16.

5 Restore Original MRV Pressure, refer to Section E,

Service Procedures.

E-172 9813/0400-1 E-172

 Section E - Hydraulics
Service Procedure
Auxiliary Relief Valves

Bucket Ram
1 Prepare the Machine

a Operate the dipper out and lower the boom to set

the bucket on the ground.

B A

C030150-1
Fig 17.

b Make the machine safe, refer to Section E,

Service Procedures.
C002690-C2
c Connect a 0 - 400 bar (0 - 6000 lb/in2) pressure Fig 18.
gauge and adaptor to port TP1 on the hydraulic
pump. c The pressure gauge reading (Bucket Open)
should be compared to the technical data at the
2 Increase MRV Pressure, refer to Section E, Service start of the section. If it is outside the limits, adjust
Procedures. the ARV.

3 Start the engine, lower the gate lock lever and run the d Close the bucket fully and then continue to
engine at minimum no-load speed in the E mode. operate the control lever, as at B.

4 Pressure Adjustment e The pressure gauge reading (Bucket Closed)

should be compared to the technical data at the
a Raise the boom. start of the section. If it is outside the limits, adjust
ARV.
b Open the bucket fully and then continue to
operate the control lever at A. Note: For accurate setting, the pressure should be
adjusted up to the required level. Release lock nut X.
Adjust setting screw Y to indicate a pressure below the
required level and then bring the pressure back up for final
setting. Tighten lock nut X.

312460-C1
Fig 19.

5 Restore Original MRV Pressure, refer to Section E,

Service Procedures.

E-173 9813/0400-1 E-173

 Section E - Hydraulics
Service Procedure
Auxiliary Relief Valves

Option ARV (Monoboom) 4 Operate the option by pressing the foot pedal. Check
the pressure on the gauge, adjust the ARV.
1 Prepare the Machine.
Note: For accurate setting, the pressure should be
a Operate the dipper out and lower the boom to set adjusted up to the required level. Release lock nut X.
the bucket on the ground. Adjust setting screw Y to indicate a pressure below the
required level and then bring the pressure back up for final
setting. Tighten lock nut X.

5 Restore Original MRV Pressure, refer to Section E,

Service Procedures.

C030150-1
Fig 20.

b Make the machine safe, refer to Section E,

Service Procedures.

c Fit two caps B to the option pipes on the dipper.

312460-C1
Fig 22.

JS06720-C1
JS06720-C1
Fig 21.

d Connect a 0 - 400 bar (0-6000 lbf/in2) pressure

gauge to TP1.

2 Increase MRV Pressure, refer to Section E, Service

Procedures.

3 Start the engine, lower the gate lock lever and run the
engine at minimum no-load speed in the E mode.

E-174 9813/0400-1 E-174

 Section E - Hydraulics
Service Procedure
Slew Motor Pressure Relief

Slew Motor Pressure Relief

TE-015

1 Prepare the machine Note: If the water-proof slew lock solenoid valve is not
removed. Full slew pressure can not be read.
a Operate the dipper out and lower the boom to set
the bucket on the ground. Note: Pressure measurement is also possible on the slew
motor, upper section.

5 If the readings are outside the limits, continue as

below.

6 Pressure Adjustment

C030150-1 a Make the machine safe, refer to Section E,

Fig 23. Service Procedures.
b Make the machine safe, refer to Section E, b Remove relief valve to be adjusted.
Service Procedures.
c The difference between the set pressure and the
2 Connect a 0-400 bar (0 - 6000 lb/in2) pressure gauge present pressure determines the number of shims
and adaptor to test point TP2. E required for adjustment.

3 Initiate slew lock procedures. 7 Remove the relief valve assembly from the slew
motor.
a Remove the water-proof connector on the slew
lock solenoid valve. Note: If both relief valves are removed at the same time,
mark them left and right to facilitate re-assembly in the
b Press the slew lock switch which is on the right correct position.
hand console inside the cab, and confirm that the
slew lock symbol appears on the monitor. 8 Disassembly

a Place the relief valve in a vice and remove the cap

A with a 14 mm hexagonal socket, take out the
piston C, liner B poppet E, spacer D, shims E and
graphicA335121I
spring F.
c Start the engine, (error codes may appear for
disconnected solenoid) and operate the engine at
around 1000 rpm, then operate the slew lever
slowly. Listen to confirm that the relief sound is
heard and that the machine does not slew.
E
d Run the engine at minimum no-load speed and in C
the E mode. F
D
e Operate the slew lever. B
A
4 The pressure gauge reading should be compared to
A405850-C1
the technical data at the start of this section. If it is
Fig 24.
outside the limits adjust the slew motor relief valve as
below.
b Add shim to increase pressure. Remove shim to
decrease pressure.

E-175 9813/0400-1 E-175

 Section E - Hydraulics
Service Procedure
Slew Motor Pressure Relief
c Re-assemble relief valve assembly

d Fix the sleeve into a vice and install the cap A with
a torque of 156.9 Nm (115.17 lb ft).

e Install the relief assembly in the slew motor unit,

and confirm the pressure.

E-176 9813/0400-1 E-176

 Section E - Hydraulics
Service Procedure
Travel Motor Relief Pressure

Travel Motor Relief Pressure

TE-016

1 Prepare the Machine 4 Start the engine, select MID speed travel, lower the
gate lock lever and run the engine at minimum no-
a Operate the dipper out and lower the boom to set load speed in the E mode.
the bucket on the ground.
5 Slowly engage the locked travel motor and measure
the pressure in forward and reverse.

6 The pressure gauge reading (travel motor) should be

compared to the technical data at the start of the
section. If it is outside the limits, adjust relief valve
pressure.
C030150-1
Fig 25. Note: For accurate setting, the pressure should be
adjusted up to the required level. Release lock nut A.
b Make the machine safe, refer to Section E, Adjust setting screw B to indicate a pressure below the
Service Procedures. required level and then bring the pressure back up for final
setting. Tighten lock nut A.
c Connect a 0 - 400 bar (0 - 6000 lb/in2) pressure
gauge to test point TP1 or TP2.

2 Increase MRV Pressure, refer to Section E, Service

B
Procedures.

3 Insert a lock pin P between the drive sprocket to be

measured and the side frame. A

∅80
∅35
P
A
B
300 150

TOOL-C1
Fig 26. 716370-C8
Fig 28.

7 Restore Original MRV Pressure, refer to Section E,

Service Procedures.

C002730-C1
Fig 27.

E-177 9813/0400-1 E-177

 Section E - Hydraulics

Fault Finding
Hydraulic Contamination
TE-002_3

Hydraulic Fluid Quality cleaning unit. K Fig 1. ( T E-178). General Bulletin 011
also refers.
This machine uses a large volume of fluid in the hydraulic
system for power transmission, equipment lubrication, rust Procedure
prevention and sealing. According to a survey conducted
by a pump manufacturer, seventy per cent of the causes of Connect the cleaning unit in place of the hydraulic filter.
problems in hydraulic equipment were attributable to K Fig 1. ( T E-178). Run the system for sufficient time to
inadequate maintenance of the quality of the hydraulic pump all the hydraulic fluid through the unit. Disconnect
fluid. Therefore, it is obvious that control of the quality of the cleaning unit and reconnect the filter. Top up the
the hydraulic fluid helps prevent hydraulic equipment system with clean hydraulic fluid as required.
problems and greatly improves safety and reliability.
Furthermore from an economic angle it extends the life of
the hydraulic fluid if quality is maintained.

Effects of Contamination
Once inside the system, hydraulic circuit contaminants
greatly effect the performance and life of hydraulic
equipment. For example, contaminants in a hydraulic
pump develop internal wear to cause internal leakage and
hence lower discharges. Wear particles generated will
circulate with the hydraulic fluid to cause further
deterioration in the performance of this and other
equipment. Contaminants also enter principal sliding
sections of the equipment causing temporary malfunction,
scuffing, sticking and leakage and can lead to major
problems.The main contaminants can be classified as
follows:

1 Solid Particles - sand, fibres, metallic particles,

welding scale, sealing materials and wear particles
etc. S168050-1
Fig 1. Cleaning Unit
2 Liquid - usually water and incompatible oils and
greases.

3 Gases - Air, sulphur dioxide etc. which can create

corrosive compounds if dissolved in the fluid.

These contaminants can appear during manufacture,

assembly and operation.

Cleaning Operation
The purpose of cleaning oil is to remove contaminants of
all types and sludge by filtering hydraulic fluid through a

E-178 9813/0400-1 E-178

 Section E - Hydraulics
Fault Finding
Hydraulic Contamination

Contaminant Standards
Dirt that damages your system is in many cases too small
to be seen with the eye. The particle size is measured in
microns.

1 micron = 0.001 mm (0.0000394 in).

Listed below are a few typical comparisons:

– Red Blood Cell = 8 microns (0.008 mm, 0.000315 in)

– Human Hair = 70 microns (0.07 mm, 0.00275 in)
– Grain of Salt = 100 microns (0.1 mm, 0.00394 in)

Smallest particle visible to the naked eye is 40 microns

(0.00157) approximately.

Standards will often be quoted to ISO (International

Standards Organisation) for which literature can be
obtained.

Filters
The filter assembly fitted to all product ranges is designed
to filter all the contamination that is generated through use
to the required level of cleanliness. The filter must be
serviced to the requirements of the machine Service
Schedules.

To ensure optimum performance and reliability it is

important that the machines hydraulic system is serviced
periodically in accordance with the manufacturers
requirements.

E-179 9813/0400-1 E-179

 Section E - Hydraulics
Fault Finding
Main Control Valve

Main Control Valve

Table 1.
Symptoms Possible Causes Countermeasures
Spool sticking 1. Oil temperature is abnormally high. Remove the obstruction.
2. Hydraulic oil is dirty Replace the hydraulic oil and clean the
circuit at the same time.
3. Port connector is tightened too much Check the torque.
4. Valve housing is deformed due to Loosen the installation bolt and check.
Installation
5. Pressure is too high Attach pressure gauge to pump port and
ram port and check the pressure.
6. Spool is bent Replace the valve assembly.
7. Return spring is damaged Replace the damaged parts.
8. Spring or cap is not on straight Loosen the cap and after aligning, tighten.
9. Temperature inside valve is not even. Warm up the circuit.
Spool does not stroke 1. Valve is clogged inside with dirt Remove the dirt (flushing).
Load cannot be maintained 1. Oil leakage from the ram Check the ram.
2. Oil is by-passing from the valve spool Replace the valve assembly.
3. Oil leakage from the port relief valve Remove the port relief from the housing
and clean the housing seat and relief valve
seat.
4. Oil leakage from the lock valve Disassemble the lock valve and clean the
poppet seat and sleeve, plug seat. If the
seat is damaged, replace the poppet, or lap
the poppet and seat.
When the spool is selected 1. Foreign matter in load check valve Disassemble the check valve and clean.
from neutral to raise position, 2. Check valve poppet or seat damaged Replace the poppet or lap the poppet and
the load falls. seat part.

E-180 9813/0400-1 E-180

 Section E - Hydraulics
Fault Finding
Relief Valve

Relief Valve

Table 2.
Symptoms Possible Causes Countermeasures
Pressure does not rise at all 1. The main poppet, sleeve or pilot poppets 1 Check whether foreign matter is in
are sticking open or foreign matter is in the each poppet.
valve seat.
2 Check whether each part is sliding
smoothly.
3 Clean all the parts.
Relief pressure is unstable 1. The pilot poppet seat is damaged. Replace the damaged parts.
2. The piston is sticking to the main poppet. Remove the surface scratches. Clean all
the parts.
Relief pressure is out of control 1. Wear due to foreign matter. Replace the worn parts
2. Lock nut and adjuster are loose. Reset the pressure and tighten the lock nut
to the rated torque.
Oil leakage 1. Damaged seat or worn O-ring. Replace damaged or worn parts. Check
whether each part is sliding smoothly.
2. Parts are sticking due to foreign matter. Check for scratches, cuts or foreign matter.
Clean all the parts.

E-181 9813/0400-1 E-181

 Section E - Hydraulics
Fault Finding
Hydraulic System

Hydraulic System

Table 3.
Symptoms Possible Causes Countermeasures
The hydraulic system is not 1. Pump problem. Check the pressure or replace the pump.
working well or not at all 2.Foreign matter clogging inside the relief Disassemble the relief valve and clean.
valve.
3. Relief valve trouble. Check according to the maintenance
procedures.
4. Ram trouble. Repair or replace.
5. Load is too heavy. Check the circuit pressure.
6. Crack in the valve. Replace the valve assembly.
7. Spool does not stroke fully. Check the spool movement and operation
link.
8. Oil level too low. Replenish hydraulic oil.
9. Filters inside circuit are clogged. Clean filter or replace.
10. Hose runs are kinked. Check the hoses.

E-182 9813/0400-1 E-182

 Section E - Hydraulics
Fault Finding
Slew Motor

Slew Motor

Table 4.
Symptom Cause External Inspection Countermeasure Repair
Motor does Internal damage to the Measure the oil drain High possibility of K Table 5. ( T E-184).
not run motor. volume. damage to the sliding
surfaces if the supply
volume is approximately
equal to the drain volume.
Dismantle and inspect.
Internal damage to the Open the motor inlet and High possibility of internal Renew damaged parts or
motor. outlet ports and apply 20 damage to the motor if renew the motor
kgf/cm2 (284 lbf/in2) pilot the supply shaft does not assembly.
pressure to the brake rotate smoothly when this
release port. Try to rotate torque is applied.
the shaft with a torque of Dismantle and inspect.
approx. 39 Nm (29 lbf ft).
Relief valve in circuit not Measure pressure. Reset to the prescribed
set correctly. setting.
Excessive Wear or damage to the Measure the oil drain Leakage is too high if the K Table 5. ( T E-184).
slip motor sliding surfaces or volume. oil drain volume exceeds
to the high-pressure seal. 5 l/min (1.1 gal/min).
Dismantle and inspect.
Oil hot and excessive Measure the oil Reduce the oil K Table 5. ( T E-184).
parts or circuit. temperature. temperature.
Abnormal Seizure of motor sliding Check for any metallic If metallic matter is Repair or renew the
heating parts or circuit. matter deposited in motor discovered or the supply damaged parts. Renew
drain oil or drain filter. shaft does not rotate the motor assembly.
Apply a 30 kgf/cm2 (427 smoothly when torque is
lbf/in2) pilot pressure to applied, there is a high
the brake release port possibility of internal
and try to rotate the shaft damage to the motor.
with a torque of Dismantle and inspect.
approx.39 Nm (29 lbf ft).
Leakage Damage or wear to oil Renew the oil seals.
from oil seal lip.
seals Damage or wear of the Repair the problem or
shaft seal. renew the motor
assembly.
Abnormal pressure in the Check the pressure in the Set the pressure in the Renew the oil seal.
casing. casing and measure the casing below 3 kg/cm2. Repair or renew the
drain volume. (43 lbf/in2) Dismantle and damaged parts. Renew
inspect if drain volume is the motor assembly.
excessive.

E-183 9813/0400-1 E-183

 Section E - Hydraulics
Fault Finding
Slew Motor

Symptom Cause External Inspection Countermeasure Repair

Insufficient Wear or seizure of the Open motor inlet and High possibility of internal Inspect the parts and
torque motor sliding surfaces. outlet ports and apply 20 damage to the motor if bearing according to a-e
kgf/cm2 (284 lbf/in2) pilot the supply shaft does not and renew any defective
pressure to the brake rotate smoothly when this parts.K Table 5.
release port.Try to rotate torque is applied. ( T E-184)
the shaft with a torque of Dismantle and inspect.
approx. 39 Nm (29 lbf ft).
Relief valve in the circuit Measure relief pressure. Reset to the prescribed
is not set correctly. setting.
Internal damage to the Check if any metallic High possibility of internal Repair or renew
motor. matter is deposited in the damage to the motor if damaged parts. Renew
motor drain oil or drain metallic matter is the motor assembly.
filter. discovered. Dismantle
and inspect.
Abnormal Large amount of air Check the oil in the tank Thoroughly bleed the air.
noise mixed in the oil. and motor casing.
Loosening of bolts or Check if the piping Tighten to the specified
pipes connections, attachment torque.
mounting bolts, motor
attachment bolts or other
bolts are loose.
Oil leakage O-ring is damaged Renew O-rings.
from mating Seal face is damaged. Repair seal face or
surfaces renew.
Bolts are loose. Check the bolt tightness. Tighten the bolts to the
correct torque.

Table 5.
No. Part Inspected Repair
a Wear of the sliding surface of balance plate Repair or renew the part
b Damage to sliding surface of cam plate Repair the part or renew the motor.
c Damage to sliding surface of the piston assemblies Repair the part or renew the motor.
d External wear to the piston assemblies Repair the part or renew the motor.
e Wear to piston bores in cylinder assembly Renew the motor.
f Damage to Teflon ring 19 or `O'-rings Renew the part.

E-184 9813/0400-1 E-184

 Section E - Hydraulics
Fault Finding
Hydraulic Pump

Hydraulic Pump

Often the regulator and attendant valves or pump are 2 Abnormal Vibration and Sound. Check to see if
combined which makes it very difficult to discover the there is any abnormal vibration or sound in the pump
reason for the trouble. Inspect the following categories main body. Check to see if it is like the regular
which will assist in discovering the abnormal point. frequency sound of the regulator's working or
attendant valve relief working. If it is an abnormal
1 Filter and Drain Oil Inspection. Inspect the filter vibration or sound, it is possible that there is damage
element. Check to see whether there is an or cavitation inside the pump.
abnormally large amount of foreign matter. There will
be a small amount of metallic powder due to wear of 3 Measure Pressure of Each Part. When it is a control
the shoe or cylinder, but if there is a large amount of problem, do not unnecessarily open ports for
metallic powder in the filter, it may be due to trouble inspection purposes, measure the pressure for each
with the shoe. Also check the drain oil in the pump section and find the abnormal item.
casing.

Table 6. Prime Mover Overload

Cause Treatment Note
Are the revolutions - pressure higher Set to pre-determined value.
than pre-determined values?
Is the regulator torque setting too high? Re-inspect regulator. Refer to regulator instructions.
Seizure or damage of pumps internal Replace damaged parts. Check the filter or drain oil for signs of
parts abnormal wear.
Wrong regulator hose connection. Correct hose lines.

Table 7. When pump flow is extremely low, delivery pressures does not increase
Cause Treatment Note
Regulator breakdown Repair the regulator Refer to regulator instructions
Seizure or damage of pump internal Replace damaged parts. Check filter, drain oil.
parts.
Pump breakdown. Replace damaged parts. Remove pump and inspect shaft
coupling.
Attendant valve breakdown. Inspect attendant valve.
Incorrect regulator hose connection. Correct hose lines.

Table 8. Abnormal Sound and Vibration

Cause Treatment Note
Cavitation. Prevent cavitation. Check to see if Boost pressure is low. Pump is broken.
hydraulic oil is white and cloudy. Air is sucked by suction pipe. Suction
resistance is high.
Damage of shoe caulking part. Replace piston, shoe, shoe plate.
Crack in cylinder. Replace cylinder
Bad installation of pump. Correct installation.
Relief valve bouncing. Repair relief valve. Refer to relief valve instructions.

E-185 9813/0400-1 E-185

 Section E - Hydraulics
Fault Finding
Hydraulic Rams

Hydraulic Rams

Hydraulic Ram Faults and Remedies ( T E-187). However, machine trouble is most often
caused, not by just one faulty part, but its relationship with
It is often not easy to find the part causing the fault. In the other parts. Not all of the possible causes and treatments
table possible problems are listed. K Table 9. ( T E-186). are listed in the tables therefore, it may be necessary for
Repair is difficult, refer to the estimated cause and the person responsible for repairs to make further
treatment listed in the table. The general phenomenon, investigations to find the cause of the trouble.
estimated causes and treatment are shown. K Table 10.

Table 9.
Item Symptoms
1 Oil leakage from piston rod sliding part
2 Oil leakage from cylinder head meeting part
3 Oil leakage from cylinder head meeting part
4 Faulty operation

E-186 9813/0400-1 E-186

 Section E - Hydraulics
Fault Finding
Hydraulic Rams
Table 10.
Item Symptoms Related Parts Trouble Treatment
On the sliding surface, there are 1 Use an oil stone and remove the scratch
scratches and rust that can be and make the sliding surface smooth.
felt by the fingernail. (Less than 1.5 S). If oil leakage continues
even though the rod surface is made
smooth, the scratch may cause damage
to the U-ring and other seals, so
disassemble and inspect.
Piston rod 2 If the scratches and rust cover such a
wide area that they cannot be repaired by
an oil stone, replace the piston rod and U-
ring, wiper ring and seals and the piston
rod bearing member.
The plating is peeling. Re-plate or replace the piston rod. Also inspect
the seal and piston rod bearing member and
replace if damaged.
Foreign matter is biting into the Remove foreign matter. If there is damage to
inner and outer surfaces of the packing, replace it.
packing.
There is a scratch on the inner Replace.
Piston rod and outer surface of the packing.
1 sliding part oil The lip and groove parts are Possibly due to burning caused by adiabatic
leakage locally carbonized (burned). compression from air remaining inside the
ram. After replacing the packing, first operating
the ram at low-pressure, low speed to
sufficiently bleed the air.
Packaging rubber elasticity is The packing life or hydraulic oil deterioration
gone and breaks into pieces. and high temperature are possible reasons.
Rod packing
(Buffer ring, U- 1 Renew hydraulic oil.
ring)
2 Check the hydraulic oil temperature
(Below 80 C is advisable).
3 Check if high temperature locally.
Lip is deficient all around. Replace.
It is possible that abnormal high pressure is
working on the packing.

1 Check the operation pressure, cushion

pressure.
2 Part which is attached to the buffer ring
may be abnormal. Inspect the buffer ring.

E-187 9813/0400-1 E-187

 Section E - Hydraulics
Fault Finding
Hydraulic Rams

Item Symptoms Related Parts Trouble Treatment

Back up ring The protrusion of the heel of the As a rule, replace the rod packing at the same
packing is excessive. time. (It is desirable to replace parts which are
attached to the buffer ring at the same time). It
is possible that abnormal high pressure is the
cause. Check the same as above (heel of
packing protruding).
Foreign matter is biting into the Remove the foreign matter.
lip. The lip is damaged.
Wiper ring
Piston rod There are also other abnormal Replace.
1 sliding part oil damage.
leakage Wear is large and the clearance Replace.
with piston rod exceeds the
*maximum permissible value.
Bushing (*Refer to maintenance
standards for maximum
permissible value.)
Large scratch on the sliding part. Replace. Also inspect the piston rod.
Cylinder head Scratches, rust on the seal Remove scratch, rust with oil stone. If it cannot
attachment parts. be repaired, replace the cylinder head.
Foreign matter biting on inner Remove foreign matter
and outer diameter. Replace 'O'-ring if damaged.
O-ring damaged. Inspect inside tube: if any scratches or
rust, make surface smooth with oil stone
Inspect cylinder head 'O'-ring groove: if
O-ring any scratches or rust, make surface
smooth with oil stone.
Inspect back up ring: if any deformation or
protrusion, replace.

Confirm the above and replace 'O'-ring.

Oil leakage Back up ring Deformation, protrusion Replace with 'O'-ring.
2 from cylinder Looseness Disassemble cylinder head and inspect
head joint 'O'-ring and back up ring.
Check tube and cylinder head thread for
Cylinder head
damage. If any damage, replace.
After inspection, tighten to specified
torque.
Bolt Looseness, stretching, broken Replace all bolts and tighten to specified
torque.
Cylinder tube Abnormal bulge Replace with new parts. Oil leakage from
connecting parts may be caused by abnormal
pressure (including cushion pressure). Inspect
the tube for bulges, deformation and check the
circuit pressure.

E-188 9813/0400-1 E-188

 Section E - Hydraulics
Fault Finding
Hydraulic Rams

Item Symptoms Related Parts Trouble Treatment

Oil leakage Crack in welding Replace with new parts.
from pipe and
cylinder tube Cracks will develop into fractures.
welded seam Cylinder tube Fractures are very dangerous, so if any
3 pipe (hollow cracks are found, stop work immediately
piston rod) and replace with new parts.
Welding on top of cracks will have no
effect.
Poor Piston rod Bending is more than the Replace with new part. The seal and sliding
operation cylinder tube specified limit. (Bending part material may be damaged too, so inspect.
distortion: Refer to maintenance If abnormal, replace.
standards)
Cylinder tube There is a recess Replace with new part. As above, inspect the
seal and sliding part material.
4
Abnormal wear, damage of Replace with new part
sliding parts. As above, inspect the seal and sliding
4-1 Piston rod part material.
Movement cylinder rod
not smooth sliding part Foreign matter intruding on Remove foreign material.
piston and cylinder head sliding As above, inspect the seal and sliding
area part material.

E-189 9813/0400-1 E-189

 Section E - Hydraulics
Fault Finding
Hydraulic Rams

Item Symptoms Related Parts Trouble Treatment

4-2 Inner oil Piston seal Scratches, wear are present Replace with new part. Inspect the cylinder
leakage. tube inner surface.
Piston rod Cylinder tube Scratches, rust on the inside Remove the scratches/rust by honing or
extends with an oil stone and make the surfaces
when work smooth.
stops or
lowers If the scratch is deep and cannot be
abnormally repaired, replace the cylinder
during work. Replace piston seal.
Also, Piston Nut Loose nut Tighten to specified torque
specified
operating Valves Leak from valve Inspect the valve leakage amount and service.
speed is not
achieved.
Note: Note: Hydraulic oil expands and contracts due to changes in temperature and pressure. Accordingly, the ram
also expands and this can be mistaken for internal leakage. When inspecting for internal leakage, do so at set
conditions
4-3 Air Air remaining inside ram Bleed the air. For rams that do not have an
Operation is unsteady airbleeder, operate back and forth several
times at low pressure and low speed to bleed
4 the air. For rams with an air bleeder, remove
the load to reduce the pressure then loosen the
air bleeder and completely bleed the air.

Note: The ram may expand if it is stopped

suddenly. This is due to the compression of the
hydraulic oil. This occurs especially with long
stroke rams.
4-4 Heavy Pin bushing, Pin Gap between installation part Measure the pin and pin bushing and replace
shock and pin bushing is too large parts if measurements exceed the
loading when specifications.
changing
from
extension to
retraction
and back
4-5 Noisy Oil supply Insufficient oil Add oil.
operation Pin bushing, Pin Scuffing at connecting part Replace with new part and add oil.
Note: If left in the state where operation is poor, the ram will no longer move and other parts will be affected
adversely. Inspect early and carry out appropriate measures.

E-190 9813/0400-1 E-190

Section F

Transmission
Service Manual - JS200 Asia Pacific
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body & Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section J - Track and Running Gear
Section K - Engine

Publication No.
9813/0400-1

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

Contents Page No.

Technical Data
Travel Equipment ...................................................................................... F-1

Track Motor
Removal and Replacement ....................................................................... F-3
Start Up and Running In ............................................................................ F-6

Track Motor
Dismantling and Assembly ........................................................................ F-9
Performance Confirmation Test ............................................................... F-59

Fault Finding
Transmission ........................................................................................... F-61

E-i E-i
 Section F - Transmission

Track Motor
Removal and Replacement

Removal
1 Remove the track Section J, Track and Running
Gear.

2 Lift the side of the undercarriage high enough to

permit drive sprocket removal. Support with wooden
blocks.

3 Stop the engine and operate the control lever to

relieve pressure in the hydraulic system, refer to
Section 3, Routine Maintenance.

4 Remove the motor cover, attach identification tags to

the motor hoses, disconnect the hoses from the Fig 2.
motor and install plugs and caps to prevent the loss of
oil and ingress of dirt.

Fig 1.

5 Support the motor so that the cables are in tension,

then remove the motor installation bolts.

F-3 9813-0400-1 F-3

 Section F - Transmission
Track Motor
Removal and Replacement

Precautions During Installation

Before installation, check the overall condition of the axial
piston motor, check for loose parts, check P1, P2 drain
ports and pilot ports are completely sealed so that
contaminants cannot enter the axial piston.
A
Replacement B

1 Before fitting, clean the assembly.

Make sure that all ports are plugged to prevent the

ingress of dirt.

2 Lift the assembly and position it on the undercarriage.

B
A

A408272-C1

Fig 4.

3 Remove the plugs and connect the motor hoses.

Fig 3.

Install the bolts and washers, using JCB Threadseal

on the bolt threads. Tighten the bolts in a diagonal
sequence. For torque settings, refer to Section 3,
Routine Maintenance.

Fig 5.

4 Do not fit the track at this stage. Follow the Start Up

and Running In procedure. K Start Up and Running
In ( T F-6).

5 Install the covers over the motor.

F-4 9813-0400-1 F-4

 Section F - Transmission
Track Motor
Removal and Replacement
6 Check the amount of oil in the gearbox, refer to
Section 3 Routine Maintenance.

7 Refit the track Section J, Track and Running Gear.

F-5 9813-0400-1 F-5

 Section F - Transmission
Track Motor
Start Up and Running In

Start Up and Running In

B B

709910-C1

Fig 6.

Start Up Note: The presence of residual air in the hydraulic circuit

will manifest itself with the presence of foam in the tank

!MWARNING and will lead to a jerking of the motor as well as excessive

noise coming from the motor and the valves.
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. 4 Start the track motor at a low speed and gradually
Before connecting or removing any hydraulic hose, increase it after having verified that it is functioning
residual hydraulic pressure trapped in the service correctly without any noises or vibrations.
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing Running In
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
!MWARNING
Fluid Under Pressure
In this first stage it is advised to follow the measures given Fine jets of fluid at high pressure can penetrate the
below: skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses and gloves.
1 Remove hose from drain port B. Fully fill the piston Hold a piece of cardboard close to suspected leaks
motor case with clean hydraulic oil at the drain port - and then inspect the cardboard for signs of fluid. If
B. Also bleed air from each part of the piping. Make fluid penetrates your skin, get medical help
sure all hoses are correctly fitted. immediately.
INT-3-1-10_3
2 Check hydraulic fluid level, top up if necessary. refer
to Section 3, Routine Maintenance. During the running-in stage follow the steps given below.

3 Check gearbox oil level, refer to Section 3, Routine 1 Check the correct revolution and direction of rotation.
Maintenance.

F-6 9813-0400-1 F-6

 Section F - Transmission
Track Motor
Start Up and Running In
2 Make sure that the motor is functioning correctly, with
out any excessive noises and vibrations.

3 Make sure that the oil temperature does not exceed

90°.

After having terminated this first running-in follow the

steps given below:

4 Check that there are no oil leakages.

5 Check the level of lubricating oil in the gear box.

6 The opening action of the brake could be slowed

down due to the presence of air during the first start-
up. It is advised to repeat the opening and closing
function of the brake by starting and stopping the
motor several times.

7 Check that there are no other problems.

F-7 9813-0400-1 F-7

 Section F - Transmission
Track Motor
Dismantling and Assembly

Track Motor
Dismantling and Assembly

Tools
Equipment and facilities

Table 1.
Name Usage Description Qty
General work bench Product disassembly / assembly
Washing tank Parts washing For rough and finish washing 1
Press machine. Fitting of bearings, etc. Min. press capacity. 9800N (1000kgf) 1
Heating tank Warming parts before fitting Heating capacity: over 100 deg C. 1
Volume: 500×500×500 or more
Compressed air Drying washed parts Pressure: 0.29.49 MPa (3-5 kgf/cm2)

F-9 9813-0400-1 F-9

 Section F - Transmission
Track Motor
Dismantling and Assembly
Special Tools Spindle removal tool

Note: Items numbered in brackets, i.e. [100], can be For removing spindle [101] from hub [1].
identified by referring to K Fig 143. ( T F-58)

Eye bolts

For lifting the motor, spindle [2] and hub [1].

Fig 2.

Spindle fixing tool

For connecting the spindle [101] to hub [1]

K Fig 3. ( T F-10) and K Fig 4. ( T F-11).
Fig 1.

Fig 3.

F-10 9813-0400-1 F-10

 Section F - Transmission
Track Motor
Dismantling and Assembly

Fig 4.

Press tool

For pressing angular ball bearing [24] into hub [1]

K Fig 5. ( T F-11), K Fig 6. ( T F-12) and
K Fig 7. ( T F-12).

Fig 5.

F-11 9813-0400-1 F-11

 Section F - Transmission
Track Motor
Dismantling and Assembly

Fig 6.

Fig 7.

F-12 9813-0400-1 F-12

 Section F - Transmission
Track Motor
Dismantling and Assembly
Oil seal installation tool

For installing oil seal [132] to spindle [101]

K Fig 8. ( T F-13).

Fig 8.

F-13 9813-0400-1 F-13

 Section F - Transmission
Track Motor
Dismantling and Assembly
Floating seal installation tool (I)

For installing floating seal [29] to hub [1] and spindle [101]
K Fig 9. ( T F-14).

Fig 9.

Floating seal installation tool (II)

For installing floating seal [29] to hub [1] and spindle [101]
K Fig 10. ( T F-14), K Fig 11. ( T F-15),
K Fig 12. ( T F-15) and K Fig 13. ( T F-16).

Fig 10.

F-14 9813-0400-1 F-14

 Section F - Transmission
Track Motor
Dismantling and Assembly

Fig 11.

Fig 12.

F-15 9813-0400-1 F-15

 Section F - Transmission
Track Motor
Dismantling and Assembly

Fig 13.

Rear flange locating guides

For guiding the rear flange during removal and

replacement.

Fig 14.

F-16 9813-0400-1 F-16

 Section F - Transmission
Track Motor
Dismantling and Assembly
Valve seat removal tool

For removing valve seat [201] from rear flange [301].

Fig 15.

Fig 16.

F-17 9813-0400-1 F-17

 Section F - Transmission
Track Motor
Dismantling and Assembly

Dismantling 8 The photographs and drawings contained in the

manual are of representative models. However,
Preparations disassembly procedure is not affected even if the
disassembled product is different from this manual.
Perform the following preparations before disassembling.

1 Workbench preparation

Prepare a travel motor workbench.

Prepare a sturdy workbench with which the internal

parts of the travel motor can be disassembled or
assembled, wide enough to place parts so they do not
move or fall off the bench while working.

Spread a rubber or vinyl sheet on the workbench.

2 Prepare all tools and facilities.

General Suggestions

Note: Internal parts are covered with hydraulic fluid and

gear oil during disassembly and are slippery.

1 Before disassembling, inspect and confirm clearly

any indication of abnormality which may be occurring
and work according to the disassembly procedure.

2 All parts are manufactured precisely. Be careful when

handling. Avoid rough contact and do not drop parts.

3 Do not bang or remove parts forcefully. Such acts

could cause burrs or damage to the parts which could
lead to failure of the assembly or inferior
performance.

4 If you leave parts disassembled or partially

disassembling, rust could develop on the parts due to
moisture or dirt. If you have to interrupt the work
before completion, take measures to protect against
rust or dust.

5 Place a mark against the mating faces of parts when

disassembling.

6 Tidy removed parts when disassembling so as not to

damage or lose the parts while working.

7 Once any type of seals are disassembled, they

should be replaced with new ones even if they show
no signs of damage. You should have new parts
ready prior to disassembling.

F-18 9813-0400-1 F-18

 Section F - Transmission
Track Motor
Dismantling and Assembly
Disassembly Procedure 5 Turn the motor horizontally so that the drain port is at
the lowest position.
Note: Items numbered in brackets, i.e. [100], can be
identified by referring to K Fig 143. ( T F-58) 6 Loosen bleed plug [30] to release any pressure and
tighten plug again loosely.
1 Fasten two eye bolts to spindle. Hook the lifting wire
in the eyebolts, hoist the motor with a crane and carry Note: If the inside of the reduction gear is pressurised, the
to the washing tank. lubrication oil may spray out when the plug [30] is
loosened.
Note: Fasten the two eye bolts symmetrically in two screw
holes used for mounting the spindle. 7 Place a container under the workbench. Loosen the
drain plug [30] slowly. Drain the lubricating oil from
2 Wash each part of the motor with a brush. drain port.

Note: Soil and sand will be captured in the clearance Note: Prepare a container which can collect 5.3 litres of
between hub [1] and spindle [101] (floating seal mounting lubricating oil in the reduction gear.
section).
8 If the lubricating oil is not draining smoothly, loosen
3 Place the motor on the workbench. the filler plug slowly and remove the plug.

Note: While matching three holes of hub [1] and screw 9 Remove O-ring [31] from the plug.
holes of the workbench, carefully place the travel motor in
the mounting holes of the workbench. Note: Do not re-use the O-rings.

4 Fix the motor onto the workbench with three bolts.

Tighten the bolts securely.

Fig 18.

10 Turn the motor so that the reduction gear is

uppermost.

11 Loosen 18 M10 bolts and remove the bolts.

12 Place a steel bar on the offset of the cover and hit

upwards using a hammer to remove cover [14] from
hub [1].

Note: The cover could move suddenly when released.

Fig 17.
Take care to prevent it falling.

F-19 9813-0400-1 F-19

 Section F - Transmission
Track Motor
Dismantling and Assembly
13 Fasten two eye bolts on the cover and use hoisting 16 Fasten three eye bolts to the tapped holes of carrier
equipment to lift it off K Fig 19. ( T F-20). [3]. Attach a wire sling and hook in the eyebolts, lift
carrier assembly by crane.

Note: When carrier assembly is lifted, the edge of the

planetary gears could damage the internal teeth of the hub.
Lift up slowly, and carefully.

17 Fasten three eye bolts to the tapped holes of the 2nd

stage reduction gear carrier [7]. Place a wire sling and
hook in the eyebolts, lift the carrier assembly by
crane.

Fig 19.

14 Fasten three eyebolts to the tapped holes of the 1st

stage reduction gear carrier [3].

Attach a wire sling and hook in the eyebolts and lift the
carrier assembly by crane.

Note: When the carrier assembly is lifted, the edge of the

planetary gears could damage the internal teeth of the hub.
Lift up slowly, and carefully.
Fig 21.

Note: When the carrier assembly is lifted, the edge of the

planetary gears could damage the internal teeth of the hub.
Lift up slowly, and carefully.

18 Remove sun gear [4].

Note: Be careful not to drop the sun gear. It could be

slippery with lubricant.

19 Remove coupling [15] from shaft [102].

Fig 20.

15 Remove sun gear [4].

Note: Be careful not to drop the sun gear. It could be

slippery with lubricant.

F-20 9813-0400-1 F-20

 Section F - Transmission
Track Motor
Dismantling and Assembly

Fig 22.

20 Turn the motor over.

Fig 24.
21 Fix Hub [1] and spindle [101] with two fixing tools
23 Remove the fixing tools securing the hub and the
positioned symmetrically K Spindle fixing
spindle.
tool ( T F-10).
24 Fasten two eyebolts on the tapped holes of spindle
[101].

Place a wire sling and hooks in the eyebolts. Lift the

spindle by crane.

Fig 23.

22 Put a flat head screwdriver into the clearance

between the two locking washers [22] and widen the
clearance. Place the tip of the screwdriver to one end
of the lock washers, tap it with a hammer and remove
the lock washers. Fig 25.

Note: Lift up spindle slowly and carefully. If the spindle is

inclined against hub it could jam. If the spindle does not
come out smoothly, do not pull forcefully. Instead, use
other tools such as a press.

25 If the spindle cannot be pulled out or there is no

workbench, place the hub's collar on a cylinder with
the spindle facing downward, position the removal
tool on the spindle, and hit the tool with a hammer

F-21 9813-0400-1 F-21

 Section F - Transmission
Track Motor
Dismantling and Assembly
until the spindle comes out K Fig 26. ( T F-22). See
K Spindle removal tool ( T F-10)

Note: When the hub is hoisted to place on the cylinder, the

spindle could fall off from the hub. Since it is dangerous to
hoist the hub quickly, do it slowly. To prevent the rear
flange from being damaged when the spindle falls off,
place a cushion inside the cylinder. When reusing the
spindle, be careful not to hit its spline otherwise the spline
will be deformed, preventing it meshing with the carrier.

Fig 27.

27 Put a steel rod on the inner race of angular ball

bearing [34], tap 3 or 4 points evenly and take care
not to damage the bearing.

Fig 28.
Fig 26.
Note: Do not remove the angular ball bearing except for
26 Grasp the inner side of the floating seal and lift it up replacing the bearing. The removal work could damage the
by hand. bearing race.

Note: Use work gloves to prevent cutting hands from the 28 To pull out parallel pin A [16], scrape the caulked part
edge of the floating seal. If lifting up by hand is difficult for of the hole B on carrier [3] by using a pencil grinder
any reason, use a flat head screwdriver as a lever. K Fig 29. ( T F-23) and K Fig 30. ( T F-23).

Note: Scraping the hole entrance excessively may cause

caulking to be ineffective, preventing re-use of the carrier.

F-22 9813-0400-1 F-22

 Section F - Transmission
Track Motor
Dismantling and Assembly

Fig 29. Fig 30.

29 Lift parallel pin by using a slotted screwdriver and pull 30 After pulling out carrier pin [6] from carrier [3], remove
out the pin. planetary gear [5], needle roller bearings [27] and
thrust washers.

Note: Since standing the carrier during work can cause

the planetary gear to fall off when the carrier pin has just
been pulled out, be careful not to get your finger caught
between the planetary gear and the carrier.

31 Lower the hub from the work table. Install the

hydraulic motor on the work table and secure with
bolts. Tighten the bolts K Fig 31. ( T F-24).

F-23 9813-0400-1 F-23

 Section F - Transmission
Track Motor
Dismantling and Assembly

Fig 31. Fig 33.

A Motor 35 Remove rear flange [301] from spindle [101].

B Plate Note: Hold rear flange with both hands, and gently remove
C Work bench it. Timing plate [109] or spring [113] could fall off and get
damaged during this work.

Fig 32.
Fig 34.
32 Turn over rear flange [301].
36 Position a steel rod on the inner race of angular
bearing [24], tap 3 or 4 points evenly but take care not
33 Remove two hexagon socket bolts [343] diagonally
to damage the bearing.
then install the rear flange locating guides K Rear
flange locating guides ( T F-16).
Note: Do not remove the angular ball bearing except to
replacing the bearing. When the outer race of angular ball
Note: Loosen the plugs on rear the flange before
bearing separates from the fitness hub, angular ball
loosening the securing bolts. This makes it easier to
bearing falls from hub.
remove the plugs later.
Place a container under the workbench and put a
34 Loosen the rest of hexagon socket bolts [343]. Then
rubber mat on it so that the angular ball bearing does
remove the bolts from rear flange [301].
not get damage if it falls.

F-24 9813-0400-1 F-24

 Section F - Transmission
Track Motor
Dismantling and Assembly
37 Turn over the motor so that the rear flange [301] is on 41 Removing the relief valve assemblies [203].
top.
a Unscrew and remove both plugs [204] and
38 Temporarily loosen the two plugs [324]. springs [207].

Note: Do not loosen the plugs if the rear flange is not to be b Pull out sleeve [203], piston [206], valve [202] and
disassembled. spring retainer [205] by putting a finger in the
sleeve hole.
39 Temporarily loosen the two plugs [352].

Note: Do not loosen the plugs if the rear flange is not to be

disassembled.

Fig 37.

Fig 35.

40 Loosen the two relief valve assemblies [203].

Fig 38.

c Pull out the valve seat [201] by hooking a steel bar

under the seat and withdrawing it as shown below
K Valve seat removal tool ( T F-17).

Fig 36.

Note: Do not reuse any O-rings and backup rings which

have been removed.

Fig 39.

F-25 9813-0400-1 F-25

 Section F - Transmission
Track Motor
Dismantling and Assembly
42 Removing the two-speed spool

a Loosen and remove adapter [364].

b Loosen and remove plug [370] and spring [366].

c Lightly push spool [363] from the adapter end and

pull out the spool, spring retainer [367] and pin
[365].

Fig 41.

46 Pull out the 2 parallel pins [34] from the spindle [101].

Fig 40.

43 Removing the throttle and check valves

a After loosening and removing plug [374], remove

throttle valve spring [373] and throttle valve [372] Fig 42.
by using a magnet.
47 Remove both O-rings [32 and 33] from spindle [2]
b After loosening and removing plug, remove check K Fig 43. ( T F-27).
valve spring [378] and check valve [377] by using
a magnet. Note: Do not reuse any O-rings and backup rings which
have been removed.
Note: If there is no magnet available they can be removed
by cleaning the hole inside with washing solvent and then
shaking the rear flange with the hole entrance facing
downward.

44 Loosen and remove the 10 hexagon socket bolts

[343] from rear flange [301].

45 Remove rear flange [301] from the spindle [101].

Note: Hold rear flange with both hands, and gently remove
it. Timing plate [109] or spring [113] could fall off and get
damaged during this work.

F-26 9813-0400-1 F-26

 Section F - Transmission
Track Motor
Dismantling and Assembly

Fig 43. Fig 45.

48 Lay removed rear flange [301] on the workbench with 51 Disassembling the brake valve parts inside the rear
the mating face upwards. flange

49 Remove timing plate [109] from rear flange [301]. a Remove 2 plugs [324] from rear flange [301].

Note: Timing plate may be stuck to the mating face of the b Remove 2 washers [325] and spring [328] from
rear flange. rear flange [301].

To separate the timing plate, insert a flat bar into the

groove of the rear flange and raise the timing plate
slowly.

Never try to pry the timing plate off with a sharp or

pointed tool or the precision finished mating faces will
suffer costly damage.

Fig 46.

c Remove spool assembly [323] from rear flange

[301] K Fig 47. ( T F-28).

Note: To remove the spool assembly, place your hand on

one part of the plug port of the rear flange and tilt it down.
The spool should then fall down. Hold the tip and remove it.
Fig 44.

50 Remove bearing [150] from the rear flange.

F-27 9813-0400-1 F-27

 Section F - Transmission
Track Motor
Dismantling and Assembly

Fig 47.
Fig 49.
d Remove O-rings [336] from plugs [324].
54 Remove piston [381] from rear flange [301]
Note: Do not reuse O-rings which have been removed. K Fig 50. ( T F-28).

Fig 50.
Fig 48.
55 Disassembling ball check valve
52 Remove both plugs [380] from rear flange [301].
a Remove both plugs [352] from rear flange [301]
53 Remove O-rings [383] from both plugs [380]
K Fig 51. ( T F-29).
Note: Do not reuse O-rings which have been removed.

F-28 9813-0400-1 F-28

 Section F - Transmission
Track Motor
Dismantling and Assembly

Fig 51. Fig 53.

b Remove O-rings [358] from plugs [352]. b Remove O-rings [135 and 139] from the piston.

Note: Do not reuse O-rings which have been removed. Note: Do not reuse any O-rings and backup rings which
have been removed.
c Remove steel balls [353] from rear flange [301].

Note: If it is hard to remove the steel balls, try using a

magnet etc.

Fig 54.

57 Disassembling rotary parts

Note: Place a container just below the motor to catch the

Fig 52. oil.

56 Disassembling the parking brake a Turn the motor 90 degrees.

Note: The sudden injection of compressed air could cause b Drain the hydraulic oil from the motor.
the piston to pop out. To ensure your safety hold a
protective cover over the piston. c Remove the 4 mating plates [116] and 3 friction
plates [115].
a Remove piston [112] from the spindle by injecting
compressed air into the across hole in the spindle. d Pull out cylinder block [104], pistons [105] and
retainer plate [107] at the same time
K Fig 55. ( T F-30).

F-29 9813-0400-1 F-29

 Section F - Transmission
Track Motor
Dismantling and Assembly

Fig 55. Fig 57.

Note: When the cylinder block is removed, shoes [106] g Remove the 9 piston assemblies (pistons [105],
may remain adhered to the swash plate, and the pistons shoes [106]) from retainer plate [107].
[105], shoes [106] etc. will come out of the cylinder block
and fall into the spindle.

Fig 58.

Fig 56. h Remove thrust ball [108] from cylinder block [104]
K Fig 59. ( T F-31)
e Draw out cylinder block [104] from shaft [102].

f Remove piston assembly (pistons [105], shoes

[106]) and retainer plate [107] from cylinder block
[104].

Note: When removing the piston assembly, grip retainer

plate [107] with both hands and remove the piston
assembly together with the retainer plate. Components of
the piston assembly cannot be obtained separately. If
replacement is necessary, replace piston assembly as one
unit.

F-30 9813-0400-1 F-30

 Section F - Transmission
Track Motor
Dismantling and Assembly

Fig 59. Fig 61.

i Remove 3 needle rollers [151] from cylinder block Note: Release the press slowly. Sudden releasing may
[104]. cause the spring to fly out, causing possible injury.

Fig 60.

58 Removing spring inside cylinder block Fig 62.

a Place cylinder block [104] on the press bench A Press

B Mandrel
Note: Spring [114] should be removed only when requiring
replacement. The spring is removed by lining up the shaft C Snap ring
centre of its holder and washer [110] in order to prevent D Spring
damage to cylinder block [104] through contact. Cover the
E Cylinder block
cylinder block with a vinyl sheet to prevent the sliding
surfaces of the cylinder block from being damaged.
c Remove snap ring [145], washer [110], spring
b Place holder on washer [110] and, while clamping [114] and washer [110] from cylinder block [104]
the holder with the press, remove snap ring [145] K Fig 63. ( T F-32).
using snap ring pliers.

F-31 9813-0400-1 F-31

 Section F - Transmission
Track Motor
Dismantling and Assembly

Fig 63.
Fig 65.
59 Removing swash plate
60 Removing bearing
a Remove swash plate [103] from shaft [102].
Note: The bearing should only be removed if it needs
Note: When removing the swash plate, ensure that the replacing
pivots are not stuck to the swash plate.
a Place a holder on the press bench and put shaft
[102] into the holder.

b Remove bearing [149] from shaft [102] by

pressing on the shaft end with a press.

Note: Do not reuse the removed bearing.

Fig 64.

b Pull out shaft [102] from spindle [101].

Note: Carefully and lightly strike the tip of the shaft on the
reduction gear side using a plastic hammer to allow the
shaft to come off easily. Otherwise the shaft may pop out.

c Remove 2 pivots [167] and 2 parallel pins [171]

from spindle [101].
Fig 66.

A Press
B Holder

F-32 9813-0400-1 F-32

 Section F - Transmission
Track Motor
Dismantling and Assembly
61 Remove snap ring [133] and oil seal [132] from
spindle [101].

Fig 69.

Fig 67.

A Spindle
B Oil seal

62 Removing spindle fittings

a Remove shim [23] from spindle [101].

Fig 68.

Note: Do not reuse floating seal [29] once it has been

removed.

F-33 9813-0400-1 F-33

 Section F - Transmission
Track Motor
Dismantling and Assembly

Cleaning Parts
1 Washing

a Separate hub [1], spindle [101], cover [14] and

rear flange [301] from other parts (hereafter called
the build-in parts).

b Put the build-in parts in the washing vessel with

kerosene and wash them.

Note: Carefully wash to remove any dirt from the external

surface.

Note: To prevent the build-in parts from being damaged

Fig 71.
by dirt during washing, immerse the parts in kerosene long
enough for any dirt or oil to loosen before washing them.

2 Finish washing

a Rinse the washed parts in the rinsing sink filled

with clean kerosene by gently shaking each part
in the kerosene.

b Using clean, lint-free cloth, wipe each rinsed part

to remove dripping kerosene.

Fig 72.

Fig 70.

Note: Dry the inside of the hub and the spindle by spraying
with compressed air until they are dry and clean. Let other
parts dry naturally. After drying, coat every part with oil.

F-34 9813-0400-1 F-34

 Section F - Transmission
Track Motor
Dismantling and Assembly

Inspection 2 Replace all seals

1 Service criteria Seal parts (O-ring, oil seal and floating seal) should
be replaced once disassembled even though no
Inspect the inside of the motor according to this damage is observed.
maintenance criterion. Handle every part carefully,
and use particular care that moving and sliding 3 Replace any severely damaged parts.
sections are not damaged.
4 Replace any parts if they have the following
abnormalities K Table 2. ( T F-35).

Note: Items numbered in brackets, i.e. [100], can be

identified by referring to K Fig 143. ( T F-58)

Table 2.
Item No Parts Trouble Reference value Allowance value
[1] Hub * Severe damage on appearance. *
Pitting on ring gear teeth.
*Abnormal wear such as scoring.
[101] Spindle *Severe damage on appearance.
*Abnormal wear such as scoring
[3][7] Carrier assembly * Abnormal wear such as scoring
others
[4] Sun gear [1]. Sun * Pitting on ring gear teeth. *
gear [2]. *Flaking on outer race of needle
[8] Planetary gear roller bearing.
[1].
[5]
Planetary gear
[9] [2]
[24] Angular ball * Dent, flaking or uneven wear on
bearing contact surface.
[301] Rear flange * Many scratches on sliding
surfaces between spool [323] and
piston [381].
[102] Shaft * Abnormal wear on contact
surface between oil seal [132].
* Abnormal wear on spline
[103] Swash plate * Marks of sticking.
[104] Cylinder block * Abnormal wear on spline.

* Abnormal wear on bore surface.

* Scratches or uneven wear on
sliding surface with timing plate
[109]

F-35 9813-0400-1 F-35

 Section F - Transmission
Track Motor
Dismantling and Assembly

[105] Piston assembly * Abnormal clearance in the axial Clearance Clearance

direction between piston [105] and
[106] Piston Shoe shoe [106]. 0.05 mm 0.15 mm

* Abnormal wear on shoe [106].

[107] Retainer plate * Uneven wear on sliding surface
with shoe [106].

* Scratches or uneven wear on

sliding surface with thrust ball
[108].
[108] Thrust ball * Uneven wear on sliding surface
with retainer plate [107].
[109] Timing plate * Sticking or uneven wear on
sliding surface.
[115] Friction plate * Uneven wear on both contact Braking torque Braking torque 206
surface. 206 N-m N-m
[116] Mating plate
* Specified torque cannot be 21.0 kgf-m 21.0 kgf-m
obtained
or over or over
* Marks of sticking
[105] Piston * Scratches on sliding surface
[149] Ball bearing * Dent, flaking or uneven wear on
contact surface.
[150]
[323] Spool *Abnormal and uneven wear on
the outer circumference.

* Severe scratching on the outer

circumference.
[381] Piston * Severe scratching on the outer
circumference.

F-36 9813-0400-1 F-36

 Section F - Transmission
Track Motor
Dismantling and Assembly

Assembly disassembling procedure is not affected even if the

products are different from this manual.
The assembly procedure is basically the reverse of
disassembly.

Note: Items numbered in brackets, i.e. [100], can be

identified by referring to K Fig 143. ( T F-58)

Preparation

Prepare the tools and facilities as required on

Disassembly.

General Precautions

1 Pay the same attention to general precautions at

paragraph 2, Disassembly.

2 When assembling, remove all foreign objects or metal

fragments from parts, and make sure there are no
burrs or dents etc. on parts. If necessary, remove
them by oilstone.

3 Replace O-rings, oil seals and floating seals with new

ones.

4 Completely remove any remaining adhesive in the

thread holes of hub [1] by using a tap (M10) and then
wash them with a solvent. After that, blow dry with
compressed air. Replace bolts [35].

5 Completely remove any remaining adhesive from the

mating surface of hub [1] and cover [14] using a
scraper.

6 Be careful not to damage O-rings, oil seals and

floating seals when mounting. Apply a small amount
of grease to them for smooth assembly.

7 Be sure to coat the moving and sliding parts of the

hydraulic motor and valves with clean hydraulic fluid.

8 Do not use cloth gloves during assembly. Fibre pieces

may cause faulty operation.

9 Bolts and plugs should be tightened to the torque

specified in Tightening Torque table below.

10 After assembling, plug all ports to protect motor from

contamination.

11 The photographs and drawings contained in this

manual are of representative models. However,

F-37 9813-0400-1 F-37

 Section F - Transmission
Track Motor
Dismantling and Assembly
Tightening Torques

Part No. Bolt/ Nut Used Width across flats (mm) Qty Tightening Torque

30 Plug PF1/2 10 3 98.1±19.6 (10±2kgf/m)

35 Bolt PT1/16 8 18 57.9±9.81 (5.9±1kgf/m)
137 Hexagon socket plug M27 (P1.5) 4 1 13.7±1.37 (1.4±0.14kgf/m)
204 Plug M27 (P1.5) 32 2 157 - 177(16 - 18kgf/m)
324 Plug M38 (P1.5) 46 21 304±324 (31 - 33kgf/m)
364 Adapter PF3/8 21 6 49.0 - 58.8 (5 - 6kgf/m)
368 Plug PF1/4 6 8 29.4±2.94 (3±0.3kgf/m)
370 Plug PF3/8 8 5 49.0 - 58.8 (5 - 6kgf/m)
374 Plug PF1/8 5 14 14.7±1.47 (1.5±0.15kgf/m)
343 Hexagon socket bolt M16 14 230±23.0 (23.5±2.35kgf/m)

Weights

Part No Name Weight (kg)

Travel Motor About 277
Assembly
1 Hub About 79
101 Spindle About 60
3 Carrier [1] Assembly About 27
7 Carrier [2] Assembly About 47

F-38 9813-0400-1 F-38

 Section F - Transmission
Track Motor
Dismantling and Assembly
Assembly Procedure A Press

General B Hub
C Press tool
Note: If reassembling after replacing parts, preload
D Ball bearing
adjustment of angular ball bearing [24] is necessary.

Therefore, before assembling, make sure the following e Apply grease on the O-ring of floating seal [29],
parts have been replaced. and fit the O-ring into the floating seal groove on
hub [1] K Floating seal installation tool
Renew all parts required for preload adjustment of angular (I) ( T F-14) and K Floating seal installation
ball bearing: Hub [1], spindle [2], angular ball bearing [24]. tool (II) ( T F-14).

Note: If reassembling after replacing the parts listed Note: When applying grease to the O-ring, remove the O-
above, be sure to use parts that have been adjusted. If you ring from floating seal, and then apply grease thinly to the
reassembly with parts that have not been adjusted, it will entire surface. Use a floating seal installation tool. Keep
cause the motor to operate poorly or break down the seal parallel (tolerance 1mm) to end surface of the
prematurely. groove. If not, it could cause the seals to seize or leak.

1 Assembling hub

a Place hub [1] on a press bench.

b Place angular ball bearing [24] on hub [1] and

press in using the press tool K Press
tool ( T F-11).

c Turn the hub over.

d Insert angular ball bearing [24] into hub [1] in the

same way.

Note: Make sure that the installing direction of the angular

ball bearing is correct.
Fig 74.

A Floating seal installation tool (I)

B Floating seal installation tool (II)
C Floating seal
D Spindle

2 Assembling spindle

a Apply grease to the O-ring of floating seal [29],

and fit the O-ring into the floating seal groove on
spindle [101] K Floating seal installation tool
(I) ( T F-14) and K Floating seal installation
tool (II) ( T F-14).
Fig 73.

F-39 9813-0400-1 F-39

 Section F - Transmission
Track Motor
Dismantling and Assembly

Fig 76.

Fig 75. Note: If hub [1], angular ball bearing [24] or spindle [2] are
replaced, clearance adjustment should be carried out. If
A Floating seal installation tool (I) this is not done, the angular ball bearings could break in a
short period.
B Floating seal installation tool (II)
C Floating seal 1 Insert lock washer [22] and measure the distance C
D Hub then remove the lock washer.

Note: When applying grease to the O-ring, remove the O-

ring from floating seal and apply grease thinly to the entire
surface. Use a floating seal installation tool. Make sure to
keep the seal parallel (tolerance 1mm) to the groove. If not,
it could cause the seals to seize or leak.

3 Install eye bolts to spindle [101] so they are

symmetrically positioned.

4 Fix spindle [101] on workbench with two hexagon

socket bolts, located symmetrically. Tighten the bolts
securely.

5 Clearance adjustment procedure for angular ball

bearing.

Fig 77.

2 Measure the distance D.

Note: Rotate hub assembly to stabilise the distance D.

F-40 9813-0400-1 F-40

 Section F - Transmission
Track Motor
Dismantling and Assembly

Fig 78.

3 Select one of the listed shims [23] to achieve the

distance (C-D) from.0.17 to.0.13mm. Refer to the
following table for available shims. Fig 80.

b Fix hub [1] to the workbench with three long

Mark T (mm) Mark T (mm) hexagon socket bolts.
A 0.9 G 1.5
B 1.0 H 1.6
C 1.1 I 1.7
D 1.2 J 1.8
E 1.3 K 1.9
F 1.4 L 2.0

Fig 81.

c Locate angular ball bearing [24] on reduction gear

and, using a steel rod tapped softly with a
hammer, assemble the bearing onto spindle [2]
keeping both centre axes parallel.

d Place lock washers [22] into the groove of spindle

[101].
Fig 79.

4 Assemble shim [23] to spindle [101].

a Insert hub [1] into angular ball bearing [24]

assembled in spindle [101] while keeping both
centre axes parallel.

F-41 9813-0400-1 F-41

 Section F - Transmission
Track Motor
Dismantling and Assembly
b Drive oil seal [132] into spindle [101] using a drift
to prevent it from being inclined. Ensure the seal
is assembled the correct way round K Oil seal
installation tool ( T F-13).

Fig 82.

e Fit lock washers [22] into the groove of spindle

[101] using an installation tool.

Fig 84.

c Install snap ring [133] using snap ring pliers.

Fig 83.

Note: Insert lock washers [22] fully into the groove so they
do not interfere with the carrier.

f Remove the long hexagon socket bolts, which

fixed hub [1] to the workbench.
Fig 85.
g Rotate hub [1] two or three times to seat the
bearing. d Install two parallel pins [171] into the pin holes of
spindle [101].
Note: Contact between the sliding surfaces of the floating
seal will be improved by rotating the spindle and prevent e Apply lithium grease to hemispherical surface of
initial oil leak. two pivots [167] and fit into parallel pins [171] of
spindle [101].
5 Turn over spindle [101].
f Assemble outer race of bearing [149] fully into its
a Apply grease to the spindle area in contact with oil bore using a suitable drift.
seal [132].

F-42 9813-0400-1 F-42

 Section F - Transmission
Track Motor
Dismantling and Assembly
g Install piston [161] into its bore in the spindle
[101].

h Coat the steel ball with grease (to hold it in place)

and install it into the piston.

Fig 86.
Fig 88.
i Mount the pivot [167] with ‘L’ mark on the left side
of the spindle. Insert pivot until the seat face A Press
contacts the spindle.
B Shaft
C Ball bearing
D Support

b Turn the workbench 90 degrees.

c Insert shaft [102] into spindle [101].

Note: Take care not to scratch or cut the lip portion of the
oil seal with the splined end of the shaft.

Fig 87.

6 Assembling shaft

Note: Wear thick leather gloves while handling the heated

bearing.

a Put inner race of bearing [149] in a heating tank at

100±10 deg C for ten minutes and then insert it Fig 89.
onto shaft [102].
7 Insert swash plate [103] into spindle [101].

F-43 9813-0400-1 F-43

 Section F - Transmission
Track Motor
Dismantling and Assembly
Note: Apply lithium grease to the swash plate where it
contacts the spindle. Make sure that the locating pivots of
the spindle enter the pivot holes of the swash plate.

Fig 92.

Note: When assembling the snap ring take care that the
tips of the pliers do not slip out of the snap ring holes or the
snap ring could jump out.
Fig 90.
Note: Press force of spring [114] is 1128N (115kgf) or
Note: Make sure that the swash plate is mounted correctly more. To prevent damage to the contact surface of the
on the two pivots. cylinder block protect by covering the cylinder block with a
vinyl sheet.

c Place a holder on washer [110] and, while

clamping with a press, fit snap ring [145] in the
groove of cylinder block [104] using snap ring
pliers.

Fig 91.

8 Assembling cylinder block components

a Insert washer [110], spring [114], washer [110]

and snap ring [145] in that order into cylinder Fig 93.
block [104].
9 Assembling rotary parts
b Place cylinder block [104] on the press bench.
a Place three needle rollers [151] into cylinder block
[104] and place thrust ball [108] on the top.

F-44 9813-0400-1 F-44

 Section F - Transmission
Track Motor
Dismantling and Assembly

Fig 96.
Fig 94.
Note: Match the round surface portion of the thrust ball
b Install nine piston assemblies into retainer plate and the retainer plate.
[107].

Note: Make sure the retainer plate is fitted the correct way
round with the tapered face as shown.

Fig 97.

d After installing cylinder block [104], turn it by hand

and make sure that it fits properly. If not, inspect it.

Note: The cylinder block is not supported until piston [112]

is fitted. If the cylinder block moves outwards, thrust ball
[108] will separate and the motor will not rotate normally.

Fig 95.

c Fit retainer plate [107] and nine piston assemblies

into cylinder block [104].

F-45 9813-0400-1 F-45

 Section F - Transmission

Technical Data
Travel Equipment

JS200
Table 1.
Type Axial piston type
Final Drive Planetary reduction, bolt on sprockets
Working Pressure 343 bar, 4975 lb/in2
Working Flow 220 litre/min
Gearbox Ratio 1:49.5
Parking Brake Disc type, spring applied, automatic hydraulic released.
Tractive effort 164.7 KN
Displacement 129cc/rev

F-1 9813-0400-1 F-1

 Section F - Transmission
Track Motor
Dismantling and Assembly
lightly and equally with a plastic hammer. Take care not to
damage the O-rings.

Fig 98.

10 Inserting parking brake

Fig 100.
Note: Immerse friction plates in hydraulic fluid before
assembly.
11 Fit the taper roller bearing
a Turn the workbench 90 degrees.
a Remove the outer race from the taper roller
bearing [150].
b Insert four mating plates [116] and three friction
plates [115] alternately. Insert mating plate first.
b Drive the taper roller bearing (150) onto the shaft
[102] using a suitable drift and hammer.

Fig 101.
Fig 99.
c Place outer race onto the inner race.
c Apply a thin coat of grease to O-rings [135] and
[139] and fit into O-ring grooves of piston [112]. 12 Clearance adjustment procedure for taper roller
bearing
d Insert piston [112] into spindle [101]. Take care to
keep the piston parallel with the spindle.

Note: If the piston does not fit into the spindle because of
the resistance of the O-rings, tap the edge of the piston

F-46 9813-0400-1 F-46

 Section F - Transmission
Track Motor
Dismantling and Assembly
Note: Clearance adjustment should be carried out if a Apply 2 or 3 drops of JCB Locking Fluid Medium
spindle, shaft, rear flange or tapered roller bearing are Strength to M6 orifice [376] and tighten orifice
replaced. If not the tapered roller bearing could break. into rear flange using a hexagon socket key. Do
not overtighten as the thread may be damaged.
a Turn the motor vertically.
Note: If sealant is applied excessively it could run down
b Tap the tapered roller bearing softly using a plastic and close off the orifice.
hammer to stabilise the shaft.

c Measure the distance A.

Fig 104.
A
14 Assembling ball check valve parts in rear flange

a Fit O-rings [358] to two plugs [352].

Note: Apply grease to O-rings.

b Insert steel ball [353] into rear flange [301].

Fig 102.

d Measure the distance B.

B Fig 105.

c Temporarily tighten plugs [352] into rear flange

[301] using hexagon wrench.

Fig 103.

e Select a shim [119] to achieve the distance A - B

from 0 to 0.17mm.

f Insert shim and outer race of taper roller bearing

[150] into bearing bore in rear flange [301].

13 Assembling M6 orifice

F-47 9813-0400-1 F-47

 Section F - Transmission
Track Motor
Dismantling and Assembly

Fig 108.
Fig 106.
Note: After carrying out the seating process, check the
15 Assembling throttle and check valve valve movement by using the pin to lift the valve slightly.

a After inserting throttle valve [372] and throttle

spring [373] into rear flange, fit and tighten plug
[374] to specified torque.

Note: The orifice of the throttle valve is very small and

could be easily blocked by foreign matter. Wash
thoroughly and check by shining a light behind the orifice.

Fig 109.
Fig 107.
Note: Since the bores for the throttle and check valves
have the same diameter make sure they are fitted into the
b After inserting check valve [377] and check valve
correct bores as shown.
spring [378], fit and tighten plug to specified
torque.

Note: If a new rear flange is used it is necessary to seat

both the throttle and check valves before assembly to
prevent subsequent leakage. Using a steel pin inserted
into the spring cavity as shown, gently tap the spool 2 or 3
times to seat the valve.

Fig 110.

F-48 9813-0400-1 F-48

 Section F - Transmission
Track Motor
Dismantling and Assembly
16 Assembling counterbalance spool the rear flange with the spool centre so as to prevent the
inner surface of the bore and the outer surface of the spool
a Insert the spool assembly [323] into almost the from being damaged due to interference. Otherwise
centre of the rear flange to prevent the bore from internal leaks will occur after reassemble, resulting in
being damaged. performance deterioration of the motor.

Note: Insert the spool in the direction shown in the b Fit two O-rings [336] to two plugs [324].
illustrations noting particularly the position of the two small
holes A and the balance grooves B. If the spool is inserted Note: Apply grease to the O-ring.
the opposite way round the parking brake will not operate.
c Attach washers [325] and springs [328] to both
plugs [324].
A

B
Fig 111.

Fig 113.

d Assemble both plugs [324] to rear flange [301].

Note: When fitting the plug to the rear flange, insert

carefully so as not to deform spring [328].

Fig 112.

b Attach spring retainers [325] and springs [330] to

both ends of the inserted spool.

c Fit plugs [324] to both ends and tighten them to

specified torque.

17 Assembling brake valve parts in rear flange

a Insert spool [323] into rear flange [301]. Fig 114.

Note: Apply hydraulic fluid to the spool and insert spool e Temporarily tighten plugs [324].
into the rear flange. To insert the spool, align the bore of

F-49 9813-0400-1 F-49

 Section F - Transmission
Track Motor
Dismantling and Assembly
b Insert two parallel pins [341] in the pin holes of
rear flange [301].

c Apply grease to the mating faces of timing plate

[109] and rear flange [301].

d Fit timing plate [109] on rear flange [301] using

parallel pins [341] as the guide.

Note: Make sure that the timing plate adheres to the rear
flange. Adhesion prevents the plate from dropping when
the rear flange is mounted on the spindle.

Fig 115.

18 Assembling two-speed spool

a Assemble adapter [364] to the rear flange.

b Assemble spool [363], spring retainer [367] and

pin [365] together and place into bore in rear
cover.

c After inserting spring [366] fit plug [370].

d Tighten the adapter and plug to specified torque.

Fig 117.

e Mount springs [113] in the holes of rear flange

[301].

Note: Apply grease to the springs in order to prevent them

from dropping from the rear flange.

Fig 116.

19 Assembling rear flange mounted parts

a Apply hydraulic fluid to ball bearing [150] and fit

into rear flange [301].
Fig 118.

F-50 9813-0400-1 F-50

 Section F - Transmission
Track Motor
Dismantling and Assembly
20 Assembling rear flange 21 Tightening bolts

a Fit O-rings [32] and [33]in the O-ring grooves of a Tighten hexagon socket bolts [343] to 102±15.7
spindle [101]. Nm (10.4±1.6 kgf/m).

Note: Fit O-ring [32] without applying grease. If

reassembled with grease applied, the grease may bleed
from the mating face of the rear flange and the spindle
when the motor is running.

b Put 1.0 litres of hydraulic fluid in spindle [101].

Fig 121.

b Tighten plugs [324] to 441±39.2 Nm (45.0±4.0 kgf/

m).

Fig 119.

c Install rear flange [301] on spindle [101] so that

two parallel pins [34] on the spindle enter the pin
holes in rear flange [301].

d Fit and temporarily tighten the ten hexagon socket

bolts [343] using a hexagon wrench.

Fig 122.

c Tighten plugs [380] to 58.8 ± 9.81 Nm (6.0±1.0

kgf/m).

Fig 120.

F-51 9813-0400-1 F-51

 Section F - Transmission
Track Motor
Dismantling and Assembly

Fig 123.
Fig 125.
22 Tighten plugs [352] to 12.3 ± 2.45 Nm (1.25±0.25 kgf/
m). c Tighten relief valve assemblies [203] to 98.1 ±
19.6 Nm (10.0±2.0 kgf/m).
23 Fitting relief valve assembly

a The orifice diameter of the valves are small

enough to be easily blocked by foreign matter.
Wash thoroughly and check orifices are clear.

Fig 126.

24 Sub assembling 1st stage planetary gears

a Insert needle roller bearing [27] into planetary

gears [5] and place into carrier [3] with thrust
washers [11] either side of gear.

Fig 124.

b Fit the two relief valve assemblies [203] to rear

flange [301].

F-52 9813-0400-1 F-52

 Section F - Transmission
Track Motor
Dismantling and Assembly

Fig 127.

Note: The planetary gears are designed with a taper

crowning so each gear should be assembled with its
identification groove uppermost as shown.

Fig 129.

25 Sub assembling 2nd stage planetary gears

a Insert needle roller bearing [28] into planetary

gears [9] and place into carrier [7] with thrust
washers [12] either side of gear.

Fig 128.

b Align the gears bores with the holes in the carrier.

c Insert each gear shaft [6] into the carrier and align
the securing pin holes.

d Insert each parallel pin B [16] and push below the

carrier’s face.

e Calk the hole entrance A using the calking tool.

Make sure the pin cannot get out by lifting the pin
with a screwdriver as shown.
Fig 130.

F-53 9813-0400-1 F-53

 Section F - Transmission
Track Motor
Dismantling and Assembly
Note: The planetary gears are designed with a taper
crowning so each gear should be assembled with its
identification groove uppermost as shown.

Identification mark
Fig 131.

b Align the gears bores with the holes in the carrier.

c Insert each gear shaft [10] into the carrier and

align the securing pin holes.

Fig 133.

26 Assembling the hub

a Place hub [1] on the press bench.

b Fit hub [1] onto the work bench with two socket
bolts located symmetrically.

c Remove the O-ring of floating seal [31], apply

grease thinly to the entire surface and fit the O-
ring into the floating seal groove on the hub.

d Fit the floating seal using the seal installation tool

Fig 132. K Floating seal installation tool (I) ( T F-14).

d Insert each parallel pin B [17] and push below the Note: Keep the seal parallel (tolerance 1mm) to the
carrier’s face K Fig 133. ( T F-54). groove. If not, it could cause the seals to seize or leak.

e Calk the hole entrance A using a calking tool. 27 Assembling 2nd stage planetary gears
Make sure the pin cannot get out by lifting the pin
with a screwdriver as shown. a Rotate the workbench so that the reduction gear
side is upwards.

b Attach sun gear [8] to carrier [7].

F-54 9813-0400-1 F-54

 Section F - Transmission
Track Motor
Dismantling and Assembly
c Fasten three eyebolts into the tapped holes of Note: When inserting the carrier assembly, take care not
carrier [7]. Place a wire sling and hook in the to damage internal teeth of hub with the edge of the
eyebolts, position carrier assembly slowly in hub planetary gears.
[1].

Fig 134. Fig 136.

Note: When inserting the carrier assembly, take care not b Insert sun gear [4] with spline towards coupling
to damage internal teeth of hub with the edge of the [15].
planetary gears.
Note: If the sun gear does not engage with the planetary
Note: Position carrier so that planetary gears are located gears, lift the carrier assembly until the sun gear spline is
as shown K Fig 135. ( T F-55). disengaged. Reposition the planetary gears then engage
the spline.

Fig 135. Fig 137.

28 Attaching coupling c Place thrust plate [13] on carrier [3].

a Attach coupling [15] to shaft [102].

29 Assembling 1st stage planetary gears

a Attach coupling [15] to shaft [102].

F-55 9813-0400-1 F-55

 Section F - Transmission
Track Motor
Dismantling and Assembly

Fig 140.
Fig 138.
c Apply JCB Locking Fluid Medium Strength to
30 Assembling cover
the 12 hexagon socket bolts [35]. Tighten socket
bolts to 66.7 ± 3.92 Nm (6.8 ± 0.4 kgf/m).
a Apply JCB Sealant Medium Strength to the
mating surface of hub [1] and cover [14].
31 Filling lubrication oil
Note: Sealant should be applied around the mating
a Fill the motor with gear oil (lubrication oil) through
surface only. Keep sealant away from gear teeth.
the filling port.

Note: Supply 2.1 litres of gear oil.

Fig 139.

b Fasten two eye bolts to the tapped holes of cover

[14]. Place a wire sling and hook in the eyebolts,
place cover [14] on hub [1] aligning the position of
bolt holes.
Fig 141.

b Fit plugs [30] to ports of cover [14] and tighten to

98.1 ± 19.6 Nm (10.0±2.0 kgf/m).

F-56 9813-0400-1 F-56

 Section F - Transmission
Track Motor
Dismantling and Assembly

Fig 142.

32 Removing reassembled motor from the workbench

a Turn the workbench upside down (motor side

upwards).

b Remove the bolts securing the motor to the

workbench.

c Fasten two eyebolts (M16) to spindle [2].

d Place a wire sling and hook in the eye bolts,

remove the motor from the workbench using a
crane.

F-57 9813-0400-1 F-57

 Section F - Transmission
Track Motor
Dismantling and Assembly

Fig 143.

F-58 9813-0400-1 F-58

 Section F - Transmission
Track Motor
Performance Confirmation Test

Performance Confirmation Test

After servicing the motor, the following test should be Test Procedure
completed.
1) Motor Mounting and Piping
Required Measuring Devices
Mount the motor and gearbox on the track frame but do not
1 Pressure gauge - 3.43 MPa (35 kgf/cm ) 2 2 pieces fit the tracks. The performance test is completed under no-
load conditions.
2 Graduated cylinder - 5 litres 1 piece
3 Stop watch 1 piece Connect the piping so that the pressure gauge is fitted into
the main feed connection. Connect a hose to the motor
drain connection and position the other end into the
graduated cylinder.

2) Warm-up Procedure

Run the motor as detailed in table below.

Speed range Motor revolving speed Pressure Rotation direction Running time
Low speed 10 rev/min.
No-load CW/CCW 1 minute each
High speed 20 rev/min.

Performance Confirmation Test

1 Carry out pre-test preparatory operation.

Operate the motor until the following temperatures

are recorded:

a Hydraulic fluid temperature: 45 - 55 deg C.

b Hub external temperature: 40 - 80 deg C.

2 Measure the following items which should be as

follows:

a Motor drive pressure:

Max. 1.57 MPa (16 kgf/cm2) at 10 rev/min.

b Hydraulic motor drain volume:

Max. 1.2 l/min. at 10 rev/min.

3 If the readings do not match the above criteria the

motor should be disassembled and re-adjusted.

F-59 9813-0400-1 F-59

 Section F - Transmission
Fault Finding
Transmission

Fault Finding
Transmission

Traction Motor

Symptom Possible Cause Remedy

a Motor does not run. 1 Device external to the piston motor or Check that the specified pressurised oil is
reduction gear malfunctioning. delivered to the motor input side. Inspect all
associated devices and repair if necessary.
2 Sliding area of motor is excessively worn, Renew the excessively worn part. Remove
allowing pressurised oil to escape. scratches and burrs from the surface and
completely clean all parts. Reassemble.
3 Malfunction resulting from damaged motor Dismantle and renew the damaged part(s).
part(s), resulting in excessive noise. Completely clean all parts and then
reassemble.
4 Relief valve operating due to excessive motor Check the load and only operate the machine
loading. with a suitable load.
b Motor speed low. 1 Oil not supplied to motor at specified rate due Check that the specified pressurised oil is
to problems in hydraulic pump, pressure control delivered to the motor input side. Inspect all
valve etc. associated devices and repair if necessary.
2 Volume efficiency of motor low. After dismantling, check for abnormal wear of
the sliding area and repair or renew the worn
parts.
c Motor speed varies 1 Large amount of pressurised oil escapes and Dismantle and renew excessively worn parts.
greatly. flows out of the drain port due to wear on the Clean all parts and reassemble.
sliding area of the motor.
2 Wear in the bearings. Renew motor bearings.
3 Motor load is excessive and automatic 2- Check the load and only operate the machine
speed function is operating. with a suitable load.
d Oil leaks. 1 Oil leaks due to damaged oil seals or O-rings. Renew damaged oil seals or O-rings. When
fitting an oil seal, be careful not to damage the
lip. Check the system to ensure the running
temperature does not exceed 80 °C. Take the
necessary steps to ensure the temperature
remains within the acceptable range.
2 Refer to a2 and/or c1. Refer to a2 and/or c1.
3 Clogging due to foreign matter in drain pipe or Clean the clogged drain piping. Recheck the
long, narrow pipes causing the oil seal to break. piping system and reduce the passage
resistance. Renew the oil seal taking care not
to damage the lip.
e Abnormal noise, 1 When the motor works as a pump, when the Recheck the hydraulic circuit and by
excessive speed and closed circuit is used, when the boost pressure remedying or renewing the double
pressure variation due is low (standard: 0.4 -5 kgf/cm2) or when the counterbalance valve, prevent the generation
to cavitation. double counterbalance valve operates of negative pressure. Dismantle the motor
improperly, negative pressure is generated on and renew any abnormally worn or broken
the suction side of the motor, resulting in parts.
cavitation.

F-61 9813-0400-1 F-61

 Section F - Transmission
Fault Finding
Transmission

Parking Brake

Symptom Possible Cause Remedy

a Braking force is low 1 Friction plates worn. Renew discs. Completely remove foreign
or insufficient. matter and repair damaged areas. After
cleaning, reassemble.
2 Counter places surface damaged or making Grind and recondition the affected area.
poor contact. Reassemble after cleaning. Renew plates if
excessively damaged.
3 Spring is deformed or damaged. Renew the spring. Completely remove
foreign matter and reassemble after
cleaning.
b Motor speed low. 1 Brake not releasing.
i Oil leaks due to broken O-ring. Renew broken O-ring.
ii Orifice is clogged. Clean and reassemble.

F-62 9813-0400-1 F-62

 Section F - Transmission
Fault Finding
Transmission

Relief Valve

Symptom Possible Cause Remedy

a Motor does not run or 1 Relief valve not closing fully:
rotation speed is slow. i Foreign matter clogging components. Completely remove foreign matter, repair
damaged part and reassemble after
cleaning. Renew if damage or leakage is
excessive.
ii Spring broken. Renew the spring. Completely remove
foreign matter, repair any damage and
reassemble after cleaning. Renew if
damage or leakage is excessive.
2 The cracking pressure of relief valve is low.
i Spring is deformed. Renew relief valve sub-assembly.
ii Poppet orifice is clogged. After cleaning, reassemble.
b Motor does not stop 1 Relief valve not closing fully.
or stops slowly. i Foreign matter clogging components. Completely remove foreign matter, repair
damaged part(s) and reassemble after
cleaning. Renew if damage or leakage is
excessive.
ii Spring broken. Renew the spring. Completely remove
foreign matter, repair any damage and
reassemble after cleaning. Renew if
damage or leakage is excessive.
2 Refer to a2. Refer to a2.
c Motor does not run or 1 Shockless function does not work.
rotation speed is slow. i Foreign matter in piston section. Completely remove foreign matter, repair
damaged part and reassemble after
cleaning. Renew if damage or leakage is
excessive.
ii Spring broken. Renew the spring. Completely remove
foreign matter, repair any damage and
reassemble after cleaning. Renew if
damage or leakage is excessive.
iii Relief valve pressure set too high. Adjust the relief valve set pressure.

F-63 9813-0400-1 F-63

 Section F - Transmission
Fault Finding
Transmission

Counterbalance Valve

Symptom Possible Cause Remedy

a Motor does not run or 1 Plunger not switching.
rotation speed is slow. i External pilot pressure not present. Inspect the piping for damage.
ii Foreign matter between plunger and body. Completely remove foreign matter, repair
any damage and reassemble after cleaning.
Renew if damage or leakage is excessive.
iii Orifice clogged. Completely remove foreign matter, repair
any damage and reassemble after cleaning.
Renew if damage or leakage is excessive.
iv Foreign matter caught between dumper piston Renew spring. Completely remove foreign
and cap. matter, repair any damage and reassemble
after cleaning. Renew if damage or leakage
is excessive.
b Motor does not stop 1 Plunger does not return.
or stops slowly. i Foreign matter between plunger and body. Completely remove foreign matter, repair
the damaged part and reassemble after
cleaning. Renew if damage or leakage is
excessive.
ii Spring broken. Renew spring. Completely remove foreign
matter, repair any damage and reassemble
after cleaning. Renew if damage or leakage
is excessive.
iii Spring not fitted. Fit spring in specified position.
iv Orifice clogged. Reassemble after cleaning.
c Rotation varies. 1 Plunger does not move smoothly.
i Foreign matter between plunger and body. Completely remove foreign matter, repair
any damage and reassemble after cleaning.
Renew if damage or leakage is excessive.
ii Orifice clogged. Reassemble after cleaning.
d Abnormal noise is 1 Plunger does not return.
heard. i Foreign matter between plunger and body. Completely remove foreign matter, repair
any damage and reassemble after cleaning.
Renew if damage or leakage is excessive.
ii Spring broken. Renew spring. Completely remove foreign
matter, repair any damage and reassemble
after cleaning. Renew if damage or leakage
is excessive.
iii Orifice clogged. Reassemble after cleaning.
e Travel not linear. 1 Dumper piston or cap is excessively worn. Renew dumper piston and cap. Completely
remove foreign matter, repair any damage
and reassemble after cleaning.

F-64 9813-0400-1 F-64

 Section F - Transmission
Fault Finding
Transmission

Speed Range Changing

Symptom Possible Cause Remedy

a Travel is not linear. 1 Plunger not switching.
i Foreign matter between plunger and body. Completely remove foreign matter, repair the
damage and reassemble after cleaning.
Replace if the damage or leakage is large.
ii Spring not installed. Install spring.
iii Spring broken. Renew spring. Completely remove foreign
matter, repair any damage, reassemble after
cleaning. Renew if the damage or leakage is
excessive.
iv Foreign matter is caught between the two Completely remove foreign matter, repair any
spools. damage and reassemble after cleaning.
Renew if the damage or leakage is large.
2 Pressurised oil leaks due to excessive wear of Renew the 2-speed control piston.
2-speed control piston. Completely remove foreign matter and
reassemble after cleaning.
3 2-speed control piston is not installed. Install 2-speed control piston.
4 Steel balls badly worn. Renew steel balls. Completely remove
foreign matter and reassemble after cleaning.
5 Set pressure is rising due to excessive spool Renew the two spools. Completely remove
wear. foreign matter and reassemble after cleaning.
6The orifice of the 2-speed piston compartment Fit a new orifice of correct diameter.
oil passage is incorrect.
7 The orifice of the 2-speed piston compartment Reassemble after cleaning.
oil passage is clogged.
8 Number of washers is different, making set Confirm number of washers.
pressure different between the left and right.

F-65 9813-0400-1 F-65

Section J

Track and Running Gear

Service Manual - JS200 Asia Pacific
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body & Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section J - Track and Running Gear
Section K - Engine

Publication No.
9813/0400-1

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 J - Track and Running Gear

Contents Page No.

Track
Removal and Replacement ....................................................................... J-1

Idler Wheel and Recoil Unit

Removal .................................................................................................... J-5
Replacement ............................................................................................. J-7

Idler Wheel
Dismantling ................................................................................................ J-9
Assembly ................................................................................................. J-11

Recoil Unit
Dismantling .............................................................................................. J-13
Assembly ................................................................................................. J-14

Grease Cylinder
Removal and Replacement ..................................................................... J-15
Dismantling and Assembly ...................................................................... J-18

Drive Sprocket
Removal and Replacement ..................................................................... J-19

Top Roller
Removal .................................................................................................. J-21
Replacement ........................................................................................... J-22
Dismantling .............................................................................................. J-23
Assembly ................................................................................................. J-26
Wear Limits .............................................................................................. J-28

Bottom Roller
Removal .................................................................................................. J-29
Replacement ........................................................................................... J-30
Dismantling .............................................................................................. J-31
Assembly ................................................................................................. J-34
Wear Limits .............................................................................................. J-36

J-i J-i
 Section J - Track and Running Gear

Track
Removal and Replacement

Removal a Remove bolts and lift off the track shoes adjacent
to the master pin.
1 Move the track link until the master pin is over the
take-up roller in the position shown, place a wooden
block under the track shoe as shown.

JS02770
Fig 3.
Fig 1.
b Position a suitable hydraulic press so that its ram
2 Slacken the check valve to bleed out the grease. aligns with the master pin.

!MWARNING
Slacken the check valve slowly and stop when grease
ie released. The grease and valve are under extremely
high pressure and could cause injury if suddenly
released.
TRANS-6-2

JS02790-C1

Fig 4.

c Insert the spacer bar between the master pin and

the hydraulic ram.

Fig 2. d Slowly operate the hydraulic ram and press out

the master pin.
3 Disconnect the track link by removing the locking pin
and knocking out the master pin.

J-1 9813/0400-1 J-1

 Section J - Track and Running Gear
Track
Removal and Replacement

!MWARNING Replacement
Stand clear and to one side of the track while you 1 Position the track under the lower frame.
remove the master pin. When the master pin is
removed the track could fall forward and injure you. 2 Remove the wooden blocks and lower the frame onto
TRACK-1-1 the track.

e Remove the seal rings from each side of the chain 3 Move the track link.
link.

4 Lift the side of the undercarriage high enough to

permit track removal. Support with wooden
blocks.

5 Operate the traction motor to remove the track.

Fig 6.

4 Clean the seal ring housing in the chain link. Insert the
seal rings and clamp into position.
Fig 5.

JS02800-C1

Fig 7.

5 Using a plastic hammer, tap the upper link down to

align holes.

Note: As the links overlap, the seal rings will be held in

position. Remove `G' clamps.

6 Insert the pointed guide pin from the inner face and
tap through its full length.

J-2 9813/0400-1 J-2

 Section J - Track and Running Gear
Track
Removal and Replacement

JS02810-C1

Fig 8.
Fig 10.
7 Position a suitable hydraulic press so that its ram
aligns with the guide pin.

8 Insert the master pin into its locating hole.

9 Slowly operate the hydraulic ram and press the

master pin into position.

JS02820-C1

Fig 9.

10 Re-locate the track shoes and tighten the bolts. For

torque settings, refer to Section 3, Routine
Maintenance.

11 Apply grease through the check valve to adjust the

track tension, refer to Section 3, Routine
Maintenance.

J-3 9813/0400-1 J-3

 Section J - Track and Running Gear
Track
Removal and Replacement

Page left intentionally blank

J-4 9813/0400-1 J-4

 Section J - Track and Running Gear

Idler Wheel and Recoil Unit

Removal
P11-J003

1 Slacken the check valve to bleed out grease.

!MWARNING
When opening the check valve always stand to one
side and loosen a little at a time until grease starts to
come out. If you over-loosen too much grease could
spurt out or the valve cover fly out and cause serious
injury.
8-3-4-5

C004520
Fig 2.

3 Fasten a sling around the idler wheel and recoil

assembly and remove it from the undercarriage.

C004260
Fig 1.

2 Disconnect the track link, see Section F, Track

Motor/Reduction Gear. Move the idler wheel and
recoil assembly to the end of the undercarriage using
a bar.

!MWARNING
Stand clear and to one side of the track while you C004530
remove the master pin. When the master pin is Fig 3.
removed the track could fall forward and injure you.
TRACK-1-1 4 Remove the bolts and remove the idler wheel from
the recoil unit.

J-5 9813/0400-1 J-5

 Section J - Track and Running Gear
Idler Wheel and Recoil Unit
Removal

!MWARNING
RECOIL UNITS ARE DANGEROUS. They must not be
dismantled without using suitable tools to compress
the spring safely. The spring pressure can cause
serious injury if suddenly released. Scrap units must
be made harmless by compressing the spring in a
hydraulic press and cutting through the end of the
shaft before slowly releasing the pressure.
TRACK-1-10

Note: See Grease Cylinder, Removal for Recoil Spring

dismantling details.

C004540
Fig 4.

J-6 9813/0400-1 J-6

 Section J - Track and Running Gear
Idler Wheel and Recoil Unit
Replacement

Replacement

1 Before fitting the idler wheel, check the oil level at A.

If required, top up with the specified oil (see Section
3). Assemble the idler wheel to the recoil unit and fit
the mounting bolts.

C004520
Fig 7.

4 Connect the track link, see Section F, Track Motor/

Reduction Gear. Apply grease through the check
valve to adjust the track tension, see Section 3,
C004560 Checking/Adjusting the Track Tension.
Fig 5.

2 Fasten a sling around the idler wheel and recoil

assembly and enter it into the undercarriage.

C004330
Fig 8.
C004570
Fig 6.

3 Position the idler wheel in the undercarriage using a

bar.

J-7 9813/0400-1 J-7

 Section J - Track and Running Gear
Idler Wheel and Recoil Unit
Replacement

Page left intentionally blank

J-8 9813/0400-1 J-8

 Section J - Track and Running Gear

Idler Wheel
Dismantling
TJ-001

1 Clean the idler wheel with a suitable solvent. Remove

the plug A from hub B and drain the oil.

G D C E
B A Fig 2.
T001060

T001050
Fig 1. 3 Remove 'O'-ring F from shaft D. Pull out the shaft D
from the idler wheel G.
2 On one side of the unit only, remove the wire clip E or
roll pin (later machines) and separate the hub C from
shaft D.

J-9 9813/0400-1 J-9

 Section J - Track and Running Gear
Idler Wheel
Dismantling

C D G C G

J
F
C
T001070
Fig 3. T001090
Fig 5.
4 Remove the wire clip E or roll pin (later machines) and
separate hub C from shaft D. Remove 'O'-ring F from 6 If badly worn or damaged, remove the bushes K from
shaft D. idler wheel G using a press or puller.

Protect parts from moisture and dust if left dismantled

for some time.
E C

F G
K
D

K
T001080-C1
Fig 4.

5 Remove floating seal J from each hub C using a pry

bar.

Remove floating seal J from each side of idler wheel

G using a pry bar. T001100
Fig 6.

J-10 9813/0400-1 J-10

 Section J - Track and Running Gear
Idler Wheel
Assembly

Assembly

1 Clean all parts thoroughly in a suitable solvent. Dry

shaft and bore of idler wheel using compressed air in C G
a place free of dust and moisture.

Check components for wear as detailed. Polish out

scratches and roughness using an oil stone. Then
apply a coat of engine oil to all parts.

Carefully drive the new bushes K into the idler wheel

G, using a suitable dolly.
J
G
K

J
C

G C
K

J J

T001091
T001100
Fig 7. Fig 8.

2 Apply a coating of grease and install a new floating Note: Ensure floating seals J are fitted correctly.
seal J into each side of the idler wheel G and hub. K Fig 8. ( T J-11)

3 Grease a new 'O'-ring F and install on one end only of

shaft D. Install shaft D into hub C. Fit new wire clip E
or roll pin (later machines).

J-11 9813/0400-1 J-11

 Section J - Track and Running Gear
Idler Wheel
Assembly

E D

E
T001080
Fig 9.

4 Coat shaft D with grease. Clean the metallic face of

the seal, coat the metallic face with engine oil and
insert the shaft into the idler wheel G.
G D C A
T001061
Fig 11.
C D G
6 Add the specified oil, refer to Section 3, Lubricants
and Capacities. Install plug using an appropriate
pipe sealant.

F
T001070
Fig 10.

5 Apply grease to a new 'O'-ring F and install it on the

A
shaft D. T001051
Fig 12.
Clean the metallic face of the seal, coat the metallic
face with engine oil and install the hub C onto the
shaft D. Fit new wire clip E or roll pin (later machines).

Wrap sealing tape around the plug A with one thread

remaining uncovered. Insert this plug but leave the
other one out until after testing.

J-12 9813/0400-1 J-12

 Section J - Track and Running Gear

Recoil Unit
Dismantling

1 Carry out steps 1 to 4 of Idler Wheel and Recoil Unit,

Removal.

2 Place the recoil unit in the spring compression jig,

yoke E uppermost, see Service Tools, Section 1.
Raise hydraulic jack A to compress recoil spring B.

Fig 2.

Fig 1.

3 Pull out roll pin C and remove castellated nut D.

Lower jack A to release the pressure on recoil spring
B.

Remove the recoil unit component parts from the jig:

yoke E first, then spring B and, finally spring guide/
retainer F.

J-13 9813/0400-1 J-13

 Section J - Track and Running Gear
Recoil Unit
Assembly

Assembly

1 Position the recoil unit component parts in the spring

compression jig, starting with spring guide/retainer F,
see Service Tools, Section 1. Then spring B and
yoke E. Raise hydraulic jack A to compress recoil
spring B.

Fig 4.

Fig 3. 4 Carry out steps 1 to 4 of Idler Wheel and Recoil Unit,

Replacement.
2 Install castellated nut D on the threaded section of
spring guide/retainer F which protrudes through yoke
E, fully tighten and then install roll pin C.

3 Lower jack A to allow recoil spring B to expand and

then remove the recoil unit from the jig.

J-14 9813/0400-1 J-14

 Section J - Track and Running Gear

Grease Cylinder
Removal and Replacement

Removal
1 Slacken the check valve to bleed out grease.

!MWARNING
When opening the check valve always stand to one
side and loosen a little at a time until grease starts to
come out. If you over-loosen too much grease could
spurt out or the valve cover fly out and cause serious
injury.
8-3-4-5

Fig 2.

3 Fasten a sling around the idler wheel and recoil

assembly and remove it from the undercarriage.

Fig 1.

2 Disconnect the track link, see Track Motor/

Reduction Gearbox, Removal and replacement,
Section F. Move the idler wheel and recoil assembly
to the end of the undercarriage using a bar.

!MWARNING Fig 3.

Stand clear and to one side of the track while you 4 Remove the bolts and remove the idler wheel from
remove the master pin. When the master pin is the recoil unit.
removed the track could fall forward and injure you.
TRACK-1-1

J-15 9813/0400-1 J-15

 Section J - Track and Running Gear
Grease Cylinder
Removal and Replacement

Fig 4.

!MWARNING Fig 5.
RECOIL UNITS ARE DANGEROUS. They must not be
dismantled without using suitable tools to compress Replacement
the spring safely. The spring pressure can cause
serious injury if suddenly released. Scrap units must 1 Re-assembly of Components.
be made harmless by compressing the spring in a
hydraulic press and cutting through the end of the a Set the components in the jig, firstly the grease
shaft before slowly releasing the pressure. cylinder F, then place the spring B on top, and
TRACK-1-10 finally, the yoke E.

Note: If it becomes necessary to dismantle the recoil b Extend jack A and compress recoil spring B.
spring assembly, the following procedure should be used.
c Install the castellated nut D on the threaded
5 Prepare the jig for Recoil Spring Disassembly. Place section of the grease cylinder F which protrudes
the re-coil spring unit as shown. through the yoke E. Tighten nut D, aligning the
castellations with the pin hole.
Jack up the hydraulic jack A and compress the Recoil
Spring B. d Remove the recoil spring assembly from the jig.
See Recoil Spring Installation.
6 Remove the Recoil Spring. Pull out the Spring Pin C
and remove the castellated nut D. Let the jack A down e Renew and install spring pin C.
to relieve the pressure on the recoil spring B.
f Release jack A carefully and allow recoil spring B
Remove the components from the jig, firstly the yoke to expand. Remove assembly from the jig.
E, spring B and finally, the grease cylinder F.

J-16 9813/0400-1 J-16

 Section J - Track and Running Gear
Grease Cylinder
Removal and Replacement

Fig 6.

J-17 9813/0400-1 J-17

 Section J - Track and Running Gear
Grease Cylinder
Dismantling and Assembly

Dismantling and Assembly

Dismantling
1 Carry out steps 1 to 3 of Idler Wheel and Recoil
Unit, Removal.

Remove the lower roller immediately below the

grease cylinder, Bottom Roller, Removal.

2 Remove bolts A and washers B and remove grease

cylinder C through the bottom of side frame D.

Fig 8.

2 Apply Threadseal to the threads of mounting bolts A.

3 When installing the grease cylinder, make sure it is

orientated so that check valve E is facing outwards to
the side of the machine.

Fig 7.

Assembly
Assembly is the reverse of dismantling.

When Assembling

1 Before installing grease cylinder C, remove check

valve E and use a press (as shown) to fully retract the
cylinder and expel the grease. Refit the check valve.

Fig 9.

4 Tighten bolts A to a torque of 267 - 312 Nm (197 - 230

lbf ft, 27 - 31 kgf m).

J-18 9813/0400-1 J-18

 Section J - Track and Running Gear

Drive Sprocket
Removal and Replacement

Removal
1 Slacken the check valve to bleed out grease.

!MWARNING
When opening the check valve always stand to one
side and loosen a little at a time until grease starts to
come out. If you over-loosen too much grease could
spurt out or the valve cover fly out and cause serious
injury.
8-3-4-5

Fig 2.

3 Lift the side of the undercarriage high enough to

permit drive sprocket removal. Support with wooden
blocks.

Fig 1.

2 Disconnect the track link, see Track Motor/

Reduction Gearbox, Removal and Replacement.

!MWARNING
Stand clear and to one side of the track while you
remove the master pin. When the master pin is
removed the track could fall forward and injure you. Fig 3.
TRACK-1-1
4 Support the drive sprocket, remove the bolts and
lever it away from the gearbox unit.

J-19 9813/0400-1 J-19

 Section J - Track and Running Gear
Drive Sprocket
Removal and Replacement

Fig 6.
Fig 4.
3 Apply grease through the check valve to adjust the
Replacement track tension (see Checking/Adjusting the Track
Tension, Section 3).
1 Support the sprocket and position it on the gearbox.

Install the bolts and washers, using Threadseal on the

bolt threads. Tighten the bolts in a diagonal sequence
to a torque of 267 - 312 Nm (197 - 230 lbf ft, 27 - 31
kgf m).

Fig 7.

Fig 5.

2 Remove the wooden blocks. Connect the track link.

J-20 9813/0400-1 J-20

 Section J - Track and Running Gear

Top Roller
Removal
P11-J004

1 Slacken the check valve to bleed out grease. 3 Loosen but do not remove the mounting bolts. Tap the
upper roller with a copper mallet to separate it from
!MWARNING the side frame.

When opening the check valve always stand to one

side and loosen a little at a time until grease starts to
come out. If you over-loosen too much grease could
spurt out or the valve cover fly out and cause serious
injury.
8-3-4-5

C004760
Fig 3.

4 Fasten a sling to the upper roller. Remove the

C004260
mounting bolts and lift the upper roller clear.
Fig 1.

2 Jack up the track high enough to permit roller

removal. Put wooden blocks between track link and
side frame.

C004770
Fig 4.

C004750
Fig 2.

J-21 9813/0400-1 J-21

 Section J - Track and Running Gear
Top Roller
Replacement

Replacement

1 Before fitting the roller, check the oil level and, if

necessary, top up, see Section 3, Fluids and
Lubricants, . Install the plug A using an appropriate
pipe thread sealant.

C004800
Fig 7.
A
5 Apply grease through the check valve to adjust the
802958
track tension, see Section 3, Checking/Adjusting
Fig 5.
the Track Tension.
2 With the track supported as shown under Removal,
step 2, install the roller.

3 Apply JCB Threadseal to the threads and install the

mounting bolts. Tighten to a torque of 259 Nm (191 lbf
ft).

C004330
Fig 8.

C004790
Fig 6.

4 Remove the wooden blocks and jack.

J-22 9813/0400-1 J-22

 Section J - Track and Running Gear
Top Roller
Dismantling

Dismantling

802950
Fig 9.
Item Part Name
A Bolt
B Plug
C Cover
D Screw
E `O'-ring
F Thrust plate
G Bush
H Shaft
J Roller
K Floating seal assembly
L Mounting bracket

J-23 9813/0400-1 J-23

 Section J - Track and Running Gear
Top Roller
Dismantling
1 Clean the upper roller L with an appropriate
detergent. Remove the plug B from the cover and
drain the oil.

802953
Fig 12.

4 Pull the upper roller J from the shaft H.

802951
Fig 10.

2 Remove the bolts A, and remove cover C. From cover

C, remove 'O'-ring E and discard.

802954
Fig 13.

5 Remove the floating seal K from the upper roller J.

802952
Fig 11.

3 Remove bolt D, and the thrust plate F from the end of

the shaft.

J-24 9813/0400-1 J-24

 Section J - Track and Running Gear
Top Roller
Dismantling

802955
Fig 14.

If badly worn or damaged, remove the bushes G, from

the roller J.

6 Remove floating seal K from bracket L using a pry

bar.

Protect parts from moisture and dust if left dismantled

for some time.

802956
Fig 15.

J-25 9813/0400-1 J-25

 Section J - Track and Running Gear
Top Roller
Assembly

802953
Fig 20.

6 Apply grease to the inside face of thrust plate F and

802951
install it on the shaft using bolts D.
Fig 22.
Note: Apply JCB Threadlocker and Sealant to threads and
fit the bolts. Torque tighten to 34Nm, 25lbf ft.

7 Apply grease to a new 'O'-ring E and install it onto

cover C. Install the cover C to the roller. Retain with
bolts A.

Note: Apply JCB Threadlocker and Sealant to threads and

fit the bolts. Torque tighten to 50Nm, 37lbf ft.

802952
Fig 21.

8 Fill with oil, see Section 3, Fluids and Lubricants.

Install plug B using JCB Threadlocker and Sealant to
threads.

J-27 9813/0400-1 J-27

 Section J - Track and Running Gear
Top Roller
Wear Limits

Wear Limits

JS200 - 260
Nominal Pitch 190.00mm
Dimension A (mm)
Wear Normal Impact
A
0% 120.00
10% 118.90
20% 117.70
30% 116.60
40% 115.40 Fig 23.
50% 114.20
60% 113.10
70% 111.90
80% 110.90
90% 109.00
100% 107.20
110% 105.40
120% 103.50

J-28 9813/0400-1 J-28

 Section J - Track and Running Gear

Bottom Roller
Removal
P11-J005

1 Slacken the check valve to bleed out grease. 3 Lift the side of the undercarriage high enough to
permit bottom roller removal. Support with wooden
!MWARNING blocks. Tap the bottom roller with a copper mallet to
separate it from the side frame.
When opening the check valve always stand to one
side and loosen a little at a time until grease starts to
come out. If you over-loosen too much grease could
spurt out or the valve cover fly out and cause serious
injury.
8-3-4-5

C004280
Fig 3.

4 Remove the roller.

C004260
Fig 1.

2 Remove the bolts securing the mounting brackets to

the side frame.

C005120
Fig 4.

C005110
Fig 2.

J-29 9813/0400-1 J-29

 Section J - Track and Running Gear
Bottom Roller
Replacement

Replacement

1 Before fitting the roller, fill with oil, see Section 3,

Fluids and Lubricants. Install the plug using an
appropriate pipe thread sealant.

With the undercarriage lifted and supported with

wooden blocks, position the roller on the track link as
shown.

Align the holes in the mounting brackets with the

tapped holes in the undercarriage.

C005110
Fig 7.

4 Apply grease through the check valve to adjust the

track tension, see Section 3, Checking/Adjusting
the Track Tension.

C005130
Fig 5.

2 Lower the undercarriage sufficient to allow the

mounting bolts to be installed.

C004330
Fig 8.

C005130
Fig 6.

3 Apply JCB Threadseal to the threads and install the

mounting bolts. Tighten to a torque of 506 Nm (373 lbf
ft).

J-30 9813/0400-1 J-30

 Section J - Track and Running Gear
Bottom Roller
Dismantling

Dismantling

802960-1
Fig 9.
Item Part Name
A Plug
B Roller
C Bush
D `O'-ring
E Floating seal assembly
F Locking pin
G Mounting bracket
H Shaft

J-31 9813/0400-1 J-31

 Section J - Track and Running Gear
Bottom Roller
Dismantling
1 Clean the roller with a suitable solvent. Remove the
plug A and drain the oil.

802963
Fig 12.
802961
Fig 10.
Using a pry bar, remove floating seals E from
2 Remove locking pins F from each end of assembly. brackets G and discard.

4 Remove and discard 'O'-rings D from shaft H. Pull out

shaft H from roller B.

802962
Fig 11.

3 Remove mounting brackets G from shaft H.

802964
Fig 13.

J-32 9813/0400-1 J-32

 Section J - Track and Running Gear
Bottom Roller
Dismantling

802965
Fig 14.

5 Remove floating seals E from roller B using a pry bar.

6 If badly worn or damaged, remove and discard

bushes C from roller B, using a press or puller.
Otherwise do not disturb.

802966
Fig 15.

Protect parts from moisture and dust if left dismantled

for some time.

J-33 9813/0400-1 J-33

 Section J - Track and Running Gear
Bottom Roller
Assembly

Assembly

1 Clean all parts thoroughly in a suitable solvent. Dry 3 Coat shaft H with grease. Insert the shaft into roller B.
shaft and bore of roller using compressed air in a Apply grease to new 'O'-rings D and install them on
place free of dust and moisture. shaft H.

Check components for wear. Polish out scratches

and roughness using an oil stone. Then apply a coat
of engine oil to all parts.

If being replaced, install bushes C into roller B, using

a dolly and hammer.

802964
Fig 18.

4 Install new floating seals E into brackets G. Coat the

802966
metallic face of each seal with engine oil.
Fig 16.

2 Install new floating seals E into roller B.

802965
802963
Fig 17. Fig 19.

J-34 9813/0400-1 J-34

 Section J - Track and Running Gear
Bottom Roller
Assembly
5 Press mounting brackets G onto shaft H and insert
new locking pins F.

802962
Fig 20.

6 Fill the unit with oil, see Section 3, Fluid and

Lubricants. Install plug A using an appropriate pipe
thread sealant.

802961
Fig 21.

J-35 9813/0400-1 J-35

 Section J - Track and Running Gear
Bottom Roller
Wear Limits

Wear Limits

JS200 - 260
Nominal Pitch 190.00mm
Dimension A (mm)
Wear Normal Impact
A
0% 150.00
10% 148.80
20% 147.50
30% 146.30
Fig 22.
40% 145.00
50% 143.80
60% 142.20
70% 140.60
80% 139.20
90% 137.60
100% 135.20
110% 133.00
120% 131.00

J-36 9813/0400-1 J-36

Section K

Engine
Service Manual - JS200 Asia Pacific
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body & Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section J - Track and Running Gear
Section K - Engine

Publication No.
9813/0400-1

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 K - Engine

Contents Page No.

Technical Data
JS200 ....................................................................................................... K-1

K-i K-i
 Section K - Engine

Contents Page No.

K-ii K-ii
 Section K - Engine
Technical Data
JS200

Technical Data
JS200

Table 1.
Model 6BT 5.9 140
Type – JS210SC: Water-cooled, 4 stroke, 6 cylinder in-line direct injection, Turbo -Charged diesel engine.
Net Power: 140 HP at 2000 Rev/min
Air filtration: Dry element with secondary safety element and cab warning indicator
Cooling: Water-cooled via large capacity radiator
Batteries: 2 x 12 volt heavy duty
Alternator: 24 volt 40 amp

For further details, see Cummins Engine Service Manual,

Publication No. 9813/4050

K-1 9813/0400-1 K-1