General Information 1

Care & Safety 2

Routine Maintenance 3
Attachments A
Body & Framework
B
Service
Manual Electrics C

JS200
Hydraulics E
JS210 Transmission F
JS220
Track & Running Gear J
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE: ©
Engine K
WORLD PARTS CENTRE
CHEADLE ROAD, UTTOXETER , ST14 7BS
ENGLAND
Tel. ROCESTER (01889) 590312
PRINTED IN ENGLAND
Introduction
This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training
by JCB Technical Training Department.

These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques
associated with the maintenance and repair of hydraulic earthmoving equipment.

Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of
course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe
connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all
else SAFETY MUST COME FIRST!

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

1 = General Information - includes torque settings and service tools.

2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 = Routine Maintenance - includes service schedules and recommended lubricants for all the
machine.

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

A = Attachments
B = Body & Framework ...etc.

The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later
issues of the manual.

Section contents, technical data, circuit descriptions, operation descriptions etc are inserted at the beginning of each
alphabetically coded section.

All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid
reference.

Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry
threads, hence for lubricated threads may be reduced by one third.

9803/6510 Issue 1
Colour Coding

The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised
throughout JCB Service publications.

Red Full Pressure

Pressure generated from operation of a service. Depending on application this may
be anything between neutral circuit pressure and M.R.V. operating pressure.
Pink Pressure
Pressure that is above neutral circuit pressure but lower than that denoted by red.

Orange Servo
Oil pressure used in controlling a device (servo).
Blue Neutral
Neutral circuit pressure.
Green Exhaust

Light Cavitation
Green Oil subjected to a partial vacuum due to a drop in pressure (cavitation).
Yellow Lock Up
Oil trapped within a chamber or line, preventing movement of components (lock up).

A390940

9803/6510 Issue 1
Section 1 General Information Section 1
i i

Contents Page No.

Machine Identification Plate 1-1

Typical Vehicle Identification Number (VIN) 1-1

Typical Engine Identification Number 1-1

Torque Settings 2-1

Service Tools
- Body and Frame 4-1
- Electrics 4-3
- Hydraulics 4-6
- Transmission 4 - 14

Sealing and Retaining Compounds 5-1

9803/6510 Issue 1
Section 1 General Information Section 1
1-1 1-1

Machine Identification Plate Typical Vehicle

Identification Number (VIN)
Your machine has an identification plate mounted ouit side
the cab at A. The serial numbers of the machine and its SLP JS915 3 E 0 930000
major units are stamped on the plate.
A B C D E
The machine serial number is in scibed ar B which is the bse
plate of the rear frame and the emgine number is at C.
A World Manufacturer Identification

B Machine Model Code

CYear of Manufacture:
2 = 2002
B 3 = 2003
A 4 = 2004
5 = 2005
6 = 2006
7 = 2007
8 = 2008

D Manufacturer Location (E = England)

401730

E Product Identification Number (PIN)

JCB HEAVEY PRODUCTS LTD

UTTOXETER, STAFFS
ST14 8TL, ENGLAND

Typical Engine
VIN Vehicle Identification Nunber Identification Number
Product
Identification 6 BGI 145941
Number
A B C
MACHINE WIEGHT kg

ENGINE SERIAL No.

ENGINE POWER A Engine Type “6 Cylinder”

kW RPM

CONSTRUCTION
YEAR B Build code

A407820
C Engine Identification Number

JS06060

9803/6510 Issue 1
Section 1 General Information Section 1
2-1 2-1

Torque Settings
Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the
figures stated. For lubricated threads the values should be REDUCED by one third.

UNF Grade 'S' Bolts

Bolt Size Hexagon (A/F) Torque Settings

in (mm) in Nm kgf m lbf ft

1/4 (6.3) 7/16 14 1.4 10

5/16 (7.9) 1/2 28 2.8 20
3/8 (9.5) 9/16 49 5.0 36
7/16 (11.1) 5/8 78 8.0 58
1/2 (12.7) 3/4 117 12.0 87
9/16 (14.3) 13/16 170 17.3 125
5/8 (15.9) 15/16 238 24.3 175
3/4 (19.0) 11/8 407 41.5 300
7/8 (22.2) 15/16 650 66.3 480
1 (25.4) 11/2 970 99.0 715
11/4 (31.7) 17/8 1940 198.0 1430
11/2 (38.1) 21/4 3390 345.0 2500

Metric Grade 8.8 Bolts

Bolt Size Hexagon (A/F) Torque Settings

(mm) mm Nm kgf m lbf ft

M5 (5) 8 7 0.7 5
M6 (6) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105

Rivet Nut Bolts/Screws

Bolt Size Torque Settings (for steel rivet nuts)

(mm) Nm kgf m lbf ft

M3 (3) 1.2 0.12 0.9

M4 (4) 3.0 0.3 2.0
M5 (5) 6.0 0.6 4.5
M6 (6) 10.0 1.0 7.5
M8 (8) 24.0 2.5 18.0
M10 (10) 48.0 4.9 35.5
M12 (12) 82.0 8.4 60.5

Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.

9803/6510 Issue 1
Section 1 General Information Section 1
4-1 Service Tools 4-1

Service Tools

SECTION B - Body and Framework

Cartridge Gun - hand operated - essential for the

application of sealants, polyurethane materials etc.

JCB part number -

892/00845

Hand Cleaner - special blend for the removal of

polyurethane adhesives.

JCB part number - 4104/1310

(454g; 1 lb tub)
S186240 S186270

Folding Stand for

Holding Glass -
essential for preparing
new glass prior to
installation.

12V Mobile Oven - 1 cartridge capacity - required to JCB part number -

pre-heat adhesive prior to use. It is fitted with a male 892/00843
plug (703/23201) which fits into a female socket
(715/04300).

JCB part number - 992/12300

S186250 S186280

240V Static Oven - available with 2 or 6 cartridge Glass Lifter - minimum 2 off - essential for glass
capacity - required to pre-heat adhesive prior to use. installation, 2 required to handle large panes of glass.
No plug supplied. Note: 110V models available upon Ensure suction cups are protected from damage
request - contact JCB Technical Service. during storage.

JCB part number: JCB part number - 892/00842

992/12400 - 2 Cartridge x 240V
992/12600 - 6 Cartridge x 240V

S186260 S186300

9803/6510 Issue 1
Section 1 General Information Section 1
4-2 Service Tools 4-2

Service Tools (cont’d)

SECTION B - Body and Framework (cont’d)

Wire Starter - used to access

braided cutting wire (below)
through original polyurethane
seal.

Cut-Out Knife - used to remove

broken glass.

JCB part number - 992/12800

JCB part number - 892/00848

S186340
S186310

'L' Blades - 25 mm (1 in) cut - replacement blades for

cut-out knife (above).

JCB part number - 992/12801 (unit quantity = 5 off)

Glass Extractor (Handles) - used with braided cutting

wire (below) to cut out broken glass.

JCB part number - 892/00846

S186320 S186350

Long Knife - used to give extended reach for normally

Braided Cutting Wire - consumable heavy duty cut-out inaccessible areas.
wire used with the glass extraction tool (above).
JCB part number - 892/00844
JCB part number - 892/00849
(approx 25 m length)

S186330 S186360

9803/6510 Issue 1
Section 1 General Information Section 1
4-3 Service Tools 4-3

Service Tools

SECTION B - Body and Framework (cont’d)

Rubber Spacer Blocks - used to provide the correct

set clearance between glass edge
and cab frame.

JCB part number - 926/15500

Nylon Spatula - (unit quantity = 500 off)
general tool used for
smoothing sealants - also used
to re-install glass in rubber glazing
because metal tools will chip the glass
edge.

JCB part number - 892/00847

S186470 S186550

826/01099 M6 x 16mm Rivet Nut

826/01101 M6 x 19mm Rivet Nut
826/01103 M8 x 18mm Rivet Nut
826/01102 M8 x 21mm Rivet Nut
826/01104 M10 x 23mm Rivet Nut
826/01105 M10 x 26mm Rivet Nut

Installation Tool Available from:

Bollhoff Fastenings Ltd.
Midacre
The Willenhall Estate
Rose Hill
Willenhall
West Midlands, WV13 2JW
S261210

9803/6510 Issue 1
Section 1 General Information Section 1
4-4 Service Tools 4-4

Service Tools

SECTION C - Electrics

Electrical Test Equipment

1 892/00283 Tool Kit Case

2 892/00281 AVO Meter

3 892/00286 Surface Temperature

4 892/00284 Microtach Digital Tachometer

5 892/00282 Shunt - open type

6 892/00285 Hydraulic Oil Temperature Probe

7 892/00298 Fluke 85 Multimeter

993/85700 Battery Tester

9803/6510 Issue 1
Section 1 General Information Section 1
4-5 Service Tools 4-5

Service Tools

SECTION C - Electrics (cont’d)

Electronic Service Tool Kit

3
892/01033 Kit comprises:

1 Data Link Adaptor (DLA), enables data exchange

between the machine ECU (Electronic Control Unit) B
J
H
C

G
D
E
F

and a laptop PC loaded with the applicable

diagnostics software.
4
2 Interconnecting cable, DLA to laptop PC. Several
cables are included to enable compatibility with
different PC port types.

3 Interconnecting cable, DLA to machine ECU

diagnostics socket.
1
4 Kit carrying case.
2

A406130

721/10885- Interconnecting cable, DLA to machine ECU B

C

A
D
E

diagnostics socket.
J F
H G

(part of 892/01033 Kit above))

A408030

9803/6510 Issue 1
Section 1 General Information Section 1
4-6 Service Tools 4-6

Service Tools (cont’d)

SECTION E - Hydraulics

Hydraulic Pressure Test Gauges and Connections

1 892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in2)
2 892/00346 Pressure Gauge 0-70 bar (0-1000 lbf/in2)
3 892/00347 Connector
4 892/00254 Hose

3
4

1/2

Pressure Test ‘T’ Adapters Pressure Test Adapters

892/00262 1/4 in BSP x 1/4 in F BSP x Test Point 892/00255 1/4 in BSP x Test Point
816/55038 3/8 in BSP x 3/8 in F BSP x Test Point 892/00256 3/8 in BSP x Test Point
816/55040 1/2 in BSP x 1/2 in F BSP x Test Point 892/00257 1/2 in BSP x Test Point
892/00263 5/8 in BSP x 5/8 in F BSP x Test Point 892/00258 5/8 in BSP x Test Point
892/00264 3/4 in BSP x 3/4 in F BSP x Test Point 816/15118 3/4 in BSP x Test Point
892/00265 1 in M BSP x 1 in F BSP x Test Point 892/00259 1 in BSP x Test Point
892/00266 1,1/4 in M BSP x 1,1/4 in F BSP x Test Point 892/00260 1,1/4 in BSP x Test Point
892/00267 1,1/2 in M BSP x 1,1/2 in F BSP x Test Point 892/00261 5/8 in UNF x Test Point

9803/6510 Issue 1
Section 1 General Information Section 1
4-7 Service Tools 4-7

Service Tools (cont’d)

SECTION E - Hydraulics (cont’d)

Hand Pump Equipment

892/00223 Hand Pump
892/00137 Micro-bore Hose 1/4 in BSP x 5 metres
892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
892/00706 Test Probe
892/00278 Gauge 0 - 40 bar (0 - 600 lb/in2) 816/50005 1/2 in BSP (A) x 1/2 in BSP (B)
892/00279 Gauge 0 - 400 bar (0 - 6000 lb/in2) 816/60096 3/4 in BSP (A) x 3/4 in BSP (B)
892/00280 Gauge 0 - 600 bar (0 - 8500 lb/in2) 816/00018 1 in BSP (A) x 1 in BSP (B)

Female Cone Blanking Plug Male Cone Blanking Plug

892/00055 1/4 in BSP 816/00294 1/4 in BSP
892/00056 3/8 in BSP 816/00189 3/8 in BSP
892/00057 1/2 in BSP 816/00190 1/2 in BSP
892/00058 5/8 in BSP 816/00197 5/8 in BSP
892/00059 3/4 in BSP 816/00196 3/4 in BSP
892/00060 1 in BSP 816/00193 1 in BSP

9803/6510 Issue 1
Section 1 General Information Section 1
4-8 Service Tools 4-8

Service Tools (cont’d)

SECTION E - Hydraulics (cont’d)

Socket Box Wrench For disassembly and assembly of slew motor

gearbox.

A408900

Nut Adapter For disassembly and

assembly of slew motor
gearbox.

A408860

9803/6510 Issue 1
Section 1 General Information Section 1
4-9 Service Tools 4-9

Service Tools (cont’d)

SECTION E - Hydraulics (cont’d)

A408880
Seal Ring Tool for assembly and disassembly of slew motor
gearbox seal

Stopper for assembly of slew motor

gearbox.

A408890

9803/6510 Issue 1
Section 1 General Information Section 1
4 - 10 Service Tools 4 - 10

Service Tools (cont’d)

SECTION E - Hydraulics (cont’d)

Bearing Rig for removal of slew

motor bearing.

A408870

9803/6510 Issue 1
Section 1 General Information Section 1
4 - 11 Service Tools 4 - 11

Service Tools (cont’d)

SECTION E - Hydraulics (cont’d)

Ram Dismantling and Assembly

Ram Piston Head Nut

Item Part Number Description Quantity

1 993/99525 Rig assembly (not including spanners and ram) 1

2 993/99522 Anchor side plate (supplied loose unwelded) 1

3 993/99523 Anchor cross member (supplied loose unwelded) 1

4 993/99524 Ram eye end modification 1

5 556/43400 Lift ram 1

6 545/18000 Lynch pin 1

7 811/50232 11/4 in Pivot pin 1

Spanner Requirements
993/99518 Bucket ram 90 mm A/F Nut
SSP0047 Boom ram 95 mm A/F Nut
993/99519 Dipper ram 100 mm A/F Nut

993/99519 Bucket ram 100 mm A/F Nut

993/99519 Boom ram 100 mm A/F Nut
993/99521 Dipper ram 115 mm A/F Nut

Note: All spanners have operating centres of 500 mm.

9803/6510 Issue 1
Section 1 General Information Section 1
4 - 12 Service Tools 4 - 12

Service Tools (cont’d)

SECTION E - Hydraulics (cont’d)

Ram Dismantling and Assembly (cont’d)

Jig for inserting and correcting seal ring

WDB 2052 Bucket 120mm Cylinder inner diameter

WDB 2054 Boom 125mm Cylinder inner diameter
WDB 2164 Boom 130mm Cylinder inner diameter
WDB 2056 Arm 150mm Cylinder inner diameter

Jig for pulling out, press-fitting bushing

WDB 2166 Bucket 80mm Piston Rod diameter

WDB 2167 Boom 85mm Piston Rod diameter
WDB 2170 Arm 100mm Piston Rod diameter
WDB 2168 Bucket 90mm Piston Rod diameter
WDB 2168 Boom 90mm Piston Rod diameter
WDB 2171 Arm 105mm Piston Rod diameter

Jig for press-fitting wiper ring

WDB 2166-1 Bucket 80mm Piston Rod diameter

WDB 2167-1 Boom 85mm Piston Rod diameter
WDB 2170-1 Arm 100mm Piston Rod diameter
WDB 2168-1 Bucket 90mm Piston Rod diameter
WDB 2168-1 Boom 90mm Piston Rod diameter
WDB 2171-1 Arm 105mm Piston Rod diameter

Jig for inserting cylinder head

WDB 2174 Bucket 80mm Cylinder rod inner diameter
WDB 2175 Boom 85mm Cylinder rod inner diameter
WDB 2178 Arm 100mm Cylinder rod inner diameter
WDB 2176 Bucket 90mm Cylinder rod inner diameter
WDB 2176 Boom 90mm Cylinder rod inner diameter
WDB 2179 Arm 105mm Cylinder rod inner diameter

9803/6510 Issue 1
Section 1 General Information Section 1
4 - 13 Service Tools 4 - 13

Service Tools (cont’d)

SECTION E - Hydraulics (cont’d)

Ram Dismantling and Assembly (cont’d)

Seal Ring and Connector Jig

WDB 2052 Seal Ring insert and connection jig set
Note: The above Part no. is applicable to a tube diameter of 120mm.

Bush Removal Jig

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

Bush Fitting Jig

WDB 2166 Bush press fitting jig
WDB 2166-1 Retainer
Note: The above Part no. is applicable to a rod diameter of 80mm.

Wiper Ring fitting Jig

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

Wiper Ring fitting Jig

WDB 2174 Cylinder Head insertion guide jig
Note: The above Part no. is applicable to a rod diameter of 80mm.

9803/6510 Issue 1
Section 1 General Information Section 1
4 - 14 Service Tools 4 - 14

Service Tools (cont’d)

SECTION F - Transmission

Track Gearbox Jig

SST0037 Re-sealing Tool
(All dimensions are in mm.)

ø315
ø270

21
24

ø304

14
SST0037 ø306

Stopper for the assembly of Hydraulic

motor on track gearbox
A409010

9803/6510 Issue 1
Section 1 General Information Section 1
4 - 15 Service Tools 4 - 15

Service Tools (cont’d)

SECTION F - Transmission (cont’d)

Track Gearbox Jig

SST0040 Ring Nut Tool
SST0041 Planet Gear Tool
(All dimensions are in mm.)

38.1sq
1x45°

30
ø9.7

90
M4x4 no.4 screw

ø9.5 no.4 dowel

30
11

SST0040 1.5x45°
8

ø233.5
ø248

ø265

20 30

1x45°

R.8
Ø35
Ø56
Ø46

R2
1.5X4.5°

SST0041

9803/6510 Issue 1
Section 1 General Information Section 1
5-1 5-1

Sealing and Retaining Compounds

JCB Multi-Gasket A medium strength sealant suitable for all
sizes of gasket flanges, and for hydraulic fittings
of 25-65mm diameter. 4102/1212 50ml

JCB High Strength Threadlocker A high strength locking fluid for use with threaded
components. Gasketing for all sizes of flange where
the strength of the joint is important. 4102/0551 50ml

JCB Retainer (High Strength) For all retaining parts which are unlikely to be
dismantled. 4101/0651 50ml

JCB Threadlocker and Sealer A high strength locking fluid for sealing 4101/0250 10ml
and retaining nuts, bolts, and screws up to 4101/0251 50ml
50mm diameter, and for hydraulic fittings up
to 25mm diameter.

Threadseal A medium strength thread sealing compound. 4102/1951 50ml

Threadlocker A locking fluid for use on threads larger than

50mm dia. 4101/0451 50ml

Activator A cleaning primer which speeds the curing rate 4104/0251 (1ltr)
of anaerobic products. 4104/0253 Bottle (200ml)

Cleaner / Degreaser For degreasing components prior to use of

anaerobic adhesives and sealants. 4104/1557 400ml

Direct Glazing Kit For one pane of glass, comprises items

marked † below plus applicator nozzle etc. 993/55700

† Ultra Fast Adhesive For direct glazing 4103/2109 310 ml

† Active Wipe 205 For direct glazing 4104/1206 30 ml

4104/1203 250 g

† Black Primer 206J For direct glazing 4201/4906 30 ml

Clear Silicone Sealant To seal butt jointed glass 4102/0933

Black Polyurethane Sealant To finish exposed edges of laminated glass 4102/2309 310 ml

JCB Cleaner & Degreaser For degreasing components prior to use of anaerobic
adhesives and sealants. 4104/1538 Aerosol

9803/6510 Issue 1
Section 2 Care & Safety Section 2
i i

Contents Page No.

Safety Notices 1-1

General Safety 1-1

Operating Safety 1-3

Maintenance Safety 1-5

Safety Decals 1-7

9803/6510 Issue 1
Section 2 Care and Safety Section 2
1-1 1-1

In this publication and on the machine, there are safety notices. Each notice starts
with a signal word. The signal word meanings are given below.

! DANGER
Denotes an extreme hazard exists. If proper precautions are not taken, it is
highly probable that the operator (or others) could be killed or seriously
injured.
INT-1-2-1

! WARNING
Denotes a hazard exists. If proper precautions are not taken, the operator (or
others) could be killed or seriously injured.
INT-1-2-2

! CAUTION
Denotes a reminder of safety practices. Failure to follow these safety practices
could result in injury to the operator (or others) and possible damage to the
machine.
INT-1-2-3

9803/6510 Issue 1
Section 2 Care and Safety Section 2
1-2 1-2

All construction and agricultural equipment can be As well as the warnings in the following pages, specific
hazardous. When a JCB Excavator is correctly operated and warnings are given throughout the book. This section is
properly maintained, it is a safe machine to work with. But designed to give a safety code for use of the machine
when it is carelessly operated or poorly maintained it can generally and for operation and maintenance practices.
become a danger to you (the operator) and others.
Note: This section includes a certain amount of operating
Do not work with the machine until you are sure that you can
safety information. But remember that whenever you drive
control it.
the machine or operate its controls, you are in effect a
Do not start any job until you are sure that you and those machine operator. Therefore you should read and
around you will be safe. understand the information given in the Operator Handbook
before driving the machine or operating its controls.
If you are unsure of anything, about the machine or the job,
ask someone who knows. Do not assume anything.
Remember

BE CAREFUL
BE ALERT
BE SAFE
GEN-1-6

General Safety

!WARNING !WARNING
Handbook Clothing
You and others can be injured if you operate or maintain You can be injured if you do not wear the proper
the machine without first studying this handbook. Read clothing. Loose clothing can get caught in the
the safety instructions before operating the machine. If machinery. Wear protective clothing to suit the job.
you do not understand anything, ask your employer or Examples of protective clothing are: a hard hat, safety
JCB distributor to explain it. Keep this handbook clean shoes, safety glasses, a well fitting overall, ear-
and in good condition. Do not operate the machine protectors and industrial gloves. Keep cuffs fastened.
without a handbook in the cab, or if there is anything on Do not wear a necktie or scarf. Keep long hair
the machine you do not understand. restrained.
INT-1-3-2 INT-1-3-6

!WARNING
Decals !WARNING
You can be injured if you do not obey the decal safety Lifting Equipment
instructions. Keep decals clean. Replace unreadable or You can be injured if you use faulty lifting equipment.
missing decals with new ones before operating the Make sure that lifting equipment is in good condition.
machine. Make sure replacement parts include warning Make sure that lifting tackle complies with all local
decals where necessary. regulations and is suitable for the job. Make sure that
INT-1-3-4 lifting equipment is strong enough for the job.
INT-1-3-7

!WARNING
Care and Alertness
All the time you are working with or on the machine, take
!WARNING
Raised Equipment
care and stay alert. Always be careful. Always be alert
Raised equipment can fall and injure you. Do not walk or
for hazards.
work under raised equipment unless safely supported.
INT-1-3-5 13-1-1-6

!WARNING ! DANGER
Alcohol and Drugs Before removing the boom from the machine, ensure
It is extremely dangerous to operate machinery when that the counterweight is adequately supported as in
under the influence of alcohol or drugs. Do not consume certain ground conditions the machine could tip
alcoholic drinks or take drugs before or whilst operating backwards. Never travel or transport the machine with
the machine or attachments. Be aware of medicines the boom removed.
which can cause drowsiness. BF 6-3
INT-1-3-9

9803/6510 Issue 1
Section 2 Care and Safety Section 2
1-3 1-3

Operating Safety

!WARNING !WARNING
Practice Exhaust Gases
You or others can be killed or seriously injured if you do Breathing the machine exhaust gases can harm and
unfamiliar operations without first practising them. possibly kill you. Do not operate the machine in closed
Practice away from the work site on a clear area. Keep spaces without making sure there is good ventilation. If
other people away. Do not perform new operations until possible, fit an exhaust extension. If you begin to feel
you are sure you can do them safely. drowsy, stop the machine at once. Get out of the cab
INT-2-1-1 into fresh air.
!WARNING INT-2-1-10

Machine Condition
A defective machine can injure you or others. Do not ! DANGER
operate a machine which is defective or has missing Sparks
parts. Make sure the maintenance procedures in this Explosions and fire can be caused by sparks from the
handbook are completed before using the machine. exhaust or the electrical system. Do not use the
INT-2-1-2
machine in closed areas where there is flammable
material, vapour or dust.
!CAUTION
INT-2-2-10
If you have an attachment which is not covered in this
handbook, don’t install it, use it or remove it until you
have obtained, read and understood the pertinent !WARNING
information. Install attachments only on the machines for Engine
which they were designed. The engine has exposed rotating parts. Do not open the
5-5-1-1
engine cover while the engine is running. Do not use the
!WARNING machine with the cover open.
INT-2-1-6/1
Entering/Leaving
Always face the machine when entering and leaving the
cab. Use the step(s) and handrails. Make sure the
step(s), handrails and your boot soles are clean and dry. !WARNING
Do not jump from the machine. Do not use the machine Passengers
controls as handholds, use the handrails. Passengers in or on the machine can cause accidents.
INT-2-1-7
The JCB Excavator is a one man machine. Do not carry
passengers.

!WARNING INT-2-2-2

Controls
You or others can be killed or seriously injured if you !WARNING
operate the control levers from outside the cab. Operate Safe Working Loads
the control levers only when you are correctly seated Overloading the machine can damage it and make it
inside the cab. unstable. Study the lifting and/or digging specifications
INT-2-1-3 in this handbook before using the attachment.
INT-2-2-11/1

!WARNING !WARNING
Visibility The Long Reach is larger and higher than a normal
Accidents can be caused by working in poor visibility. excavating rig. You must take extra care when you are
Keep windows clean and use your lights to improve working in dangerous or restricted height locations such
visibility. Do not operate the machine if you cannot see as under power lines, bridges, etc.
properly. 8-2-8-10
INT-2-1-11

!WARNING
Machine Limits
Operating the machine beyond its design limits can
damage the machine, it can also be dangerous. Do not
operate the machine outside its limits. Do not try to
upgrade the machine performance with unapproved
modifications.
INT-2-1-4

9803/6510 Issue 1
Section 2 Care and Safety Section 2
1-4 1-4

Operating Safety (cont’d)

!CAUTION
Because of the extra length and height of the Long
Reach boom and dipper, you must be very careful when
slewing. Do not slew quickly and strike the dipper
against any obstacle. You may cause severe damage to
the rig structure.
8-2-8-11

!WARNING
Airborne particles of light combustible material such as
straw, grass, wood shavings, etc. must not be allowed to
accumulate within the engine compartment or in the
propshaft guards (when fitted). Please inspect these
areas frequently and clean at the beginning of each work
shift or more often if required. Before opening the engine
cover, ensure that the top is clear of debris.
5-3-1-12/2

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

Buried Electric Power Cables

Before you start using the machine, check with your
electricity supplier if there are any buried power cables
on the site.
Overhead Electric Power Cables
There is a minimum clearance required for working
beneath overhead power cables. You must obtain details
from your local electricity supplier.
2-2-5-4

!CAUTION
With certain combinations of bucket or attachment and
boom/dipper configuration, it is possible for the bucket
teeth or attachment extremities to contact and cause
damage to the structure of the machine. Check the limit
of free movement as the dipper is brought in towards the
machine.
8-2-5-2

!WARNING
Hazardous Atmospheres
This machine is designed for use in normal outdoor
atmospheric conditions. It should not be used in an
enclosed area without adequate ventilation. Do not use
the machine in a potentially explosive atmosphere, i.e.
combustible vapours, gas or dust, without first
consulting your JCB Distributor.
INT-2-1-14

9803/6510 Issue 1
Section 2 Care and Safety Section 2
1-5 1-5

Maintenance Safety

!WARNING !WARNING
Modifications and Welding Fires
Non-approved modifications can cause injury and If your machine is equipped with a fire extinguisher,
damage. Parts of the machine are made from cast iron; make sure it is checked regularly. Keep it in the
welds on cast iron can weaken the structure and break. operator’s cab until you need to use it.
Do not weld cast iron. Contact your JCB distributor for
advice before modifying the machine. Do not use water to put out a machine fire, you could
INT-3-1-2/1 spread an oil fire or get a shock from an electrical fire.
Use carbon dioxide, dry chemical or foam extinguishers.
Contact your nearest fire department as quickly as
!WARNING possible. Firefighters should use self-contained
Electrical Circuits breathing apparatus.
INT-3-2-7/1
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong
connection can cause injury and/or damage. !WARNING
INT-3-1-4
Hot Coolant
The cooling system is pressurised when the engine is
!WARNING hot. Hot coolant can spray out when you remove the
Diesel Fuel filler cap. Let the system cool before removing the filler
Diesel fuel is flammable; keep naked flames away from cap. To remove the cap; turn it to the first notch and let
the machine. Do not smoke while refuelling the machine the steam pressure escape, then remove the cap.
or working on the engine. Do not refuel with the engine INT-3-2-9/1
running. There could be a fire or injury if you do not
follow these precautions.
INT-3-2-2 !CAUTION
Cleaning
!WARNING Cleaning metal parts with incorrect solvents can cause
Oil corrosion. Use only recommended cleaning agents and
Oil is toxic If you swallow any oil, do not induce vomiting, solvents. INT-3-2-11
seek medical advice. Used engine oil contains harmful
contaminants which can cause skin cancer. Do not
handle used engine oil more than necessary. Always use
!WARNING
Soft Ground
barrier cream or wear gloves to prevent skin contact.
A machine can sink into soft ground. Never work under
Wash skin contaminated with oil thoroughly in warm
a machine on soft ground.
soapy water. Do not use petrol, diesel fuel or paraffin to INT-3-2-4
clean your skin.
INT-3-2-3
!CAUTION
Rams
!WARNING The efficiency of the rams will be affected if they are not
Hydraulic Fluid
kept free of solidified dirt. Clean dirt from around the
Fine jets of hydraulic fluid at high pressure can penetrate
rams regularly. When leaving or parking the machine,
the skin. Do not use your fingers to check for hydraulic
close all rams if possible to reduce the risk of weather
fluid leaks. Do not place your face close to suspected
corrosion.
leaks. Hold a piece of cardboard close to suspected INT-3-2-10
leaks and then inspect the cardboard for signs of
hydraulic fluid. If hydraulic fluid penetrates the skin, get
medical help immediately.
!WARNING
INT-3-1-10/1
Hydraulic Hoses
Damaged hoses can cause fatal accidents.
Inspect the hoses regularly for:
!WARNING Damaged end fittings
Hydraulic Pressure
Chafed outer covers
Hydraulic fluid at system pressure can injure you. Before
Ballooned outer covers
disconnecting or connecting hydraulic hoses, stop the
Kinked or crushed hoses
engine and operate the controls to release pressure
Embedded armouring in outer covers
trapped in the hoses. Make sure the engine cannot be
Displaced end fittings.
started while the hoses are open. INT-3-3-2
INT-3-1-11/1

9803/6510 Issue 1
Section 2 Care and Safety Section 2
1-6 1-6

Maintenance Safety (cont’d)

!CAUTION !WARNING
'O' rings, Seals and Gaskets Arc Welding
Badly fitted, damaged or rotted 'O' rings, seals and Before carrying out any arc welding on the machine,
gaskets can cause leakages and possible accidents. completely remove the Control Computer and The
Renew whenever disturbed unless otherwise instructed. Display Monitor to avoid damage to the circuits; also
Do not use Trichloroethane or paint thinners near 'O' disconnect the alternator and battery leads.
rings and seals.
INT-3-2-12 When welding items to the mainframe make sure that the
earth clamp is positioned on the mainframe and when
!WARNING welding to the undercarriage make sure that the earth
Battery clamp is positioned on the undercarriage. If you earth
A battery with frozen electrolyte can explode if it is used one and weld the other, you may cause severe damage
or charged. Do not use a machine with a frozen battery. to the slew ring.
To help prevent the battery from freezing, keep the
battery fully charged. Always connect the earth clamp to any other component
INT-3-1-7 being welded, i.e. boom or dipper, to avoid damage to
pivot pins and bushes.
0008
!WARNING
Battery Gases
Batteries give off explosive gases. Keep flames and
sparks away from the battery. Do not smoke close to the !WARNING
battery. Make sure there is good ventilation in closed Repairs
areas where batteries are being used or charged. Do not Do not try to do repairs or any other type of maintenance
check the battery charge by shorting the terminals with work you do not understand. Get a Service Manual from
metal; use a hydrometer or voltmeter. your JCB distributor, or get the work done by a specialist
INT-3-1-8 engineer.
INT-3-1-1

!WARNING
Battery Terminals !WARNING
The machine is negatively earthed. Always connect the Metal Splinters
negative pole of the battery to earth. You can be injured by flying metal splinters when driving
metal pins in or out. Use a soft faced hammer or drift to
When connecting the battery, connect the earth (-) lead remove and fit metal pins. Always wear safety glasses.
last. INT-3-1-3

When disconnecting the battery, disconnect the earth (-)

lead first.
INT-3-1-9

!CAUTION
Never use water or steam to clean inside the cab. The
use of water or steam could damage the on-board
computer and render the machine inoperable. Remove
dirt using a brush or damp cloth.
8-3-4-8

!WARNING
Petrol
Do not use petrol in this machine. Do not mix petrol with
the diesel fuel; in storage tanks the petrol will rise to the
top and form flammable vapours.
INT-3-1-6

9803/6510 Issue 1
Section 2 Care and Safety Section 2
1-7 1-7

Safety Decals

WARNING
DO NOT OPERATE OR WORK ON THIS MACHINE
UNLESS YOU HAVE READ AND UNDERSTAND THE
INSTRUCTIONS AND WARNINGS IN THE OPERATION
AND MAINTENANCE MANUAL. FAILURE TO FOLLOW
THE INSTRUCTIONS OR HEED THE WARNINGS
COULD RESULT IN INJURY OR DEATH.
CONTACT ANY J.C.B. DEALER FOR REPLACEMENT
COPIES. PROPER CARE IS YOUR RESPONSIBILITY.

*
817/01639 WARNING : MOVING PARTS INSIDE

24 V

JS08793

Note: The decals illustrated are in English. Your JCB

Distributor will advise you on the availability of labels in
other languages.

* On ‘Supershort’ booms only.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
i i

Contents Page No.

Identification of Machine Components 1-1

Lubricants - Health and Safety

Hygiene 2-1
Storage 2-1
Handling 2-1
First Aid - Oil 2-1
Spillage 2-1
Fires 2-1

Service Capacities and Lubricants 3-1

Service Schedules 3-2

Checking for Damage 4-1

Cleaning the Machine 4-1

Daily Checks 5-1

Greasing 6-1

Fuel System
Types of fuels 7-1
Filling Tank and Check Fuel Level 7-2
Changing Fuel Filter Element 7-2
Draing Fuel Tank Impurites 7-3
Draining Sediment Bowl 7-3
Bleeding the Fuel System 7-4

Engine
Changing the Oil and Filter 8-1
Checking Oil Level 8-1
Changing the Air Filter 8-2
Adjustment/Changing Fan Belt 8-4
Checking Coolant Level 8-6
Cleaning the Radiator and Oil Cooler 8-6
Changing Coolant 8-7

Hydraulic System
Checking the Hydraulic Fluid Level 9-1
Releasing Tank Pressure 9-2
Topping-up Fluid Level 9-2
Changing the Hydraulic Fluid 9-3
Draining Water and Sediement from the Hydraulic Tank 9-4
Cleaning/Changing Suction Strainer 9-4
Changing the Return Filter 9-5
Changing the Plexus Filter 9-5
Changing the Air Breather Element 9-6
Changing the Servo Oil Filter (Pilot) 9-7
Changing the Breaker In-line Filter 9-7
Changing the Drain Line Filter 9-8
Air Bleeding from Hydraulic Pump
Air Bleeding from Rams 9-9
Air Bleeding from Slew Motor 9-9

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
ii ii

Contents Page No.

Battery
Warning Symbols 10 - 1
Checking Electrolyte 10 - 2
Battery Disconnection/Relplacement 10 - 3
Terminal Cleaning 10 - 3

Slew Unit
Checking the Slew Gearbox Oil Level 11 - 1
Changing the Slew Gearbox Oil 11 - 1

Travel Gear Box

Checking the Track Gearbox Oil Level 12 - 1
Changing the Track Gearbox Oil 12 - 1

Tracks and Running Gear

Checking/Adjusting the Track Tension 13 - 1
Checking Rollers and Idler Wheels for Oil Leaks 13 - 2
Cleaning the Tracks 13 - 4

Bucket
Checking/Adjusting for Side Play 14 - 1

Safety Related Components

Periodic Replacement 15 - 1

Trouble Shooting 16 - 1

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
1-1 1-1

Identification of Machine Components

1 Bucket 21 Upper Roller

2 Bucket Link 22 Recoil Spring
3 Dipper Link 23 Idler Wheel
4 Bucket Ram 24 Front Attachment Pin 10 11 37 33 30 12 29 31 36
5 Dipper 25 Engine Oil Pan 26
6 Dipper Ram 26 Servo (Pilot Line) Filter 34
7 Boom 27 Fuel Filter
8 Boom Ram 28 Engine Oil Filter
9 Operator’s Cab 29 Return Filter
10 Slew Gearbox 30 Suction Strainer
15
11 Fuel Tank 31 Drain Line Filter
32 Air Filter 16
12 Hydraulic Oil Tank
13 Battery 33 Air Breather 25
14 Air Cleaner 34 Plexus Filter
15 Engine and Radiator 35 Breaker Filter 27
16 Counterweight 36 Hydraulic Pump
17 Slew Ring 37 Main Valve block 9 35 32
18 Track Plate
6 24 7 24 8 9 13 14 15 16
19 Track Gearbox
20 Lower Roller

28

24 5 4 1 3 24 2 23 22 21 20 19 18

9 24 8 7
16 15 12 11

18

19 20 21 22 23 1 2 3 4 5
401910

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
2-1 Lubricants- Health and safety 2-1

It is most important that you read and understand this 2 Apply a barrier cream to the skin before handling used
information and the publications referred to. Make sure oil.
all your colleagues who are concerned with lubricants
read it too. 3 Note the following when removing engine oil from skin:

Hygiene a Wash your skin thoroughly with soap and water.

JCB lubricants are not a health risk when used properly for b Using a nail brush will help.
their intended purposes.
c Use special hand cleansers to help clean dirty
However, excessive or prolonged skin contact can remove hands.
the natural fats from your skin, causing dryness and
irritation. d Never use petrol, diesel fuel, or paraffin for washing.

Low viscosity oils are more likely to do this, so take special 4 Avoid skin contact with oil soaked clothing.
care when handling used oils, which might be diluted with
fuel contamination. 5 Don't keep oily rags in pockets.

Whenever you are handling oil products you should maintain 6 Wash dirty clothing before re-use.
good standards of care and personal and plant hygiene. For
details of these precautions we advise you to read the 7 Throw away oil-soaked shoes.
relevant publications issued by your local health authority,
plus the following. First Aid - Oil

Storage Eyes.
In the case of eye contact, flush with water for 15 minutes. If
Always keep lubricants out of the reach of children. irritation persists, get medical attention.

Never store lubricants in open or unlabelled containers. Swallowing.

If oil is swallowed do not induce vomiting. Get medical
advice.
Waste Disposal
Skin.
All waste products should be disposed of in accordance In the case of excessive skin contact, wash with soap and
with all the relevant regulations. water.
The collection and disposal of used oil should be in
accordance with any local regulations. Never pour used
Spillage
engine oil into sewers, drains or on the ground.
Absorb on sand or a locally approved brand of absorbent
granules. Scrape up and remove to a chemical disposal
Handling area.
New Oil
There are no special precautions needed for the handling or
Fires
use of new oil, beside the normal care and hygiene
practices. Extinguish with carbon dioxide, dry chemical or foam. Fire-
fighters should use self-contained breathing apparatus.
Used Oil
Used engine crankcase lubricants contain harmful
contaminants.

Here are precautions to protect your health when handling

used engine oil:

1 Avoid prolonged, excessive or repeated skin contact

with used oil.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
3-1 Service Capacities and Lubricates 3 -1

JS200/JS210/JS220 and Variants

Item Lubricant International Specification Capacity

ENGINE (see separate chart) 22 litres

(4.87 UK gal)
(5.81 US gal)

TRACK GEARBOX JCB HD90 Gear Oil API-GL-5, MIL-L-2105 2 x 3.5 litres
(2 x 0.77 UK gal)
(2 x 0.92 US gal)

SLEW GEARBOX JCB HD90 Gear Oil API-GL-5, MIL-L-2105 5 litres

(1.09 UK gal)
(1.31 US gal)

TRACK ROLLERS JCB HD90 Gear Oil API-GL-5, MIL-L-2105

AND IDLER WHEEL

RECOIL SPRING JCB Special HP Grease Lithium complex (NLGI) inc.

CYLINDER extreme pressure additives

HYDRAULIC SYSTEM JCB Hydraulic 203 litres

Fluid 46 ISO VG46 (44.64 UK gal)
(53.6 US gal)

SLEW RING
- BEARING JCB Special HP Grease Lithium complex (NLGI) inc. --
extreme pressure additives

- GEAR TEETH JCB Special HP Grease Lithium complex (NLGI) inc. 17 kg (37.48 lb)
extreme pressure additives

ALL OTHER GREASE

POINTS JCB Special HP Grease Lithium complex (NLGI) inc. --
extreme pressure additives

COOLING SYSTEM see Coolant Mixtures 23 litres

(5.0 UK gal)
(6.0 US gal)

FUEL TANK see Type of Fuel 343 litres

(75.5 UK gal)
(90.6 US gal)

ENGINE LUBRICATION CHART

Use according to ambient temperature (°C)

-30 -20 -10 0 10 20 30 40

JCB SUPER 15W/40 MULTIGRADE ENGINE OIL

API CF4/SG MIL L-2104F

JCB SUPER 10W/30 MULTIGRADE ENGINE OIL

API CF4/SG MIL L-2104F

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
3-2 Service Schedules 3-2

Regular Maintenance and Lubrication Schedules

A poorly maintained machine is a hazard. Doing the regular Initial Precautions for New Machine Usage
maintenance and lubrication jobs listed in these schedules
will help keep the machine in safe running order.
!CAUTION
Apart from the daily jobs, the schedules are based on If the machine is operated at full load before its initial
machine running hours. Keep a regular check on the hour run-in procedure is complete it may cause scuffing and
meter reading. Do not use a machine which is due for a seizing which can adversely effect the life of the
regular service. Rectify any defects found during regular machine.
maintenance before clearing the machine for use. 8-3-1-5

A new machine is only dispatched when all inspection

!WARNING procedures are complete, but operating it under severe
Maintenance must be done only by suitably qualified and conditions from new will affect its performance and shorten
competent persons. its service life.
Before doing any maintenance make sure the machine is
safe, it should be correctly parked on level ground. 1 Carry out the daily inspection procedure.

To prevent anyone starting the engine, remove the 2 Always warm up the machine (see Warming-up under
starter key. Disconnect the battery when you are not Using Your Machine).
using electrical power. If you do not take these
precautions you could be killed or injured. 3 Check to see if the machine is running normally.
8-3-1-1

4 Avoid running or slewing the machine rapidly.

5 Avoid sudden shocks e.g. suddenly stopping the boom

when lowering.

6 Where applicable, grease the front pins daily.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
3-3 Service Schedules 3-3

Every 10 Operating Hours or Daily Every 250 Operating Hours or Monthly

Whichever occurs first Whichever occurs first
1 Clean 1 Do a 50 hour service plus:
a Machine generally.
2 Clean
2 Grease a Drain water and deposits from hydraulic oil tank.
(If operating in very wet or severe conditions) b Air cleaner dust valve.
a Boom/bucket/dipper pivot points. c Pre-cleaner
a Battery terminals.
3 Check (Engine Stopped)
a Generally for damage.
3 Grease
b For oil and coolant leakage.
a Door and canopy hinges.
c Security of bolts and nuts †.
b Slew ring bearing.
d For disconnected or shorted wiring, loose terminals.
e Hydraulic fluid level. 4 Check (Engine Stopped)
f Engine oil level. a Battery electrolyte level.
g Track tension. b Security of major unit mounting bolts and nuts.
h Windscreen washer fluid level. If loose, tighten to specified torque.
j Fuel system for leaks. c Track and slew gearbox oil level.
k Fuel level. d Fan belt adjustment.
l The auxiliary circuit hydraulic oil filter visual e Air inlet system security
indicator (if using a rockbreaker) f Hoses and pipework for chafing or damage.
g Condition of ram piston.
† Tapping with a hammer will identify any loose nuts and
bolts which should then be tightened to the specified h Bucket pivot pin grease seals .
torque. j Track plate condition and bolt torque.
4 Check (Engine Running) k Track and running gear.
a Operation of warning lights and audible alarm. l Top and bottom track rollers for oil leaks .
b Operation of other electrical equipment. m Track idler wheels for oil leaks.
c Exhaust for excessive smoke. n Wiring for chafing.
d Excavator operation. o Radiator for damage.
e Transmission operation. p Oil cooler for damage.
f Operation of track and slew brakes.
g Operation of hour meter. 5 Check (Engine Running)
a Operation of throttle system .
b Operation of overload warning.
Every 50 Operating Hours or Weekly
c Operation of stop control .
Whichever occurs first
1 Do the daily jobs plus:

2 Clean
a Drain water and sediment from fuel tank.
b Drain fuel water separator.

3 Grease
a All pivot pins. (except boom base and boom/ dipper
pivot - EMS bushes).

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
3-4 Service Schedules 3-4

Every 500 Operating Hours or 3-Monthly Every 1000 Operating Hours or 6-Monthly
Whichever occurs first Whichever occurs first
1 Do a 250 hour service plus: 1 Do a 500 hour service plus:
2 Clean
2 Clean
a Radiator, grille and oil cooler fins.
a Fuel lift pump strainer.
3 Grease b Hydraulic fluid suction strainer.
a Slew ring teeth.
3 Grease
4 Change a Pivot pins - including the boom base pivot and the
a Engine oil. boom /dipper main pivot EMS bushes.
b Engine oil full flow filter element.
4 Change (Engine Stopped)
c Fuel filter element.
a Engine air filter element (outer).
d Engine oil filter by-pass element.
b Hydraulic tank air breather element.
c Track and slew gearbox oil.
5 Check (Engine Stopped)
d Return filter element.††
a Fan belt adjustment.
e Plexus filter.††
b Accumulator operation.
f Servo oil filter element.††
c Battery electrolyte level.
g Drain filter.††
d Exhaust system security.
e Teeth and sidecutters. 5 Check (Engine Stopped)
f Exhaust system security. a Track wear.
g Top and bottom track rollers for oil leaks.
h Track idler wheels for oil leaks.
Every 2000 Operating Hours or Yearly
j Hydraulic oil (check the degradation and cleanliness
by sampling). Whichever occurs first
k Seat belt condition and security. 1 Do a 1000 hour service plus:
l Teeth and sidecutters. 2 Check (Engine Stopped)
cleanliness by sampling). a Sample hydraulic oil and replace if necessary.
m Engine oil (check the degradation and cleanliness
by sampling). 3 Change
a Hydraulic fluid suction strainer.
6 Check (Engine Running) b Engine air filter element (inner).
a Operation of throttle system. c Hydraulic Oil (for machines with biodegradable oil).
b Operation of overload warning.
c Operation of stop control. Every 4000 Operating Hours or 2 Years
Whichever occurs first
1 Do a 2000 hour service plus:
2 Change
a Long life coolant.
b Fuel hose (fuel tank - engine).
c Fuel hose (fuel filter - injection pump).
d Hydraulic pump exit hose (pump - operation valve).
e Boom ram line hose.
f Dipper ram line hose.
g Bucket ram line hose.

†† If using a breaker, crusher or pulverizer, see revised

servicing schedules.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
3-5 Service Schedules 3-5

Every 5000 Operating Hours or 2 Years

6 Months
Whichever occurs first
1 Do a 1000 hour service plus:
2 Change
Hydraulic oil (for machines with non biodegradable oil).

Hydraulic tank air breather element.

Hydraulic suction filter. ††

†† If using a breaker, crusher or pulverizer, see revised

servicing schedules.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
3-6 Service Schedules 3-6

Service Intervals for Hydraulic Oil and Filters when using a Breaker, Crusher or Pulverizer

When using a breaker, crusher or pulverizer, contamination and degradation of the hydraulic oil occurs much more quickly
than in normal excavating use. If the machine is used with increasingly degrading oil it can cause problems in the control
valve, premature wear of the hydraulic pump and damage to the hydraulic system as a whole.

Servicing of the hydraulic oil and filters must be done more frequently according to the percentage of total operating hours
involving use of the breaker, crusher or pulverizer. When a breaker, crusher or pulverizer is fitted, ensure that the oil and filters
are changed at the intervals shown in the table below.

The hydraulic oil must be sampled and checked for contamination and degradation at the intervals shown. Consult
your JCB Distributor who will have the facilities to do this work and ensure that the hydraulic system is properly
maintained.

Service Intervals for Hydraulic Oil and Filters according to Frequency of Breaker, Crusher or Pulverizer Use

Use Frequency Use Frequency Use Frequency Use Frequency

100% 40% 20% 10%
Item Time (hrs) 10 100 600 10 300 1500 10 600 3000 10 800 4000
Hydraulic Oil ! ! ! ! ! ! ! !
Return Filter ! ! ! !
Suction Filter " ! " ! " ! " !
Drain Filter ! ! ! !
Servo Filter ! ! ! !
Plexus Filter ! ! ! !
Breaker In-Line Filter ! ! ! !
Hydraulic Oil Sampling Every 200 hrs Every 300 hrs Every 600 hrs Every 800 hrs

! Check oil level and top up as required ! Change " Clean

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

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
4-1 Checking For Damage 4 -1

Inspect steelwork for damage. Note damaged paintwork Check all bucket teeth for damage and security.
for future repair.
Check all lamp lenses for damage.
Make sure all pivot pins are correctly in place and secured
by their locking devices. Check that all safety decals are in place and undamaged.

Ensure that the steps and handrails are undamaged and Fit new decals where necessary.
secure.
Check for sufficient track tension and any loose Track Plate
Check for broken, cracked or crazed window glass. bolts.
Replace damaged items.

Cleaning the Machine

Exterior Interior
Clean the exterior of the machine using water and/or steam.
If steam is used the machine must be completely greased !CAUTION
afterwards. (See Greasing). Never use water or steam to clean inside the cab. The
use of water or steam could damage the on-board
Pay particular attention to the cab windows. Make sure that computer and render the machine inoperable. Remove
the radiator grille is not blocked. dirt using a brush or damp cloth.
8-3-4-8

Do not allow mud to build up on the tracks and running gear.

(See Tracks and Running Gear).

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
5-1 Daily Checks 5 -1

Daily Checking

It is vital to check certain machine functions and f Engine oil level check and refilling
components daily to ensure that the machine can be Check the oil level before starting the engine and
operated safely and efficiently. 30 minutes or more after stopping the engine.
Use dipstick A to check that the oil level is correct.
1 Engine (Inspection Before Starting) If low, refill with engine oil through oil filler port B.
a Follow steps 1-3 of daily checking. Re-check the oil level about 10-15 minutes after
refilling.
2 Prepare the Machine
Park the machine on level ground, lower the bucket to !WARNING
the ground. The coolant system is pressurised when the coolant is
hot. Hot coolant will burn you. Make sure that the
3 Locate the Components to be Checked engine is cool before checking the coolant level or
(See Identification of Machine Components). draining the system.
2-3-3-3

4 Stop the Engine

g Coolant level check and refilling.
Remove the starter key.
Check the level of coolant in the reserve tank C. If
low, carefully remove the cap D, let any pressure
5 Visual Check
escape. Remove the reserve tank cap F and refill
Check the machine for the following: with coolant. The correct level is between the FULL
a Oil, fuel and coolant leakage. and LOW markings.
b Fasteners properly attached.
6 Checking After Initial Start-up
c Wire breakage, short circuit of cables and terminal
anchorage. a Operation of horn and gauges.
d Oil cleanliness. b Ease of engine starting, abnormal noise and
exhaust gas colour.
e Dust accumulation.
c Oil, fuel and coolant leakage.

428050

403620

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
5-2 Daily Checks 5 -2
Daily Checking (cont’d)

7 Fuel level check 9 Crawler

a Check the fuel level by inspecting the fuel gauge A a Check the shoes E for looseness, wear and
located on the front of the tank and the monitor breakage.
display. If low, refill through the fuel filler port B. b Check the track motor, F upper/lower rollers G, H
and idler wheel J for oil leakage and wear.

Note: The illustration below is only typical. The number of

upper rollers G and lower rollers H varies according to the
machine model.
c Check each mounting bolt for looseness and/or
missing bolts.

A
D
F

C H
G

JS03642 10 Boom/Dipper
a Check the high pressure hoses/joints and the
hydraulic rams for oil leakage.
!WARNING
DO NOT remove the hydraulic tank filler or cover plate 11 Bucket and Linkage.
when the engine is running. The hydraulic system is a Check the bucket teeth and side cutter for
under pressure. looseness, wear and breakage
You or others could be injured. First stop the engine b Check the lubrication of the linkage K and
and then release the pressure. surrounding parts. Check to see if the bucket side
8-3-4-4/2
play is within allowable range. (Refer to the Bucket
8 Hydraulic oil level check and refilling Section for side play adjustment.)
a Follow steps 1-3 of the daily checking procedure
leaving the boom, dipper and bucket positioned as
shown above.
b Check to see that the hydraulic oil level is near the
centre of the level gauge C
c If it is low, remove the filler plug D and refill. Take K
care that no dirt or dust gets into the hydraulic oil
when refilling.
d Check the mounting bolts of the fuel and hydraulic
oil tanks for looseness and for fuel and hydraulic oil
leakage.
e Check the mounting bolts of the electrical parts and
battery terminals for looseness and wire breakage.

JS03755

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
6-1 Greasing 6-1

General Notes
For the type of grease to use at each point, (see Lubricants !WARNING
and Capacities). You will be working close into the machine for these
jobs. Lower the attachments if possible. Remove the
Do not mix different types of grease. Keep them separate.
starter key and disconnect the battery. This will prevent
the engine being started.
8-3-1-3

Slew Ring Bearing

1 The two grease nipples are grouped together on the
front of the machine and one on the front of the ring.

Slew Ring Teeth and Slew Pinion

Ensure slew ring is kept full of grease. Always grease
whenever the machine has been steam-cleaned.

For location of the slew ring gear refer to Identification of

Machine Components.

1 Make the Machine Safe

Stop the engine and remove the starter key.

2 Grease the Slew Ring

a Remove the Inspection port cover A (on the lower
centre section).
b Remove the grease discharge port cover B (on the
lower inner side).
C
c Remove contaminated grease. A
d Replace the discharge port cover.
B
e Apply grease to the slew ring via aperture C.

3 Slew the Machine

Start the engine and slew the machine a few degrees.
Stop the engine, remove the starter key and apply JS03671
grease again.

Repeat until the whole ring is greased. Check that

grease exudes around the entire circumference.

4 Refit the Cover

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
6-2 Greasing 6 -2

Excavator End

!WARNING
You will be working close into the machine for these Grease
jobs. Lower the attachments if possible. Remove the Greasing Points Points Hours
starter key and disconnect the battery. This will prevent A Boom Base 3 1000
the engine being started. 8-3-1-3
B Boom ram, eye end pin 2 50
C Dipper ram, dump end pin 1 50
N O D Boom ram, dump end pin 1 50
E Bucket ram to Bucket linkage 3 50
K
F Bucket linkage to Bucket pin 1 50
G Dipper to Bucket Linkage pin 1 50
H Dipper to Bucket pin 1 50
M
J J Bucket ram, dump end pin 1 50

C K Dipper ram, eye end pin 1 50

L Boom to Dipper, connecting pin 1 1000
M TAB positioning ram, dump end pin 1 50

B N TAB positioning ram, eye end pin 1 50

O TAB upper/lower boom pivot pin 1 50

429301

A B
C

B
L
B
K
C

A A A
JS03482

E
E
G

H E

F
D D

JS03750
JS03722

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
7-1 Fuel System 7 -1

Types of Fuel Filling the Tank and Fuel Level Checking

Use good quality diesel fuel to get the correct power and For location of fuel tank refer to Identification of Machine
performance from your engine. The recommended fuel Components at the end of this section
specification is given below.
!WARNING
Cetane Number: 45 (minimum) Diesel fuel is flammable. Keep flames away from the
Viscosity: 2.5/4.5 centistokes at 40°C (104°F) machine. Do not smoke while fuelling the machine or
Density: 0.836/0.866 kg/litre (1.046/1.084 lb/pint) working on the engine. Do not refuel with the engine
Sulphur: 0.5% of mass (maximum) running. There could be a fire and injury if you do not
Distillation: 85% at 350°C (662°F) follow these precautions.
INT-3-2-2
Cetane Number
Indicates ignition performance. Fuel with a low cetane 1 Prepare the Machine
number can cause cold start problems and affect Park the machine on level ground. Lower the bucket
combustion. to the ground.

Viscosity 2. Stop the Engine

This is the resistance to flow. If this is outside limits, the Remove the starter key.
engine performance can be affected.
3 Filling the tank
Density a At the end of every working day, fill the tank with
Lower density will reduce engine power. Higher density will the correct type of fuel. This will prevent overnight
increase both engine power and exhaust smoke. condensation from developing in the fuel tank.

Sulphur b We recommend that you lock the fuel cap to prevent

High sulphur content can cause engine wear. (High sulphur theft and tampering.
fuel is not normally found in North America, Europe or
Australia). If you have to use a high sulphur fuel you must c After filling, check the fuel level by looking at the
also use a highly alkaline engine lubricating oil; or change fuel gauge.
the normal oil more frequently.

Distillation Petrol
This indicates the mixture of different hydrocarbons in the !WARNING
fuel. A high ratio of lightweight hydrocarbons can affect the Do not use petrol in this machine. Do not mix petrol with
combustion characteristics. the diesel fuel, in storage tanks the petrol could rise to
the top and form flammable vapours.
Low Temperature Fuels INT-3-1-6
Special winter fuels may be available for engine operation at
temperatures below 0°C (32°F). These fuels have a lower
viscosity. They also limit wax formation in the fuel at low
temperatures. (Wax forming in the fuel can stop the fuel
flowing through the filter).
Flow improvers may also be available. These can be added
to the fuel to reduce wax formation.

Advice
Consult your fuel supplier or JCB distributor concerning the
suitability of any fuel you are not sure about. If you have to
use non-standard fuels, contact your JCB distributor for
advice on engine adjustments and oil change periods.

Fatty Acid Methyl Ester Fuels as a replacement for Diesel

Fuels

Fuel resources such as Rape Methyl Ester and Soybean

Methyl Ester, collectively known as Fatty Acid Methyl Esters
are being used as alternatives and extenders for mineral oil.

Fatty Acid Methyl Esters must conform to certain standards

to be of acceptable quality, just as mineral oils do at present.

Consult your JCB distributor for advice about the use of

Fatty Acid Methyl Ester fuels, as improper application may

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
7-2 Fuel System 7 -2

Changing the Fuel Filter Element

!WARNING
Fuel oil is highly flammable. Completely wipe off any
spilt fuel which could cause a fire.
8-3-4-3

1 Prepare the Machine

Park the machine on level ground, lower the bucket to
the ground.

2 Stop the Engine

Remove the starter key.

3 Open the Engine Compartment

Locate the fuel filter.

4 Remove the Element

Using a chain wrench, unscrew the filter element A from
the filter head.

5 Fit the New Element

Smear the new filter element sealing ring with fuel oil
and hand tighten onto the filter head.
Use a chain wrench to tighten by a further 2/3.
Bleed the system (see Bleeding the Fuel System)

Wipe up any spilt fuel.

A409641

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
7-3 Fuel System 7 -3

Draining Fuel Tank Impurities

1 Stop the engine and remove the key.

2 Remove screws and take off the cover plate from below
the fuel tank.

3 Position a suitable container under the drain tap.

4 Loosen the drain tap X on the underside of the fuel

tank. Drain the water and deposits until clean diesel oil
flows out.

5 Close the drain tap firmly and refit cover.

!WARNING
Fuel oil is highly inflammable. Completely wipe off any
spilt fuel which could cause a fire.
8-3-4-3

X
Draining the Water Separator 401801

The water separator should be drained at least every 50

hours, but more often if necessary.

1 Stop the engine and remove the key.

C
2 Drain off any water in the bowl by turning tap A.

3 Make sure tap A is turned off and secure.

D
Cleaning the Water Separator
If the bowl B contains sediment carry out the following: B
1 Hold the bowl B and unscrew the domed nut C.
A
2 Remove the bowl, wash the bowl in clean fuel.

3 Clean strainer D.

4 Refit the bowl. Make sure the gasket is in good

condition and positioned correctly.

5 Retighten the nut C, take care not to over tighten.

6 Bleed the fuel system. See Bleeding the Fuel System.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
7-4 Fuel System 7 -4

Bleeding the Fuel System

Air in the fuel system could cause misfiring or failure to start.

Air will enter the system if any part of it is disconnected or
emptied.

Note: Running the engine with air in the system could

damage the fuel injection pump. After maintenance, remove
air from the fuel system as detailed below.

1 Stop the Engine

Switch off the engine and remove the key.

2 Disconnect the Battery

Remove the -ve lead to chassis.

3 Open the Engine Compartment

Locate the priming pump.

4 Prepare for Bleeding

Loosen the knob A on the priming pump B by turning it
anti-clockwise. The knob will be lifted by spring
pressure.

5 Bleed the System

a Loosen the eye bolt C. Operate the priming pump A409640

knob A until fuel filter is full.

B
b Next, tighten the eye bolt C, and continue to move
the feed pump handle.

c When the handle becomes difficult to move and the

A
air is heard being expelled, then air bleeding is
complete.
C
6 Restore the System to Normal
Depress knob A and turn clockwise to lock into the
priming pump B.

!WARNING
Fuel oil is highly inflammable. Completely wipe off any
spilt fuel which could cause a fire.
8-3-4-3

Wipe up any spilled fuel. Then start the engine and check
for leaks.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
8-1 Engine 8 -1

Changing the Oil and Filter

!CAUTION
Hot oil and engine components can burn you. Make sure
the engine is cold before doing this job.
2-3-3-2
1 Prepare the Machine
Park the machine on level ground. Lower the bucket to
the ground.

2 Stop the Engine

a Remove the starter key.
b Let the engine stand until it is warm. Do not check
the oil straight after the engine has stopped, the oil
level indicated will actually be lower than it is.

2 Drain the Oil A

a Place an oil collecting container of suitable size
beneath the engine sump drain point.

Note:The machine is fitted with a self sealing drain plug A .

b Remove the self sealing drain plug outer threaded

cover.
c Fit the self sealing drain kit threaded union (with
attached pipe) B and drain sump oil into a suitable
container. B
d Remove the self seal drain kit, clean and refit the
outer cover. (Do not over tighten the cover).

3 Change the Filters

a Remove the filter D.
b Clean the filter head.
c Smear the seal on the new filter D with oil.
d Tighten the filter until the seal bites onto the filter
housing.
e Tighten the filter a minimum of one more full turn.
C
4 Fill the System
Fill the engine with new oil through filler C (see
Lubricants and Capacities) for the type and amount.
Wipe off any spilt oil. Check for leaks. Make sure the
filler cap is correctly refitted.
5 Check for Leaks
Before starting the engine, turn the engine over with the
Emergency Stop Button ON until the oil pressure D
warning light goes out.
Allow the engine to stand before checking the oil level
(see Checking the Oil Level).
A409643

Checking the Oil Level

3 Open the Engine Compartment

4 Check the Oil Level 428050

Locate the dipstick E and remove. Oil should be

between the two marks. Add oil if necessary through
filler C. Use only the recommended oil, (see
Lubricants and Capacities). Re-check the oil level E
about 10-15 minutes after refilling.
Make sure that the dipstick and filler cap are secure.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
8-2 Engine 8 -2

Air Filter

Changing the Outer Element

!CAUTION 1 Stop the engine.

The outer element must be renewed immediately if the
warning light on the instrument panel illuminates. 2 Press clips A and lift off cover B. Remove outer element
2-3-3-1 C. Take care not to tap or knock the element.

Note: Do not attempt to wash or clean the elements - they 3 Clean the inside of cover B and canister D.
must only be renewed.
4 Insert a new element into the canister, check seal E is
Note: Do not run the engine with the dust valve F removed. fully seated. Fit cover B with dust valve F at the bottom.
Push the cover firmly into position and make sure it is
Note: Change the outer element more frequently if operating secured by clips A.
in dusty conditions. A new inner element must be fitted at
least every third time the outer element is changed. As a 5 Make sure that the wire is connected to the Air Filter
reminder, mark the inner element with a felt tipped pen each Blocked switch.
time the outer element is changed.
6 Check all hoses for condition and tightness.

A
A336941
F

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
8-3 Engine 8 -3

Air Filter

Changing the Inner Element

Note: Do not attempt to wash or clean the elements - they 4 Clean the inside of cover B and canister D.
must only be renewed.
5 Carefully insert the new inner element G into the
Note: Do not run the engine with the dust valve F removed. canister. Make sure it seats correctly. Check seal H is
fully seated.
Note: A new inner element must be fitted at least every third
time the outer element is changed. As a reminder, mark the 6 Insert a new outer element C into the canister, check
inner element with a felt tipped pen each time the outer seal E is fully seated. Fit cover B with dust valve F at
element is changed. the bottom. Push the cover firmly into position and
make sure it is secured by clips A.
1 Stop the engine.
7 Make sure that the wire is connected to the Air Filter
2 Press clips A and lift off cover B. Remove outer element Blocked switch.
C.
8 Check all hoses for condition and tightness.
3 Lift up pulls J and remove inner element G.

G
H
C
J
B

F A336941

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
8-4 Engine 8 -4

Checking the Fan Belt Tension

!WARNING
Make sure that the engine cannot be started. Disconnect
the battery before doing this job. A
2-3-3-5

1 Prepare the Machine

Put the machine on level ground, lower the bucket to
the ground.
B
2 Stop the Engine
Remove the starter key.

3 Check the Fan Belt Tension

There must be 10 mm (0.4 in) slack midway between A344071

the alternator and water pump.

4 Loosen the Alternator

Slacken bolts A and B.

5 Adjust the Fan Belt

a Use a lever to re-position the alternator so as to
adjust the fan belt tension.

Note: If the fan belt is stretched so much that it cannot be

adjusted correctly, fit a new belt.

b While levering the alternator pinch the bolt A and

check the tension on the belt.

c If it is not correctly tensioned complete steps 4

and 5.

d When correct tension is achieved fully tighten bolts

A and B.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
8-5 Engine 8 -5

Fitting a New Fan Belt

Complete steps 1 and 2.

1 Loosen the Alternator A C

Slacken bolts A, B and adjust plate C so that the
alternator is levered towards the engine, so that the fan
belt D can be removed.

2 Fit a New Fan Belt

Remove the fan belt D and replace it with a new one,
make sure the ‘V’ profile locates in the pulleys correctly.
B
Note: It may be necessary to apply leverage to the new belt
to get it over the pulleys. D
A344071
3 Adjust the Fan Belt
Carry out step 5 of Adjusting the Fan Belt.

4 Re-check the Fan Belt Tension

Check after running the machine for 1 hour.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
8-6 Engine 8 -6

Checking the Coolant Level

1 Park the Machine on Level Ground

Stop the engine and let it cool down. Open the engine
compartment. A
!WARNING
The cooling system is pressurised when the coolant is
hot. Hot coolant will burn you. Make sure that the
engine is cool before checking the coolant level or
draining the system.
2-3-3-3

2 Release System Pressure

For location of engine cooling radiator, refer to
Identification of Machine Components.
Carefully slacken cap A. Let any pressure escape.
Remove the cap.

3 Check the Level B

The level should be between the FULL and LOW
marks on the expansion bottle C. Remove the Cap B
and Top-up the bottle with pre-mixed water/antifreeze
if necessary. Refit Cap B (See Coolant Mixtures).

4 Refit the Pressure Cap A

Make sure it is tight.

Note: Check the quality of the antifreeze mixture every

year before the cold weather starts. Change it every two
years. C
A344180

Cleaning the Radiator and Oil Cooler

A clogged radiator and/or oil cooler can lead to engine
overheating. Regularly check for a build-up of dirt and
debris and if necessary, use compressed air to clean-out
the grille. At the same time check all hoses for damage or
perishing, and replace if necessary.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
8-7 Engine 8 -7

Changing The Coolant Coolant Mixtures

To prevent the coolant freezing in cold conditions, antifreeze
1 Do Steps 1 and 2 of Checking the Coolant Level.
must be added. JCB Four Seasons Antifreeze and
Summer Coolant will give protection down to the
2 Drain the system.
temperatures shown in the table.
Remove the radiator pressure cap. Open the radiator
drain tap A. Remove the cylinder block drain plug B.
Antifreeze Solution Starts to freeze at
Remove the expansion bottle cap (see Checking the
55% -36°C (-33°F)
Coolant Level). Let the coolant drain out.
Never use less than a 50% solution, otherwise there will not
!CAUTION be enough corrosion protection.
Keep your face away from the drain hole when removing
the drain plug. Never use more than 60% solution, otherwise the cooling
2-3-3-4
system may be damaged.
3 Flush the system
If necessary. Use clean water. Leave the antifreeze in all the year round as it gives
protection against corrosion.
4 Refit the drain plug
Clean and refit the cylinder block drain plug, making Check the strength of antifreeze solution at least once a
sure it is tight. Close the radiator drain tap. year, preferably at the start of the cold period. Always renew
the antifreeze every two years.
5 Fill the system
Using the necessary mix of clean, soft water and A 50% antifreeze mixture should be used even if frost
antifreeze (see Coolant Mixtures) fill via the protection is not needed. This gives protection against
expansion bottle cap until the level in the bottle is corrosion and raises the coolant's boiling point.
between the FULL and LOW marks.

6 Refit the Radiator Pressure Cap

Make sure it is tight.

7 Refit the Expansion Bottle Cap

Make sure it is tight.

8 Check for Leaks

Run the engine for a while to raise the coolant to
working temperature and pressure. Stop the engine.
Check for leaks. Re-check the level in the expansion
bottle and top up if necessary.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
9-1 Hydraulic System 9 -1

!WARNING
The temperature of the hydraulic oil will be high soon
after stopping the engine. Wait until it cools down (less
than 40°C) before beginning maintenance. A
8-3-4-10

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

Checking the Hydraulic Fluid Level

1 Prepare the Machine
Position the machine on level ground with the bucket
and dipper rams fully extended and the boom lowered
to rest the attachment on the ground, as at A.

2 Check the Level

B
Look at the fluid level in the sight tube B. The level
should be between the two marks on the tube. If the
fluid is cloudy, water or air has entered the system.

Water or air in the system could damage the hydraulic

JS03641
pump.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
9-2 Hydraulic System 9 -2

Releasing Tank Pressure

!WARNING
DO NOT remove the hydraulic tank filler cap or cover
plate when the engine is running. The hydraulic system B
is under pressure. You or others could be injured. First
stop the engine and then release the pressure.
8-3-4-4/1

1 Prepare the Machine

Position the machine on level ground. Stop the engine.
Remove the starter key.

2 Locate the Hydraulic Oil Tank Filler Plate C

Refer to Identification of Machine Components.

3 Release Tank Pressure

Remove the box nut B of the breather on top of the
hydraulic oil tank, press the projection and release
the pressure from the tank.
.

Topping-up Fluid Level

1 Prepare the Machine

Position the machine on level ground. Stop the engine.
Remove the starter key.

2 Release Tank Pressure

(See Releasing Tank Pressure)

3 Add Fluid
a Remove plug C

b Refill oil through the filler port using a suitable

tundish.

c Check the level through the level gauge on the side

of the tank. CA
JS 03610
d Refit plug C.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
9-3 Hydraulic System 9 -3

Changing the Hydraulic Fluid

1 Prepare the Machine A

B B
C
Position the machine on level ground. Stop the engine.
Remove the starter key.

2 Locate the Filler Port and Drain Plug

3 Release Tank Pressure

(See Releasing Tank Pressure)

4 Remove the Oil

FE
a Remove cover A and O-ring B.

b Use a pump and discharge the hydraulic oil into an

empty container. DE

c Remove the drain plug C on the bottom of the tank

and drain the remaining oil from the tank.

Note: Have a drain pan ready.

5 Renew the Suction Strainer D and Return Filter E D

C
(See Changing the Suction Strainer and Changing JS03760
the Return Filter).

6 Tighten the Drain Plug C Securely

7 Refill the tank with the specified oil to the specified

level.

8 Seal the System

a Install the O-ring B and filler port cover A.

Note: If the O-ring is damaged, replace it with a new one.

9 Bleed air from the hydraulic components

(See Air Bleeding Procedures).

10 Start the engine and run it for 5 minutes without load.

Slowly operate the rams several times and then put the
machine in the hydraulic oil checking position.

11 Check that the hydraulic oil is within the proper range.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
9-4 Hydraulic System 9 -4

Draining Water and Sediment from the

Hydraulic Tank
1 Prepare the Machine
Position the machine on level ground. Stop the engine.
Remove the starter key.

2 Release Tank Pressure

(See Releasing Tank Pressure).

3 Draining the Water and Sediment

Carefully loosen the drain plug A on the bottom of the
tank and drain the sediment and water accumulated at
the bottom of the tank.

Note: Have a drain pan ready. The task is complete when

clean hydraulic fluid flows out.

4 Seal the System

Tighten the drain plug A.

JS03761
A

Cleaning/Changing the Suction Strainer

1 Prepare the Machine on level ground A B
Stop the engine. Remove the starter key.

2 Locate the Suction Strainer

3 Release the Tank Pressure

(See Releasing Tank Pressure).

4 Remove the Suction Strainer

a Remove the filler port cover A and O-ring B.

b Remove the suction strainer C from the tank and

renew.

5 Fit the Suction Strainer C

Fitting is a reversal of removal. When changing the
suction strainer, fit a new O-ring seal to the filler port
cover A and secure the fasteners.

6 Check the Hydraulic Fluid Level

JS03761

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
9-5 Hydraulic System 9 -5

Changing the Return Filter

1 Prepare the Machine A B

Position the machine on level ground. Stop the
engine.
C
Remove the starter key.

2 Locate the Return Filter.

3 Release Tank Pressure

(See Releasing Tank Pressure)
D
4 Remove the Element
a Remove the cover A and O-ring B.
E
b Remove spring C, valve D and return filter E from
the tank.

5 Fit a New Element

Re-assemble in reverse order using a new filter
element E and a new cover O-ring B.

Changing the Plexus Filter

1 Prepare the Machine E J

D
Position the machine on level ground. Stop the F A
engine.
Remove the starter key.
G
2 Locate the Plexus Filter
H
3 Release Tank Pressure A
(See Releasing Tank Pressure).

4 Remove the Plexus Filter

a Close the two filter case cocks B and C by turning
them to position X.
b Remove bolts and washers E.
c Slacken the nuts G and insert the screws F to lift
off the cover D.
d Remove the cover D and remove the O-ring H.
e Lift up the Plexus filter A carefully and remove.
Take care not to drop any sediment.
X
5 Fit a New Element B
a Slowly immerse the new Plexus filter A. Install the
C
O-ring H, cover D, nuts G and bolts F and bolts E.
b Torque tighten bolts E to 20Nm (14.75 lbf ft)
c Open the cocks B and C by turning them to Y
position Y.

6 Priming the Plexus Filter

a Start the engine and set at low idling, loosen plug
J, then tighten the plug when hydraulic oil flows C
out.
b Stop the engine, check the hydraulic oil level and
top-up if low. (See Checking the fluid level). B

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
9-6 Hydraulic System 9 -6

Changing the Air Breather Element

1 Prepare the Machine

Position the machine on level ground. Stop the engine.
Remove the starter key. F
A
2 Release Tank Pressure
(See Releasing Tank Pressure). B
G
3 Locate the Air Breather Element
C
4 Replace the Air Breather Element
a Remove first the hexagonal nut A, seal washer B
E
and cover C.
D
Note: The cover C can only fit in one of two positions
because of the slot G in the cover which locates over a
similar shaped protrusion on the mounting stud.

b Remove the old filter element D together with the

sponge packing E.

c Replace the old filter element D, with a new one.

When installing the new filter element D place the
sponge packing E on the element. JS03660

5 Refit the Filter cover C

a Adjust the cover so that it fits over the stud, and
install in the following order: Seal washer B,
hexagonal nut A and box nut F.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
9-7 Hydraulic System 9 -7

Changing the Pilot Oil Filter (Servo)

1 Prepare the Machine

Position the machine on level ground. Stop the engine.
Remove the starter key.

2 Release Tank Pressure

(See Releasing Tank Pressure).

3 Locate the Pilot Oil Filter

(Refer to Identification of Machine Components).

4 Dismantle the Filter

a Using a wrench on the case, unscrew the filter case
A from the filter head B.Take care not to spill the oil
it contains.
b Remove and discard the element C and O-ring D.

5 Clean the Filter Base and Case

Discard any fluid in the filter case. Clean out the case
and the underside of the head.

6 Fit New Filter Components

a Coat the new O-ring D with hydraulic fluid and
locate in the filter head B. JS03793
b Coat the seal area of the new element C and install
it in the filter case A.
c Screw the filter case A to the head B and torque B
tighten with the wrench.
D
Torque Settings
Item Nm kgf m lbf ft C
A 24.5 to 34.3 2.5 to 3.5 18.07 to 25.5

Note: When refitting the pilot filter bowl after changing the filter
element, it is important that the filter bowl is tightened carefully A
to avoid damaging the threads in the filter housing.

Changing the Breaker In-line Filter

Note: This filter should be changed at the intervals stated in X
Service Schedules or when the visual indicator X has
popped up. DO NOT USE THE BREAKER WITH A BLOCKED
FILTER. B
1 Prepare the Machine
Position the machine on level ground. Stop the engine.
Remove the starter key.

2 Release Tank Pressure

(see Releasing Tank Pressure).

3 Locate the Filter

A
4 Remove the Oil Filter
Unscrew and remove filter A from head B.

5 Fit the New Filter JS06700

Coat the seal of the new filter with clean hydraulic fluid.
Screw the new filter into head B and tighten. Check and
top up the hydraulic fluid level.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
9-8 Hydraulic System 9 -8

Changing the Drain Line Filter

1 Prepare the Machine
Position the machine on level ground. Stop the engine.
Remove the starter key.

2 Release Tank Pressure

(see Releasing Tank Pressure). B
3 Locate the Filter

4 Remove the Oil Filter

Unscrew and remove filter A from head B. A
5 Fit the New Filter
Coat the seal of the new filter with clean hydraulic fluid.
Screw the new filter into head B and tighten. Check and
top up the hydraulic fluid level. JS02830

Air Bleeding Procedures

After replacing the hydraulic oil or repairing or replacing
hydraulic components or removing hydraulic pipes, bleed air
from the hydraulic circuit.

Bleeding Air from the Hydraulic Pump

If the air is not completely bled, damage could occur within
the pump.

1 Prepare the Machine

Position the machine on level ground. Stop the engine.
Remove the starter key. C
2 Locate the Hydraulic Pump

3 Temporarily loosen the air bleeding plug C to check

that oil does not come out of the plug.

4 If oil comes out re-tighten the plug, if it does not come

out remove the air bleeding plug C and pour hydraulic
oil into the pump case through the air bleeding port until
the pump body is full. Retighten the bleed plug.

5 Run the machine at idle for five minutes.

A409710

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
9-9 Hydraulic System 9 -9

Air Bleeding from Rams

If air is not bled from the rams when replaced or repaired,
the piston and/or seals may be damaged.

1 Prepare the Machine

Idle the engine at low speed and extend and retract
each ram 5 times, stopping the ram 100 mm before the
end of each stroke.

2 Bleeding
Operate each ram 4 times for the full stroke to
completely bleed the air.

Air Bleeding from the Slew Motor

If air is not completely bled from the slew motor the motor A
bearing or other parts may be damaged.

1 Prepare the Machine

Position the Machine on level ground, stop the Engine.

2 Locate the Slew Motor

3 Checking Oil Procedure

a Loosen the Air Bleeding Plug A and check that oil
seeps out from the Air Bleeding Port.

b If no oil comes out, remove the Air Bleeding Plug A,

and fill the motor case with Hydraulic Oil.
c Tighten the Air Bleeding Plug A.

4 Sealing the System

a Idle the Engine at low speed and slowly slew the
machine left to right evenly, two times.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
10 - 1 Battery 10 - 1

!WARNING Checking the Electrolyte Level

Batteries give off an explosive gas. Do not smoke when Maintenance free batteries used in normal temperate climate
handling or working on the battery. Keep the battery applications should not need topping up. However, in certain
away from sparks and naked flames. conditions (such as prolonged operation at tropical
Battery electrolyte contains sulphuric acid. It can burn temperatures or if the alternator overcharges) the electrolyte
you if it touches your skin or eyes. Wear goggles. Handle level should be checked as described below.
the battery carefully to prevent spillage. Keep metallic
items (watches, rings, zips etc) away from battery 1 Open the Battery Compartment A
terminals. Such items could short the terminals and burn Remove the bolts securing the metal plate above the
you. batteries. Remove the plate.

Set all switches in the cab to OFF before disconnecting

the battery. When disconnecting the battery, take off the
earth (-) lead first.
When reconnecting, fit the positive (+) lead first.
Re-charge the battery away from the machine, in a well-
ventilated area. Switch the charging circuit off before
A
connecting or disconnecting the battery. When you
have installed the battery in the machine, wait five
minutes before connecting it up.
JS03353
First Aid - Electrolyte
Do the following if electrolyte:
2 Check the Level
GETS INTO YOUR EYES Remove the covers and check the electrolyte level in
Immediately flush with water for 15 minutes always get each cell. The electrolyte should be 15 mm (0.6 in)
medical help. above the plates.
Top-up if necessary with distilled water or de-ionised
IF SWALLOWED water.
Do not induce vomiting. Drink large quantities of water or
milk. Then drink milk of magnesia, beaten egg or vegetable
oil. Get medical help. !WARNING
Do not top the battery up with acid. The electrolyte
could boil out and burn you.
GETS INTO YOUR SKIN 2-3-4-6
Flush with water, remove affected clothing. Cover burns with
a sterile dressing then get medical help. 3 Check the Connections
5-3-4-3/1 Make sure that the terminals are tight and clean. Coat
them with petroleum jelly to prevent corrosion.
!CAUTION
Do not disconnect the alternator, the battery, or any part
of the charging circuit with the engine running.
8-3-4-1

A361680

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
10 - 2 Battery 10 - 2

Battery Disconnection/Replacement Terminal Cleaning

1 Prepare the Machine 1 Prepare the Machine

Position the machine on level ground. Position the machine on level ground.
Stop the engine. Remove the starter key. Stop the engine. Remove the starter key.

2 Open the Battery Compartment 2 Open the Battery Compartment

a Disconnect the earth - terminal first. a Remove the terminals, (see Battery
For connection, connect the earth - terminal last. Disconnection).
b If removing the battery, remove the bolts securing b If the terminal is dirty, clean the post.
the battery retaining plates above the battery. Then c If the terminal post is corroded and generates white
remove plates above the battery. Then remove both powder wash the terminal with hot water. If
batteries after cable disconnection. considerable corrosion is detected, clean with a
c Replacement is a direct reversal of the removal wire brush or abrasive paper.
procedure. d After cleaning, apply a thin coat of petroleum jelly to
the terminal.
3 Replacement e Re-connect the terminals according to the Battery
When replacing the battery do not mix old and new Disconnection/Replacement procedure.
batteries together, they must be replaced as a pair, as
the service life of the new battery will be shortened.

A361680

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
10 - 3 Battery 10 - 3

Warning Symbols

The following warning symbols may be found on the battery.

!WARNING
Do not disconnect the battery while the engine is
Symbol Meaning
running, otherwise the electrical circuits may be
damaged.
INT- 3- 1-14
!WARNING
Keep away from children. Understand the electrical circuit before connecting or
. disconnecting an electrical component. A wrong
connection can cause injury and/or damage.
INT-3-1-4
A289230

!DANGER
Battery electrolyte is toxic and corrosive. Do not breathe
Shield eyes. the gases given off by the battery. Keep the electrolyte
away from your clothes, skin, mouth and eyes. Wear
A289260
safety glasses.
INT-3-2-1/3

No smoking, no naked flames, !CAUTION

no sparks. Damaged or spent batteries and any residue from fires or
spillage should be put in a closed acid proof receptacle
A289280 and must be disposed of in accordance with local
environmental waste regulations.
INT-3-1-12

Explosive Gas !WARNING

Batteries give off explosive gases. Keep flames and
A289250 sparks away from the battery. Do not smoke close to the
battery. Make sure there is good ventilation in closed
areas where batteries are being used or charged. Do not
check the battery charge by shorting the terminals with
metal; use a hydrometer or voltmeter.
Battery acid. INT-3-1-8

A289240

Note operating instructions.

A289270

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
11 - 1 Slew Unit 11 - 1

Checking the Slew Gearbox Oil Level

1 Prepare the Machine

Position the machine on level ground. Stop the engine
and remove the starter key.

2 Locate the Slew Gearbox

(Refer to the Identification of Machine Components).

3 Check the Level

a Remove the dipstick A, wipe it clean and re-fit.
b Remove the dipstick again and check that the oil
level is within the range B. A
c If necessary, top up through filler port C.
(Refer to Lubricants and Capacities for oil
type).
D
4 Refit the Dipstick

B
Changing the Slew Gearbox Oil

1 Prepare the Machine

Position the machine on level ground. Stop the engine C
and remove the starter key.

2 Drain the Oil

a Remove the drain plug D. Allow the oil to drain out.
b Wipe the drain plug clean. Remove any metallic
particles.
c Refit the drain plug. Make sure it is tight.

3 Fill with New Oil

(Refer to Lubricants and Capacities for oil type and
volume).
Fill with new oil through filler port C until it reaches the
full mark on the dipstick A. Refit the dipstick.

4 Check for Leaks

Run the machine, operate the slew controls and make
sure there are no leaks.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
12 - 1 Travel Gear Box 12 - 1

Checking the Track Gearbox Oil Level

1 Prepare the Machine
Position the machine on level ground with the level and
drain plugs as illustrated.

2 Check the Level on One Side

Clean the area around filler/level plug A and remove it. TOP
Oil should be level with plug A. Top up through plug A if
necessary. (See Lubricants and Capacities for oil A
types).

3 Clean and Refit the Plug

Make sure it is tight.
B
4 Check the Level on the Other Side
Repeat steps 1 to 3.

Changing the Track Gearbox Oil 315840

1 Prepare the Machine

5 Check for Leaks
See Checking Track Gearbox Oil Level.
Run the machine, operate the tracking controls and
2 Drain the Oil on One Side then make sure there are no leaks.
a Place a container below the drain plug to catch the
oil. The container must be large enough to hold the Key
maximum gearbox capacity (see Lubricants and A filler/level plug
Capacities). B drain plug

!CAUTION
Oil will run from the hole when the drain plug is removed.
Keep to one side when you remove the drain plug.
2-3-4-2

b Remove filler/level plug A and drain plug B. Allow

the oil to drain out.

c Wipe the plugs clean. Make sure you remove all

metal particles.

3 Fill with New Oil

See Lubricants and Capacities for oil type and
volume.

a Pour new oil through filler/level plug A until oil runs

out of plug A.

b Check the condition of the o-ring, renew if it is

damaged. Refit drain plug.

4 Change the Oil on the Other Side

Repeat steps 1 to 3.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
13 - 1 Tracks and Running Gear 13 - 1

Checking/Adjusting the Track Tension

1 Prepare the Machine Note: Excessive tension can cause the track rail to wear the
Position the machine on level ground. Run it drive rollers and sprocket, insufficient tension can cause
backwards and forwards several times. Stop after wear to the drive sprocket and track rail.
running it forwards.
Carry out steps 1 to 3 of Cleaning the Tracks. Block up 4 Lower the Track
the undercarriage frame. Finish track rotation by running Remove the blocks from beneath the undercarriage
the track forwards. Stop the engine and remove the and lower the track to the ground using the boom and
starter key. dipper controls.

!WARNING 5 Repeat for the Opposite Track

Slew the boom round to the other side and repeat steps
NEVER position yourself or any part of your body under a
1 to 4 above.
raised machine which is not properly supported. If the
machine moves unexpectedly you could become trapped
and suffer serious injury or be killed.
INT-3-3-7

2 Check the Tension

Measure gap A in line with the third roller from the front
and between the lower surface of the track frame and
the upper surface of the shoe. The dimension should be
275-295 mm for hard ground conditons. For operation
on soft sand or sticky mud it should be 340-360mm.

3 Adjust the Track Tension

Adjustment is made by either injecting or releasing
grease from the check valve B. Inject grease to reduce
A JS03770
the gap (increase the tension) or open to release grease
and increase the gap.

!WARNING
When opening the check valve always stand to one side B
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

!WARNING
Under no circumstances must the check valve be
dismantled or any attempt made to remove the grease C
nipple from the check valve
8-3-4-9

If a gap C exists between the idler wheel shaft and

the track frame, you may use pressure to apply the
grease. If there is no gap C after the application of
grease, then the necessary repairs must be carried out A
by your JCB distributor.

A343970

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
13 - 2 Tracks and Running Gear 13 - 2

Checking Rollers and Idler Wheels for Oil Track Plate Inspection
Leaks 1 Prepare the Machine
Position the machine on level ground. Stop the engine.
1 Prepare the Machine Remove the starter key.
(See Checking/Adjusting the Track Tension, step 1).
Note: If a shoe bolt is used when it is loose, it may be
2 Look for Oil Leaks broken. Immediately tighten the shoe bolts whenever they
Check the top and bottom rollers and the idler wheels are found to be loose.
for oil leaks. If leaks are found contact your JCB
distributor for service. 2 Check and Tighten
Torque tighten the bolts in the sequence shown and
!CAUTION check that the nuts and shoe are closely fitted to the
Do not run the machine if you discover oil leaks in the link joining surface.
top or bottom rollers or idler wheels. Failure to rectify
such leaks could cause damage to the machine.
8-3-4-6/1 Machine Torque

3 Lower the Track JS200/JS210/JS220 640-750Nm (472-553 lbf ft)

(See Checking/Adjusting the Track Tension, step 4). 3 Repeat the Procedure
a Start the engine and move the machine forwards or
4 Repeat for the Opposite Track backward. Stop the engine.
Slew the boom to the other side and repeat steps 1 to 3
above. b Repeat the above procedure until the whole track is
tightened.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
13 - 3 Tracks and running Gear 13 - 3

Cleaning the Tracks 3 Rotate the Track

!WARNING !WARNING
If two people are doing this job make sure that the Rotating the tracks off the ground may cause stones and
person working the controls is a competent operator. If other debris to be thrown with considerable force. If you
the wrong control lever is moved, or if the controls are are on the outside, keep well clear. Keep other people
moved violently, the other person could be killed or well clear.
injured. 8-3-3-2

If you will be working with another person, make sure When it is safe to do so and you are sure that everyone
you both understand what the other will be doing. Learn is clear of the machine, operate the controls to rotate
and use the recognised signalling procedures. Do not the track which is off the ground. Rotate it first one way
rely on shouting - he will not hear you. and then the other to shake off the mud. If necessary,
the person outside may use water to get the mud off.
To clean the tracks you must turn them. When the tracks 4 Inspect the Track
are turning, keep clear of rotating parts. When you have finished, inspect the track rollers,
sprockets and idler wheels for damage and oil leaks.
Before starting this job, make sure that you have no
loose clothing (cuffs, ties, etc.) which could get caught in 5 Lower the Track
rotating parts. Operate the boom and dipper controls to lower the
track to the ground
Keep people not involved with the job well away!
8-3-3-1
6 Repeat for the Opposite Track
1 Prepare the Machine Swing the boom round to the other side and repeat
Park the machine on level ground. Open the bucket and steps 2 to 5 inclusive for the other track.
swing the boom until it is at 90° to the track. Lower the
bucket to the ground.

2 Raise the Track

Operate the boom and dipper controls so that the track
on the side nearest the bucket is lifted up clear of the
ground.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
14 - 1 Bucket 14 - 1

Checking/Adjusting for Side Play

It is possible to compensate for lateral wear which leads to

sideways play of the bucket. Regular use of this
compensating facility leads to less wear on the bucket swivel
pin A and the dipper bushes B.

1 Prepare the machine

Position the machine on level ground. Set the bucket
as shown opposite. Turn it slightly to the left and
position it so that the dipper end is pressed to the side
which is not to be adjusted. Stop the engine, remove
the starter key.

2 Measure the Clearance at C

The clearance should be approximately 0.8 mm JS03353

3 Check the clearance

JS03751

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
15 - 1 Safety Related Components 15 - 1

Periodic Replacement of Safety Related Components

Routinely replace important parts concerned with safety. It is difficult to determine by visual inspection or from operation the
service life of specific parts, so routinely replace them as important parts every 2 years.
SAFETY PARTS CHART

Fuel System
Important Parts Replacement Interval

Fuel Hose (Fuel Tank - Engine)

Every 2 years or every 4000 hours,
whichever comes first
Fuel Hose (Fuel Filter - Injection Pump)

Hydraulic System

Important Parts Replacement

Interval
Every 2 years or
Pump Exit Hose (Pump - Operation Valve) every 4000 hours,
whichever comes
first

Important Parts Replacement

Interval
Boom Ram Line Hose Every 2 years or
Dipper Ram Line Hose every 4000 hours,
whichever comes
Bucket Ram Line Hose first

If any abnormality is found with any of these parts before the replacement time, repair or replace as you would do normally.
When replacing the hoses, if the hose clamps are found to be deformed or cracked, replace the clamps at the same time as
the hoses.
Regarding hydraulic hoses not included in the routine replacement of safety parts, carry out the inspection described below
and re tighten, replace, etc, when any abnormality is found.

Note: Replace O-rings, gaskets at the same time as hoses.

Carry out inspection of the hydraulic hoses and fuel hoses at the routine inspection listed below.
Inspection Classification Inspection Item
Start-up Inspection • Fuel, Hydraulic hose connections, Oil Leakage from caulked parts
Special Independent Inspection • Fuel, Hydraulic hose connections, Oil Leakage from caulked parts
(Monthly Inspection) • Fuel, Hydraulic hose damage (cracks, wear, picking)
Special Independent Inspection • Fuel, Hydraulic hose connections, OIl Leakage from caulked parts
(Yearly Inspection) • Fuel, Hydraulic hose interference, squeezing, aging, twisting,
damage (cracks, wear, picking)

Obtaining Replacement Parts

The machine's serial number is stamped on a data plate on the right hand side inside the cab. (See Identifying Your
Machine). The data plate also shows the engine serial number. But remember if the engine has been changed the serial
number on the data plate may be wrong. Check on the engine itself.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
16 - 1 Trouble Shooting 16 - 1

To extend the service life and improve the operation of the machine, daily inspection and lubrication are necessary as well as
immediately isolating any problem found and dealing with it. If the machine is operated with the problem uncorrected, it may
lead to larger trouble and possibly to a big accident.
If trouble occurs, search for the cause in the items below and make adjustments, repairs, etc. as necessary.

Engine and Related Area

Problem Cause Remedy

Defective starter switch (Starter does not run) Connect, repair connection.
Defective rotation of starter (Starter rotates slowly) Discharged battery, starter problems,
contaminated or loose wiring connection.
Improper viscosity of engine oil Inspect and replace as necessary.
Excessive cooling of engine (Cold weather) Preheat with air heater.
Warm up the coolant (add hot water).
Engine does not start Possible seizure in engine *Repair.
Incomplete air bleeding of fuel system Completely bleed air.
No fuel in fuel tank Refill.
Fuel quality unsuitable Inspect and replace as necessary.
Fuel filter clogged Clean or replace.
Low compression *Repair
Defective fuel injection pump *Repair.

No fuel in fuel tank Refill.

Engine stops during Fuel filter clogged Clean and replace.
operation Air is mixed in the fuel system Retighten fuel pipe connections and bleed
system.

Low oil Refill.

Defective oil pressure switch Replace.
Low oil Oil filter clogged Replace element.
pressure Low oil viscosity Replace with oil of viscosity matching
temperature.
Improper operation of oil pump *Replace parts.
Oil leakage at connections Tighten connections.

Excessive oil consumption Disassemble and repair, replace parts.

Excessively low oil viscosity Replace with correct oil.
Exhaust gas from Excessive cooling by radiator Adjust.
engine is white or blue Improper fuel injection timing *Adjust or replace if necessary.
Low compression *Disassemble and repair, replace parts.

Improper fuel Replace with correct fuel.

Exhaust gas from Improper valve clearance Adjust.
engine is black or Defective fuel injection pump/injectors *Adjust or replace if necessary.
dark grey Low compression *Disassemble and repair, replace parts.
Insufficient air intake (air cleaner clogged) Clean or replace the element.

Defective fuel injection pump *Adjust or replace if necessary.

Improper spray from fuel injection nozzle *Adjust or replace if necessary.
Excessive fuel Improper fuel injection timing *Adjust or replace if necessary.
consumption Improper fuel Replace with correct fuel.
Low compression Disassemble and repair, replace parts.
Insufficient air intake Clean or replace element.

Excessive oil Drain oil to proper level.

Low oil viscosity Replace with oil of viscosity matching
Excessive engine oil temperature.
consumption Oil leakage Retighten and replace parts if necessary.
Worn cylinder piston rings *Disassemble and repair, replace parts.

Abnormal noise.(Fuel Bad fuel Replace.

or mechanical) Damage inside muffler Replace.

* Refer to Engine Service Manual Publication No. 9803/2210

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
16 - 2 Trouble Shooting 16 - 2

Engine and Related Area (cont’d)

Problem Cause Remedy

Low coolant Refill.
Water leakage Repair.
Elongated or oil dirtied belt Clean or replace.
Engine overheating Defective radiator Repair or replace.
(Water temperature Broken fan Replace.
reads too high) Incorrect mixture of anti-freeze solution Replace.
Defective thermostat Replace.
Defective water pump Replace.
Defective water sensor Replace.
Improper belt tension Adjust.
Wiring trouble Repair.
Defective battery Defective battery Replace.
charge Defective regulator Replace.
Defective alternator Replace.

* Refer to Engine Service Manual Publication No. 9803/2210

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
16 - 3 Trouble Shooting 16 - 3

Monitor Display - Fault Messages

Message Cause Remedy

WATER TEMP Water leakage Repair.
Belt elongation, soiled with oil Clean or replace.
Defective radiator Repair or replace.
Broken fan Replace.
Improper anti-freeze mixture Replace.
Defective thermostat Replace.
HYDRAULIC OIL TEMP Defective water pump Replace.
Dirty oil cooler (clogged) Clean.
Dirty radiator (clogged) Clean.
Defective dust protection net (clogged) Clean.
Defective monitor Replace.

LOW OIL PRESSURE Low Engine oil Refill.

Oil leakage at connections Repair.
Defective engine oil pressure sensor Replace.
Engine oil viscosity low Replace with oil of viscosity matching the
temperature.
Defective engine oil pump Adjust, clean, replace.
Defective monitor Replace.

AIR FILTER Air filter element clogged Clean, replace.

Intake system clogged, foreign matter inside Clean.

LOW FUEL LEVEL Fuel low Refill.

Defective sensor Replace.

ALTERNATOR Belt tension Adjust.

Wiring fault Repair.
Defective battery Replace.
Defective regulator Replace.
Defective alternator Repair or replace.
LOW COOLANT Coolant low Refill.
Defective sensor Replace.

ENG. OIL FILTER Engine oil dirty Replace engine oil, oil filter.
Defective sensor Replace.

ELEC. FAULT Short circuit, etc abnormalities Inspect, repair.

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
16 - 4 Trouble Shooting 16 - 4

Operations

Problem Cause Remedy

Foreign matter caught on control valve spool Wash the control valve.
Operating controls Valve sticking Repair or replace valve assembly.
hard to operate Improper lubrication of lever link Grease.
Lever link seizure Grease .

Hydraulic Pump
Problem Cause Remedy
Oil not delivered by Low hydraulic oil Refill.
oil pump Clogged suction filter Repair.
Oil leakage inside hydraulic pump Replace hydraulic pump.
Hydraulic pump does Air inside the hydraulic pump Refill oil or check hose on suction side.
not build pressure Main relief valve pressure set too low Adjust pressure.
Cavitation resulting from deformed hose on the
suction side or suction filter clogged Replace filter, replace hydraulic oil if dirty.
Abnormal noise from Joint of the suction side is loose or hydraulic oil Retighten or grease the joints.
hydraulic pump is low and air is being sucked in Check that oil is filled to proper level inside
casing.
Cavitation resulting from excessively high
viscosity of hydraulic oil Replace with hydraulic oil of suitable viscosity.
Oil leakage from Defective seal in hydraulic pump Replace seal or hydraulic pump.
hydraulic pump

Working Attachments
Problem Cause Remedy
Insufficient engine output Refer to Engine Service Manual.
Function drops due to wear of hydraulic pump Replace hydraulic pump.
Defective main relief valve Adjust the pressure or replace.
Overall low power Low hydraulic oil Refill.
Viscosity of hydraulic oil incorrect Replace with hydraulic oil of proper viscosity.
Suction filter clogged Replace suction filter.
Defective operations Hydraulic pump broken Replace hydraulic pump.
Hydraulic oil low Replace suction filter.
Set pressure for main or port relief valve is low Adjust pressure or replace relief valve.
or incorrect
Insufficient work power Damaged hydraulic ram seals Replace hydraulic ram seals.
Damaged hydraulic ram, cylinder Replace hydraulic ram/cylinder or the assembly.
Damaged hydraulic ram seals Replace hydraulic ram seals.
Attachment sinks Damaged hydraulic ram, cylinder Replace hydraulic ram/cylinder or the assembly.
down Oil leakage inside control valve Repair valve assembly, replace.
Oil leakage inside holding valve Repair valve assembly, replace.
Abnormal noise from Insufficient grease Grease.
joints of the Connecting pin seizure Replace the bushing and/or pin.
attachment

9803/6510 Issue 1
Section 3 Routine Maintenance Section 3
16 - 5 Trouble Shooting 16 - 5

Travel

Problem Cause Remedy

Pressure setting for main relief valve is too low Adjust the pressure.
Insufficient Defective counterbalance valve Replace the counterbalance valve.
travel force Performance reduction of travel motor Replace travel motor.
Swivel joint packing damage Replace swivel joint packing.
Performance reduction of hydraulic pump Replace hydraulic pump.
Excessively tightened track Adjust to proper tension.
Stone or foreign matter caught in track Remove stone or foreign matter.
Rough travel Defective valve Repair valve or replace.
Performance reduction of travel motor Replace travel motor.
Air in travel motor Refill with oil.

Left and right tracks are not equally tightened Bleed air from left and right, adjust tracks to equal
tension.
Performance reduction of hydraulic pump Replace hydraulic pump.
Crooked travel Performance reduction of travel motor Replace travel motor.
Oil leakage inside control valve Replace valve housing assembly.
Swivel joint packing damage Replace swivel joint packing.
Loose lever link Adjust.

Slew
Problem Cause Remedy
Insufficient Performance reduction of slew motor Replace slew motor.
slew force Thermal seizure of slew shaft Supply grease or replace the slew shaft.
Low setting of brake valve Adjust the pressure.
Idle slew during Clogged valve Wash the valve.
slew braking Performance reduction of slew motor Replace slew motor.
Internal oil leakage of control valve Repair or replace valve assembly.
Low setting of brake valve or port relief valve Adjust the pressure.
Idle slew during Clogged valve Wash the valve.
slew stopping Performance reduction of slew motor Replace slew motor.
Internal oil leakage of control valve Repair or replace valve assembly.
Abnormal noise Air in slew motor Refill with oil.
during slew Insufficient greasing of slew bearing Add grease.

Hydraulic Ram
Problem Cause Remedy
Low pressure setting for the relief valve Adjust the pressure.
Insufficient force of Oil leakage inside the hydraulic ram Replace the ram seals.
hydraulic ram Damage of the hydraulic ram or rod Replace the hydraulic ram or rod.
Oil leakage inside the control valve Repair or replace the valve assembly.
Oil leakage outside Defective hydraulic ram seals Replace hydraulic ram seals.
the hydraulic ram Hydraulic cylinder rod damage Replace hydraulic ram rod.

9803/6510 Issue 1
Section B Body & Framework Section B
i i

Contents Page No.

Service Tools 1-1

Technical Data
Static Dimensions 2-1
Dig Depth Charts 2-3
Shipping Weights 2-5
Attachments Specification 2-9
Air Conditioning 2 - 15

Basic Operation
Air Conditioning 3-1

Fault Finding
Air Conditioning 10 - 1

Service Procedures
Direct Glazing
- Removing Broken Glass and Old Sealant 21 - 1
- Preparing and Installing New Glass 21 - 4
Cab Structure - Checks 22 - 1
Checking the FOPS Structure 22 - 2
Cab Panel - Removal 30 - 1

9803/6510 Issue 1
Section B Body & Framework Section B
1-1 Service Tools 1-1

Service Tools

Cartridge Gun - hand operated - essential for the

application of sealants, polyurethane materials etc.

JCB part number -

892/00845

Hand Cleaner - special blend for the removal of

polyurethane adhesives.

JCB part number - 4104/1310

(454g; 1 lb tub)
S186240 S186270

Folding Stand for

Holding Glass -
essential for preparing
new glass prior to
installation.

12V Mobile Oven - 1 cartridge capacity - required to JCB part number -

pre-heat adhesive prior to use. It is fitted with a male 892/00843
plug (703/23201) which fits into a female socket
(715/04300).

JCB part number - 992/12300

S186250 S186280

240V Static Oven - available with 2 or 6 cartridge Glass Lifter - minimum 2 off - essential for glass
capacity - required to pre-heat adhesive prior to use. installation, 2 required to handle large panes of glass.
No plug supplied. Note: 110V models available upon Ensure suction cups are protected from damage
request - contact JCB Technical Service. during storage.

JCB part number: JCB part number - 892/00842

992/12400 - 2 Cartridge x 240V
992/12600 - 6 Cartridge x 240V

S186260 S186300

9803/6150 Issue 1
Section B Body & Framework Section B
1-2 Service Tools 1-2

Service Tools (cont’d)

Wire Starter - used to access

braided cutting wire (below)
through original polyurethane
seal.

Cut-Out Knife - used to remove

broken glass.

JCB part number - 992/12800

JCB part number - 892/00848

S186340
S186310

'L' Blades - 25 mm (1 in) cut - replacement blades for

cut-out knife (above).

JCB part number - 992/12801 (unit quantity = 5 off)

Glass Extractor (Handles) - used with braided cutting

wire (below) to cut out broken glass.

JCB part number - 892/00846

S186320 S186350

Long Knife - used to give extended reach for normally

Braided Cutting Wire - consumable heavy duty cut-out inaccessible areas.
wire used with the glass extraction tool (above).
JCB part number - 892/00844
JCB part number - 892/00849
(approx 25 m length)

S186330 S186360

9803/6150 Issue 1
Section B Body & Framework Section B
1-3 Service Tools 1-3
Service Tools (cont’d)

Rubber Spacer Blocks - used to provide the correct

set clearance between glass edge
and cab frame.

JCB part number - 926/15500

Nylon Spatula - (unit quantity = 500 off)
general tool used for
smoothing sealants - also
used to re-install glass in rubber
glazing because metal tools will chip
the glass edge.

JCB part number - 892/00847

S186470 S186550

826/01099 M6 x 16mm Rivet Nut

826/01101 M6 x 19mm Rivet Nut
826/01103 M8 x 18mm Rivet Nut
826/01102 M8 x 21mm Rivet Nut
826/01104 M10 x 23mm Rivet Nut
826/01105 M10 x 26mm Rivet Nut

Installation Tool Available from:

Bollhoff Fastenings Ltd.
Midacre
The Willenhall Estate
Rose Hill
Willenhall
West Midlands, WV13 2JW
S261210

9803/6150 Issue 1
Section B Body & Framework Section B
1-5 Service Tools 1-5

Rivet Nut Tool Procedure

A 'Rivet Nut' is a one piece fastener installed 'blind' from
one side of the machine body/framework. The rivet nut is
compressed so that a section of its shank forms an 'upset'
against the machine body/framework, leaving a durable
thread (see illustrations).

Rivet nuts are fitted to various parts of the machine body

and framework. They are used in a number of applications,
for instance, hose clamp and hydraulic valve retention etc.

Various sized rivet nuts are available, see the table below to
determine the size of rivet nut to be used for particular
applications.

If for any reason a new rivet nut requires fitting, then the
correct installation procedure must be followed:
A
1 Drill a hole in the machine body/framework where the
rivet nut is to be fitted. De-burr hole edges.

2 Screw the rivet nut onto the mandrel of the installation

tool. The bottom of the mandrel should be in line with
the bottom of the rivet nut, shown at A.

3 Wind the body of the installation tool down the

threaded mandrel until it touches the head of the rivet
nut, shown at B.

4 Insert the rivet nut (assembled to the tool) into the hole B
drilled in step 1.

5 Hold handle C and at the same time draw the mandrel

into the installation tool by turning nut D. The rivet nut
will contract in length and form an 'upset' (smooth
bulge) seating itself against the body/framework (see
inset E).
C
Note: The thread of the rivet nut must not be stripped, take
care when 'upsetting' the rivet nut.

6 Remove the installation tool.

E
D
Specifications (all dimensions in mm)

Rivet Nut Rivet Nut Material Rivet Drill

Thread Outside Thickness Length Hole
Diameter Diameter (Total) Dia.

M5 7 0.25 - 3.00 14.00 7.10

3.00 - 5.50 17.00
S150970
M6 9 0.50 - 3.00 16.00 9.10
3.00 - 5.50 19.00

M8 11 0.50 - 3.00 18.00 11.10

3.00 - 5.50 21.00 Note: In an emergency, and if no installation tool is
available, it is possible to fit a rivet nut by using a nut and
M10 13 1.00 - 3.50 23.00 13.10 bolt the same thread diameter as the rivet nut being
3.50 - 6.00 26.00 installed. However, this is not the recommended method.

9803/6510 Issue 1
Section B Body & Framework Section B
2-1 Technical Data 2-1

Static Dimensions
JS200/JS210/JS220

E Monoboom
J K

F L

I N
M

A C
B D
401770

Dimensions in millimetres (ft. in) S N LC

A Track length on ground 3370 (11ft 1 in) 3370 (11 ft 1 in) 3660 (12 ft 0 in)
B Undercarriage overall length 4170 (13 ft 8 in) 4170 (13 ft 8 in) 4460 (14 ft 8 in)
C Track gauge 2200 (7 ft 2 in) 1990 (6 ft 6 in) 2390 (7 ft 10 in)
D Width over tracks (500 shoes) - 2490 (8 ft 2 in) -
D Width over tracks (600 shoes) 2800 (9 ft 2 in) 2590 (8 ft 6 in) 2990 (9 ft 10 in)
D Width over tracks (700 shoes) 2900 (9 ft 6 in) 2690 (8 ft 10 in) 3090 (10 ft 2 in)
D Width over tracks (800 shoes) - - 3190 (10 ft 6 in)
D Width over tracks (900 shoes) - - 3290 (10 ft 10 in)

Dipper lengths 1.91 m 2.40 m 3.0 m

E Transport length with Monoboom 9570 (31 ft 5 in) 9560 (31 ft 4 in) 9440 (31 ft 0 in)
F Transport height with Monoboom 3055 (10 ft 0 in) 3060 (10 ft 0 in) 2860 (9 ft 5 in)
G Transport length with T.A. Boom 9598 (31 ft 6 in) 9573 (31 ft 5 in) 9499 (31 ft 2 in)
H Transport height with T.A. Boom 3128 (10 ft 3 in) 3065 (10 ft 1 in) 2913 (9 ft 7 in)

Dimensions in millimetres (ft in) S/N/LC

I Counterweight clearance 1066 (3 ft 6 in)
J Tailswing radius 2770 (9 ft 1 in)
K Width of superstructure* 2500 (8 ft 2 in) * with cab handrail removed
L Height over cab 2930 (9 ft 7 in)
M Ground clearance 486 (1 ft 7 in)
N Track height 885 (2 ft 11 in)

G T.A. Boom
J K

H L

I N
M

A C
B D 401900

9803/6510 Issue 1
Section B Body & Framework Section B
2-2 Technical Data 2-2

Static Dimensions
Long Reach (LR)

JS03822
E

With the exception of E and F detailed in the table below, the following dimensions are the same as those for the JS200/JS220
LC machine as listed on the previous page, i.e. A, B, C, D (900 shoes), I, J, K, L, M, N.

Note: G and H do not apply.

Dimension

E Transport length 12520 mm (41 ft 1 in)

F Transport height 3000 mm (9 ft 10 in)

9803/6510 Issue 1
Section B Body & Framework Section B
2-3 Technical Data 2-3

Dig Depth Charts

JS200/JS210/JS220

Monoboom T.A. Boom

A
A B
B G
G
10
1
1
10
9

8 9

7 8

6 7

5 6
D
4 5
E D
3
4
2 E
3
1
2
0
1
Metres

Metres
C F
F

11 10 9 8 7 6 5 4 3 2 1 0 Metres
401780

10 9 8 7 6 5 4 3 2 1 0 Metres
401790

Boom 5.70 m Monoboom 5.71 m T.A. Boom

Dipper 1.91 2.40 3.00 1.91 2.40 3.00

m (ft in) m (ft in) m (ft in) 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) 9.00 (29 6) 9.44 (31 0) 9.98 (32 9)
B Maximum digging reach (on ground) 8.70 (28 7) 9.16 (30 1) 9.70 (31 10) 8.81 (28 11) 9.26 (30 5) 9.81 (32 2)
C Maximum digging depth 5.35 (18 2) 6.02 (19 9) 6.60 (21 8) 5.51 (17 5) 5.78 (19 0) 6.35 (20 10)
D Maximum digging height 8.95 (29 4) 9.20 (30 2) 9.40 (30 10) 10.20 (33 6) 10.51 (34 6) 10.88 (35 8)
E Maximum dumping height 6.31 (20 8) 6.53 (21 5) 6.75 (22 2) 7.29 (23 11) 7.63 (25 0) 7.99 (26 3)
F Maximum vertical wall cut depth 4.90 (16 1) 5.47 (17 11) 6.07 (19 11) 4.58 (15 0) 5.09 (16 8) 5.67 (18 7)
G Minimum swing radius 3.76 (12 4) 3.71 (12 2) 3.60 (11 10) 2.59 (8 6) 2.53 (8 4) 2.34 (7 8)

9803/6510 Issue 1
Section B Body & Framework Section B
2-4 Technical Data 2-4

Dig Depth Chart

Long reach (LR)

4m

B JS03832

Working Dimensions

Machine fitted with 15 m long reach boom and dipper.

A Maximum reach (ground level) 15.49 m (50 ft 10 in)

B Maximum reach (@ 4 m depth) 14.4 m (47 ft 3 in)

9803/6510 Issue 1
Section B Body & Framework Section B
2-5 Technical Data 2-5

Shipping Weights (Approximate)

Approximate weight when equipped with monoboom, medium length dipper, bucket, operator and full fuel tank except where
indicated otherwise.

Model Track Shoe Width Weight

JS210/210/220 500 mm 19630 kg
JS210/210/220 600 mm 20010 kg
JS210/210/220 700 mm 20690 kg

9803/6510 Issue 1
Section B Body & Framework Section B
2-6 Technical Data 2-6

Weights

A C

G
H D

F
I

9803/6510 Issue 1
Section B Body & Framework Section B
2-7 Technical Data 2-7

Weights (cont’d)
Machine fitted with 3 m boom, 600 mm grouser shoes, 0.7 m3 bucket

Weight (kg)
Position
Symbol
Name

A Overall Mass 18700

B Upper Mechanism 8340

Includes counterweight and
slew ring bearing

C Counterweight 3710

D Undercarriage (with grouser shoe) 6650

E Shoe (600 mm grouser) (one side) 1270

F Machine Main Body 14990

G Attachment 3659

H Boom (including ram) 2050

I Dipper (including ram and link) 974

J Bucket 682

9803/6510 Issue 1
Section B Body & Framework Section B
2-8 Technical Data 2-8

Weights (cont’d)

Dry Weight (kg)

Part Name

1 Travel motor 270

2 Drive Sprocket 51
3 Take-up roller 88
4 Upper roller assembly 17
5 Lower roller assembly 37
6 500 mm grouser shoe assembly 1266
7 600 mm grouser shoe assembly 1473
8 700 mm grouser shoe assembly 1601
9 - -
10 Slew mechanism 194
11 Slew ring 216
12 Counterweight 3710/5010
13 Engine 490
14 Radiator 106
15 Hydraulic pump 150
16 Fuel Tank 81
17 Sump Tank 127
18 Control valve 166
19 Rotary joint 31
20 Boom 1305
21 Dipper 613
22 Bucket 682
23 Boom ram 179
24 Dipper ram 277

9803/6510 Issue 1
Section B Body & Framework Section B
2-9 Technical Data 2-9

Attachments

A296590

Boom and Slew Frame Installation A

Equipment Part Code Standard Service
Name Name Value (mm) Limit (mm)

1. Boom and Slew frame a 682 692

slew frame
installation Boom b 681 679

Shim for
Clearance c 1.0-3.5 adjustment
KRV1180

Pin d ø90 ø89

Bushing
e ø90 ø91.5
(boom)

2. Boom ram Slew frame a 106 112

and slew
frame Boom ram
b 105 103
installation (dump end)
Shim for
Clearance c 1.0-2.5 adjustment
KRV1197

Pin d ø80 ø79

Bushing
e ø80 ø81.5
(boom ram)

9803/6510 Issue 1
Section B Body & Framework Section B
2 - 10 Technical Data 2 - 10

Attachments (cont’d)

A296590

Boom Ram Installation B

Equipment Part Code Standard Service
Name Name Value (mm) Limit (mm)

3. Boom and Boom ram a 100 98

boom ram (dump end)
installation
Boom b 525 519

Shim for
Clearance c 1.0-2.5 adjustment
KRV1178

Pin d ø85 ø84

Bushing e ø85 ø86.5

(boom ram)

Dipper Ram Installation C

Equipment Part Code Standard Service
Name Name Value (mm) Limit (mm)

4. Dipper ram Boom a 121 127

installation
Dipper ram b 120 118
(dump end)
Shim for
Clearance c 0.5-3.0 adjustment
KRV1197

Pin d ø80 ø79

Bushing e ø80 ø81.5

(Dipper ram)

9803/6510 Issue 1
Section B Body & Framework Section B
2 - 11 Technical Data 2 - 11

Attachments (cont’d)

A296590

Dipper Pivot Installation D

Equipment Part Code Standard Service
Name Name Value (mm) Limit (mm)

5. Dipper Pivot Boom a 286 289.5

installation

Dipper b 285.5 283.5

Shim for
adjustment
Clearance c 0.5-1.1 KRV1180

Pin d ø90 ø89

Bushing e ø90 ø91.5

(Dipper)

Bushing f ø90 ø91.5

(boom)

Boom g ø80 78

Dipper and Dipper Ram Installation E

Equipment Part Code Standard Service

Name Name Value (mm) Limit (mm)

6. Dipper and Dipper a 121 127

Dipper ram
installation
Dipper ram b 120 118
(eye end)
Shim for
Clearance c 0.5-3.0 adjustment
KRP1349

Pin d ø80 ø79

Bushing e ø80 ø81.5

(Dipper ram)

9803/6510 Issue 1
Section B Body & Framework Section B
2 - 12 Technical Data 2 - 12

Attachments (cont’d)

G
A296590

Bucket Ram Installation F

Equipment Part Code Standard Service
Name Name Value (mm) Limit (mm)

7. Bucket Ram Dipper a 101 107

installation
Bucket
ram b 100 98
(eye end)
Shim for
Clearance c 0.5-3.0 adjustment
KRV1176

Pin d ø75 ø74

Bushing e ø75 ø76.5

(bucket ram)

Dipper and Dipper Link Installation G

Equipment Part Code Standard Service
Name Name Value (mm) Limit (mm)

8. Dipper and Dipper Link a 46 43

Dipper
link installation
Dipper b 280 278
Shim for
adjustment
Clearance c 1.0-1.5 KHV0169

Pin d ø75 ø74

Bushing e ø75 ø76.5

(Dipper)

9803/6510 Issue 1
Section B Body & Framework Section B
2 - 13 Technical Data 2 - 13

Attachments (cont’d)

A296590

Bucket and Bucket Link Installation H

Equipment Part Code Standard Service
Name Name Value (mm) Limit (mm)

9. Bucket and Bucket a 307 313

bucket link
installation
Bucket link b 306 304
Shim for
Clearance c 1.0-3.5 adjustment
KRV1197

Pin d ø80 ø79

Bushing e ø80 ø81.5

(bucket link)

Bucket Link and Bucket Ram Installation I

Equipment Part Code Standard Service

Name Name Value (mm) Limit (mm)

10. Bucket link Dipper Link a 46 43

and bucket
ram
installation
Bucket link b 280 278
Shim for
Clearance c 1.0-1.5 adjustment
KHV0170
Shim for
Bucket link d 96 adjustment
KHV0170

Bucket
ram e 95 93
(eye end)

Clearance f 1.0-2.0

Pin g ø85 ø84

Bushing h ø85 ø86.5

(Bucket link)

Bushing
(Bucket i ø85 ø86.5
ram)

9803/6510 Issue 1
Section B Body & Framework Section B
2 - 14 Technical Data 2 - 14

Attachments (cont’d)

A296590 J

Bucket and Dipper Installation H

Equipment Part Code Standard Service
Name Name Value (mm) Limit (mm)

11. Bucket and Bucket a 307 313

dipper installation

Dipper b 306 304

Shim for
Clearance c 1.0-3.5 adjustment
KRV1159

Bushing d 16 8
(bucket)

Pin e ø80 ø79

Bushing f ø80 ø81.5

(bucket)

Bushing g ø80 ø81.5

(bucket)

9803/6510 Issue 1
Section B Body & Framework Section B
2 - 15 Technical Data 2 - 15

Air Conditioning (Option)

Binary Pressure Switch Settings

Low Pressure 2.1 bar (2.14 kgf/cm2 30.4 lbf/in2)

High Pressure 28 bar (28.56 kgf/cm2 406 lbf/in2)

Refrigerant

R-134a 1.415 Kg +/- 10g

Oil

PAG Oil 150g +/- 5g PAG (PolyAlkylene Gycol) oil to ISO 100

9803/6510 Issue 1
Section B Body and Framework Section B
3-1 Basic Operation 3 -1

Air Conditioning

2
8

Direction of 3
flow through air
conditioning
system

7 A407001

6
1 Compressor
5 2 Condenser
3 Receiver/Drier
4 4 Expansion Valve
5 Evaporator Coil
6 Air Filter
7 Air Filter
8 Binary Switch

9803/6510 Issue 1
Section B Body and Framework Section B
3-2 Basic Operation 3 -2

Air Conditioning (cont’d)

Fresh Air/Recirculated Air
Operation
Turn rotary switch D fully anti-clockwise for fresh air, turn it
fully clockwise for recirculated air. (Intermediate positions
To maintain optimum operator comfort in warm climates or give a mixture of fresh and recirculated air.)
during seasons of high ambient temperature, the air
conditioning system recirculates, clean, dehumidified air into Air Conditioning System Operation
the cab. Cooling is provided by passing the recirculated air,
over an evaporator coil in the air conditioning unit. Air conditioning system power is generated from the engine,
The air conditioning system is a closed circuit through which via an electromagnetic clutch to the compressor. Three
the refrigerant is circulated, its state changing from gas to switches, connected in series, are included in the clutch
liquid and back to gas again, as it is forced through the supply line, all must be closed for the clutch and therefore
system. the air conditioning system to operate.

The major components of the system are the compressor 1, The compressor 1 draws in low pressure refrigerant gas
condenser 2, receiver drier 3, expansion valve 4 and from the suction line (evaporator to compressor) and
evaporator coil 5. increases refrigerant pressure through compression. This
Heater/Air Conditioning Controls process also increases the refrigerant temperature.

Located on the Left side of the Rear Panel, the heater/air High pressure refrigerant is forced from the compressor to
conditioning controls are used in conjunction with the heater the condenser 2, which is mounted on the radiator on the
fan controls. side of the engine. Ambient air is drawn across the
Heater Controls condenser by the engine-driven cooling fan. In the
condenser, the refrigerant changes state to a high pressure,
high temperature liquid but with a lower heat content.
Heater Fan
Turn rotary switch A clockwise to turn on the heater fan. The refrigerant passes through the receiver drier 3, which
The volume of air from the heater increases by rotating the contains a desiccant to remove moisture from the system.
switch further clockwise. The receiver drier serves as a reservoir for refrigerant and
also includes a filter to remove foreign particles from the
Temperature system.
Turn rotary switch B fully anti-clockwise for minimum
temperature, turn it fully clockwise for maximum
temperature. (Intermediate positions give intermediate
temperatures.)

Air Conditioning Controls (if fitted)

Turn rotary switch C clockwise to select air conditioning.
Turn the rotary switch C fully clockwise for maximum
cooling.(Intermediate positions give intermediate cooling.)

A B C D

429260

9803/6510 Issue 1
Section B Body and Framework Section B
3-3 Basic Operation 3 -3

Air Conditioning (cont’d)

Air Conditioning System Operation (cont'd) Note: In dusty conditions, it is recommended that air be
The high temperature, high pressure refrigerant is forced by recirculated within the cab, otherwise the filter may become
compressor action into the expansion valve 4, which meters clogged.
the amount of refrigerant entering the evaporator. In the
expansion valve the refrigerant instantaneously expands to Two air vents are located in the cab rear panel, and two air
become a low pressure, low temperature liquid. vents and are located on the right hand console. One air
vent is located under the drivers seat. The vents can be
The refrigerant is drawn through the evaporator coil 5 by the turned to direct the air flow where required. When the vents
suction of the compressor. The temperature of refrigerant is are open, hot or cold air will flow directly into the cab.
now considerably below that of the air being drawn across
the evaporator coil by the blowers. Heat is transferred from For the most effective front window demisting, the air vents
the ambient and recirculated air to the refrigerant, causing should be closed and air circulation control turned fully to
the low pressure liquid to vaporise and become a low the left.
pressure gas. Moisture in the air condenses on the
evaporator coil and is drained away via condensate. Safety Procedures
The air conditioning system includes a pressurised closed
Cool de-humidified air is emitted through air vents into the circuit containing a non-CFC, environmentally friendly
cab. refrigerant, Type R-134a. Any service procedure which
breaks into the closed circuit and therefore requires
The low temperature, low pressure, high heat content discharging of the system, must only be carried out by
refrigerant gas, is now drawn by suction back to the service personnel with specialist knowledge of air
compressor, where the cycle is completed. conditioning systems. The following guidelines should be
adhered to by all personnel servicing the air conditioning
Control system.
Control of the system is achieved by the cyclic action of the ! WARNING
compressor's electromagnetic clutch. When current is fed to
The air conditioning system is a closed loop system and
the field coil of the compressor's clutch, a magnetic field
contains pressurised refrigerant. No part of the system
develops between the field coil and the armature which pulls
should be disconnected until the system has been
the field coil, complete with clutch assembly, onto the
discharged by a refrigeration engineer. or a suitable
compressor's rotor. Since the clutch assembly is turned
trained person You can be severely frostbitten or injured
constantly by the crankshaft pulley drive belt, the
by escaping refrigerant
compressor armature turns, starting the refrigeration cycle. 4-3-4-1/2
! CAUTION
Current is fed to the field coil through three series switches
Do not operate the air conditioning system when there is
whose contacts are controlled by the following:
no refrigerant in the system, otherwise the compressor
will be damaged.
1 The manual switch C in the cab 4-3-4-4

2 The thermostat switch monitoring the evaporator 1 It is critical that the correct refrigerant (R-134a) is used
temperature and that charging is done only by qualified personnel.
As a precaution, in case of accidental leakage,
3 The high and low level pressure switch discharging and charging of the vehicle refrigerant
system must be conducted in a well ventilated area.
Switch D will start the refrigeration cycle provided that the
ambient temperature in the cab is greater than 0°C and the 2 Containers of refrigerant should be stored in a cool
refrigerant pressure remains within the specified limits. environment away from direct sunlight.

The thermostat has its sensor inserted in the evaporator coil. ! WARNING
It controls the refrigeration cycle by switching the
compressor clutch on and off to prevent freezing of the Do not carry out welding operations close to the air
condensate on the evaporator coil. conditioning refrigerant circuit. A poisonous gas is
produced when refrigerant comes into contact with
The pressure level switch is housed in a common assembly naked flames. Do not smoke or allow naked flames close
located on the Receiver Drier. If the refrigerant pressure to the refrigerant circuit.
BF 1- 9
exceeds the upper pressure limit specified or falls below the
lower limit, the contacts will open and the clutch will
disengage, closing down the refrigeration cycle. 3 Do Not perform welding operations close to refrigerant
hoses (maintain a distance of at least 0.5m from hoses).
Pressures Switch Settings
4 Do Not steam clean refrigerant system components.
High Pressure Switch 28 bar (406 lbf/ in2)
Low Pressure Switch 2.1 bar (30.4 lbf/ in2)

9803/6510 Issue 1
Section B Body and Framework Section B
3-4 Basic Operation 3 -4

Air Conditioning (cont’d)

Safety Procedures (cont'd)

5 When charging or discharging the refrigerant system
refrain from smoking. Naked flames must not be
allowed in the immediate vicinity. The refrigerant does
not give off a poisonous odour, however, when it
comes into contact with a naked flame, a poisonous
gas is produced.

6 When handling refrigerant, rubber gloves and goggles

should be worn. Operators should ensure that no
refrigerant comes into contact with the skin. Particular
care should be taken when connecting or
disconnecting charging hoses or pressure switches.
When these components are connected to the system,
a short release of refrigerant occurs. This results in a
high velocity, very cold gas being emitted from the
connection point.

9803/6510 Issue 1
Section B Body and Framework Section B
10 - 1 Air Conditioning 10 - 1

Fault Finding

Preliminary Checks

Before any checks are carried out on the refrigerant circuit

the following checks should be made:

1 Check the compressor drive belt is serviceable and

correctly tensioned.

2 Check the condenser and engine radiator are not

blocked by debris, clean with compressed air or water if
necessary.

3 Check that the condenser fins are not flattened or

damaged, the fins must allow air to pass freely.

4 Check the cab fresh air inlet filter for blockage.

5 Check that, with the ignition switch on (engine not

running), the blower operates over whole speed range.

6 Check that, with the ignition switch on (engine not

running), the blower and air conditioning switched on,
the compressor clutch engages.

Charge level:
Note: It is not possible to check refrigerant charge level with
R134a systems using the receiver drier sightglass. Any
bubbles seen at the sight glass on the receiver drier may be
bubbles of oil and are perfectly normal.
Note:
- Gas -1415g R134A +/- 10g
- Oil - 150g +/- 5g PAG (PolyAlkylene Gycol) oil to ISO 100

Fault finding:
Important: Refer to appropriate remove and replace
procedures before working on any system component

9803/6510 Issue 1
Section B Body and Framework Section B
10 - 2 Air Conditioning 10 - 2

Fault Finding (cont'd)

Fault Cause Action

Blower fails to operate Ignition not switched on Switch ignition on.

or does not operate correctly.
Blown fuse Check fuse, replace if necessary.

Motor seized Check blower rotors are free to turn.

Loose wire or connections Check electrical connectors and wires to the

blower. Check that there is power across the
terminals of the blower.

Motor failure If power is reaching the motor and it is free to

turn then motor failure is the likely cause,
remove and replace blower.

Faulty Control Panel Check system with replacement Control

Panel.

PWM Module Damaged Check system with replacement Control

Panel.

Switch ignition on Check system with replacement Module

inside HVAC Unit.

Compressor clutch does not engage Ignition not switched on Switch ignition on.

Blower not switched on Switch blower on any speed.

Air conditioning not switched Switch air conditioning on.

on

Blown Fuse Check fuse, replace if necessary.

Loose wire or connections Check electrical connectors and wires to the

blower. Check that there is power being fed
to the compressor clutch.

Faulty freeze protection When the temperature is above the cut in

thermostat temperature shown in the technical
information section the freeze protection
thermostat should be closed circuit. If found
to be faulty remove and replace.

Faulty compressor If power is fed to the compressor. If the

compressor clutch is being fed power then it
should be engaged. If this is not the case
check the wiring on the compressor itself. If
the compressor is found to be faulty then
remove and replace.

Faulty pressure switch If the binary pressure switch detects

pressure within the limits in technical
information section then it should be closed
circuit. If the binary switch is not closed
circuit then this indicates either incorrect
pressure in the system or a faulty switch.

Slipping compressor belt Loose belt. Adjust belt to correct tension.

System overcharged Evacuate system and recharge to correct

level.

Air present in system Evacuate system and recharge.

9803/6510 Issue 1
Section B Body and Framework Section B
10 - 3 Air Conditioning 10 - 3

Fault Finding (cont'd)

Fault Cause Action

Excessive wear of compressor belt. Pulley misaligned Align pulley.

Belt too tight Adjust or replace.

Belt wrong width Replace with correct belt.

Compressor vibration or noise. Faulty compressor Replace compressor.

Air present in system Evacuate system and recharge.

Stuck compressor or clutch Replace compressor.

Drive pulley loose Tighten pulley.

Overcharge of system Evacuate system and recharge to correct

level.

Compressor mounting or Tighten mounting or belt.

belt loose

Belt tension incorrect Adjust belt to correct tension.

Noise from compressor with Faulty clutch bearing Replace clutch bearing.
clutch engaged.

Noise from compressor with Clutch loose Tighten clutch mountings.

engaged or disengaged.

Noise from compressor. Clutch rubbing on coil Realign clutch.

Belt faulty Replace belt.

Oil level low in compressor Add PAG oil to compressor.

Compressor knocks or chatters. Valve plate is broken Repair or replace.

Rubbing or scraping noises from Fan blade or blower damaged Repair or replace.
main evaporator housing.

Hissing noise from main evaporator Low refrigerant charge or Repair the leak, recharge system
housing. refrigerant leak

Chatter or knocking noises from Faulty thermal expansion Replace TXV.

main evaporator housing. valve (TXV)

Squealing noise from main Dry or damaged blower Replace blower and ensure that filters are
evaporator housing. motor bearings fitted and clean.

Rattling noise from main evaporator Loose brackets or screws Tighten.

housing.

Air conditioning works intermittently. Moisture present in system Replace receiver drier.

Air conditioning fails to operate or Loss of refrigerant Check for leaks in system, repair and
cuts out after short period. recharge.

Moisture present in system Replace receiver drier.

Thermostat failure Replace thermostat.

Compressor clutch faulty Check that clutch operates correctly - adjust

or replace.

9803/6510 Issue 1
Section B Body and Framework Section B
10 - 4 Air Conditioning 10 - 4

Fault Finding (cont'd)

Note: refer to HVAC Electrical Data
ISSUE: for connector, pin and voltage data
System DOES NOT COOL Regardless
of Temperature Setting

Look at the control panel of the air

There is no A/C function
conditioning system.
available for the panel.
Is there an A/C knob? No
Contact your
(Second knob position, of four, from
sales representative
left)

Yes
Bad Clutch
On the control panel of
Is the control panel A/C knob the air conditioning system,
turn the A/C knob to an A/C position and Switch Position
of the air conditioning system No Yes Yes
the temperature knob to the coldest Error
set to an A/C position? position.
Do you now get cooling?
Replace the air conditioning
system clutch.
Yes No Is the issue resolved?
No No

Disconnect the clutch and test the Apply Batt+ to the E554 wire to the
Yes The cause is unknown.
Does the clutch engage? No voltage on wire E554. clutch. Yes
Contact technical support.
Is it within specification? Does the clutch engage?

No No

Reconnect clutch and Remove the unit harness-vehicle connector.

Check fuses and
test for Batt+ on the C585 wire Test for Batt+ on wire 124 at the vehicle
No No vehicle harness. Yes
at the A/C Clutch Relay. harness.
Problem found?
Is it within specification? Is it within specification?

Fuse or Harness
Yes Yes
Error

Connect the unit harness-vehicle connector.

Test for Batt+ on E554 at the
Repair the Test for Batt+ on the 124 Wires (two) at the
A/C Clutch Relay. No No
Unit Harness. BATT Relay. Repair the
Yes Is it within specification?
Is it within specification? Unit Harness.

Yes No
Yes

Test the voltage on E575 at the Test the voltage on 124 at the
BATT Relay. No Blower Module.
Test for Batt+ on E554 at the
Yes Repair the Is it within specification? (<0.5) Is it within specification?
unit harness-vehicle connector.
Vehicle Harness.
Is it within specification?
Yes Yes

Replace the Replace the

BATT Relay. Blower Module.

Perform an actuator check on the Perform a mechanical check of

Is the air conditioning system still
Yes Blend Air/Water Valve actuator. Yes the Blend air door/Water Valve
heating?
Does the actuator check out fire? (stuck open?).

No

No
Replace the actuator and
The cause is unknown.
retest. No
Contact technical support.
Does it work correctly?

Yes Retest air conditioning system.

Test the voltage on C585 at the

Yes Low Pressure switch. No
Is it within specification?
No

Test the voltage on E546 at the Test the voltage on E546 at the
Repair the
Low Pressure switch. Yes High Pressure switch. No No
Unit Harness.
Is it within specification? Is it within specification?

No Yes
Test the voltage on C511 at the
Perform Refrigeration A/C Relay Socket.
System test including the Test the voltage on E548 at the Is it within specification?
functioning of the Low No High Pressure switch.
Pressure, High Pressure, Is it within specification?
and Evap Temperature
Switches Yes

Yes No
No

Test the voltage on C509 at the

Test the voltage on C511 at the Test the voltage on E548 at the User Interface connector.
Evap Temperature switch. Yes Evap Temperature switch. Is it within specification?
Is it within specification? Is it within specification?

No
Yes

Replace the
control panel.

A409300

9803/6510 Issue 1
Section B Body and Framework Section B
10 - 5 Air Conditioning 10 - 5

Fault Finding (cont'd) Note: refer to HVAC Electrical Data

for connector, pin and voltage data

ISSUE:
System always BLOWS HOT
AIR

Turn the Temperature knob to the

Coldest position (full CCW).
Wait for 1 minute Switch position
No
Is the system still Blowing Hot Error
Air?

Yes

Perform an actuator check on the Perform a mechanical check of

Blend Air/Water Valve actuator. Yes the Blend Air door/Water Valve Retest Heating system.
Does the actuator check cut fine? (stuck open?)

Yes
No

Test the voltage on E574 at the Test the voltage on E550 at the Replace the actuator and
actuator connector. Yes actuator connector. Yes retest.
Is it within specification? (12V) Is it within specification? Does it work correctly?
No

No No

Test the voltage on E574 at the Test the voltage on E550 at the
Repair the The cause is unknown.
Blower Module. Yes Yes User Interface connector.
Unit Harness. Contact technical support
Is it within specification? Is it within specification?

No

Test the voltage on E574 at the

No User Interface connector.
Is it within specification?

No Yes
No

Replace the
control panel.

Test for Batt+ on the C585 Wire Remove the unit harness-vehicle connector.
Test for Batt+ on wire 124 at the vehicle Check fuses and
at the BATT Relay. No No vehicle harness.
Is it within specification? harness.
Is it within specification? Problem found?

Yes
Yes
Yes Yes
Fuse or Harness
Error
Test for Batt+ on the C585 Wire Connect the unit harness-vehicle connector.
at the Blower Module. Repair the Test for Batt+ on the 124 Wires (two) at the
No No
Is it within specification? Unit Harness. BATT Relay.
Is it within specification?

No
Yes Yes

Test the voltage on 124 at the Test the voltage on E575 at the
Replace the Blower Module.
Yes No BATT Relay.
Blower Module. Is it within specification? Is it within specification? (<0.5)

Yes

Replace the
BATT Relay.

A409310

9803/6510 Issue 1
Section B Body and Framework Section B
10 - 6 Air Conditioning 10 - 6

Fault Finding (cont'd) Note: refer to HVAC Electrical Data

for connector, pin and voltage data

ISSUE:
NO HEAT is provided to the cab,
but the blower motor functions.

Turn the Temperature knob to the

Hotest position (full CW). Switch Position
Yes
Wait for 1 minute Error
Is the system Blowing Hot Air?

No

Check the water valve on the Open the engine block water
engine block. No valve. After one minute, with the Yes
engine up to temperature, is heat
Is the valve open? felt?

No

Replace the block water The cause is unknown.

Yes valve and retest. No
Contact technical support.
Is the issue resolved?

Yes

Perform an actuator check on the Perform a mechanical check of

Blend Air/Water Valve actuator. Yes the Blend air door/Water Valve Retest Heating system.
Does the actuator check out fine? (stuck closed?).

Yes No
No

Test the voltage on E574 at the Test the voltage on E550 at the Replace the actuator and
actuator connector. Yes actuator connector. Yes retest.
Is it within specification? (12V) Is it within specification? Does it work correcly?
No

No

Test the voltage on E574 at the Test the voltage on E550 at the
Repair the
Blower Module. Yes Yes User Interface connector.
Unit Harness.
Is it within specification? Is it within specification?

No

Test the voltage on E574 at the

No User Interface connector. No
Is it within specification?

Yes
No

Replace the
control panel.

Remove the unit harness-vehicle connector.

Test for Batt+ on the C585 Wire Check fuses and
Test for Batt+ on wire 124 at the vehicle
at the BATT Relay. No No vehicle harness.
harness.
Is it within specification? Problem found?
Is it within specification?

Yes
Yes Yes
Fuse or Harness
Error
Connect the unit harness-vehicle connector.
Test for Batt+ on the C585 Wire
Repair the Test for Batt+ on the 124 Wires (two) at the
at the Blower Module. No No
Unit Harness. BATT Relay.
Is it within specification?
Is it within specification?

No
Yes Yes

Test the voltage on 124 at the Test the voltage on E575 at the
Replace the
Yes Blower Module. No BATT Relay.
Blower Module.
Is it within specification? Is it within specification? (<0.5)

Yes

Replace the
BATT Relay.

A409320

9803/6510 Issue 1
Section B Body and Framework Section B
10 - 7 Air Conditioning 10 - 7

Fault Finding (cont'd)

Note: refer to HVAC Electrical Data
for connector, pin and voltage data

ISSUE:
CONSTANT BLOWER SPEED,
can't change speed.

Does the speed increase when

you turn the Blower knob
clockwise, the speed decrease Yes Operation
when you turn the Blower knob Error
counterclockwise?

No

Test the voltage on E584 at the

User Interface connector.
Is it within specification?
Yes

Test the voltage on C584 at the

Blower Module. No
Is it within specification?
No
Yes

Test the voltage on E574 at the

User Interface connector. Replace the Repair the
Yes
Is it within specification? control panel. Unit Harness.

No

Test the voltage on E574 at the

The cause is unknown.
Blower Module. Yes
Contact technical support.
Is it within specification?

No
No

Test for Batt+ on the C585 Wire Remove the unit harness-vehicle connector.
Test for Batt+ on wire 124 at the vehicle Check fuses and
at the BATT Relay. No No vehicle harness.
Is it within specification? harness.
Is it within specification? Problem found?

Yes
Yes Yes
Fuse or Harness
Error
Test for Batt+ on the C585 Wire Connect the unit harness-vehicle connector.
No Repair the Test for Batt+ on the 124 wires (two) at the
at the Blower Module. No
Unit Harness. BATT Relay.
Is it within specification?
Is it within specification?

No
Yes Yes

Test the voltage on 124 at the Test the voltage on E575 at the
Replace the
Yes Blower Module. No BATT Relay.
Blower Module.
Is it within specification? Is it within specification? (<0.5)

Yes

Replace the
BATT Relay.

A409330

9803/6510 Issue 1
Section B Body and Framework Section B
10 - 8 Air Conditioning 10 - 8

Fault Finding (cont'd) Note: refer to HVAC Electrical Data

for connector, pin and voltage data

ISSUE:
The BLOWER MOTOR is
NONFUNCTIONAL and other
functions work correctly.

Connect the motor + lead to

Disconnect the motor and check
Battery voltage and the motor -
the voltage on wire C585 of the
lead to ground.
mating connector. Yes No
Does the motor turn without
Does it measure approximately
excessive noise, vibration or
Battery voltage?
rubbing?

Yes

Replace the blower

motor of the air
Is the motor current within conditioning system Blower Motor
No Yes
specification? and retest. Is it within Problem
specification?
No

No

The cause is unknown.

Yes No
Contact technical support.

Remove the unit harness-vehicle connector.

Test for Batt+ on the C585 Wire Check fuses and
Test for Batt+ on wire 124 at the vehicle
at the BATT Relay. No No vehicle harness.
harness.
Is it within specification? Problem found?
Is it within specification?

Yes
Yes Yes
Fuse or Harness
Error
Test for Batt+ on the C585 Wire Connect the unit harness-vehicle connector.
Repair the Test for Batt+ on the 124 Wires (two) at the
at the Blower Module. No No
Unit Harness. BATT Relay.
Is it within specification?
Is it within specification?

No
Yes Yes

Replace the Test the voltage on 124 at the Test the voltage on E575 at the
Blower Module. Yes Blower Module No BATT Relay.
Is it within specification? Is it within specification? (<0.5)

Yes

Replace the
BATT Relay.

A409340

9803/6510 Issue 1
Section B Body and Framework Section B
10 - 9 Air Conditioning 10 - 9

Fault Finding (cont'd)

Note: refer to HVAC Electrical Data
for connector, pin and voltage data

ISSUE:
The BLOWER MOTOR is
NONFUNCTIONAL and other
functions work correctly.

Connect the motor + lead to

Disconnect the motor and check
Battery voltage and the motor -
the voltage on wire C585 of the
lead to ground.
mating connector. Yes No
Does the motor turn without
Does it measure approximately
excessive noise, vibration or
Battery voltage?
rubbing?

Yes

Replace the blower

motor of the air
Is the motor current within conditioning system Blower Motor
No Yes
specification? and retest. Is it within Problem
specification?
No

No

The cause is unknown.

Yes No
Contact technical support.

Remove the unit harness-vehicle connector.

Test for Batt+ on the C585 Wire Check fuses and
Test for Batt+ on wire 124 at the vehicle
at the BATT Relay. No No vehicle harness.
harness.
Is it within specification? Problem found?
Is it within specification?

Yes
Yes Yes
Fuse or Harness
Error
Test for Batt+ on the C585 Wire Connect the unit harness-vehicle connector.
Repair the Test for Batt+ on the 124 Wires (two) at the
at the Blower Module. No No
Unit Harness. BATT Relay.
Is it within specification?
Is it within specification?

No
Yes Yes

Replace the Test the voltage on 124 at the Test the voltage on E575 at the
Blower Module. Yes Blower Module No BATT Relay.
Is it within specification? Is it within specification? (<0.5)

Yes

Replace the
BATT Relay.

A409340

9803/6510 Issue 1
Section B Body and Framework Section B
10 - 10 Air Conditioning 10 - 10

Fault Finding (cont'd) Note: refer to HVAC Electrical Data

for connector, pin and voltage data

ISSUE:
Can't change the Fresh Air
damper.

Turn the A/C knob to a Recirc

position. Switch Position
Yes
Is the Recirc actuator in the Error
correct position?

No

Perform an actuator check on the Perform a mechanical check of

Recirc Air actuator(s). Yes the Recirc Air mechanism. Retest Heating system.
Does the actuator check out fine? (stuck?)

Yes
No

Test the voltage on E574 at the Test the voltage on E551 at the Replace the actuator and
actuator connector. Yes actuator connector. Yes retest.
Is it within specification? (12V) Is it within specification? Does it work correctly?
No

No No

Test the voltage on E574 at the Test the voltage on E571 at the
Repair the The cause is unknown.
Blower Module. Yes Yes User Interface connector
Unit Harness Contact technical support.
Is it within specification? Is it within specification?

No

Test the voltage on E574 at the

No User Interface connector
Is it within specification?

No Yes
No

Replace the
control panel.

Test for Batt+ on the C585 Wire Remove the unit harness-vehicle connector.
Test for Batt+ on wire 124 at the vehicle Check fuses and
at the BATT Relay. No No vehicle harness.
Is it within specification? harness.
Is it within specification? Problem found?

Yes
Yes Yes
Fuse or Harness
Error
Test for Batt+ on the C585 Wire Connect the unit harness-vehicle connector.
at the Blower Module. Repair the Test for Batt+ on the 124 Wires (two) at the
No Unit Harness No
Is it within specification? BATT Relay.
Is it within specification?

No
Yes Yes

Test the voltage on 124 at the Test the voltage on E575 at the
Replace the Blower Module.
Yes No BATT Relay.
Blower Module Is it within specification? Is it within specification? (<0.5)

Yes

Replace the
BATT Relay.
A409350

9803/6510 Issue 1
Section B Body and Framework Section B
10 - 11 Air Conditioning 10 - 11

HVAC Electrical Data

Flowchart Wire function Pin Wire Colour

reference
124 Switched battery + 10 on Unit connector Black
C509 A/C Clutch relay 6 on Unit connector Yellow / Red
C511 Relay coil power 86 on clutch relay Red
C584 Fan control signal 4 on Unit connector Green / White
C585 Relay out V batt + 1 on Unit connector Green
E546 Press switch 2 on Unit connector Orange
E548 Press switch 2 on Unit connector Orange
E550 Watervalve actuator signal 5 on Unit connector Blue
E551 Recirc actuator signal 7 on Unit connector Blue / White
E554 A/C Clutch power 3 on Unit connector White
E574 Actuator motor +12V 9 on Unit connector Blue / Orange
E575 Batt + relay 4 on PWM / 85 on batt relay Brown

Pin out Functions and Voltages

Control Panel:

Pin # Function Notes

1 Signal ground

2 +12V power from PWM Should read ~12.9V.

3 Switched +24V power from unit Supplies power to backlight LEDs.

4 Mode 1 output Provides the output signal to the mode

actuator. It should vary between 0 and 12
volts as the mode switch is adjusted.

5 Mode 2 output Provides the output signal to the secondary mode

actuator. It should vary between 0 and 12 volts as the
mode switch is adjusted.
6 Recirc output Provides the signal for the recirc/fresh air door
actuator. It should vary between 0 volts and 12 volts,
as the Fresh/Recirc switch is adjusted.
7 A/C clutch output Provides the output for the AC clutch relay. It provides
a low output to the relay to activate the relay. With the relay
connected, the output should be approximately 24
volts with AC off, and .7 volts with the AC on.
8 Temperature potentiometer output Provides the output signal for the blend door or the
water valve. It should vary between 2.5 and 7 volts,
when the temp potentiometer is adjusted.
9 Blower fan output Provides the fan speed control signal to the PWM
module. It should vary from 6 to 10 volts as the blower
potentiometer is adjusted. Fully CCW the output is
grounded.
10 NOT USED
11 NOT USED
12 NOT USED

9803/6510 Issue 1
Section B Body and Framework Section B
10 - 12 Air Conditioning 10 - 12

HVAC Electrical Data (cont’d)

PWM Module:

Pin # Function Notes

1 Switched +24V power from the unit

2 NOT USED

3 Protected power Output from power relay.

4 Power okay Output to power relay coil.

5 +12V output Supply for control panel and actuators.

6 Fan control signal Input from control panel used to adjust blower speed.

7 Fan drive low Output to the negative side of motor. Used to control fan
speed. Square wave with duty cycle varying between 50% and
100%.
8 NOT USED
9 NOT USED
10 NOT USED
11 NOT USED

9803/6510 Issue 1
Section B Body and Framework Section B
10 - 13 Air Conditioning 10 - 13

System Diagnosis
Having carried out the previous preliminary checks and fault
finding and either found no fault a failed to diagnose a
problem then pressure gauges should be connected to allow
further diagnosis, this should only be done by a properly
trained engineer familiar with air conditioning systems.

Gauge Conditions Other Symptoms Action

Low side High side
Normal Normal Insufficient cooling especially Air or moisture in system:
in the hot part of the day 1. Leak test system
2. Remove refrigerant
3. Repair leaks if detected
4. Replace receiver-drier
5. Evacuate the system
6. Add refrigerant charge
Discharge air warm or hot Incorrect operation of water valve:
1. Check heater matrix, if hot check operation
of water valve
Low Low Insufficient or no cooling
Discharge air slightly cool, high pressure Loss of refrigerant - indicates leak:
side hoses cool or frosting/sweating 1. Leak test system
2. Remove refrigerant
3. Repair leaks
4. Replace receiver-drier
5. Evacuate the system
6. Add refrigerant charge
Receiver/drier malfunction or high 1. Remove refrigerant
pressure line restriction:
2. Check for high side blockage, take
corrective action if required
3. Replace receiver-drier if defective
4. Evacuate the system
5. Add refrigerant charge

High Low Compressor belt loose or worn Compressor malfunction

Belt drive malfunction:
1. Check belt for excessive wear and correct
tension
2. Replace or re-tension if required

Compressor malfunction: 1. Leak test system

2. Remove refrigerant
3. Replace compressor
4. Evacuate the system
5. Add refrigerant charge

High High Discharge air warm, High side Condenser air passage blocked:
hoses very hot 1. Check condenser for blockages, clean with
compressed air or water
2. With the engine running check for air flow
across condenser, take corrective action if
required
If air passage is clear condenser
malfunctioning or over charge:
1. Remove refrigerant
2. Check condenser for free flow of
refrigerant, replace if necessary
3. Check operation of expansion valve,
replace if necessary
4. Replace receiver-drier
5. Evacuate the system
6. Add refrigerant charge

9803/6510 Issue 1
Section B Body and Framework Section B
10 - 14 Air Conditioning 10 - 14

System Diagnosis (cont’d)

Gauge Conditions Other Symptoms Action

Low side High side
High High Discharge air slightly cool Air or moisture in system:
1. Leak test system
2. Remove refrigerant
3. Repair leaks if detected
4. Replace receiver-drier
5. Evacuate the system
6. Add refrigerant charge

9803/6510 Issue 1
Section B Body & Framework Section B
21 - 1 Service Procedures 21 - 1

Direct Glazing
The following procedures explain how to correctly remove
and install panes of glass that are directly bonded to the cab
frame apertures. When carrying out the procedures, relevant
safety precautions must be taken.

1 Always wear safety glasses during both removal and

replacement.

2 Use protective gloves - heavy duty leather gauntlet type

gloves when cutting out the broken glass; 'non-slip'
type gloves when handling/moving panes of glass;
surgical type gloves when using the polyurethane
adhesives.

3 Wear protective overalls.

4 DO NOT smoke - the activators and primers used in the

procedures are highly flammable.

5 Do not attempt to handle or move panes of glass

unless you are using glass lifters (see Service Tools,
Section 1).

Several special tools are required to successfully complete

the removal and replacement procedures. Reference is
made to the tools in the text. The majority of these tools can
be obtained locally and the remainder from JCB Service (see
Service Tools, Section 1).

The work must only be carried out in a dry, frost free

environment. A protective canopy may be required or the
machine/frame must be moved to a sheltered area. In damp
or wet conditions, hinged doors and window frames can be
removed from the machine and taken to a more suitable
(dry) environment.

Glass should not be replaced at temperatures below 5°C

(41°F).

Removing the Broken Glass and Old Sealant

! WARNING
Always wear safety glasses when removing or installing
screen glass. Never use a power operated knife when
removing the sealant around a toughened glass screen.
The action of the knife could cause particles of glass to
be thrown with sufficient force to cause serious injury,
even when safety glasses are being worn. Use only hand
operated tools when working with toughened glass.
BF 2-3/1

9803/6510 Issue 1
Section B Body & Framework Section B
21 - 2 Service Procedures 21 - 2

Direct Glazing (cont'd)

Removing the Broken Glass and Old Sealant (cont'd)

1 Position the machine on level ground and apply the B D

parking brake. Stop the engine. Put protective covers
over the cab seat and control pedestals.
E
2 Toughened glass - remove as much of the shattered
glass as possible prior to cutting out the old sealant.
C D
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:
E

a Braided Cutting Wire and Handles B. This method

uses a 3-core wire, a wire starter tube and two D
handles (see Service Tools, Section 1).

(i) Insert the steel tube C into the old sealant on the
S189870
inside of the glass.

(ii) Insert the braided cutting wire D down the centre

of the steel tube. If necessary, from the outside,
cut out local sealant at the point of the tube to
gain access to the wire.

(iii) Using suitable pliers, pull the cutting wire through

the sealant to the outer side of the glass.
C
(iv) Secure each end of the braided cutting wire in
the special handles E.

(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
S189880
sealant.

9803/6510 Issue 1
Section B Body & Framework Section B
21 - 3 Service Procedures 21 - 3

Direct Glazing (cont'd)

Removing the Broken Glass and Old Sealant (cont'd)

b Cut-out Knife F. The cut-out knife can be used as a F

left handed or right handed tool. For the knife and its
replaceable blades, refer to Service Tools, Section
1.

(i) Insert the knife blade into the sealant.

(ii) Make sure that the blade of the knife is against

the glass as shown at G.

(iii) Use the 'pull-handle' to pull the knife along and G

cut out the old sealant.

c Craft Knife H. The blades are replaceable.

(i) Insert the knife blade into the sealant.

S189890
(ii) Pull the knife along and cut out the old sealant.

Note: There are other tools available to cut out the old
sealant. For example, there is a long handle type craft knife
to give extended reach. Refer to Service Tools, Section 1, H
for details of this and any other tools.

4 Toughened glass - remove the cut off sealant and all

remaining particles of shattered glass.

5 If necessary, trim off the remaining old sealant to leave

approximately 1 to 2 mm on the upright face of the cab
frame aperture, as shown at J. S186370

6 Apply a coat of 'Black Primer 206J' to the paintwork if:

a Paintwork was damaged or scratched during the

glass/sealant removal procedures.
J
b The old sealant was inadvertently cut back to the
cab frame during the glass/sealant removal
procedures.

Preparing the Cab Frame Aperture

1 If damp or wet, dry the aperture area using a hot air gun
(sourced locally).

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.
S189900
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.

9803/6510 Issue 1
Section B Body & Framework Section B
21 - 4 Service Procedures 21 - 4

Direct Glazing (cont'd)

K
Preparing the New Glass

1 Make sure that the new glass correctly fits the frame
aperture K. M
a Put two spacer blocks L onto the bottom part of the
frame aperture.

b Install the new glass on the spacer blocks - ALWAYS

USE GLASS LIFTERS M (see Service Tools, Section
1). 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.
L
IMPORTANT: The glass edges MUST NOT touch the frame, S189910

otherwise movement of the frame will chip and eventually

break the newly installed glass.

2 After checking for size, remove the new glass and place N
it on a purpose made glass stand N (see Service
Tools, Section 1).

Small panes of glass will need locating on a 600 x 700 mm x

15 to 19 mm thick plywood board P (sourced locally to fit
the glass stand N). 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 S186280
clearance of the cartridge nozzle tip during application of the
polyurethane sealant.

3 Make sure the glass is positioned on the stand the

correct way up (i.e. with the black ceramic ink band
upwards) ready for application of primer etc.
P
4 a Use 'Active Wipe 205' to thoroughly clean and
'prime' the black ceramic ink band printed on the
glass (see Note 1). Use a lint free cloth to apply the
'Active Wipe 205', allow 5 minutes flash off (drying)
time.

Note 1: Do not touch the glass after cleaning with the

'Active Wipe 205'. S186291

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 as shown R
at R.

S189920

9803/6510 Issue 1
Section B Body & Framework Section B
21 - 5 Service Procedures 21 - 5

Direct Glazing (cont'd)

Preparing the New Glass (cont'd)

5 Install the Ultra Fast Adhesive cartridge (see Sealing

and Retaining Compounds, Section 1 and Note 2
below) into a suitable applicator gun: 10-15mm

a Remove the aluminium disc cover from the base of

the cartridge and discard the 'dessicant capsule'.
8-10mm
b Make sure that the rolled edge of the cartridge is not A186410
damaged - if necessary, the edges should be
pressed flat, otherwise it will be difficult to remove
the cartridge from the applicator gun.

c Pierce the front 'nozzle' end of the cartridge to its

maximum diameter.

d Fit the pre-cut nozzle shown at S.

e Install the cartridge in the applicator gun.

Note 2: Cold material will be very difficult to extrude. The

cartridges must be pre-heated in a special oven (see
T
Service Tools) for 1 hour to a temperature of 80°C (176°F). S189930
Pre-heating the cartridges makes the adhesive more
workable and also brings the 'curing' time down to 30
minutes.

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

in a corner). Keep the nozzle guide T against the edge
of the glass and make sure that the adhesive forms a
continuous 'pyramid' shape.

Note 3: Once the pre-heated adhesive has been applied to

the glass, install the glass in the aperture as soon as
possible. After approximately 10 minutes the sealant will
form a 'skin', this will prevent the glass from bonding.

7 After applying the adhesive, leave a small amount of

sealant protruding from the nozzle. This will prevent any JS06800

adhesive left in the cartridge from 'curing'.

Installing the New Glass

1 If the internal trim strip is damaged, renew it (cut to X

length as required) before fitting the new glass. Make
sure the two spacer blocks are in position (see step 1 of
Preparing the New Glass).

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 as shown W.

b Sit the bottom edge of the glass on the spacer

blocks as shown X.

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 S189910
press too hard or too much adhesive will squeeze
out.

9803/6510 Issue 1
Section B Body & Framework Section B
21 - 6 Service Procedures 21 - 6

Direct Glazing (cont'd)

Installing the New Glass (cont'd)

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.

4 All exposed edges must be sealed using Black

Polyurethane Sealant (see Sealing and Retaining
Compounds, Section 1).

5 Fit the external trim strip by cutting to length and

pressing into position.

6 Clean the glass after installation:

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.

a Small amounts of sealant can be cleaned from the

glass using the 'Active Wipe 205'.

b Large amounts of excess sealant should be left to

'cure' (see Note 4) and then cut off with a sharp
knife.

Note 4: 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.

7 On completion of the glass installation procedures tidy

the work area:

a Remove ALL broken glass from the cab area.

b Remove the protective covers from the cab seat and

control pedestals.

c Renew all 'warning' and 'information' decals so that

the new installation conforms with the original cab
installation.

9803/6510 Issue 1
Section B Body & Framework Section B
22 - 1 Service Procedures 22 - 1

Cab Structure - Checks

Failure to take these precautions could result in death or

injury to the operator.

Check the structure for damage. Check that the six mounting
bolts A are installed and undamaged. Check the bolt torques.
Tighten them to the correct torque if necessary.

Torque Settings

Item Nm kgf m lbf ft

A 130 14 96

A408110

9803/6510 Issue 1
Section B Body & Framework Section B
22 - 2 Service Procedures 22 - 2

Checking the FOPS Structure

All excavators are designed so that an operator’s protective Check that all the FOPS mounting bolts are in place and
structure can be fitted. In certain applications such as demo- undamaged. Check the FOPS mounting bolts for correct
lition, machines must be fitted with the optional Falling torque tightness.
Objects Protection Structure (FOPS). It is the operator’s
responsibility to identify the risk of an application. Torque Setting
A Torque tightness is 78 Nm (57.5 lbf ft)
!WARNING B Torque tightness is 343 Nm (253 lbf ft)
If a machine requires a Falling Objects Protection C Torque tightness is 343 Nm (253 lbf ft)
Structure (FOPS), you could be killed or seriously injured D Torque tightness is 78 Nm (57.5 lbf ft)
if you operate the machine in a dangerous application E Torque tightness is 343 Nm (253 lbf ft)
with a damaged or missing FOPS Structure. If the FOPS F Torque tightness is 137 Nm (101 lbf ft)
has been in an accident, do not use the machine until the
structure has been renewed. Modifications that are not
approved by the manufacturer may be dangerous and will
invalidate the FOPS certification. 8-3-5-4

B
A

F E D

9803/6510 Issue 1
Section B Body & Framework Section B
30 - 1 Service Procedures 30 - 1

Cab Panel Removal

Remove the screws as shown in the following illustrations.

Note: Care must be taken not to force the panels away from
cab frame, as this could result in breakage of the cab panel.

Right Hand Cab Panels

A408500

9803/6510 Issue 1
Section B Body & Framework Section B
30 - 2 Service Procedures 30 - 2

Cab Panel Removal (cont’d)

Left hand Cab Panels

A408510

9803/6510 Issue 1
Section C Electrics Section C
i i

Contents Page No.

Service Tools 1-1

Technical Data 2-1

Basic System Operation

Switches and Controls 3-1
Circuit Symbols 3 - 16
Component Identification 3 - 17
Main Schematic 3 - 19
AMS (Advanced Management System) -
System Over View 4-1
Circuit Concepts 4-3
Circuit Descriptions
ECU1/EMS/FACIA Power Supply and Network 5-1
ECU 1 Supply to Output Drivers 5-2
Engine Throttle Control 5-3
Auto Pressure Boost 5-9
Engine Reverse Rotation Prevention 5 - 12
Engine Pre Heat (Glow plugs) 5 - 13
Engine Automatic Warm Up 5 - 14
Engine Automatic Idle 5 - 15
Engine One touch Idle 5 - 15
Engine Stop Solenoid/Emergency Stop 5 - 17
Limp Mode System 5 - 19
Pump Control for each mode 5 - 21
Lever Lock 5 - 25
Wiper and Lower Wiper 5 - 27
Washer 5 - 30
Horn 5 - 32
Travel Alarm 5 - 34
Soft/Hard (Cushion) 5 - 36
Boom Down Delay 5 - 38
Slew/Boom Priority (High Dump) 5 - 40
Slew Brake 5 - 42
Slew lock (100% Slew Brake) 5 - 44
3-Speed Travel 5 - 46
Work Lamps 5 - 49
Fuel Level Sensor/Warning 5 - 51
Engine Temperature Sensor/Warning 5 - 53
Coolant Level Warning 5 - 55
Air Filter Blocked Warning 5 - 55
Hydraulic Temperature Sensor/Warning 5 - 57
Alternator/No Charge Warning 5 - 59
Alternator Charging and Battery Relay 5 - 60
Quick hitch 5 - 61
Overload Caution 5 - 63
Beacon 5 - 65
Grab/Rotate 5 - 67
Hammer (Breaker) 5 - 69
Hammer/Auxiliary Combined 5 - 71
Hammer/Auxiliary Combined and Merged 5 - 72
Scrap Magnet Option 5 - 73
Cab Interior Lamp 5 - 74
Refueling Pump 5 - 76
Air Conditioning 5 - 77
Heated Seat 5 - 78
24 to 12 Volt Converter, Radio and Cigar Lighter 5 - 79
9803/6510 Issue 1
Section C Electrics Section C
ii ii

Contents Page No.

Basic System Operation cont’d

Service Required Warning 5 - 81
EMS Set Menu. 5 - 83
EMS Set + Mode (5 Sec) Menu. 5 - 84
EMS Set+Mode (20 sec) Menu. 5 - 86

Fault Finding
JCB Service Master Diagnostic Tool
JCB Service Master 9-1
Using Service Master 9-1
Selecting Sevice Tool Applications 9-1
System Menus 9-2
HP Setup Overview 9-3
Using HP Setup 9-3
Connecting the Data Link Adatptor 9-4
Starting HPSetup 9-4
Data Link Adaptor 9-9
HP Data Logs 9 - 10
Flash Programming Aplication 9 - 20
Introduction to the Diagnostics Tool 10 - 1
Connecting to the Vehicle 10 - 2
Starting Diagnostic Mode 10 - 2
Circuit Diagrams 10 - 3
Indicator Lights (LEDs) 10 - 3
Stopping Diagnostic Mode 10 - 4
Language Setting 10 - 4
List of Text Messages Displayed on the EMS 10 - 5
Fault Finding Without using the JCB Service Master
-Diagnostic Tool 10 - 9

Service Procedures
Electrical Testing Methods 19 - 1
Using a Multimeter 19 - 1
- Measuring DC Voltage 19 - 3
- Measuring Resistance 19 -3
- Measuring Continuty 19 -3
- Testing a Diode 19 -3
Testing of ECU (Electronic Control Unit) 20 - 1
-Inputs and Outputs 20 - 2
Wiring Harness
Repair Procedure 23 - 1
Battery 24 - 1

Harness Data
Harness Location and Interconnection 150 - 1
Main Harness Connector Location 150 - 2
Main Harness: Key to Connectors 150 - 3
Main Harness Drawings 150 - 4
Main Harness Data 150 - 8
Facia Link Harness Connector Location 150 - 10
Facia Link Harness: Key to Connectors 150 - 10
Facia Link Harness Drawings 150 - 12
Facia Link Harness Data 150 - 14
Cab Harness Connector Location 150 - 15

9803/6510 Issue 1
Section C Electrics Section C
iii iii

Contents Page No.

Harness Data cont’d

Cab Harness: Key to Connectors 150 - 16

Cab Harness Drawings 150 - 17
Cab Harness Data 150 - 23

9803/6510 Issue 1
Section C Electrics Section C
2-1 Technical Data 2-1

! CAUTION
Fuses
Always replace fuses with ones of correct ampere rating
to avoid electrical system damage.
8-3-3-5

Fuses
The electrical circuits are protected by fuses. The fuses are
located in fuse box A on the rear console to the right behind
the drivers seat. Open the lid in the rear stowage space and
A
remove the fuse box cover by releasing the top fastener.

If a fuse blows, find out why before fitting a new one.

Fuse Box A

416400
Fuse Circuit(s) Protected Rating

1 Diagnostic 10A
2 ECU-STD, EMS Battery Supply 10A
3 Key Switch 10A
4 Radio (Memory), Cab Interior Lamp Switch 10A
1
5 Work Lamps,Opt Hyd, Radio (Ign), Lighter 20A

13
6 Refuel pump, Wiper,Heated Seat 20A 2

7 Heater/Air Conditioner, Auto fan 20A 3

8 Controller Outputs 23-28 10A 4

14

9 Controller Outputs 17-28 10A 5

10 Controller Outputs 13-16 15A
6
11 Controller Outputs 7-12 15A
7
12 Controller Outputs 1-6 15A
8
15

13 Spare
9
14 Spare
16 ECU-STD, EMS, Fascia Ign Supply 5A 10

17 Auxiliary 15A
16

11

12

A407020

9803/6510 Issue 1
Section C Electrics Section C
3-1 Basic System Operation 3-1

Switches and Controls

Location of Controls and Components

5 4

!
6

7
2
8
@
%
$ 9
£
1

0
401740

1 Right Console 9 Left Console

2 Right Excavator Joystick Control 10 Cigarette lighter/ mobile phone charger

3 Display Monitor (adjustable view) 11 Optional Circuit Pedal (if fitted)

12 Fascia Switch Panel

4 Right Hand Track Control

13 Air Cond./Heater Controls

5 Left Hand Track Control

14 Interior light switch (Timed)

6 Travel Speed Range Change Switch

15 Facia Switch Panel

7 Left Excavator Joystick Control

8 Control Lock Lever

9803/6510 Issue 1
Section C Electrics Section C
3-2 Basic System Operation 3-2

Switches and Controls (cont’d)

12
0
11
O
IS

E
SA

9
2

416410

1 ISO

SAE

3 4 5 6

Right Console

1 Starter Switch lll Start

This is operated by the starter key. It has four positions. Operates the starter motor to turn the engine.
The key can only be removed when in the 'O' position. The starter switch has an inhibitor to stop the switch
being turned ON when the engine is running.
O Off/Stop Engine
Turn the key to this position to stop the engine. Make Note: Do not operate the starter for more than 20 seconds at
sure the controls are in neutral and the excavator and one time.
dozer are lowered before stopping the engine.
2 Throttle Dial
I On This rotary control provides progressive engine speed
Turning the key in this position connects the battery to control over the full range.
the electrical circuits The key will spring back to this
position when released from ll. Note: If the engine speed does not change even after
turning the throttle dial it is because the auto idle or the
II Heat Position one touch switch is ON. Push the idle switch to OFF to
Holding the key in this position switches on the glow reactivate the throttle dial.
plugs. The glow plugs warm the engine combustion
chambers for cold weather starting. Do not hold in this If the engine is started with the throttle dial not at the
position for more than 60 seconds. The key will spring minimum position, no engine speed control will be
back to I when released. possible until the dial is turned to the minimum position.

9803/6510 Issue 1
Section C Electrics Section C
3-3 Basic System Operation 3-3

Switches and Controls (cont’d)

Right Console (cont'd)

12 Cigar Lighter/12V Powerpoint
3 SAE/ISO Indicator Light To operate the lighter D, press it fully into its socket.
The light indicates the mode the servo controls are set When it has heated up sufficiently it will spring
in. The indicator light will always be illuminated in the forward a little way out of its socket. It can then be
selected mode when the engine is running. removed for use. REMEMBER IT WILL BE HOT.
Return the lighter to its socket after use.
4 Hammer Switch (if fitted)
Press the switch to change the additional hydraulic This machine is equipped with a 12V system and
circuit from hammer (reduced flow) circuit to auxiliary can be used for mobile phone chargers or other 12v
(full flow) circuit. powered devices ( maximum draw 5A).

5 Heated Seat Switch (if fitted)

The switch turns the heated seat ON or OFF.

6 Lower Wiper Switch (if fitted)

The switch turns the lower wiper ON or OFF.

7 Boom Priority Switch

Press the switch to change priority of boom raise to
swing. Selecting the boom priority switch during
simultaneous slew and boom operation will restrict flow
to the slew motor and therefore give more flow to the
boom up operation.

When the switch is pressed the monitor will display

“BOOM PRIOR” acknowledgement message.

8 Radio Mute Switch (if fitted)

This switch is used to temperarely switch the sound
from the radio OFF. When the mute switch is selected
the indicator light will illuminate. When the switch is
reselected the radio sound will resume and the
indicator will extinguish.

9 Work light Switch

Press the switch to the first position to switch ON the
Standard work lights (on boom and the right hand of
the machine). Press the switch to the second position
to switch ON the optional lights (on the cab and the
counterweight - if fitted).

10 Auxiliary Circuit Switch

This three-position rocker switch, spring loaded to the
central OFF position, provides bi-directional flow for
relevant attachments, e.g. weedcutter, grab rotate.
Press and hold the switch to the right or left, as
appropriate, for as long as the attachment is to be
used. Release the switch to turn off the attachment.

11 One Touch Idle Switch

Pressing this switch instantly changes the engine rpm
back and forth between that selected for working and a
‘low idling’ speed. When ‘low idling’ has been selected
the message “LOW IDLE” is displayed on the Display
Monitor. This facility is overridden when the
Manual/Auto Change switch is set to ‘Auto’.

9803/6510 Issue 1
Section C Electrics Section C
3-4 Basic System Operation 3-4

Switches and Controls (cont’d)

4 A335460

Left Console

1 Horn Switch 3 Boom Priority Switch

When the horn switch is pressed the horn will sound. Press and hold the switch to change priority of slew to
boom raise. Release the switch to deselect boom
priority.
2 Control Lock Lever
Raising the lever provides a method of isolating the
hydraulic controls and is an integral part of the 4 Courtesy light
procedure for vacating the cab. Lower the lever to A courtesy light is provided if cabin lighting is required
activate the hydraulic controls. during entering or preparing to leave the cab. The timed
light switch is located on the side of the left hand control
console, facing the door at 4. The light will self
extinguish after 5 minutes or after a second press of the
switch.

399791

9803/6510 Issue 1
Section C Electrics Section C
3-5 Basic System Operation 3-5

Switches and Controls (cont’d)

Monitor Panel

1 Display Panel Monitor

The monitor panel is located at the front of the cab in
the line of sight from the operator’s seat. It provides the
interface with the machines system. The display has 20
segment bar graph gauges for fuel, hydraulic and water POWER
MODE
temperatures, a clock, gear, power, mode and hours
run meter. The panel also has an eleven character 1
message area.

2 Mode Switch
Press to select working mode. The machine will be in
the same mode as when last switched off. Each press
2
cycles through the modes as follows:
E➨A➨P➨L➨E➨A➨P➨L
3 5
(The applied mode is indicated next to the POWER
MODE message.)
Select the appropriate work mode suitable for the work 4 6
to be carried out:

A - AUTO MODE
for heavy digging or increased work output and general
digging. Not recommended for grading as engine RPM
and pump horsepower varies.
7
ECONOMY MODE
digging, loading and grading applications with low fuel
consumption. A335120

P - PRECISION MODE
for precise or light duty work.

L- LIFTING MODE
for operations requiring maximum accuracy, including
lifting, with extra hydraulic pressure permanently Indicates that machine hours are displayed top
available. left of the display. This symbol flashes when the
machine is operating, this signifies that the hour
3 Set Switch meter is increasing the service time.
Press the SET switch to access the monitor menu. The
menu can be scrolled through using the Scroll Up and Indicates the time at the top right of the display.
Scroll Down switches.

4 ACK Switch
Press to acknowledge warnings shown on the display. Indicates that transmission information is
This will clear the message but will not put out warning displayed top centre of the display.
lamps. The ACK Switch can cancel the warning buzzer
when sounding.

5 Scroll Up Switch

6 Scroll Down Switch !CAUTION

All the warning lights should go out within 10 seconds of
7 Warning lamps the engine being started. Rectify any faults immediately.
Eighteen tell tale warning light indicators are included 0009
on the monitor.

9803/6510 Issue 1
Section C Electrics Section C
3-6 Basic System Operation 3-6

Switches and Controls (cont’d)

Monitor Panel (cont’d)

Warning Lights

High Engine Coolant Temperature Slew Lock ON

Illuminates if the engine coolant temperature Illuminates when the machine slew lock is
rises to high. Put the engine into low idle and engaged. Press the slew lock switch to
wait until the temperature is normal (inspect disengage the slew lock.
the engine cooling system).

Servo Isolator ON
Low Engine Oil Pressure Illuminates when the machines servo isolator is
Illuminates if the engine oil pressure drops too engaged. Lower the lock lever or press the
far. The light should go out when the engine is isolator switch to disengage the isolator.
started. If illuminated, stop engine, check oil
level, inspect for leaks and check pump.

Engine Air Filter Blocked

Illuminates if the engine air filter is blocked.
Charging System Fault Replace the element.
Illuminates when the battery voltage is low. If
Illuminated check electrical circuit.

Low Hydraulic Oil Level (Option)

Indicates low oil in the hydraulic tank. Check oil
Service Required level.
This warning is illuminated when a service is
required. The warning flashes when a minor
service is required (250 hours) and can be
cancelled by pressing the ACK switch on the Direction Indicator (Not used)
monitor. The warning will illuminate Wheeled machine only.
continuously when a major service is required
(500 hours)

Hazard Warning Lamps Indicator (Not used)

Wheeled machine only.
Low Air Pressure (Not used)

Main Beam Indicator (Not used)

Wheeled machine only.

High Hydraulic Oil Temperature

Illuminates if the hydraulic fluid temperature
rises too high. Put the engine into low idle and Dozer Mode Indicator (Not used)
wait until the temperature is normal (check Wheeled machine only.
hydraulic cooling system).

Park Brake ON (Not used)

Low Coolant Level Wheeled machine only.
Illuminates if the engine coolant level drops too
low. Inspect and refill coolant.

Emergency Steer Mode (Not used)

Wheeled machine only.
Engine Oil Filter Blocked (Not used)

9803/6510 Issue 1
Section C Electrics Section C
3-7 Basic System Operation 3-7

Switches and Controls (cont’d)

Monitor Panel (cont’d)
Set Switch
Press SET switch to access the monitor menu. Use the SET menu to change the settings of some of the machines functions.
The menu can be scrolled through using the scroll up and scroll down switches. When the required item is displayed or after
adjusting settings, press the ACK switch to confirm.
Set clock - Use to adjust the displayed time.
CLOCK
ACK
12/24? Use scroll keys to change 12h or 24h clock
ACK
12:10 Use scroll keys to change time
ACK
Auto idle time - Used to adjust the time delay for the automatic idle system.
AUTO IDLE T
ACK
5 Use scroll keys to change time
ACK
Language - Used to change the language of the display messages.

Intermittent wiper speed - Used to adjust the time delay for the intermittent wiper.
INT WIPER S
ACK
WIPER SPD -1 Use scroll keys to change speed
ACK
Engine speed for hammer - Used to set the maximum engine speed, when using a Rockbreaker. When using a Rockbreaker
it may be necessary to limit the engine speed - consult your JCB Dealer.
HAMMER RPM
ACK
RPM 1200 Use scroll keys to change rpm
Date - Used to adjust to date
DATE
ACK
02-10-1999 Use scroll keys to change date
ACK
Hammer hours - Used to view the total cumulative hours the hammer has been used, also used to reset the hour count since
the last hammer service.
HAMMER HRS
ACK
12345 1234
(Total amount of hours hammer used) (Hours since last hammer service)
ACK
RESET HRS? Resets the hour count since the last hammer service
ACK

When adjustments are complete or at anytime press the SET switch again to exit the SET menu and return to the normal
display.

9803/6510 Issue 1
Section C Electrics Section C
3-8 Basic System Operation 3-8

Switches and Controls (cont’d)

Monitor Panel (cont’d)

List of Monitor Messages

Message Display Meaning

LOW IDLE Engine at low idle (when in auto idle mode or one touch idle on)
SWING LOCK Slew lock on
POWER UP Power boost on, when switch is pressed the power is increased for 8 seconds then normal power is resumed
OVERLOAD Warning when machine is lifting greater than capacity
OVERLOAD ON Overload warning system switched on -warning will be given if lifting load exceeds safe capacity
AUTO WARM Automatic engine warm up system on (auto warm up is cancelled if the one touch idle switch is pressed,
the throttle dial moved or the excavator joysticks operated)
PREHEAT Engine preheat on. When the temperature is low, turn the key switch to the HEAT position for 15 to 30
seconds (maximum) before starting the engine.
Q/H DISCON? Bucket quick hitch disconnect ? (Press ACK to confirm)
Q/H DISCON Bucket quick hitch disconnected
LOW FUEL Low fuel level in fuel tank
RES FUEL Reserve level in fuel tank
EMER STOP Emergency stop (engine is shutdown and switch must be pressed again to allow engine to be restarted)
NO THROTTLE Fault with engine control system - consult JCB Dealer
LIMP MODE Machine is in emergency back up mode (see emergency back up switch)
AUTO For heavy digging or increased work output and general digging.
ECON Digging and loading with low fuel consumption.
PRECISION For precise or light duty work
LIFT For operations requiring maximum accuracy, including lifting, with extra hydraulic pressure if required.

9803/6510 Issue 1
Section C Electrics Section C
3-9 Basic System Operation 3-9

Switches and Controls (cont’d)

Fascia Panel

4 5 6 7
3 8
2 9
1 0
A335110

1 Emergency stop 6 Quick hitch (option) - Position bucket on floor

Press to stop the engine. The monitor will display “EMER When a quick hitch system is fitted, press to release the
STOP” acknowledgement message. Press again to allow hitch. The monitor will display “Q/H DISCON?” and the
the engine to be re-started. alarm will sound, press ACK switch on the monitor within
5 seconds. The monitor will display “Q/H DISCON”
2 Slew lock acknowledgement message. Press again to re-apply the
Press the switch to apply the slew lock The monitor will quick hitch.
display “SWING LOCK” acknowledgement message.
Press again to release the slew lock. 7 Beacon (option)
When a beacon is fitted, press the switch to activate the
3 Overload caution (Option) beacon. The monitor will display “BEACON ON”
In A, E & P mode the overload caution system is set acknowledgement message. The switch gives power to
OFF. Press the switch to activate the system. the jack socket into which the rotating beacon or the
In L mode the overload caution system is set ON. Press service inspection lamp is plugged.
to switch the system OFF.
When the system is ON, if a load exceeding the lift 8 Washer
capacity of the machine is lifted the monitor will display Press to use windscreen washer, washer will stop when
“OVERLOAD” warning message and a buzzer will sound. released. The wiper will operate when the washer is
used.
4 Cushion
The soft mode is automatically ON when starting the 9 Wiper
machine. Press to change to hard mode. The monitor
will display “HARD MODE” acknowledgement message. Press once to operate the wiper in intermittent mode. The
monitor will display “WIPER INT” acknowledgement
This switch selects or deselects the cushioned mode of message. The frequency of wipe can be adjusted by the
operation of the boom raise/lower rams and the dipper monitor menu. Press a second time to operate the wiper
in/out rams. In the cushioned mode the hydraulic system continuously. The monitor will display “WIPER ON”
is protected from the potentially harmful effects of acknowledgement message. This switch is in-active on
suddenly stopping any of the rams with a heavily loaded wheeled machines.
bucket or other attachment. For lighter work it may be
desirable to operate in the non-cushioned mode. 10 Auto idle
Press the switch to activate the automatic engine idle
system. The monitor will display “AUTO IDLE”
At engine start-up, the cushioned mode is automatically acknowledgement message. The engine speed will drop
selected, with the switch lamp off. Press the button to to idle when the machine has been idle for 5 seconds,
select the non-cushioned mode and light the switch the monitor will display “LOW IDLE”. The time delay can
lamp. Press again to select the cushioned mode. be adjusted by the monitor menu. (see Monitor panel,
Set switch.)
5 Isolator Note: In auto mode, this function is permanently
Press to isolate the servo system. The monitor will engaged.
display “ISOLATOR” acknowledgement message. When
pressed the controls are isolated and no machine
movement is possible.

9803/6510 Issue 1
Section C Electrics Section C
3 - 10 Basic System Operation 3 - 10

Switches and Controls (cont’d)

Emergency back-up switch Travel Speed Change Button

Under normal conditions the switch A is OFF. Under The travel speed of the machine can be changed to
emergency conditions it becomes necessary to press the high, medium and low. (The travel speed is recorded at
switch ON. The switch has a lock in the cap which must be engine shutdown and the travel speed is re-applied at the
slid towards the centre of the switch when pressing. next engine start up). Each time the button A is pressed, the
speed is changed to the next higher speed. (When it is at
By switching the emergency back -up switch the engine can high speed, it then selects low).
be started and the hydraulic functions are operating. The
engine will run at idle speed, in emergency back up mode
the monitor will display “LIMP MODE”. The machine should Note: Do not change the mode when travelling. Stop the
only be operated in this mode to allow the machine to be machine to select different speeds.
moved to a safe position

Travel Mode Choice Selected

A Use when the ground is level.
High When climbing a slope and the load
Speed increases, it automatically changes to
medium and when the load reduces, it
returns automatically to high.
A335470
Medium
Speed

Low Use when climbing or descending a

Speed slope or when the ground is rough. It
does not change automatically.

A
A 416401

Mechanical Engine RPM Override

To use the machine in redundancy mode, adjust the
mechanical engine RPM override screw using a 8mm allen
key. Increase the RPM to an intermediate speed sufficient for
the machine to operate. 401870

9803/6510 Issue 1
Section C Electrics Section C
3 - 11 Basic System Operation 3 - 11

Switches and Controls (cont’d)

ISO/SAE Controls (option)

The machines excavating controls can be set to two
operating patterns, either ISO or SAE format. The controls
patterns are shown on a decal on the windscreen. The
switch to select the different patterns is located behind the
seat at A. The selected pattern is indicated on a flashing
display on the right console B.
The standard machine control pattern conforms to ISO.

ISO

SAE
A

SERVO CONTROLS IMMOBILISATION

There are two means of immobilising the machine working

servo controls:

1 Raising the Control Lock Lever A.

2 Pressing the Servo Isolator Switch B.

B
Note: If either of the two methods of isolating the hydraulic
controls is carried out the other method cannot be used to
re-activate the controls.

!WARNING
Servo Isolation Switch
Use the servo isolation switch when you are not
operating the machine, to avoid accidentally operating
399791
the controls and causing a dangerous movement of the
machine.

Before adjusting the cab environment, e.g. opening the

windows or adjusting the seat, you must always isolate
the controls using the servo isolator switch.
8-1-2-7

A335110

9803/6510 Issue 1
Section C Electrics Section C
3 - 12 Basic System Operation 3 - 12

Switches and Controls (cont’d)

Cab Interior Lights

a The interior light G is located on the left of the cab
back wall. G
b To turn it on, press the right hand side of the light.
To extinguish press the side of the light to return it to
the centre position. The lamp can also be switched on
using the switch on the left hand console for a five
minute period.

399750

Radio
The radio, located on the cab rear wall above the seat, A F
operates only with the Starter Switch ON. It has the following
controls:

A Tone control
C
B On/off switch and volume control B E
C Tuning display (waveband, memory number, frequency)

D Waveband/frequency select buttons

E Pre-set memory store/select buttons

F Cassette loading/control features

399760
Removal
Remove the screws from the stowage box and remove the
stowage box. Remove the retaining nut, behind the radio,
which can be accessed through the storage space. Insert the
bows as shown, lock the bows in and press outwards to
release the retaining catches.. Remove the radio.

Replacement
Push in the radio until it engages the retaining catches and fit
the retaining nut. Refit the stowage box and the retaining
screws.

Note: This machine is fitted with a radio mute switch. Ensure

this switch is in the correct position when operating the
radio.

9803/6510 Issue 1
Section C Electrics Section C
3 - 13 Basic System Operation 3 - 13

Switches and Controls (cont’d)

Heater/Air Conditioning Controls
Located on the right console, the heater/air conditioning c Set control A fully clockwise to direct air into the
controls are used in conjunction with the heater fan controls. body of the cab.

Heater Controls
d Set control B fully anti-clockwise to avoid re-heating
the de-humidified conditioned air. If the in-cab
Heater Fan temperature drops too low adjust clockwise the
Turn rotary switch A clockwise to turn on the heater fan. The setting of the heat control to remedy the situation.
volume of air from the heater increases by rotating the switch
further clockwise. 2 In cold/damp weather, to minimise misting.

Temperature a Close the door and windows.

Turn rotary switch B fully anti-clockwise for minimum
b Set control D fully anti-clockwise so as to avoid
temperature, turn it fully clockwise for maximum
drawing damp air in from outside the cab.
temperature. (Intermediate positions give intermediate
temperatures.)
c Set control A fully clockwise to direct air onto the
windscreen.
Air Conditioning Controls (if fitted)
Turn rotary switch C clockwise to select air conditioning. d Set control B fully clockwise to heat the de-
Turn the rotary switch C fully clockwise for maximum humidified conditioned air, de-mist the screen and
cooling. generally de-humidify the cab air.

Fresh Air/Recirculated Air

Turn rotary switch D fully anti-clockwise for fresh air, turn it
fully clockwise for recirculated air. (Intermediate positions
give a mixture of fresh and recirculated air.)

Using the Air Conditioning

1 In hot weather to produce comfortable working
conditions.

a Close the door and windows.

b Set control D fully anti-clockwise so as to avoid

drawing hot air in from outside the cab.

A B C D

429260

9803/6510 Issue 1
Section C Electrics Section C
3 - 16 Basic System Operation 3 - 16

Circuit Symbols
The following notations are used in the l description circuit, drawings.

Circuit Symbols.

Normally Closed
PWM Pressure Switch
Solenoid Valve

Normally Open
Pressure Switch
Solenoid Valve

Frequency Input

Analogue Input
(Potentiometer)

ºt
Float Switch
Analogue Input
(Thermistor)

Switched Input D.C. Supply

(Latching) (Alternator)

Switched Input
(Push to make)

Switched Input
(Push to Break)

Inputs and Outputs

The letters I/p and O/p refer to input and output. ECU1
O/p (C-21)
The letters in brackets i.e. (C-21) refer to the
connector and pin number. I/p (A-32)

I/p (A-29)

I/p (A-39)

sys (B-5)

9803/6510 Issue 1
Section C Electrics Section C
3 - 17 Basic System Operation 3 - 17

Component Identification
The item numbers in the following table are identified on the Wiring schematics in this section.

Item Part number Description Location

1 728/18500 Electronic control unit 1 Behind the rear cab panel.
2 728/19700 Electronic monitor Front of cab.
3 701/80369 Facia switch panel Right hand side of cab.
4 Fuse box Behind the rear cab panel.
5 716/30070 Throttle dial On Right hand console.
6 701/80184 Key switch On Right hand console.
7 701/80214 Redundancy switch Behind the drivers seat.
8 30/925585 Air-conditioning box Below the rear cab panel.
9 T.B.A. Heater Below the rear cab panel.
10 30/92558 Air-conditioning controller On Right hand console.
11 701/60030 Switch body Under right hand console.
12 701/58826 12Working lamp switch On Right hand console.
13 71712900 Cigar lighter (12v) On Right hand console.
14 717/09200 Radio cassette Rear of cab in the roof.
15 701/80215 Lever lock switch Below the lever lock bar.
16 701/60041 Cab lamp switch Outer side of left hand console.
18 700/43900 Work lamp Toolbox.
19 JHR0151 Work lamp Boom.
20 JHR0183 Breaker pressure switch Under the cab on the breaker pedal.
21 25/220836 Lever switch Left hand joystick.
22 25/220837 Lever switch Right hand joystick.
23 717/20154 Voltage Converter Behind the rear cab panel on top of the heater box.
25 6900/0624 Wiper Front windscreen.
26 6900/0587 Cabin lamp Rear of cab in the roof.
27 KHR1241 Battery relay In the left hand side compartment.
28 708/10020 Batteries In the left hand side compartmen.
29 KHR1589 25A Fuse In the left hand side compartment.
30 KHR1592 60A Fuse In the left hand side compartment.
31 716/30091 Stop Relay In the right hand side pump bay.
32 25/220829 8 spool solenoid valve In the right hand side pump bay.
33 25/22096 Slew brake valve In the left hand side compartment.
34 01/145151 Engine Rear of machine.
35 701/80374 Upper pilot pressure switch Bottom switch on Right hand side of Main Control Valve.
36 701/80375 Travel pilot pressure switch Top switch on Right hand side of Main Control Valve.
37 701/80373 Boom up pressure switch On the Shuttle Valve in the left hand compartment.
38 Throttle position sensor In the right hand side pump bay.
39 928/60027 Engine control solenoid In the right hand side pump bay.
40 717/07700 Travel alarm Below the counterweight.
41 20/925309 Pump In the right hand side pump bay.
42 JNH0027 Refuel pump Toolbox.
43 Lower wiper Under the cab.
44 700/26700 Beacon Centre section.
45 714/40226 Air-conditioning compressor Front of engine.
46 30/925618 Binary switch On air-conditioning condenser in the radiator bay.
47 704/36300 Horn Between the boom rams.
48 JHN0160 Washer bottle Toolbox.
49 AEH0021 Glow plug relay In the left hand compartment under the battery relay.
50 716/30111 Temperature switch In the hydraulic pump suction tube.

9803/6510 Issue 1
Section C Electrics Section C
3 - 18 Basic System Operation 3 - 18

Component Identification - (cont’d)

Item Part number Description Location

51 701/80328 Overheat switch In the hydraulic pump suction tube.
52 716/30142 Fuel level sensor In Left hand side of fuel tank.
53 331/13929 Coolant level switch In the expansion bottle in the radiator bay.
54 JNH0070 Air-filter vacuum switch In the air induction tube.
55 701/80192 Overload pressure switch Back of the manifold between the boom ram feet.
56 701/80372 Auto mode pressure switch On the shuttle block in the left hand compartment.
57 701/80371 Auto boost pressure switch Lower front of main valve block.
58 701/60000 Radio mute button On Right hand console.
59 701/60031 Heated seat switch On Right hand console.
60 40/910552 Heated seat switch Cab.
61 JRJ0343 Direction control valve Centre section.
62 25/220536 Merge solenoid In the left hand compartment on the bulkhead plate.
63 35/910041 Priority valve solenoid In the right hand side pump bay.
(W/cutter)
63 35/910042 Priority valve solenoid.
(Grab rotate)
64 721/10455 Hammer only Connector
65 701/60032 Hammer/Aux switch
66 701/80223 Hammer/Aux/Merge switch
67 721/10456 Hammer/Aux link harness
68 721/10457 Hammer/Aux/Merge link-
harness
Note:Items 64 to 68 are part numbers for the bridging
harnesses and switches for the option switch in the Right
hand console

64 E

G
F
C160 C160
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1

A B

H I
66
65

A408581

8 7 6 5 4 3 2 1 10 9 14 3 13 11 16 6 12 15

67 68

C160 C160 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

C D
A408580
9803/6510 Issue 1
Section C Electrics Section C
3 - 19 Schematic Diagram 3 - 19

4
14 25 19

26 1 ECU-STD O/P 1-6 9 RADIO (MEMORY), CAB INT LAMP SW

2 ECU-STD O/P 7-12 10 KEY SWITCH
3 ECU-STD O/P 13-16 11 ECU-STD, EMS BATT SUPPLY
4 ECU-STD O/P 17-22 12 DIAGNOSTIC CAB MAIN FRAME
12V RADIO MAIN WIPER EARTH EARTH 5 ECU-STD O/P 23-28 13 AUXILIARY 8R
HEADER 2 HEADER 4 6 HEATER/ AIR CON, AUTO FAN 14 ECU-STD,EMS, FASCIA IGN SUPPLY
CAB ROOM CAB LH CAB RH 7 REFUEL PUMP, HEATED SEAT, WIPER 15 SPARE
0.5 BO 25A 29 60A
LAMP LAMP LAMP 1 1
8 WORK LAMPS, OPT HYDS, RADIO (IGN), LIGHTER 16 SPARE 27 30
2 2 0.5 BO C92 C91
2 1 2 1
BATT SUPPLY M 3 3 0.5 BO 4W 8R
C113

IGN SUPPLY
0.5 BG 0.5 BU 0.5 BO
4 4 C5 4 WB C105

8W
GROUND
21 22 5 5 0.5 BO
1
4W +24V BATT SUPPLY C104
6 0.5 BU 6 0.5 BO
15 0.5 BG
C114
7 0.5 BU 7 0.5 BO C6 8R +24V IGNITION SUPPLY
0.5 BU 1 C107
1 2 1 2 8 8
LOCK LEVER SW
- + - +
LH LEVER SWITCHES RH LEVER SWITCHES 9 0.5 BU 9
10 0.5 BU 10 C108
EARTH 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
C109
HORN DOZER DOZER HAM/BOOM ONE TOUCH GRAB GRAB C111

0.5 WR
TRAVEL

0.5 BU

0.5 BU
HEADER 1
0.5 B
C39 SW ON SW OFF SW PRIORITY SW CHANGE SW IDLE SW CW SW CCW SW 20 12V 12V

10A

15A

15A
15A

15A

15A

10A

10A

20A

20A

20A

10A

10A

10A
6 5 4 3 2 1
28

5A

5A
BREAKER

COM
1U 2U 3U 4U 5U 6U 7U 8U 9U 10U 11U 12U 13U 14U 15U 16U C25 31

NO
NC
PILOT SW
0.5 BW

0.5 RY

33
0.5 R

0.5 U A HOLD
1 2 3 4 5 6 7 8 9 10 C65 2.5 W B PULL
HEATED 0.5 UG 1
C56 2.5 B C
EN G

PRIOR
BOOM
C1 STOP
AUTO
AUX 1 AUX 2
HEATED SEAT SW SEAT 0.5 B 2
SOLENOID
C115 FAN CONNECTOR A 0.5 UB 1 C54

SWING
60
0.5 B
0.5 B
1.0 B
0.5 B
1.0 B
0.5 B
0.5 B
0.5 B
1.0 B

C37 C58

LOCK
C224 12 11 10 9 8 7 6 5 4 3 2 1 3 2 1 1 2 3 1 2 3 4 1 2 3 1 2 3 4 1 2 3 4 1 1 2 1 2 1 2 59 0.5 SB
1
0.5 SB NEG FLOW SOL V
0.5 LGW 1
0.5 B 2

TRAVEL
C34 C33 C32 C31 C30 C27 C26 C226 C112 0.5 UY 0.5 UY 2 STAGE RELIEF SOL V ISUZU ENGINE

SPEED
24V/12V DROPPER
2

HIGH
0.5 OW 0.5 OW MAX FLOW CONT SOL V 0.5 B 2
3 0.5 UR 1

0.5 LGR
0.5 LGY
23

0.5 UW

0.5 WU
0.5 BW

0.5 BW

0.5 BW

0.5 BW

0.5 BW
0.5 GR

0.5 UG
0.5 BO

0.5 BG

0.5 PG

0.5 NU

0.5 UR

0.5 UR

0.5 UR
0.5 BU

0.5 BU
0.5 LGW

0.5 PU

0.5 BU

0.5 BU

0.5 BU
0.5 BY
0.5 LGW TRAVEL CHANGE SOL V 60 B

BRAKE
SWING
0.5 U
4 C59 B
0.5 UW 0.5 UW SWING SHUT OFF SOL V 0.5 B 2 34
+12V SWITCHED

0.5 BW
5
M
+24V BATTERY
+12V MEMORY

0.5 UY 1
+24V IGNITION

2 STAGE
0.5 GW

0.5 BW

0.5 WR C
0.5 GR
0.5 RG
0.5 RY

0.5 RB
0.5 RY

RELIEF
0.5 G

0.5 G

6
0.5 R

R
8 7 3 2 1 2
0.5 RG
7
0.5 RG TRAVEL ALARM 0.5 B 2 C55
E
C202 C203 0.5 BG 0.5 BG LEVER LOCK SOL V (RET)
GND

GND

0.5 OG
8
0.5 OG LEVER LOCK SOL V (OUT)
C60 C94 40 2.5 W
9 0.5 SB 1 0.5 RG 2

0.5 BO

0.5 BO

TRAVEL
1.5 UG

1.5 RG
1.0 GB

1.0 UR
1.0 SR
1.0 RB

1.0 RY

1.0 UY
0.5 UR

1.0 LG
0.5 UR SWING BRAKE SOL V

0.5 G

0.5 G

ALARM
0.5 Y

0.5 Y
STARTER MOTOR

FLOW
1.0 O

1.5 G
1.0 N

1.0 R

CONT
1.0 S

1.0 P
10

NEG
6 5 4 3 2 1 0.5 UB 0.5 UB SWING LOCK SOL V 0.5 B 2 0.5 B 1
11

C117 0.5 SR
12
0.5 SR SOFT/HARD SOL V
C61 1.0 B
C97
0.5 BW

0.5 BW

13 0.5 OG 1 E
0.5 RG
0.5 LG
0.5 R
0.5 Y

0.5 YU 0.5 YU AIR FILTER SW 8R

LEVER
14 B C98

LOCK
0.5 YW 0.5 YW RESERVE TANK SW 0.5 BG 2 0.5 WR
15 3 L
0.5 UB 0.5 UB OIL FILTER SW 0.5 BU
16 C62 2 R C99
0.5 YG
17
0.5 YG OIL PRESSURE SW
0.5 UW 1
32 1
0.5 GB 0.5 GB MERGED FLOW SOL V
49

SWING
C84 ALTERNATOR

SHUT
18

OFF
0.5 NB 0.5 NB PUMP PROP SOL V (OUT) 0.5 B 2
19 0.5 YG 1
0.5 SB AIR PRESS SW (NOT USED) HEAT
20 C63 0.5 B 2 OIL PRESS

C102

C103
0.5 UG 0.5 UG BOOM PRIORITY SOL V RELAY
EARTH 21 0.5 SR 1
0.5 O 0.5 O BOOM LWR PILOT SW
HEADER 3

SOFT/
HARD
22
0.5 UO 0.5 UO BOOM UP PILOT SW 0.5 B 2 4R 4 0.5 RY
23
0.5 OB 0.5 OB BW
24
UPPER PILOT SW
C64 C162
0.5 NY 0.5 NY SWING PILOT SW 0.5 BR 2 C86
AIR CONDITIONER 0.5 LG
25
0.5 LG
0.5 OW 1
0.5 RG 1 0.5 YB 1
OVERHEAT
TRAVEL PILOT SW SW
50

FLOW
CONT
26

MAX
0.5 YR 0.5 YR WINDOW WASHER 0.5 B 2 0.5 SG 2
WATER 6 KEY SWITCH 0.5 WR
27
1 2 3 4 5 6 7 8 9 10 FACIA SW PANEL THERMO RECIRC VALVE BATTERY CLUTCH
THROTTLE CAB INT LAMP SW BOOM PRIORITY SW LOWER WIPER SW 0.5 RS
28
0.5 WR
0.5 RS
ALTERNATOR SIGNAL
C101
C87 WATER TEMP SENSOR
STAT ACTUATOR ACTUATOR RELAY RELAY BOOM WORKLAMP
29
VOL DIAL OFF 0.5 RW 0.5 RW 0.5 WY 1
5 0.5 GW
30
0.5 GW
TOOLBOX WORKLAMP
HORN 0.5 S 2
0.5 BW
0.5 BW
0.5 BW
0.5 BW
0.5 BW
0.5 BW
0.5 BW
0.5 BW
0.5 BW

AUTO IDLE 31
IGN 0.5 G 0.5 G A/C BINARY P SW
16 0.5 W
32
0.5 W A/C COMPRESSOR
33 ENG REV SENSOR
HEAT 0.5 O 0.5 O A/C BINARY P SW C66 4 BW
WIPER 34
41 C28 18
0.5 GW
35
0.5 GW AUTO MODE P SW 0.5 B 1 C100
PUMP
CRANK 0.5 RU 0.5 RU CWT LAMP 0.5 RU 1
WASHER 36 CONTROL C'WEIGHT
3 2 8 7 3 2 8 7 3 2 0.5 RG 0.5 RG LAMP SUPPLY 0.5 NB 2 0.5 RG 2
30 17 15/54 50a 19 C222 C43 C200 37 SOL V LAMP
C21 0.5 NW 0.5 NW BEACON
38
1 0.5 G 1 2 30 1 2 3 4 5 6 7 8 9 0.5 GU AUX (NOT USED)
BEACON GLOW PLUG

0.5 RW

0.5 RG

0.5 RG
0.5 BO

0.5 BO

0.5 NU

0.5 BO

0.5 BO
39

0.5 LG
C23A C23B C80 47

0.5 K
2 0.5 O 0.5 GY 0.5 GY BOOST PS
C22 40
C89
3 0.5 W 0.5 B 1 C74
58 3 QUICK HITCH 41 46
2 4 0.5 GW 0.5 G 1 A/C 0.5 GW 2 HORN 0.5 NW 1
50

0.5 NW
C223 42

0.5 B
0.5 SU
0.5 SR
5 0.5 U 0.5 O 2 BINARY 0.5 SG 2

0.5 S
MONITOR (EMS) 6 0.5 YR
43
P SW
RADIO MUTE SW ISOLATOR 44 44 2 1
38 C81 C163 HYD OIL TEMP SENSOR
7 0.5 UW
45
18
8 1.5 UG C166 C67 0.5 RW 1 0.5 NW 1
HYD OIL
CUSHION 9 0.5 UO
46
BEACON 0.5 SU 1 0.5 RG 2
TOOLBOX
LAMP
0.5 SG 2 OVERHEAT SW 51
47
10 0.5 BU 0.5 WG 2
48
O/LOAD 11
C2
0.5 S 3
C82 18 C75
12 CONNECTOR B 0.5 YR 1 FUEL SENSOR

0.5 BW
0.5 BU

0.5 RB
1.0 RY
0.5 RG 1

1.0 R
0.5 R 0.5 R ENG CONT SOL (OUT) BOOM 0.5 S 2
SLEW BRAKE A 0.5 RS 2
8 7 3 2 B
THROTTLE POSITION LAMP 52
0.5 U C68 SENSOR C76
0.5 U ENG SHUT DOWN
C
EMERG STOP 0.5 SU 0.5 SU THROTTLE LEVER +5V REF 0.5 R 1 C79 WASHER 48 0.5 YW 1
GND (FACIA SW PANEL)

D 39 RESERVE TANK LSW 53

0.5 RY

0.5 S 0.5 S SENSOR 0V REF 0.5 YR 1 0.5 B 2

M
SPI SHIELD (SPARE)
0.5 Y

0.5 B

0.5 Y

M 0.5 UR
E 2
CHASSIS (SPARE)

HAMMER P SW (NOT USED) 0.5 B 0.5 B 2

IGNITION SUPPLY
IGNIION SUPPLY

F
0.5 WG 0.5 WG C77
REDUNDANCY

THROTTLE LEVER SIG

EMERG STOP
EMERG STOP
BATT SUPPLY

MRST-E (SPI)

MTSR-E (SPI)

G
SCLK-E (SPI)
MTSR-E (SPI)
MRST-E (SPI)
SCLK-E (SPI)
CAN SHIELD

BLOWER 0.5 BR 0.5 BR HEAT RELAY 0.5 YU 1

ENGINE CONTROL C110
BATT GND

H
MOTOR CONTROLLER 0.5 BU 0.5 BU KEY SW - BATT RELAY SOLV 0.5 B 2 AIR FILTER 54
SPARE

J
SPARE

CAN H
CAN L

SHLD
SHLD

0.5 BW 0.5 BW
GND

STARTER RELAY
K
0.5 YB 0.5 YB WATER TEMP SENSOR
C159 L
0.5 Y 7 LOWER WIPER 0.5 WY
M
0.5 WY ENG REV SENSOR
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
8 0.5 RY 0.5 RY ENGINE OVERHEAT
C40 0.5 Y 0.5 SG
N
0.5 SG SENSOR +5V REF C93
M
12V CIGAR
C14 C15
REDUNDANCY SW 0.5 YR
P
0.5 YR FUEL SENSOR 0.5 GU 1
0.5 B
OPT HYDS 43 R
0.5 RW

0.5 RW
0.5 OG

0.5 OG
0.5 UG

0.5 UG
0.5 PU

0.5 SR

0.5 UK
0.5 LG

0.5 LG

LIGHTER 0.5 NW 0.5 NW OIL TEMP SENSOR 2

0.5 R
0.5 U

0.5 U
0.5 P

0.5 B

0.5 B

0.5 B
0.5 P

A/C COMP
S
55 C90
C41 SWITCH (SEE 2/2) 0.5 K 0.5 K QUICK HITCH 3 C69 35
DIAGNOSTIC
0.5 GU
T
0.5 GU OVERLOAD 0.5 B 4 OVERLOAD 0.5 OB 1 UPPER
0.5 W 1 45
CONNECTOR U
13 8 7 6 5 4 3 2 1 C160 0.5 G
V
0.5 G FUEL PUMP PRESSURE 0.5 B 2 PILOT
SW P SW
C18 W 36
BATTERY (+24V)

1 0.5 B 1 C70
CAN SHIELD

1 2 3 4

0.5 LGR
0.5 WU
0.5 RG
0.5 GU
0.5 GB

0.5 BO

0.5 UR
2 0.5 UO 2
A/C
CONTROL 3 0.5 P
4 6 5 1 3 2 C161 3
0.5 LG 1 TRAVEL C72
CAN H
CAN L

PANEL 3.0 B 3.0 B EARTH 0.5 B 2 PILOT

C201
GND

4 0.5 UW 4 C116 P SW 0.5 O 1 BOOM LWR

C157 37

0.5 GU
5 0.5 B 2 PI LOT

0.5 G
0.5 N

0.5 B
0.5 K 1
C164 QUICK C71 PSW
6 C11 2
1.0 PG
1.0 PU

A B C D E F G H J 0.5 B
1.0 P

0.5 B HITCH REFUEL PUMP

7 0.5 YR 1
C13

PREHEAT
0.5 UO 1 BOOM
8 0.5 U 2 C73
9 0.5 GW
C83 42 0.5 B 2 UP
0.5 NY 1
P SW SWING
1.0 UY

10 C4 0.5 G
37
0.5 R
0.5 U
0.5 B

10 M 0.5 B 2 PILOT
0.5 YB DOZER (NOT USED)
P SW
11
C180 0.5 YU
1
0.5 YU GRAB CW SOL V 37
12 2

0.5 RB
0.5 Y 0.5 Y GRAB CCW SOL V
0.5 P 0.5 P 3 C220
1 0.5 YG 0.5 YG PRIORITY V
0.5 SR 0.5 SR 4 0.5 GY 1
2 0.5 PS BREAKER (NOT USED)
0.5 PU 0.5 PU 5 0.5 B 2 BOOST 57
WORKLAMP SW 3 0.5 LG TRAVEL P SW

0.5 GB
0.5 B 0.5 B 0.5 UY 6 (NOT USED)
P SW
4
0.5 R 0.5 R
11 12 0.5 U
5
0.5 U 1.0 P C221
6
0.5 BW 0.5 GW 1 AUTO
0.5 U
7
0.5 U C155 0.5 B 2 MODE 56
8 0.5 UK
0.5 UK 0.5 UK P SW
9
10
C156
8 7 3 6 5 2
C24 C225 STD-WHEELED CAN LINK
0.5 UO 0.5 UO C12

0.5 GB
0.5 YG
0.5 YU
0.5 UY

0.5 B

0.5 Y

0.5 B

0.5 B

0.5 B
0.5 P

0.5 B

0.5 Y

0.5 P

0.5 P

0.5 UW 0.5 UW
2 1
0.5 YR 0.5 YR
3 0.5 U 2 2 1 2 1 2 1 2 1
0.5 U 0.5 U
4 0.5 R 3

C165
C137

C138

C139
0.5 GW 0.5 GW
5
0.5 Y 0.5 Y
6
0.5 OG

0.5 RY 0.5 RY CAN LINK

7
0.5 UY 0.5 UY LOW FLOW MERGED PUMPS
8
0.5 Y 0.5 Y PRIORITY SOL V
NOT USED 9 LOW FLOW DIRECTION V
FOR JX210/250 10 63 62
61
0.5 RS
1
8 7 3 6 5 2 0.5 RW
C49 2

C181
0.5 RW
0.5 RS

0.5 SR

0.5 SR
0.5 P

0.5 B

1.0 SR
0.5 NU

0.5 NU

0.5 OG
0.5 LGW
0.5 LGR

0.5 LGY
0.5 GW

0.5 OW

0.5 GW
0.5 WG
0.5 UW

0.5 NW

0.5 UW

0.5 NW
0.5 WR

0.5 RW

0.5 RW
0.5 YW

0.5 BW
0.5 WY

0.5 OG
0.5 GR

0.5 UO

0.5 GU

0.5 UG

0.5 GU

0.5 GR

0.5 RG
1.0 GB
1.0 GB
0.5 YG

0.5 UR
0.5 OB

0.5 SG

0.5 NU

0.5 GY
0.5 PG

0.5 UR

0.5 RU

0.5 YG
0.5 YU
0.5 YR

0.5 RB

0.5 UB

0.5 UY
0.5 SR

0.5 SU

0.5 PU

0.5 NY

1.0 PU
1.0 SR
1.0 RB
1.0 RB

0.5 NB
0.5 UB

0.5 RB

0.5 YR

0.5 SR
0.5 UK
0.5 UY

0.5 YU

0.5 RS
0.5 BR
0.5 RY

0.5 RY
0.5 YB

0.5 SB

0.5 BY

0.5 PS

0.5 YB

0.5 SB
0.5 LG

0.5 O

1.0 O

0.5 G
0.5 U

1.0 N
1.0 N
0.5 R

0.5 U

0.5 R
0.5 K

0.5 S

0.5 Y

1.0 S

0.5 B

1.0 B

0.5 B
1.0 B

0.5 B
0.5 B

0.5 K

0.5 Y

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
CONNECTOR A CONNECTOR B CONNECTOR C
C8 C9 C10
O/P15 HIGH SPEED TRAVEL

O/P10 SWING SHUT OFF 3

O/P23 NEG FLOW CONT

I/P5 ENGINE OVERHEAT

O/P22 ENG SHUTDOWN

I/P25 AUTO MODE P SW

I/P28 BOOM LWR PILOT

I/P14 ONE TOUCH IDLE

O/P24 2 STAGE RELIEF

I/P16 KEY SW (CRANK)

I/P6 THROTTLE LEVER

I/P34 TRAVEL CHANGE

O/P1 THROTTLE CONT

O/P30 TOOLBOX LAMP

O/P26 TRAVEL ALARM

O/P20 LOW FLOW PRI

O/P5 BOOM PRIORITY
O/P3 MAX FLOW CUT
I/P19 BOOM UP PILOT

O/P9 SWING BRAKE 2

+5V REF (THROTTLE)
I/P35 ENG OIL PRESS

O/P11 LOWER WIPER

I/P20 HAMMER PILOT

O/P14 CAB RH LIGHT

I/P13 O/LOAD PRESS
I/P18 BOOM PRI/HAM

O/P13 CAB LH LIGHT

O/P8 SWING LOCK 1
I/P21 LOWER WIPER

O/P25 QUICK HITCH

I/P8 THROTTLE VOL
I/P27 TRAVEL PILOT

O/P2 CAB INT LAMP

O/P21 LEVER LOCK

O/P29 BOOM LIGHT

I/P37 RES TANK SW

O/P32 HEAT RELAY

I/P29 SWING PILOT
I/P26 UPPER PILOT

I/P1 HYD OIL TEMP

I/P7 CAB INT LAMP

I/P15 BOOST P SW

I/P32 LEVER LOCK

O/P28 SOFT/HARD

O/P19 CCW GRAB

O/P33 CWT LIGHT
I/P2 WATER TEMP
I/P3 ALTERNATOR

O/P7 PUMP PROP

I/P17 ENG SPEED

I/P22 DOZER OFF

I/P10 OPT LAMPS

SUPPLY O/P17-22
SUPPLY O/P23-28

SUPPLY O/P13-16
SUPPLY O/P13-16
I/P31 GRAB CCW

O/P18 CW GRAB
I/P4 FUEL LEVEL

I/P33 AIR PRESS

I/P23 DOZER ON

SUPPLY O/P7-12
SUPPLY O/P7-12

O/P27 BREAKER
GND I/P7,8,15,16
I/P9 STD LAMPS
I/P11 AIR FILTER

O/P16 WASHER
I/P30 GRAB CW

SUPPLY O/P1-6
SUPPLY O/P1-6
I/P36 PREHEAT

O/P4 BEACON

O/P17 DOZER
O/P1A SPARE
O/P7A SPARE

O/P36 SPARE
O/P31 SPARE

O/P34 SPARE
O/P35 SPARE
O/P12 WIPER
RS/SPI SHLD
I/P12 SPARE

GND I/P9-14
I/P24 HORN

O/P6 HORN
RS232 RX

RS232 TX

CAN SLD

CHASSIS
+5V REF

CAN Lo
0V REF

SPARE

CAN Hi
SPARE

SPARE

PROG
BATT

GND
GND
IGN

A409980 331/31714 06/01

OV

INPUTS SYSTEM OUTPUTS

ECU -STANDARD

9803/6510 Issue 1
Section C Electrics Section C
4-1 Basic System Operation 4-1

A.M.S (Advanced Management System)

Operation:
The JCB A.M.S system is a whole machine electronic control
system. The system controls engine speed, pump power,
transmission, excavator functions, lights, wiper, auxiliary
circuits, warning lamps, etc. The system is a 'CAN BUS'
system which links Electronic Control Units (ECUs) on the
vehicle. This stands for 'Controlled Area Network' and uses a
special cable in the vehicle harness which consists of two
signal wires twisted together covered by a metal foil to
prevent any electrical interference. These signal wires form
the CAN -BUS. The CAN - BUS is used to send text and fault
codes between the ECUs.
The electronic units receive inputs from switches and A
sensors and drive outputs such as solenoids, lamp bulbs and
motors. The outputs of the ECUs are rated to the current
requirement of the actuator.

The system comprises of the following main electronic

components:

A Electronic Control Unit -1 (ECU-1) A407730

B Electronic Monitoring System (EMS)

C Fascia switch panel (FSP).

401740

9802/6510 Issue 1
Section C Electrics Section C
4-2 Basic System Operation 4-2

The AMS System

SWITCH
PANEL

NETWORK

DIAGNOSTICS
A3
35
11
0

POWER
MODE

ELECTRONIC CONTROL
NETWORK UNIT (ECU-1)

A335120

ELECTRONIC
MONITOR
SYSTEM

THROTTLE
ENGINE CONTROL S S S LAMPS,
E W O WIPER,
N I L WASHER,
S T E ETC
O C N
PUMP R H O
PUMP CONTROL S E I
S D
S

INPUTS OUTPUTS
A405630

9802/6510 Issue 1
Section C Electrics Section C
4-3 Basic System Operation 4-3

Circuit Concepts
Inputs

There are two main types of input, Digital and Analogue.

Digital type inputs are on/off type inputs (i.e. switches) and
can be Low side inputs or High side inputs. Low side inputs
are inputs that provide a ground to the ECU. High side inputs
are inputs that provide a positive feed to the ECU.
Analogue Inputs are sensor type inputs that provide a
varying type input to the ECU, this input could be a
resistance or frequency type input.

Digital inputs (on/off switch type inputs)

Switch (rocker,
ECU momentary, pressure,
a Low side input
level, etc.)
The low side input is the most frequently used input on
the A.M.S system. The low side input can be in the form 24v
of rocker switches or pressure switches. Input

b High side input

The high side input is used on circuits that require a Switch (lights, engine
positive feed when the ignition is switched off, i.e. preheat, etc.)
ECU
sidelights or hazard lights. The high side input is also
used on the engine preheat circuit.

Input 24v

c Analogue input (i.e. sensor type inputs) Outputs

Throttle Throttle Water Hyd oil Fuel Engine

ECU-1 dial position temp temp level speed
sensor sensor sensor sensor sensor
Sensor ref voltage
5v
Sensor ref 0 voltage

ºt ºt
Throttle dial input
(Potentiometer type input)

Throttle dial input

(Potentiometer type input)

Engine temp. input

(Temp. variable resistance type input)

Hydraulic oil input

(Temp. variable resistance type input)

Fuel level input

(Float variable resistance type input)

Engine speed input

(Frequency type input)

9802/6510 Issue 1
Section C Electrics Section C
4-4 Basic System Operation 4-4

Circuit Concepts
Outputs
There are three main types of outputs Low side output, High
side output and Modulated output.
In the Low side output circuit the actuator (solenoid, relay
etc) which is being driven already has a positive feed
available, the ECU then provides the ground side of the
circuit.
In the High side output circuit the actuator which is being
driven already has a ground available, the ECU provides the
positive side of the circuit.
In the Modulated Output circuit the ECU provides a PWM
(Pulse Width Modulation) signal to a proportional valve. As
the ECU varies the duty cycle of the signal the proportional
valve will select more or less depending on the change in
duty cycle. Actuator; relay coils
ECU
a Low side output
Circuits using low side output are pre heat relay, stop
solenoid relay and work lights. 24v
Output

Actuator (solenoid, motor,

ECU bulb, horn,relay)

b High side output

24v
The high side output is used to operate solenoids, Output
bulbs and horn.

Proportional solenoid
ECU
c Modulated outputs
Circuits using the modulated output are throttle control,
pump control and boom priority. Output

9802/6510 Issue 1
Section C Electrics Section C
4-5 Basic System Operation 4-5

Pulse Width Modulation (PWM)

Ohms law states that, the amount of current flow in a circuit
is determined by the voltage, and the resistance. A 24v
circuit with a resistance of 6 ohms, would draw a current of
4 amps. This would be the case for a standard solenoid,
which is either on or off. 5

4
Once the voltage is applied to the circuit, it is present 100%
of the time. This would be known as a 100% duty cycle. Current
Therefore the circuit will draw 4 amps constantly.

A proportional solenoid requires differing amounts of

current, depending on its condition. As the coil has a fixed
resistance, changing the current rating can be done in either Time
of two ways,

1 Having lots of different resistors switched in and out of

the circuit at different times to change the current
flowing. Voltage

2 To change the duty cycle of the solenoid.

It is easier, more economical, and more reliable to change Time

the duty cycle of the circuit, especially using today's
computer/ controller technology.

The duty cycle is the amount of time a component is

switched on compared to the time it is switched off. If a
solenoid is on for three seconds, then off for one second, on
for three, off for one etc. this would be a 75% duty cycle.

5
A
4

Current

ON 75% Duty cycle

The graph A although unstable would give a current rating 1cycle

of three amps. To stabilize the current in the circuit, the 5
frequency would need to be increased. If the timescale on B
the graph A was one second, the frequency would be 4Hz 4
(Hertz (cycles per second)). The graph B shows the same
duty cycle, but at a higher frequency of 32 Hz. The Current
proportional solenoids fitted to JS machines operate at a
frequency of 125 Hz.

9802/6510 Issue 1
 4 5-1
5A C6
P

9803/6510
IGNITION SUPPLY
1 SR 5A
ECU1 BATTERY SUPPLY
Section C

ECU1-B 10A C5
C9

4 C12
PU STD-WHEELED CAN LINK
IGNITION 5
SR R
BATTERY 6 3
U
10 2 C11
B DIAGNOSTIC
OV 11 1
R CONN
CAN HI 15
G B
16 A
B UY
GND I/P9~14 17 B
R
CAN SHIELD 18 C
U U
CAN LO 21 D
B
CHASSIS 22 E
B
GND I/P7,8,15,16 23 F
24 H
J

REDUNDANCY SWITCH C13

1 PU
ECU1/EMS/FACIA Power Supply and Network

2 P
B
3
Electrics

P
B
R
U

SR
PU
B
B
1 2 3 4 5 6 7
Basic System Operation

C180 B
B

P
B
R
U

SR
PU
EARTH
HEADER 1

P
PU
B
SR
B
R
RW
UG
OG
LG
OG
RW
LG
UG
B
P

U
C14 C15 3

9
8
7
6
5
4
3
2
1
2
SHLD 5

SHLD

CAN L
SCLK-E 4

MRST-E 6

CAN H
MTSR-E 3

SPARE 12
SPARE 11
SPARE 10
SPARE
SCLK-E
MRST-E
GROUND 2
IGNITION 1

MTSR-E

IGNITION 16
BATTERY 13
GND (FSP) 14
CAN SHIELD

REDUNDACY 15
BATTERY GND
FASCIA SWITCH PANEL A406740

Issue 1
5-1
Section C
 5-2

9803/6510
Section C

ECU1
1

ECU1-B
C9
O 4
SUPPLY TO O/P17 ~ 22 1
ECU 1 Supply to Output Drivers

S
O/P23 ~ 28 2 GB 1 15A

RB N 2 15A
O/P13 ~ 16 7
RB
O/P13 ~ 16 8 RB 3 15A

N O 4 10A
O/P7 ~ 12 13
Electrics

N
O/P7 ~ 12 14 S 5 10A
Basic System Operation

GB
O/P1 ~ 6 19
GB C6 1 C5
O/P1 ~ 6 20

+24V +12V
IGN IGN
SUPPLY BATTERY
SUPPLY
A406750

Issue 1
5-2
Section C
Section C Electrics Section C
5-3 Basic System Operation 5-3

Engine Throttle Control

Engine speed is controlled by the electro hydraulic throttle control system. The system consists of a proportional pressure
reducing valve (throttle control valve), a hydraulic cylinder (throttle actuator), a throttle position sensor, an engine speed
sensor and throttle dial (potentiometer).

ECU1
Throttle Dial
Throttle Dial
Input I/p A29

Engine Speed Idle Full Speed

Sensor Input Position Position
I/p A32
Engine Speed Sensor

Throttle
Position
Sensor Input
I/p A39
Throttle Position Sensor

Throttle Actuator

Throttle Control Valve

Throttle
Control Valve
Output
I/p C21

9803/6510 Issue 1
Section C Electrics Section C
5-4 Basic System Operation 5-4

Engine Throttle Control (cont’d)

Throttle Control System

Throttle control is achieved by an electro-hydraulic E
proportional solenoid. The ECU supplies a modulated output
(which is determined by the working mode selected and
throttle dial position) the throttle control valve works as a
pressure reducing valve and supplies hydraulic pressure to A
the throttle actuator which in turn moves the throttle cable to
increase/decrease engine speed. A sensor on the throttle
lever gives feedback to the ECU on the throttle lever
position.

Throttle Control Circuit C

Further developments to improve the operation of the
throttle and also to protect the engine against poor operator F
driving procedures have been made.

If the engine is started with the throttle dial above the ¼ full
D
speed position, the engine will start at idle. No engine speed
control will then be possible until the operator turns the
throttle dial to a position which is lower than the ¼ full speed Note: Throttle position sensor (behind the throttle lever).
position. The throttle control will then function as normal.
A Throttle control valve
If the operator stops the engine from full speed then the B Throttle linkage
throttle actuator will ramp down over a two second time C Throttle actuator
period, reducing the engine rpm before stopping. D Stop solenoid
E Throttle cable
If the operator has selected the one touch idle function F Stop cable
before stopping the engine, then when the engine is
restarted the throttle control will still be in one touch idle
function (i.e. the ECU remembers that one touch idle was
selected).

9803/6510 Issue 1
Section C Electrics Section C
5-5 Basic System Operation 5-5

Engine Throttle Control (cont’d)

Throttle PWM ECU1 EMS
CAN Data
Sol. Valve O/p1 (C-21)
RPM
Flywheel I/p 17 (A-32)

Throttle volume pot (5K Ohm)

I/p 8 (A-29)

Throttle lever (5K Ohm)

I/p 6(A-39)

Ignition Switch
sys 22(B-5)

Operation
Engine speed is controlled by the pressure from the throttle control valve moving the throttle actuator, which in turn moves the
throttle linkage. The output pressure from the throttle control valve is determined by the PWM signal supplied to the valve from
the ECU.
The PWM signal supplied to the throttle control valve by the ECU is determined by :
- Throttle dial position
- Mode selected
- Auto idle / one touch idle selected or not.
As pressure is supplied to the throttle actuator it moves the throttle linkage. The movement of the throttle linkages adjusts the
position of the throttle lever potentiometer; this then gives a voltage signal to the ECU, indicating the position of the throttle
linkage. When the ECU detects that the throttle linkage is in the correct position the ECU keeps the duty cycle in such a
condition as to hold a constant position of the lever potentiometert, and thus holding a constant engine speed.
The system also has a self checking facility, when starting the machine the ECU will detect the closed (Idle) resistance setting
of the throttle position sensor. The resistance value should be within 5% of previously recorded idle resistance value. If not
within tolerance or if the operator changes the position of the throttle dial potentiometer, and after 20 seconds the targeted
value of throttle position sensor has been detected by the EMS (i.e. throttle linkage has not moved to correct position) , then
display will show the error message 'No Throttle'.
When the throttle system is calibrated, the throttle dial has to be moved between minimum and maximum positions; this gives
the ECU the operating parameters of the dial. The ECU will then send a 90% duty cycle to the proportional solenoid (much
more than required), and the throttle linkage will move to the maximum stop position on the injection pump and also compress
the spring damper. The engine speed sensor will tell the ECU the speed of the engine at all times, by sending a frequency to
the ECU.

The ECU will start to reduce the duty cycle down from 90% in 1% increments. This will take out the compression in the
damper, but not change the engine RPM until the duty cycle gets down to approx. 70%.

When the engine speed does change, the ECU remembers the position of the lever potentiometer. This becomes maximum
revs for 'A' mode, the engine revs reduce by 100 rpm and the ECU remembers the position of the lever potentiometer, this
becomes 'E' mode’s maximum engine speed. The procedure is then repeated for 'L' & 'P' modes (which are the same engine
rpm). The ECU ramps down the duty cycle, which in turn reduces the engine speed.

When the engine speed will not reduce anymore, (due to the set up of the cable) i.e. the frequency of the transducer not
changing. The ECU remembers the position of the lever potentiometer; this will be approx. 45% duty cycle.

From the calibration process the ECU now has the operating range of the throttle dial and the corresponding positions for the
lever. (Note: - not the same voltage signals back to the ECU).

If the machine is switched off before completing calibration, when the machine is restarted then EMS will display the message
'Calibrate' and throttle calibration will have to be done again.

9803/6510 Issue 1
 5-6
39

9803/6510
C68 ENGINE CONTROL S.V.

5 R 1
Section C

1 2 3 C22 B 2
THROTTLE VOLUME DIAL
1

SG
SR
B
ECU1 C8 C2
CONN A CONN B
31 SU R A
+5V THROTTLE
34
C87
20 S SU D
0V REF ENGINE SPEED SENSOR
WY 1
Engine Throttle Control (cont’d)

29 SR S E S 2
I/P 8 THROTTLE VOL.

32 WY WG G
I/P 17 ENGINE SPEED

39 WG WY M
I/P 6 THROTTLE LEVER
C67
C8 C1 38
ECU1-A ECU1-A SU 2
Electrics

I/P 25 AUTO MODE P SW GW WG 3

S 1
C9
CONN B
Basic System Operation

AUTO MODE P SW
5 P
IGNITION

C10
CONN C

4
21 R
O/P 1 THROTTLE CONT.

14 5A
P
+24V IGNITION

A406970

Issue 1
5-6
Section C
Section C Electrics Section C
5-7 Basic System Operation 5-7

Engine Throttle Control for Each Mode

ECU1
Throttle PWM EMS
Sol. Valve O/p 1 (C-21)
CAN Data A, E, P, L
I/p 17 (A-32)

Flywheel Mode
I/p 6 (A-29)

I/p A-29
Throttle volume pot (5K Ohm)

Throttle lever (5K Ohm) I/p 6 (A-39)

Upper pilot switch

I/p 26 (A-6)

Travel pilot switch I/p 27 (A-16)

Auto mode pilot I/p 25 (A-4)

switch

A405640

Operation
The JS machines can operate in one of four different modes, depending upon the application required. The modes are
selected by the "Mode" button on the EMS. The EMS displays the selected mode alongside the power mode legend. Selecting
the different modes has the effect of setting the maximum possible engine speed for each working mode. Successive presses
of the Mode switch will cycle through the different modes in the order as shown below.

Note: The last operating mode when the machine was stopped will be restored when the machine is restarted.

E (Economy) A (Auto) P (Precision) L (Lifting)

"A" Auto Mode

In Auto mode the EMS displays the letter "A" next to the power mode icon. The engine is allowed to operate over its selected
rev range as defined by its programmed rev limit and the throttle sense input, (ECU1 I/p6) in direct proportion to the throttle
input. The maximum rev limit is the same as the maximum permissible engine revolutions.

When in auto mode the auto idle feature is permanently active, if the throttle dial position is changed, the engine speed will not
change until either the travel p SW (I/p 27), the upper p SW (I/p 26) or the auto mode p SW (I/p 25) are closed.

When the upper pressure switch is closed the engine speed will rise to full speed less 200 rpm (or in proportion to the throttle
target input if less than 100%). When the upper pressure switch re-opens the engine speed will remain at this position for 3
seconds and then drop to 70% of this position for the pre-set auto idle time, after which it will drop to idle.

When the auto mode pressure switch is closed, the engine speed will rise to the full available engine speed. When the auto
mode pressure switch re-opens the engine speed will drop to the full speed less 200 rpm for three seconds and then down to
70% of this position for the pre-set auto idle time, after which it will drop to idle.

When the travel pressure switch is closed, the engine speed will rise to the full available engine speed. When the travel
pressure switch re-opens the engine speed will remain at full for three seconds, then will drop to the full speed less 200 rpm
for the pre-set auto idle time, after which it will drop to idle
The engine speed will vary according to the following characteristic:

9803/6510 Issue 1
Section C Electrics Section C
5-8 Basic System Operation 5-8

Engine Throttle Control for Each Mode (cont’d)

Auto mode throttle characteristic

2150 rpm A

1945 rpm B

1360 rpm C

no load engine
speed (decided by
throttle lever
position)
D
ON
Auto mode Pressure
switch I/p 25 OFF
ON
Upper Pressure
Switch I/p 26 OFF
F
ON
Travel Pressure
Switch I/p 27 OFF
3s Xs 3s Xs 3s Xs

X = pre-set auto idle Time

time.
A408650

"E" Economy mode.

In standard mode the EMS displays the letter "E" next to the power mode icon. The engine is allowed to operate over its
selected rev range as defined by its programmed rev limit and the throttle sense input, (ECU1 I/p A 39) in direct proportion to
the throttle input. However the maximum rev limit of 100 rpm less than the maximum permissible is imposed. Thus for a full
throttle potentiometer setting the engine revolutions is 100 lower than it would be in the Auto mode.

"P" Precision
In Precision mode the EMS displays the letter "P" next to the power mode icon. The engine is allowed to operate over its
selected rev range as defined by its programmed rev limit and the throttle sense input, (ECU1 I/p A 39) in direct proportion to
the throttle input. However the maximum rev limit of 200 rev/min less than the maximum permissible is imposed. Thus for a full
throttle potentiometer setting the engine revolutions is 200 lower than it would be in the Auto mode, the same as it is for Lifting
mode.

"L" Lifting mode

In Lifting mode the EMS displays the letter "L" next to the power mode icon. The engine is allowed to operate over its selected
rev range as defined by its programmed rev limit and the throttle sense input, (ECU1 I/p A 39) in direct proportion to the throttle
input. . However the maximum rev limit of 200 rev/min. less than the maximum permissible is imposed. Thus for a full throttle
potentiometer setting the engine revolutions is 200 lower than it would be in the Auto mode, the same as it is for Precision
mode.

9803/6510 Issue 1
Section C Electrics Section C
5-9 Basic System Operation 5-9

Engine Throttle Control for each mode (cont’d)

Typ revs Idle Max revs Flywheel teeth

6 Cyl 900 2195 129

Relationship between mode and engine revolutions per minute

During calibration the ECU detected the maximum possible engine speed, and noted the position of the throttle position
sensor. This point became A mode maximum. Next the controller found the position of the throttle position sensor when the
engine speed was 100 rev/min. less than the maximum speed possible, E mode maximum and 200 rev/min. less than
maximum P+ L mode maximum.

When the working mode is selected the ECU will scale the full deflection of the throttle dial (O ~ 5v) to adjust the engine speed
between the idle position and the maximum speed for the particular mode selected.

Maximum Possible

Maximum Permissible
“A” mode Max.
REV/MIN
“E” mode Max.
-100 RPM
-100 RPM
“P & L” mode max.

Idle

5K Ohm Throttle Potentiometer

9803/6510 Issue 1
Section C Electrics Section C
5 - 10 Basic System Operation 5 - 10

Auto Boost Pressure

2 Stage Relief Valve
EMS
ECU1
O/p 24 (C-27) Power Up

CAN
I/p 27(A-16) Data
Mode
Travel Pilot Switch

I/p 15 ( A-25)

Boost p.s.w

Operation

The auto pressure boost function is only available when the excavator is in “Auto (A)” mode. By default it is not available in
“Precision (P)” mode and is permanently on (although not indicated on the EMS) in “Lifting (L)” mode.

In Auto mode ,when the boost pressure switch is closed the EMS displays the message “Power UP” and the 2 stage relief
valve (ECU1 O/p 24) is energised (according to the logic below). This allows a pressure increase in the excavating hydraulic
circuit thus generating “extra digging force.”

The valve and message are displayed for a period of four seconds from activation.

The valve cannot be re-energised (or the message displayed) for 9 seconds after the end of the last activation.

However during travel operation (denoted by the travel pilot switch input) the 2 stage relief valve is de-energised.

Default operation is off.

Travel P ON
sw (I/p 27)

OFF

L Work E,P
mode

Boost P OFF
sw (I/p 15)

ON

> 9 secs NO
fromactivation

YES

S
2 stage relief sol valve 2 stage relief sol
valve Set OFF
Set ON for 3

A406980

9803/6510 Issue 1
 5 - 11
57

9803/6510
Section C

ECU1 1

40
Auto Boost Pressure

C8
ECU1-A

GY
16 LG
I/P27 TRAVEL PILOT S.W.

25 GY
I/P15 POWER UP SWITCH

C59
C10 2 STAGE RELIEF S.V.
ECU1-C 32
C1
B 2
CONN A
27
Electrics

UY UY 2 UY UY 1
O/P 24 2 STAGE RELIEF
LG 26 LG
C70
Basic System Operation

TRAVEL PILOT SWITCH

36
LG 1

B 2
B

A406830

Issue 1
5 - 11
Section C
Section C Electrics Section C
5 - 12 Basic System Operation 5 - 12

Engine Reverse Rotation Prevention

ECU1
I/p A-3 CAN Data EMS
Oil Pressure Switch
I/p A-32
Flywheel O/p c-26
Emergency Esos Sol Valve
I/p A-35 Stop
Crank +V
I/p A-35
Ignition Switch

Operation
It is possible for the engine to run backwards, which can result in damage to both the engine and hydraulic pump. This feature
is included to prevent serious damage occurring to these components.

When the engine is running backwards the oil pump is unable to produce sufficient pressure within the engine, if from starting
(cranking) the engine, no oil pressure is detected for 12 seconds then the Engine stop (Esos) solenoid valve is de-energised
(O/p C26 ) thus shutting off the fuel to the engine and stopping it. A delay of 12 secs is built in to give the engine time to start
up and build up oil pressure and prevent false shutdown of the engine from low oil pressure.

Low engine oil pressure is detected between 12 and 15 secs after cranking when engine oil pressure switch provides a
ground on ECU1 I/p A-3.

Note: The engine oil pressure switch is normally closed with the engine stopped and the engine oil pressure opens the switch
so the ECU will detect low engine oil pressure when the engine oil pressure switch is closed.

Engine Pre Heat (Glow plugs)

This feature allows the engine cylinders to be pre heated, before engine cranking to assist cold start performance.

When the Pre Heat input (I/p 36) is valid the EMS displays the message "PRE HEAT" and the pre-heat output (O/p 32) is
turned on according to the characteristic below (these are maximum times, assuming the operator keeps the key switch in the
pre-heat position). The EMS message "PRE HEAT" is displayed for two seconds less than output 32 is switched on.

16
Pre-heat tim er (sec)

14
12
10 EMS display "PRE HEAT"
8
6 Pre heat output (O/P 32)
4
2
0
-25 -20 -15 -10 -5 0 5 10 15
Engine w ater tem p (deg C)

When the engine water temperature is below 5 deg C, pre-heat output (O/P 32) is turned on for 40 seconds after crank input
(I/P 16) is valid, regardless of the status of the pre-heat input (I/P 36) prior to cranking. No EMS message is displayed during
this process. The pre-heat output is kept on for the full 40 seconds even if the engine is started. This "after glow" process is
to reduce white smoke at cold start up.

In order to prevent false alarms whilst this output is valid, all engine alarms will be ignored (E.g. Oil pressure etc.) and the
delay timers will not increment.

9803/6510 Issue 1
 6
5 - 13
30 17 15/54 50a 19
OFF

9803/6510
IGN
HEAT
CRANK
Section C

C23A 4 1 8 C23B
KEY SWITCH

RY
RB

BW
Engine Pre-heat (Glow Plugs)

1
4
ECU1 C8 C25 60A
ECU1- A
30
20A
12 RG 8 +24V IGNITION
RB
I/P 36 PRE-HEAT
35 BW RY 10
I/P 16 CRANK C91
+24V BATTERY 2 1
10A
R W +24V IGNITION

49
HEAT RELAY
Electrics

C102 C103
C1 R BW
CONN A 34
C10 RG 37 RG
Basic System Operation

ECU1- C C100

40 BR
O/P 32 HEAT RELAY

1 2
C101
RG
BR

C2
CONN B GLOW PLUGS

BR H BR

A406790

Issue 1
5 - 13
Section C
Section C Electrics Section C
5 - 14 Basic System Operation 5 - 14

Engine Automatic Warm Up

Throttle Sol. Valve ECU1

Auto Warm
O/p C-21

CAN
Data
Upper Pilot EMS
I/p A-6
I/p A-16
Travel Pilot

I/p A-18
Water Temp

I/p A-32
Flywheel

Operation
This feature allows the engine to quickly warm up to normal operating temperature if the vehicle is not being used.

Automatic warm up will only be performed 15 seconds after the engine is started and provided the following conditions are
satisfied:

a Water temperature is less than 50 ºC. (I/p A18)

b Upper pilot pressure switch is off ( excavator services not selected) (I/p A6)
c Travel pilot pressure switch is off (travel service not selected) (I/p A16)
d If the throttle volume input changes during auto warm up then the auto warm up function is cancelled.

The engine will run at the throttle dial setting for 5 minutes, the engine revs are then increased in 300 rev/min. steps in 3
minute intervals up to the maximum of 1800 rev/min. After 3 minutes of running at 1800 rev/min. the engine revs will return to
the throttle dial setting.

If during the automatic warm up sequence any of the required conditions change ie engine water temperature reaches 50 ºC
or the operator moves the throttle dial or selects an excavator service auto warm up will stop.

When automatic Warm up is activated the EMS will display the message "Auto Warm"

Typical example of auto warm up cycle if machine Typical example of auto warmup cycle if machine
is started at low idle speed of 900 rev/min. is started at 1500 rev/min.

Engine rev/min. Engine rev/min.

1800 1800

1500 1500

1200 1200

900 900

5 min 3min 3min 3min TIME 5 min 3min TIME

9803/6450 Issue 1
Section C Electrics Section C
5 - 15 Basic System Operation 5 - 15

Engine Automatic Idle

Throttle Sol. Valve ECU1

Low Idle FSP
O/p 1 C-21
(FS10)
Upper Pilot Switch

I/p 26 A-6 CAN

EMS Auto Idle
Data
Travel Pilot Switch I/p 27 A-16

I/p 28 A-26
Boom Lower Pilot

I/p 14 A-37
One Touch Idle (JSR4)

Operation
When auto idle function has been selected via the switch on the Facia Switch Panel (FSP) the engine will return automatically
to the low idle setting if no services have been selected for 5 seconds (default). This time can be varied between 5 and 30
seconds via the set menu on the EMS.

The EMS will display the "Auto Idle" message to confirm selection. A second press of this switch will disable the function. If
the Upper, Travel and boom lower pilot switches have been inactive for the pre set time period, the automatic idle function will
operate and the engine revs will drop to the idle value. The EMS will display the message "Low Idle".

The engine revs can be increased by pressing the Auto idle switch on FSP, or by the change of state of the pilot switches (ie if
excavator/travel service is selected). When released from Auto Idle the engine revs return to the setting of the throttle dial. By
default Automatic idle is off.

The auto idle function is peramently active in Auto mode. The Auto idle switch FS10 is disabled when in Auto mode.

Engine One Touch Idle

ECU1
Throttle Sol Valve
CAN
O/p 1 C-21 Data
Low Idle

I/p 14 A-37 EMS

One Touch Idle
R.H. Controller

Operation
When one touch idle is selected via the button on the RH hand controller the engine will return to the low idle setting,
regardless of any other input, the EMS will display the " Low Idle" message to confirm selection.

A second press of this switch will disable the function and the engine revs will return to the setting of the throttle dial.

The status of the one touch idle is retained when switching the ignition off. (e.g. If one touch idle is selected and the ignition
turned off, when the vehicle is started again one touch idle is automatically activated.)

9803/6510 Issue 1
 5 - 16

9803/6510
C69 UPPER PILOT SWITCH
Section C

1 22 35
OB 1
3 4 C31
ECU1 RH LEVER SWITCH B 2

BY
BW
EARTH
HEADER 3
BW C70 TRAVEL PILOT SWITCH
C8 C1 LG 1 36
ECU1-A CONN A
6 OB B 2
I/P 26 UPPER PILOT SWITCH O 22 O
16 LG
I/P 27 TRAVEL PILOT SWITCH OB 24 OB
26 O C72 BOOM PILOT SWITCH
Engine Auto Idle and One Touch Idle

I/P 28 BOOM PILOT SWITCH LG 26 LG O 1 37

37 BY
I/P 14 ONE TOUCH IDLE
B 2

C10 C2
ECU1-C CONN B C68 ENGINE CONTROL S.V.
Electrics

21 R R A R R 1
O/P 1 ENGINE CONTROL 39
B 2
Basic System Operation

2 3

LOW IDLE FS10

CANBUS SPI

FASCIA

EMS

A346090

Issue 1
5 - 16
Section C
Section C Electrics Section C
5 - 17 Basic System Operation 5 - 17

Engine Start/Stop

FSP
Emer. Stop

Engine Stop Solenoid (ESOS)

ECU1 CAN
Pull Hold Data Emergency
O/p 22 C-26 Stop

+V ign
EMS

Sys B-5
Limp mode
Switch
+V ign O/p 31 C-30

+V Crank I/p 16 A-35

A409790

Operation

Starting / Stopping the engine;

When the ignition key is turned to the crank position, 24v is input to the ECU on I/p A-35. The same crank signal is seen at
the starter motor relay at position 5 which will also energise the pull section of the stop solenoid.

The solenoid will then energise and move the fuel lever on the injection pump to the 'fuel on' position. When the ignition key is
released to the run position, 24v is no longer supplied to the coil of the shutdown relay, the relay will de energise (If the key had
been held in the cranking position for longer than 0.5secs then the ECU would switch off O/p C-30). The ECU provides a 24v
O/p C-26, through the closed contacts of the emergency stop button on the FSP to the hold section of the stop solenoid, the
solenoid will hold the fuel lever in the 'fuel on' position.

When the engine is running, if the ignition key is switched off, the 24v which was holding the stop solenoid energised is lost
due to the O/p C-26 being fed from an ignition live fuse. The stop solenoid will de-energise and move the fuel lever to the 'fuel
off' position, stopping the engine.

Pressing the emergency stop button;

If the emergency stop button on the FSP is pressed whilst the engine is running the ECU switches off the 24v from O/p C-26
to the hold section of the stop solenoid - the solenoid will de energise and move the fuel lever to the 'fuel off' position and the
engine will stop. At the same time the EMS will display the message 'EMER STOP' In this condition the engine can be
cranked but will not start due to the hold section not being energiised.

If the ignition is switched off and then back on, the system retains the emergency stop function until the emergency stop
button on the FSP is pressed again.

9803/6510 Issue 1
 10A
11 +24V BATTERY
6
5 - 18
30 17 15/54 54a 19

9803/6510
OFF
IGN
HEAT
CRANK BATTERY
Section C

RELAY
+24V BATTERY
C104 +
C23A
KEY SWITCH
28
27
C111
DIODE

BW
RY
C2 2 1
Engine Start/Stop (cont’d)

BW CONN B C54 STOP SOLENOID

U
B
EARTH U c U U A HOLD 6 0
HEADER 3 B
BW k BW W B PULL B
60
R 1 R B C COMM 0.5 BW
0.5 WR
W 2 W

B
31
2.5 W

B 34
BW

BW
WR

UK
YR
1 M
Electrics

ALTERNATOR
C180

C8
C10
W STARTER MOTOR

35
26
30

ECU1-A
ECU1-C
9 8
3 C99
Basic System Operation

WR 34

UK
3
2 U 7 FS1

UK 8

CANBUS SPI

I/P16 KEY SWITCH (CRANK)

O/P22 ENGINE SHUTDOWN
O/P31 SHUTDOWN RELAY
ECU1 EMS FASCIA
C15

A406780

Issue 1
5 - 18
Section C
Section C Electrics Section C
5 - 19 Basic System Operation 5 - 19

Limp Mode System

EMS
Limp Mode

15 Ignition
16 Limp mode

Key
Switch
1 ECU1
2
+V Crank Limp mode
Switch 1
2A Sys B-5
2

+V ign
ESOS

Pull Hold O/p C-26

Emer. Stop
O/p C-36
Isolator Sol.
Valve I/p A-33
Lever Lock
Switch

Operation
In the event of a failure of the ECU1 that causes the machine to fail to start and/or fail to switch on the isolator solenoid valve,
the limp mode switch can be selected which will allow these two functions to operate.

24v is available through the now closed contacts of limp mode switch via a diode to the 'hold' section of the shutdown
solenoid, to hold the fuel lever in the run position.
24v is also available through the contacts of the limp mode switch and via a second diode to energise the coil of servo
isolator solenoid.

At the same time the EMS will permanently display the message "LIMP MODE" and all bar graph bars will illuminate together
and flash on/off at half second intervals. The internal warning buzzer will also sound, but this can be cancelled by pressing the
"ACK" button.

Note: The engine will run at idle, increased engine speed can only be achieved by adjustment of the overide screw which acts
directly on the throttle linkage.

9803/6510 Issue 1
 5 - 20
C115 C13

9803/6510
LOCK 15 REDUNDANCY 4
LEVER SWITCH 7
Section C

5A
P 14 +24V IGNITION

3 2 1 4 6 5 1 3 2 C155 C156
Limp Mode System

DIODE DIODE

B
1

PU
PG

BO
BG
ECU1
1 2 1 2

UK

PG
PG
OG
EARTH
HEADER 4
C9
ECU1-B C61
LEVER
C1 LOCK S V
BG 1
5 PU CONN A
IGNITION
BG 2 BG OG 2

OG 1 OG
C10 32
ECU1-C
26 UK
Electrics

O/P 22 ENGINE SHUTDOWN

C54
C2
O/P 20 LEVER LOCK 36 OG STOP
CONN B
SOLENOID
Basic System Operation

C180
UK

PU U C U U A
P
U

2 3 1 8 9
LIMP MODE FS1 31
U 7
3
16 P
IGNITION UK 8
15 PU
REDUNDANCY
CANBUS SPI FASCIA
EMS
C15
C14
A406760

Issue 1
5 - 20
Section C
Section C Electrics Section C
5 - 21 Basic System Operation 5 - 21

Pump Control for Each Mode

Pump PWM ECU 1 CAN

Sol. Valve O/p 7 (C-2) DATA E,A,L,P

MODE
Flywheel I/p 17 (A-32)

Operation
The machine can operate in four different modes, depending upon the type of work required (see Engine Throttle Control). The
pump output horsepower is varied by means of a PWM signal to the pump control solenoid valve which varies for each mode.
The output has internal current sensing circuitry, which is used to supply a constant current over differing environmental
ranges ( ie changes in temperature of the solenoid coil )

Engine and pump torque matching

Engine nett torque curve Pump absorption
Torque

300 mA
A mode matching point

0 mA
E mode matching point
Torque

P +L mode matching point

Engine speed rev/min. -200 -100 Full A351070

Pump torque is set by pump control mA signal

A mode: Maximum engine power is used, engine set to maximum speed. Pump torque is set to match engine torque at
maximum power point. Pump control is by engine speed sensing, if pump torque exceeds engine available torque, the pump
torque is reduced and the control will hunt to find the matching point. If engine speed is set below maximum, pump torque is
set to E mode.

E mode: Improved fuel consumption is used, maximum engine speed is reduced by 100 rev/min., maximum pump absorption
torque is fixed above 1400 rev/min. Below 1400 rev/min. (when engine speed is rising) pump torque is set to L mode to avoid
engine stalling.

L +P mode: Pump absorption torque is set to minimum for all engine speeds, maximum engine speed is reduced by 200
rev/min.

9803/6510 Issue 1
 5 - 22

9803/6510
Section C

ECU1 1
C87
C8 C2 ENGINE SPEED SENSOR
WY
ECU1-A CONN B
20 S S E S 34
0V REF
Pump Control for Each Mode

32 WY WY M
ENGINE SPEED

C66 PUMP CONTROL S.V.

C1
Electrics

C10
CONN A B 1
ECU1-C
NB NB 19 NB 41
2 NB 2
Basic System Operation

PUMP CONTROL
B

A346070

Issue 1
5 - 22
Section C
Section C Electrics Section C
5 - 23 Basic System Operation 5 - 23

Pump Control for Each Mode - (cont’d)

"A" Auto Mode

The pump output power is set to absorb 100% of the available engine power. The pump control signal varies with engine
speed according to the figure below

Pump control characteristic - A mode

G,A
70
60 D,B E,B
50 A405650
F,B
Pump signal

40
30 Rising
20 Falling
10
0
1000 1500 2000 2500
Engine speed (rpm)

"E" Economy mode.

The pump output power is set to absorb 90% of the available engine power. The pump control signal varies with engine speed
according to the figure below :-

Pump control characteristic - E mode

D,C E,C
60

40
Pumpsignal

20
Rising
Falling
0
1000 1500 2000 2500
Engine speed (rpm)

"L" Lifting mode & "P" Precision mode

The pump output power is set to absorb 70% of the available engine power. The pump control signal is set to zero PWM
percent, regardless of engine speed. The pump mA value against engine speed characteristic varies by model as shown in the
table below :

"A" "E" "P&L" PWM Engine Speed

Mode Modes Hz. (RPM)
Max (A) Min (B) (C) (D) (E) (F) (G)
540 320 320 0 75Hz 1200 1400 1900 2000

9803/6510 Issue 1
Section C Electrics Section C
5 - 24 Basic System Operation 5 - 24

Pump Control for Each Mode - (cont’d)

YES Engine
Below 1200
RPM

NO

ON One touch/
Auto idle?

OFF

ON
Breaker
Psw?

OFF

YES
In P or L
mode?

ON
Upper NO
ON
Psw?

YES In E
mode?

ON YES
Travel
Psw?
Engine water temp
>101ºC?
YES

OFF NO
Hydraulic oil temp
>98ºC?

A mode?

Read engine speed Read engine speed

Determine pump PWM Determine pump mA

value from table value from table

P,L mode mA set E mode mA A mode mA

to zero set value set value

9803/6510 Issue 1
Section C Electrics Section C
5 - 25 Basic System Operation 5 - 25

Lever Lock
Limp mode switch
Ign +V

Isolator Sol. ECU1 EMS

Valve O/p 21 C-36

CAN
Data
Lever Lock
Gate Switch I/p 32 A-33

Operation
The machine is equipped with an control lock lever, which has to be raised to exit the cab and lowered before any hydraulic
operationof the machine is possible.

When the control lever lock is in the lowered position there is no ground available to ECU I/p A 33. This causes the O/p C 36 to
the isolator valve to be energised and when a ground is available through the lever lock switch operation of the excavator
controls is possible.

When the lever lock is raised to the upright position the ground circuit for the solenoid is no longer complete. There is a ground
input to ECU1 I/p A-33 and the lever lock warning light is illuminated.

In limp mode the lever lock solenoid valve is supplied directly from the limp mode switch.

Servo Isolator

Ign +V
Limp mode switch

Isolator Sol. ECU1 EMS FSP

Valve (FS6)
O/p 21 C-36
Isolator

CAN Isolator
Lever Lock Data
Gate Switch I/p32 A-33

Operation
The operator has the ability to isolate the excavator controls by pressing the isolator switch on the facia switch panel.

When the Isolator switch is pressed the EMS displays the message "Isolator" to acknowledge selection and illuminates both
the warning Lamp and the switch status indicator. ECU1 now de-energises the output to the isolator solenoid valve (O/p C
36).

A second press of the isolator switch extinguishes both the warning lamp and the switch status indicator. ECU1 now
energises the isolator output (O/p C 36) and provided the lever lock is in the correct position, operation of the excavator
controls is possible

9803/6510 Issue 1
 5 - 26

9803/6510
LOCK LEVER
Section C

EARTH SWITCH
HEADER 4
15
ECU1 1

BO
C115
3 2 1
C8
ECU1-A

BO
U
BG
Lever Lock and Servo Isolator

33 U
I/P 32 LOCK LEVER
C113 C114

C1
CONN A

BG
BG
LOCK
C10 C61 LEVER S.V.
ECU1-C
BG 8 BG 2

36 OG OG 9 OG 1
Electrics

O/P 21LOCK LEVER

32
Basic System Operation

2 3

FS5
CANBUS SPI

FASCIA

EMS

A406800

Issue 1
5 - 26
Section C
Section C Electrics Section C
5 - 27 Basic System Operation 5 - 27

Wiper

ECU1 EMS FSP

Wiper motor
M O/p C-17
Ign. + Volts Wiper int

CAN Wiper
Data

Operation

The wiper has three modes of operation, intermittent, permanently on and off. Timing for the intermittent function is performed
by ECU1, and can be varied via the set menu on the EMS.

When the wiper switch on the Facia Switch Panel (FSP) is pressed once the EMS displays the acknowledge message "wiper
int" and O/p C 17 on ECU1 is pulsed for 0.5 seconds to start the wiper stroke. A hold on contact within the motor assembly
retains power for the return stroke of the blade. A time delay of variable seconds is activated before the output is energised
again, thus giving intermittent operation.

A second press of the switch enables the wiper to operate continuously and the output is permanently energised. EMS
displays 'Wiper on'.

A third press of the switch disables wiper operation.

Lower Wiper (option)

ECU1
Wiper Motor
ign. +Volts M O/p C-15

Lower Wiper Switch

O/p A-4

Operation

The lower wiper is a customer selected option and is fitted to the lower glass panel at the front of the operator’s cab.

The wiper has three modes of operation intermittent, continuous and off. Timing for the intermittent function is performed by
ECU1. The same timer as utilised for the standard wiper is used to synchronise both wipers together.

When the lower wiper button is operated the ECU1 output number C 15 is energised to start the wiper stroke. A hold on
contact within the motor assembly retains power for the return stroke of the blade. A time delay equal to that set for the main
wiper is activated before the output is energised again, giving intermittent operation.

A second press of the switch enables the wiper to operate continuously and the output is permanently energised.
A third press of the switch disables wiper operation.

Note: If the upper (main) wiper is energised then the lower wiper output is energised at the same time, synchronising both
wipers.

9803/6510 Issue 1
 5 - 28

Wiper

9803/6510
Section C

ECU1 1

C37 CAB CONN

M

GW 11
BW 7
G 6
GR 5
C10
ECU1-C

EARTH
17 HEADER 3
Electrics

GR
O/P 12 WIPER BW
4
Basic System Operation

C25
G 7 20A +24V IGNITION
2
3

FS9
CANBUS SPI

FASCIA

EMS

A406810

Issue 1
5 - 28
Section C
 5 - 29

9803/6510
Section C

LOWER WIPER SWITCH

20A C6
RG FUSE No 8 +24V
IGN
C200 20A
Lower Wiper (option)

G FUSE No 7

8 7 3 2

RG
LOWER WIPER

M
1

ECU1 C8
ECU1- A
Electrics

1 K
I/P 21 LOWER WIPER
Basic System Operation

1 2 3 4 C201
N
G
GU

C10
ECU1- C

15 GU
O/P 11 LOWER WIPER

399840

Issue 1
5 - 29
Section C
Section C Electrics Section C
5 - 30 Basic System Operation 5 - 30

Washer
ECU1 EMS FSP
Washer
M O/p C-8
motor

CAN Washer
Wiper motor
M Data
Ign. + Volts O/p C-17

Operation

When the washer switch on the facia switch panel is pressed the ECU1 operates the output O/p C 8 to the washer pump. The
ECU output is only energised whilst the facia switch is pressed.

Whenever the Washer output is energised the Wiper output (ECU1 O/p C17) is also energised. When the washer switch is
released the wiper will do three additional strokes and then turn itself off.

9803/6510 Issue 1
 5 - 31

9803/6510
Washer
ECU1
Section C

C110
DIODE C79
YR B WASHER 48
YR 1
C10
ECU1-C B 2
C1
CONN A
8
YR YR 27 YR
O/P 16 WASHER
Electrics

B
Functional Description

2 3

FS8
CANBUS SPI

FASCIA

EMS

A346040

Issue 1
5 - 31
Section C
Section C Electrics Section C
5 - 32 Basic System Operation 5 - 32

Horn
ECU1

Horn O/p 6 (C-14)

CAN
Horn switch I/p 24 ( A-14) Data

ECUW
O/p C-14

Column horn switch I/p A-14

Operation

When the left joystick rear button is pressed, input ECU1 I/p A 14 is selected the horn output ECU1 O/p C 14 is energised
whilst the button is pressed.

Horn (Wheeled models) In addition to the left joystick trigger a horn pushbutton is provided on the steering column. When the
stalk button is pressed, ECUW I/p A 14 is selected. ECU O/p C 14 is energised whilst the button is pressed.

9803/6510 Issue 1
 Horn
5 - 33

9803/6510
Section C

HORN 21
SWITCH

ECU1 1
1 2 3 C34
LH LEVER EARTH
HEADER 3
C8

GR
BW
ECU1-A

BW
I/P24 HORN 14 GR

B
C80
HORN 47
C1 1
B
CONN A
C10 GW 31 GW
Electrics

GW 2
ECU1-C

14 GW
O/P6 HORN
Functional Description

A406820

Issue 1
5 - 33
Section C
Section C Electrics Section C
5 - 34 Basic System Operation 5 - 34

Travel Alarm

ECU1
Travel Alarm
O/p 25 (C-23)

I/p 27 (A-16)

Travel Pilot Switch

Operation

The travel alarm is available as an option on the tracked machines. Whenever travel movement is requested travel pressure
switch ECU1 I/p A-16 is selected. When this input is grounded the travel alarm output ECU1 O/p C 23 is energised.

9803/6510 Issue 1
 5 - 35

9803/6510
Section C

Travel Alarm

B
C94
ECU1 1 TRAVEL ALARM 40
B 1

C8 RG 2
ECU1-A
I/P27 TRAVEL PILOT SW 16 LG
C1
CONN A

RG 7 RG C70
TRAVEL PILOT SW
26 36
LG LG LG 1
B 2

B
C10
Electrics

ECU1-C

23 RG
O/P26 TRAVEL ALARM
Functional Description

A345950

Issue 1
5 - 35
Section C
Section C Electrics Section C
5 - 36 Basic System Operation 5 - 36

Soft/Hard (Cushion)

ECU1 EMS FSP

Hard mode
O/p 28 (C-25) Soft mode

CAN Cushion
Data
Cushion Sol.Valve

Operation

The soft/hard mode allows the operator to select the response of the hydraulic circuits, soft being controlled and hard being
fierce when de selecting boom and dipper functions. Soft mode is the default setting when starting the machine.

To change to hard mode the operator must select the option by pressing cushion switch on the facia switch panel. This will
cause the EMS to display the "HARD MODE" message to acknowledge the request. Cushion solenoid output ECU O/pC 25 is
energised.

The Hard mode is cancelled either by turning the ignition off, or by pressing the cushion switch for a second time. In which
case the EMS displays the message "SOFT MODE" to acknowledge de-activation.

9803/6510 Issue 1
Section C Electrics Section C
5 - 37 Functional Description 5 - 37

Soft/Hard (Cushion)

A406840
32

FASCIA
FS4
CUSHION S.V.
C63
2

1
SR
B

SPI
2

EMS
CONN A
C1

13
SG
1

SG

CANBUS
ECU1-C
C10

25
ECU1

O/P 28 CUSHION

9803/6510 Issue 1
Section C Electrics Section C
5 - 38 Basic System Operation 5 - 38

Boom Down Delay

ECU1
Negative Control
Sol.Valve
O/p 23 (C- 37)

Travel Pilot O/p 27 (A-16)

Pressure Switch

Boom Lower O/p28 (C-26)

Pressure Switch

Operation

When the Boom lowering pressure switch I/p A 26 is selected the negative control solenoid valve O/p C 37 is switched on for
0.4 of a second. This holds the hydraulic pump at minimum flow while the boom starts to move.

If travel has been selected simultaneously, travel pilot switch input I/p A 16 is also selected and no output is given to boom
down delay solenoid.

9803/6510 Issue 1
 5 - 39

9803/6510
Section C

Boom Down Delay

ECU1 1

C8
ECU1-A
I/P27 TRAVEL PILOT 16 O

B
C60
32
C1
I/P28 BOOM PILOT 26 LG CONN A NEGATIVE CONTROL S.V.
B 2
SB 1 SB
SB 1
O 22 O

LG 26 LG
C10 C72
ECU1-C BOOM PILOT SW
Electrics

SB 37
O/P23 NEGATIVE CONTROL 37 O 1
B 2
Functional Description

C70
TRAVEL PILOT SW
36
LG 1
B 2
B

A406850

Issue 1
5 - 39
Section C
Section C Electrics Section C
5 - 40 Basic System Operation 5 - 40

Slew/Boom Priority (High Dump)

ECU1 EMS
Boom Priority
(High Dump)
Sol.Valve Boom Priority
O/p 5 (C- 13)

CAN
Boom Up Pilot I/p19 (A- 21)
Data

Slew/Boom Priority
Switch I/p 18 (A- 22)
(Permanent Switch)
Slew/Boom Priority
Switch
(momentary switch)

Operation
This feature allows the operator to give hydraulic priority to either the slew or boom movements. This is used when loading
vehicles at either 90 or 180 degrees to the current operating path. (If the vehicle is at 90 degrees, then Boom has priority and if
the vehicle is at 180 degrees, then slew has priority).

The operator changes from slew Priority (Default) to boom priority by activating the priority switch on the Right hand switch
panel (RS5) The EMS will acknowledge the operation of the switch by displaying the message “Boom Priority”. When the
switch is deactivated the EMS will acknowledge the operation by displaying the message “Slew Pri.”

As long as the switch (RS5) is made and the Boom Up pilot (I/p19 ) is valid, ECU1 energises the boom priority solenoid valve.
(O/p5 ) (100 % duty cycle).

Logic Diagram
OFF
Slew pilot
switch

ON

ON
Priority
switch

ON

ON
Boom up
pilot switch

ON

Boom priority sol v. Boom priority sol v.

Set Off Set On

9803/6510 Issue 1
 5 - 41

9803/6510
Section C

C43
BOOM
PRIORITY 8 7 3 2
SWITCH

RG
BO
BC
NU
4

15A
8 +24V IGNITION

ECU1 C8 1
Slew/Boom Priority (High Dump)

ECU1- A

21 UO
I/P 19 BOOM UP PILOT C32 LH LEVER SWITCH
22 NU NU 1
I/P 18 BOOM PRIORITY
21
BW 2

EARTH HEADER 4
Electrics

EARTH HEADER 3
BW

C65
Basic System Operation

BOOM PRIORITY S.V.

C10 C1
CONN A
B 2 32
ECU1- C UG

13 UG 21 UG UG 1
O/P 5 BOOM PRIORITY
UO 23 UO
C71
BOOM UP PILOT SWITCH

UO 1 36
B 2
B

A406860

Issue 1
5 - 41
Section C
Section C Electrics Section C
5 - 42 Basic System Operation 5 - 42

Slew Brake

ECU1
Swing Brake
Sol.Valve
O/p 9 (C- 4)

I/p 29 (A- 36)

Swing Pilot
Pressure Switch

Operation

When the machine is started, ECU1 output to the slew brake solenoid O/p C 4 is 24V. This gives an effective 50% brake to
hold the position of the machine.

When the operator selects slew the slew pressure switch will close giving a ground to I/p A 36, the ECU will switch off O/p C
4 , this gives an effective 0% brake to allow the machine to slew.
5 seconds after the slew service is returned to neutral the ECU will again switch on O/p C4 (24v) to swing brake solenoid. (The
5 second delay is provided so that machine will brake hydraulically against the slew cross line relief valves) .

Slew lever position Swing brake solenoid output (O/p C 4 )

Slew service not selected Output on ( 24v )

Slew service selected Output off
Slew lever returned to neutral Output on (24v ), 5 secs after swing
lever returned to neutral

9803/6510 Issue 1
 5 - 43

9803/6510
Section C

Slew Brake

B
ECU1 1

C8 C1
ECU1-A CONN A
UR 10 UR C73 SWING PILOT S.W.
37
36 NY NY 25 NY NY 1
I/P 29 SWING PILOT
B 2
Electrics

C55 SWING BRAKE S.V.

B 2 33
C10
Functional Description

ECU1-C UR 1

4 UR
O/P 9 SWING BRAKE

A406870

Issue 1
5 - 43
Section C
Section C Electrics Section C
5 - 44 Basic System Operation 5 - 44

Slew lock (100% Slew Brake)

ECU1 EMS FSP

Slew Lock 1
Sol.Valve
Slew Lock
O/p 8 (C- 3)

Slew Brake 2 Slew Lock

Sol. Valve
O/p 9 (C- 4)

Slew Shut OFF 3

Sol. Valve
O/p 10 (C- 16)

I/p 29 (A- 36)

Slew Pilot
Pressure Switch

Operation

Slew lock is selected by pressing the Slew lock switch on the facia switch panel. When pressed, the EMS displays the
message "Slew Lock", and the warning light illuminates. The Slew shut off ( O/p C 16 and Slew brake solenoids (O/p C 4)
are energised by the ECU1, (effectively isolating the joystick) This transfers pilot pressure to both ends of the Slew main spool.
5 seconds later the Slew lock solenoid is energised ( O/p C 3 ), effectively providing 100% braking torque.
The Slew lock is de-activated by a second press of the facia switch . This causes the EMS warning lamp to be extinguished.
The ECU1 de-energises the Slew lock and Slew shut off solenoid valves.

Slew Lock Slew Lock Sol Valve Slew Brake Sol Valve Slew shut off EMS Display
( O/p C 3 ) ( O/p C 4 ) Sol Valve
(O/p A36 )

Not selected OFF ON OFF No display

Slew lock selected On 5 secs after ON ON Slew Lock
Slew lock selected

9803/6510 Issue 1
 5 - 45

9803/6510
Section C

B
1 C62 SWING SHUT OFF S.V.
ECU1
B 2
32
UW 1
C8
ECU1-A
Slew Lock (100% Slew Brake)

C1
CONN A C55 SWING BRAKE S.V
36 NY
I/P 29 SWING PILOT
UW 5 UW B 2

UR 10 UR 1
33
UR

UB 11 UB

C10 NY 25 NY
ECU1-C C56 SWING LOCK S.V.
B 2
Electrics

3 UB
O/P8 SWING LOCK UB 1

4 UR
O/P9 SWING BRAKE
Basic System Operation

16 UW C73 SWING PILOT S.W.

O/P10 SWING SHUT OFF
37
NY 1

B 2

2 3

FS2
CANBUS SPI

FASCIA

EMS

A406880

Issue 1
5 - 45
Section C
Section C Electrics Section C
5 - 46 Basic System Operation 5 - 46

3-Speed Travel
ECU1
High Speed Travel
Sol. Valve
O/p C- 7
EMS
Max flow Cut Hare, Tortoise
Sol. Valve
O/p C1
Mode
CAN
Data

Upper I/pA-6
Pressure Switch

Travel
Pressure Switch I/pA- 16

Travel I/pA-13
Change Switch

Operation

Using a combination of two solenoids (high speed travel solenoid and max flow cut solenoid), pump flow and swash plate
position of the travel motor are used to give three travel speeds. The selected travel speed is indicated on the EMS as either a
Hare (High), double arrow (Middle), or Tortoise (Creep) and is changed by successive presses of the travel change switch. The
current operating mode of the machine alters the logic in which the solenoids operate.

Creep (Tortoise) Mid (Double Arrow) High (Hare)

Note: The last selected travel speed when machine is stopped is re-instated when the machine is restarted.

"E" Economy, "P" Precision & "A" Auto Modes.

At the mid travel speed the motor swash plate is in the maximum swash position (low speed) and the pump is at the standard
setting. The max flow cut and high speed travel solenoids are de-energised and the statuses of the travel and upper pressure
switches are ignored. The EMS displays the "Arrow" gear icon.

When the travel change switch (ECU1 I/p A 13) is pressed the EMS displays the "Hare" gear icon. The high speed travel
solenoid is energised (ECU1 O/p C 7 ), thus moving the swash plate to the minimum swash position (high speed). The
pressure switch inputs are ignored. The machine is now in the high speed travel mode.

When the travel change switch is pressed again the EMS displays the "Tortoise" gear icon. The machine is now in creep travel
speed mode. The high speed travel solenoid (ECU1 O/p C 7) is de energised. If the travel pressure switch is activated ie travel
selected (ECU1 I/p A 16) then the Max flow cut solenoid is energised (ECU1 O/p C 1) and the pump is put in "Q cut "mode.
The max flow cut solenoid is only energised whilst the travel pressure switch is activated. The input from the upper pressure
switch is ignored. The next successive press of the travel change switch (ECU1 I/p A 13) selects the mid travel speed and the
EMS displays the "Arrow" gear icon.

9803/6510 Issue 1
Section C Electrics Section C
5 - 47 Basic System Operation 5 - 47

3-Speed Travel (cont’d)

Relationship between Travel Modes A / E + P , travel motor swash plate position

and Pump "Q max cut output"

Travel Speed High speed travel solenoid output Q max cut solenoid output
ECU 1 O/p C 7 ECU 1 C1
Creep (Tortoise) OFF On (24v) only when travel
pressure switch has been selected ie travel
selected
Middle (Arrow) OFF OFF
High (Hare) ON (24v) OFF

"L" Lifting Mode.

In the mid travel speed the motor swash plate is in the maximum swash position (low speed), the high speed travel solenoid
(ECU1 O/p C 7) is de-energised. When only the travel pressure switch (ECU1 I/p A 16) is selected, the max flow cut solenoid
(ECU1 O/p C 1) is de-energised. When the upper pressure switch (ECU1 I/p A 6) only is selected, the max flow cut solenoid
valve is energised, thus setting the pump to the "Q -cut" setting. If both the travel pressure switch (ECU1 I/p A 16) and the
upper pressure switch (ECU1 I/p A 6) are selected, the max flow cut solenoid (ECU1 O/p C 1) remains energised, thus leaving
the pump in "Q cut" mode. The EMS displays the "Arrow" gear icon.

When the travel change switch (ECU1 I/p C 7) is pressed, the EMS displays the "Hare" gear icon. The high speed travel
solenoid (ECU1 O/p C 7 ) is energised, moving the travel motor swash plate to minimum swash position (high speed). When
only the travel pressure switch (ECU1 I/p A 16) is selected, the max flow cut solenoid (ECU1 O/p C 1) is de-energised. When
the upper pressure switch (ECU1 I/p26) is selected, the max flow cut solenoid valve is energised, thus setting the pump to the
"Q -cut" setting. If both the travel pressure switch (ECU1 I/p A 16) and the upper pressure switch (ECU1 I/p A 6) are selected,
the max flow cut solenoid (ECU1 O/p C 1) remains energised, thus leaving the pump in "Q cut" mode.

When the travel change switch is pressed again the EMS displays the "Tortoise" gear icon. The high speed travel solenoid
(ECU1 O/p C 7) is de energised, thus the swash plate is set to the high swash position (low speed). The Max flow cut solenoid
(ECU1 O/p C 1) is energised, thus putting the pump in "Q cut" mode. The machine is now in creep travel speed mode. The
operation of the travel pressure switch (ECU1 I/p A 16) and the upper pressure switch (ECU1 I/p A 6) are ignored.

The next successive press of the travel change switch (ECU1 I/p34) selects the mid travel speed and the EMS displays the
"Arrow" gear icon.

F mode and travel combination

Middle speed travel only - pump standard.

Excavating only - Q max cut.
Travel & excavating - Q max cut.

High speed travel only - pump standard.

Excavating only - Q max cut.
Travel & excavating - Q max cut.

Creep speed travel only - Q max cut.

Excavating only - Q max cut
Travel & excavating - Q max cut

9803/6510 Issue 1
 5 - 48

9803/6510
Section C

3 Speed Travel

1 17
ECU1

C29 1 2 EARTH
C8 TRAVEL HEADER 2
ECU1-A CHANGE SWITCH
OB

BU
LGY
BU
I/P26 UPPER PILOT 6
43
13 LGY C64
I/P34 TRAVEL CHANGE
MAX FLOW CUT S.V.
16 LG
I/P27 TRAVEL PILOT C1 B 2
CONN A
OW 3 OW OW 1
C10
ECU1-C LGW 4 LGW
C58
OW OB 24 OB HIGH SPEED TRAVEL S.V.
O/P3 MAX FLOW OUT 1
Electrics

B 2
7 LGW LG 26 LG
O/P 15 HIGH SPEED
TRAVEL SOLENOID LGW 1
Basic System Operation

C69
UPPER PILOT SW
35
OB 1
B 2

C70
TRAVEL PILOT SW
36
LG 1
B 2
B

A406890

Issue 1
5 - 48
Section C
Section C Electrics Section C
5 - 49 Basic System Operation 5 - 49

Work Lamps
ECU1
Cab (LH) Opt.
Work light O/p 13 (C-5)

70W
Cab (RH) Opt.
Work light O/p 14 (C-6)

70W

Boom (Std.)
Work light +24V O/p29 (C-39)

70W
Tool Box (Std.)
Work Light +24V O/p 30 (C-20)

70W
Counterweight
Work Light Opt. +24V O/p 33 (C-18)

70W
Std. Work Light
Switch +24V
I/p 9 (A-28)

Opt. Work Light

+24V
Switch I/p 10 (A-38)

Operation

Work lamps are located on the boom and front body (tool box) of the machine. An optional set of three additional work lamps
can be fitted to the cab and counter weight.

When the work light switch is moved to the first position, the input A 28 to the ECU1 is selected. This in turn enables outputs
to be turned on to the Boom (ECU1 O/p C 39) and lower front body (Tool Box) (ECU1 O/p C20 ).

A second press of the same switch selects ECU1 I/p C 39 and C 20 which in turn energises the second optional set of cab
work lamps (ECU1 O/p C5 + C6 and counter weight (ECU1 O/p C18 )), if they are fitted and provided that these options have
been selected in the machine setup tool.

The switch is returned by pressing in the reverse direction boom and tool box work lamps and the optional work lamps are
extinguished.

9803/6510 Issue 1
 WORK LAMP SWITCH
5 - 50
+24V

9803/6510
IGNITION
4 11
Section C

Work Lamps

5A
ECU1 1

EARTH 14 C24 8 7 3 6 5 2
C8 HEADER 1
C25 C180

P
ECU1-A

P
P

P
B
Y

B
UY
P 1 P
28 UY 4
I/P 9 STD. LAMPS 4
B B
I/P 10 OPT. LAMPS 38 Y
UY 13 UY 20A
RG 8
Y 14 Y
C10
ECU1-C
C35 CAB LAMP
5 RB 1
O/P 13 CAB LAMP
19
OPT 6 RY RY 2
O/P 14 CAB LAMP
18 RU
O/P 33 COUNTERWEIGHT LAMP C36 CAB LAMP
20 RW 1
O/P 30 TOOLBOX LAMP
19
STD
39 RS RB 2
Electrics

O/P 29 BOOM LAMP

C82
BOOM LAMP
Basic System Operation

18
RG 1
RS 2

C81
C1 TOOLBOX LAMP 18
CONN A RW 1
RS 29 RS RG 2

RW 30 RW
C28
RU 36 RU COUNTERWEIGHT LAMP
RY 1 18
RG 37 RG RG 2

A406900

Issue 1
5 - 50
Section C
Section C Electrics Section C
5 - 51 Basic System Operation 5 - 51

Fuel Level Sensor/Warning

ECU1
EMS

0V ref. Low Fuel

Fuel Level
sensor
CAN
I/P 4 (A-8) DATA

5Ω 5Ω

19 x 5 Ω

A406990

Operation

A float sensor is fitted to the fuel tank to measure the level of fuel in the tank. A magnetic float rises up a tube containing a
series of 5 ohm resistors with switches in parallel. The fuel level is displayed to the operator by means of a bar graph gauge.
The actual values can be displayed via the EMS's SET+ MODE menu. Both the actual value and bargraph values should be
an average of consecative readings to provide a degree of dampening to prevent false readings

Text warnings are provide for both Reserve fuel and low fuel conditions. Low fuel is also backed up by a floashing bargraph
and an audiable alarm. The audiable alarm can be cancelled by pressing the "ACK" button on the EMS.

Bar No Symbol Float Height Ohms EMS Action

From Full
0 Empty >646 >107.5 Flashing Bargraph + Buzzer+ "LOW FUEL"
1 646 >102.5 "RES FUEL"
2 612 >97.5
3 578 >92.5
4 544 >87.5
5 510 >82.5
6 476 >77.5
7 442 >72.5
8 408 >67.5
9 374 >62.5
10 Half 340 >57.5
11 306 >52.5
12 272 >47.5
13 238 >42.5
14 204 >37.5
15 170 >32.5
16 136 >27.5
17 102 >22.5
18 68 >17.5
19 34 >12.5
20 Full 0 <12.5

9803/6510 Issue 1
Section C Electrics Section C
5 - 52 Basic System Operation 5 - 52

Fuel Level Sensor/Warning

A345920
52
SENSOR
FUEL
C75

YR 1

2
S
YR

2
S
CONN B
C2

EMS
YR R
E
S
1

YR

CANBUS
ECU1-A
C8

20
ECU1

I/P 4 FUEL LEVEL

OV REF

9803/6510 Issue 1
Section C Electrics Section C
5 - 53 Basic System Operation 5 - 53

Engine Temperature Sensor/Warning

ECU1
+V ref
Engine Over heat
water temp OVERHEA
sensor

I/p 2 (A-18)
Engine over CAN
heat switch Data
I/p 5 (A-40)

ºt

Operation
The engine is fitted with a thermistor sensor and thermal switch to measure the water temperature. The temperature is
displayed to the operator by means of a bar graph gauge. The actual values can be displayed via the EMS's SET+ MODE
menu.

When the engine temperature reaches 98 ºC the EMS will illuminate the warning lamp. If the temperature continues to rise the
bargraph will flash on-off and an audible warning and "ENG.TEMP" message will be given. The audible warning can be
cancelled by pressing the "ACK" button on the EMS.

The over heat switch is included as a safety measure in case of the thermistor failure. If this input is grounded then the EMS
will illuminate the warning lamp, sound the audible alarm and display the overheat message. The audible warning can be
cancelled by pressing the "ACK" button on the EMS.

The Engine Water Temperature bargraph gauge operates as follows:

Bar No Colour Temp On Temp Off EMS Action

1+2 Green 50 48
3+4 Green 75 73
5+6 Green 82 80
7+8 Green 85 83
9+10 Green 88 86
11+12 Green 91 89
13+14 Green 93 91
15+16 Green 95 93
17+18 Red 98 96 Warning LED illuminated
19+20 Red 103 101 Warning LED illuminated + Flashing Bargraph +
buzzer + "ENG.TEMP"

Overheat 101 94 Warning LED Illuminated

switch OVERHEAT message + buzzer

Coolant temperature sensor characteristic

40000
35000
30000
25000
Sensor
resistance 20000
15000
10000
5000
0
-10 0 10 20 30 40 50 60 70 80 90 100 110 120
Temperature deg. C

9803/6510 Issue 1
 5 - 54

9803/6510
Section C

ECU1 1

C86 ENGINE TEMP. SENSOR

C8
YB 1 50
ECU1-A
+V REF 10 SG SG 2
C2
CONN B

I/P 2 ENGINE TEMP. 18 YB YB L YB

C162 OVERHEAT SW.

N
Engine Temperature Sensor/Warning

40 RY RY RY RY 1 50
I/P 5 OVERHEAT SW.

SG SG
Electrics

2
Basic System Operation

CANBUS

EMS
A345910

Issue 1
5 - 54
Section C
Section C Electrics Section C
5 - 55 Basic System Operation 5 - 55

Coolant Level Warning

ECU1 EMS

OVERHEA
Coolant Low

Coolant Level CAN

Sensor (Float) Data
I/p A-2

Operation
A float switch is fitted to the engine coolant reservoir. When the reservoir is empty the float switch ECU1 I/p A 2 is connected
to ground. This causes the EMS to illuminate the warning lamp and displays the message "COOLANT LOW" and sounds the
internal buzzer.

The buzzer can be cancelled by pressing the ACK button on the EMS.

Air Filter Blocked Warning

ECU1 EMS

Air Filter

CAN
Data
Air Filter Switch

I/p A-7

Operation

A pressure switch is fitted to the engine air filter. When the filter is blocked the pressure increases, thus triggering the switch
and the ECU1 I/p A-7 is connected to ground. This causes the EMS to illuminate the warning lamp and displays the message
(AIR FILTER) and sounds the internal buzzer.

The buzzer can be cancelled by pressing the ACK button on the EMS.

9803/6510 Issue 1
 5 - 56
C77

9803/6510
AIR FILTER CLOG SWITCH

B
YU 1 54
Section C

B 2

C84
C1 ENGINE OIL PRESSURE SWITCH
CONN A
Warning Indicator Lamps

YG 1 34
1 YU 14 YU
B 2
YW 15 YW
ECU1 C8
ECU1- A
UB 16 UB
2 YW C76
I/P 37 COOLANT LEVEL COOLANT LEVEL SWITCH
YG 17 YG
3 YG 53
I/P 35 ENGINE OIL PRESSURE YW 1
SB 20 SB
4 GW B 2
I/P 25 HYDRAULIC OIL LEVEL
WR 28 WR
7 YU
I/P 11 AIR FILTER CLOG
GW 35 OPT
9 WR
I/P 3 ALTERNATOR
Electrics

17 UB
I/P 12 OIL FILTER CLOG

23 SB
I/P 33 AIR PRESSURE
Basic System Operation

C99 ALTERNATOR
WARNING LED's 34
3
CANBUS
WR
2
EMS 1

A406930

Issue 1
5 - 56
Section C
Section C Electrics Section C
5 - 57 Basic System Operation 5 - 57

Hydraulic Temperature Sensor/Warning

ECU1 EMS

+V ref
OVERHEA
Hyd Temp

ºt

I/p 1 (A-19) CAN

Data

Hydraulic Oil Temp sensor/

Hydraulic overheat switch ºt

Operation
The hydraulic system is fitted with a thermistor and a thermal switch to measure temperatures. The temperature is displayed to
the operator by means of a bar graph gauge. The actual values can be displayed via the EMS's SET and MODE menu.
When the hydraulic oil temperature reaches 95 ºC the EMS will illuminate the warning lamp. If the temperature continues to
rise the bargraph will flash on-off and an audible warning and "HYD.TEMP" message will be given. The audible warning can be
cancelled by pressing the "ACK" button on the EMS.

The overheat switch is included as a safety measure in case of the thermistor failure. If this input is grounded then the EMS will
illuminate the warning lamp, sound the audible alarm and display the overheat message. The audible warning can be
cancelled by pressing the "ACK" button on the EMS.

The Hydraulic Oil Temperature bargraph gauge will operate as follows:

Bar No Colour Temp On Temp Off EMS Action

1+2 Green 0 -2
3+4 Green 20 18
5+6 Green 35 33
7+8 Green 50 48
9+10 Green 60 58
11+12 Green 70 68
13+14 Green 80 78
15+16 Green 92 90
17+18 Red 95 93 Warning LED illuminated
19+20 Red 98 96 Warning LED illuminated + Flashing Bargraph + buzzer
Overheat 98+/-2 91+/-4 Warning LED Illuminated
switch OVERHEAT message + buzzer

Temperature Sensor Characteristic.

40000
35000
30000
Sensor 25000
resistance 20000
15000
10000
5000
0

-10 10 30 50 70 90 110
Temperature deg. C

9803/6510 Issue 1
 5 - 58

9803/6510
Section C

ECU1 1

C74 HYD. OIL TEMP. SENSOR

C8 C2
CONN B NW 1 50
ECU1-A
+V REF 10 SG SG P SG SG 2

I/P 1 HYDRAULIC TEMP. 19 NW NW S NW C132 HYD. OIL OVERHEAT SW.

Hydraulic Temperature Sensor/Warning

NW 1

51
SG 2
Electrics
Basic System Operation

CANBUS

EMS

Issue 1
5 - 58
Section C
Section C Electrics Section C
5 - 59 Basic System Operation 5 - 59

Alternator/ No Charge Warning

ECU1 EMS
Alternator + Volts

I/p A-9 Alternator

CAN
Data
Flywheel 0 ref

I/p A-32

Operation
The output of the alternator is monitored by the ECU1 and a warning alarm sounded if the output voltage falls below a set
value.

When the value of the alternator input (Ecu1 I/p A-9) falls below 23 volts or above 32 volts, the ECU1 sends a CAN message
to the EMS which in turn illuminates the warning lamp.

If the engine is running, as detected by the flywheel input (I/p A-32) then the internal buzzer on the EMS is sounded and the
message "Alternator" is displayed in addition to the warning light.

9803/6510 Issue 1
 5 - 60

9803/6510
25A 60A
Section C

29 30

C92 C91
2 1 FUSE LINK 2 1 FUSE LINK
C5

W
BATTERY
W W WB R
SUPPLY
TO FUSES
27 W

C6 BATTERY RELAY
IGNITION
SUPPLY R C105 B
28
TO FUSES C104

- +
WR C107
BATTERY
Alternator Charging and Battery Relay

BU
C108

B
C109 34
ALTERNATOR
R
B C98
Electrics

C2 WR 3 L
CONN B
6
Br B BU J BU BU 2 R
Basic System Operation

C99
OFF 1

IGN

STARTER MOTOR
B
B

C23 5 1 WR
R C96
KEY SWITCH

BU
RY
4 34
10A
10 +24V BATTERY
RY
A406730

Issue 1
5 - 60
Section C
Section C Electrics Section C
5 - 61 Basic System Operation 5 - 61

Quick hitch (option)

Quick
Hitch
Sol.Valve ECU1 EMS FSP

Q/H Discon?
O/p 23 (C-28)

CAN Quick
ACK
Data Hitch

Operation

The Quick hitch option allows the operator to quickly change the attachment from within the cab.
There are two types that can be fitted and they operate in different ways.

Quick hitch type 1: Q/H off = output is switched on

Q/H on = output is switched off

Quick hitch type 2: Q/H off = output is switched off

Q/H on = output is switched on

The system can be enabled and switched between types via the SET + MODE (5 seconds) menu:

SET + MODE (5 secs) Scroll to Q/H option

QH ENABLE? ACK
QH ON Scroll up/down to toggle between ON and OFF, ACK
QH TYPE? ACK
QH TYPE 1 Scroll up/down to toggle between type 1 and 2 ACK

When the Quick hitch switch is activated the EMS will display the " Q/H discon?" message to verify the switch operation.and
the switch status indicator will illuminate.

If the "Ack" switch on the EMS is not pressed within 5 seconds then the display reverts to normal and the switch status
indicator is extinguished.

The solenoid valve will only be energised / de energised once the "ACK" button on the EMS is activated. This is included as a
safety feature to prevent accidental operation of the quick hitch system.

Once the ACK button is pressed the EMS displays the message "Q/H discon" and the ECU1 O/p C 28 is de-energised (type
1) or energised (type 2). Buzzer is sounded while quick hitch is disconnected.

A second press of the quick hitch button changes output (ECU1 O/p C 28) to energised (type 1) or de-energised (type 2) and
buzzer switched off.

9803/6510 Issue 1
Section C Electrics Section C
5 - 62 Basic System Operation 5 - 62

Quick hitch (option)

A345890
3

FASCIA
FS6
QUICKHITCH
C157

2
K

SPI
B

EMS
K
CONN B
C2

ACK
T
K
1

CANBUS
ECU1-C
C10

28
O/P 23 QUICKHITCH
ECU1

9803/6510 Issue 1
Section C Electrics Section C
5 - 63 Basic System Operation 5 - 63

Overload Caution (option)

ECU1 EMS FSP

Overload Pressure Switch
Overload
O/p C-27

CAN Overload
Data

Operation

The overload caution is used as a warning to the operator that the machine is lifting a mass which is exceeding the safe load
capacity of the machine. An overload is indicated after the overload pressure switch (ECU1 I/p A 27) has been activated.

By default the overload override option is not enabled in A (Auto), E (Economy) & P (Precision) modes until overload switch is
selected. When selecting overload switch on FSP the EMS displays the acknowledge message "overload on" A second press
of the switch disables the overload override function and the status LED is extinguished.

When entering L (Lifting) Mode, the overload override warning system is automatically activated.
The status indicator for FS6 illuminates. The operation of overload switch will cancel the overload warning system.

If overload condition is reached whilst overload function is selected, EMS will display 'Overload' and buzzer will sound.

9803/6510 Issue 1
 5 - 64

9803/6510
Section C

ECU1 1

C8
ECU1-A C93
C2 OVERLOAD CAUTION
CONN B PRESSURE SWITCH 55
27
Overload Caution (option)

GU GU U GU 1 1
I/P 13 OVERLOAD
B 2 2

B
Electrics
Basic System Operation

2 3

FS3

FASCIA

EMS

A345870

Issue 1
5 - 64
Section C
Section C Electrics Section C
5 - 65 Basic System Operation 5 - 65

Beacon

ECU1 EMS FSP

Beacon ON
O/p C-22

CAN Beacon
Roof Mounted Beacon
data

Operation
Beacon is activated by pressing the beacon switch on the facia switch panel This causes the EMS to display the
acknowledge message "Beacon on", and ECU1 O/p C 22 is switched on.

Beacon operation is cancelled by a second press of the facia switch thus disabling the ECU1 output and extinguishing the
status LED.

9803/6510 Issue 1
 5 - 66

9803/6510
Beacon
Section C

ECU1 1

B
C10 C166
ECU1-C BEACON
44
C1 B 1
CONN A
22
NW NW 38 NW NW 2
Electrics

O/P 4 BEACON
Basic System Operation

2 3

FS7
CANBUS SPI

FASCIA

EMS

A345860

Issue 1
5 - 66
Section C
Section C Electrics Section C
5 - 67 Basic System Operation 5 - 67

Grab/rotate

Low Flow
Priority valve
(optional) O/p 20 (C-35)

Grab CW (Clockwise) ECU1

Sol. Valve
O/p 18 (C-33)

EMS
Grab CCW (Counter
Grab CW
Clockwise) Sol. Valve O/p 19 (C-34)

CAN
Grab CW JSR3 I/p 30 ( A-5) Data

I/p 31 (A-15)
Grab CCW JSR2

Operation

The grab input can be either clockwise or counter clockwise. When activated, the EMS will display the message "GRAB" and
the direction selected "CW or CCW" to acknowledge activation of the button. The ECU1 will operate the correct direction
solenoid valve for as long as the joystick button is pressed.
If the optional low flow (priority) solenoid valve is fitted, the ECU1 will also energise this output if either of the grab outputs are
energised.

Note: For a tracked machine, when the travel pressure switch is selected, the low flow priority solenoid is de-energised.

For machines equipped with the low flow option, the operator can select (by the SET + MODE 5 s menu), the enabling of low
flow priority valve when the travel pressure switch is valid. By default the priority valve is disabled when the travel pressure
switch is valid. When the SET + MODE buttons are pressed for 5 seconds, until the service menu appears, the operator can
scroll to the message “LF + TRACK”, when the ACK button is pressed, the message “LF + TR OFF” appears. The system can
be switched on or off using the scroll arrow buttons followed by ACK. When switched on the low flow priority valve can be
energised when the travel pressure switch is valid. The status of this system is stored at ignition off so at ignition on the same
status will be restored. These EMS messages to be non translatable.

Grab CW Grab CCW Grab CW Grab CCW Low Flow EMS

Input Input Valve Output
I/p A-5 I/p A-15 O/p C-33 O/pC-34 O/p C-35 Display
OFF OFF OFF OFF OFF
ON OFF ON OFF ON GRAB CW
OFF ON OFF ON ON GRAB CCW
ON ON OFF OFF OFF

9803/6510 Issue 1
 5 - 68
GRAB CW GRAB CCW

9803/6510
Section C

Grab/rotate

ECU1 1
EARTH
HEADER 2 1 2 3 4 22
C30
C8 RH LEVER
ECU1-A

BU
UR

UR
BU
UW
BU
5
I/P30 GRAB CW

15 UW
I/P31 GRAB CCW

C137

B
C4 GRAB CW S.V.
C10 OPTIONS B 1 88
ECU1-C CONN

33 YU YU 2 YU YU 2
O/P18 GRAB CW
34 Y Y 3 Y
Electrics

O/P19 GRAB CCW

C138
35 YG YG 4 YG GRAB CCW S.V.
O/P20 PRIORITY V
Basic System Operation

B 1 88

Y 2

C139
PRIORITY S.V.
B 1
90

YG 2

A345850

Issue 1
5 - 68
Section C
Section C Electrics Section C
5 - 69 Basic System Operation 5 - 69

Hammer (Breaker)
Throttle Sol. Valve

ECU1

O/p 1 (C-21) Hammer

CAN
Data EMS

I/p 20 (A-11)
Breaker PSw

Operation

The hammer is operated by means of a foot pedal which gives a pilot pressure signal to the main valve. A pressure switch in
the pilot line senses the hammer operation. When the hammer pilot switch ECU1 I/p A 11) is grounded, the engine speed is
reduced to a level which is preset in set menu.

To acknowledge the request for hammer operation, the EMS will display the message "HAMMER" whilst the pressure switch is
on.

If the engine revolutions are greater than the pre-set hammer revolutions then the engine speed is automatically reduced to the
preset value. The throttle potentiometer has the ability to increase/decrease the engine revs up to but not exceeding the preset
hammer value, regardless of its maximum position. The maximum hammer revolutions can be set by the operator via the "Set"
menu on the EMS. The up and down buttons will increase/decrease the rev/min. value by 25 for a single press. What ever
value is set by the operator is stored and becomes the new default. The original default value for hammer revolutions is 1,200
rev/min.

9803/6510 Issue 1
 5 - 70

9803/6510
Section C

2 3 4 C160
OPT HYDRAULIC SWITCH

BO
WG

LGR
Hammer (Breaker)

ECU1 1

C8
ECU1- A C112 HAMMER PILOT SWITCH
11 LGR LGR 1
I/P 20 HAMMER 20
WU 2

EARTH HEADER 4
BO
Electrics
Electrical Schematics

C10 C2
ECU1- C CONN B C68 ENGINE CONTROL S.V.
21 R R A R R 1
O/P 1 THROTTLE CONTROL
B 2 39
B

A346150

Issue 1
5 - 70
Section C
 5 - 71

9803/6510
Section C

0 = HAMMER CIRCUIT
1 = AUXILIARY CIRCUIT
105

7 1 2 6 4 5

4
C25
20A
C160 2 3 4 7 +24V IGNITION
8
Hammer/Auxiliary Combined

OPT
HYDRAULICS

BO
RG

WU
SWITCH

LGR
ECU1 1

C8
C112
ECU1- A HAMMER PILOT SWITCH

1 20
11 LGR LGR
I/P 20 HAMMER
WU 2
Electrics

EARTH HEADER 4

BO 1
Basic System Operation

C10 C2 C68
ECU1- C CONN B ENGINE CONTROL S.V.

21 R R A R R 1
O/P 1 THROTTLE CONTROL

B 2 39
B

A406910

Issue 1
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Section C
 5 - 72

9803/6510
0 = MERGED CIRCUIT
1 = AUXILIARY CIRCUIT
2 = HAMMER CIRCUIT
Section C

10 9 14 3 11 13 16 6 12 15 106

20A
8 +24V IGNITION
2 3 4 5 7

ECU1

BO
GB
RG

WU
1 C160

LGR
OPT
HYDRAULICS
C8
C112
SWITCH
ECU1- A HAMMER PILOT SWITCH
Hammer/Auxiliary Combined and Merged

20
11 LGR LGR 1
I/P 20 HAMMER
WU 2
Electrics

EARTH HEADER 4

BO 1 B
Basic System Operation

C10 89
ECU1- C B C165
MERGED PUMPS S.V.
21 R C1
O/P 1 THROTTLE CONTROL
CONN A B 2

GB 18 GB GB 1

C2 C68
CONN B ENGINE CONTROL S.V.
39
R A R R 1

B 2

B
A460920

Issue 1
5 - 72
Section C
Section C Electrics Section C
5 - 73 Basic System Operation 5 - 73

Scrap Magnet Option

Throttle Sol. ECU1

Valve O/p C-21 Scrap Mag?

EMS
CAN
Data
ACK

When a scrap handling magnet attachment is fitted to the machine, the high voltage required for its operation is supplied by an
engine driven generator. If the minimum engine rev/min. is too low, the supply voltage to the magnet may decrease to the point
where any material on the magnet may drop off. To prevent this the machine has the capability to set the minimum engine
speed so that it doesn't fall below a predetermined level whilst the scrap magnet is being used.

The feature can be switched on or off and the minimum rev/min. set via the SET menu of the EMS by the "SCRAP MAG"
option. When this feature is enabled the throttle volume potentiometer is re-scaled so that in the minimum position the engine
rev/min. is that pre-set through the following procedure.

To set the minimum engine rev/min. for scrap magnet use

Press the 'SET' button on the EMS for 5 seconds then use the scroll buttons until 'SCRAP MAG' is displayed.
Press the 'ACK' button. (This will alternate the function On/Off. Set the display to 'ON' display will change between 'MAG ON'
and 'MAG OFF').

Press the 'ACK' button, display will change to 'RPM 1000'. Pressing the scroll buttons will then change the rev/min. value in
50 rev/min. increments (allowable range to be the low idle setting to S mode full engine speed setting for the particular model).
The default setting for the minimum engine speed is 1000 rev/min.

The RPM setting of this feature is stored and is used each time the machine is used whilst the scrap magnet function is
enabled. The scrap magnet option is switched off through the EMS SET menu.

If a target value less than the machines idle rpm is selected, then the machine will default to the original Idle setting.

9803/6510 Issue 1
Section C Electrics Section C
5 - 74 Basic System Operation 5 - 74

Cab Interior Lamp

Light switch
(momentary)
ECU 1
+24v
I/p 7 (A-30)

Cab interior
lamo 10W O/p 2 (C-11)

+24v ign
A406960

Operation

A switch near the cab door can be pressed to switch on the cab interior light for access to the machine in the dark. The input
(I/p 7) activate’s the ECU1 when the ignition is switched off. When the light switch is pressed the cab light will be switched on
for 5 minutes or until a second press of the light switch within the 5 minute period.

The cab interior light has an integral override switch to switch on the lamp independently of the ECU1.

9803/6510 Issue 1
 5 - 75

9803/6510
Section C

CAB INTERIOR
LAMP SWITCH
Cab Interior Lamp

4
C5
10 10A + 24V
1 BATTERY
3 2 C222
C6
9 20A +24V
C8
IGN
ECU1-A

I/P 7 CAB RW
INTERIOR LAMP

CAB INTERIOR
26 LAMP
C37
G
Electrics

RG
C10
B
Basic System Operation

ECU1-C
O/P 2 CAB
INTERIOR LAMP G

401700A

Issue 1
5 - 75
Section C
Section C Electrics Section C
5 - 76 Basic System Operation 5 - 76

Refueling Pump

A406940
42
C83

G
CONN B
C2

V G
20A
7
4

+24V IGNITION

9803/6510 Issue 1
 5 - 77

9803/6510
8
TOR AIR CONDITIONER
AIR CON
C89
Section C

WATER BINARY SW
THERMO RECIRC VALVE BATTERY CLUTCH G 1
STAT ACTUATOR ACTUATOR RELAY RELAY
C1 O 2
Air Conditioning

CONNA
G 32 C90
W 33 W AIR CON
C21 COMPRESSOR
O 34
1 0.5 G
2 0.5 O
3 0.5 W
4 0.5 GW
5 0.5 U
6 0.5 YR
7 0.5 UW C6
20A
8 0.5 UG UG FUSE No 6 +24V
9 0.5 UO IGN
10 0.5 BU
11 5A
P FUSE No 4 +24V
12 IGN
Electrics

U
YR

UO
UW
GW
M
C225 1 2 3 4 5
BLOWER
MOT OR U
Basic System Operation

YR

UO
UW
GW

CONTROLLER 1 4
C180
P
B

10 B
1
UO
2
P
3
UW
4
5
AIR CONDITIONER 6
YR
CONTROL PANEL 7
U
8
GW
9
10
11
12 399850
C18

Issue 1
5 - 77
Section C
Section C Electrics Section C
5 - 78 Basic System Operation 5 - 78

Heated Seat

401710
60
59

9803/6510 Issue 1
Section C Electrics Section C
5 - 79 Functional Description 5 - 79

24 to 12 Volt Converter, Radio and Cigar

Lighter
24 to 12 Volt Converter.
The machine is fitted with a voltage converter, which
provides power to the radio and cigar lighter / mobile phone
charger.

The dropper is situated at the side of the cab heater

assembly.

The converter is fed by a permanent battery supply via fuse

No9 to pin 1 of the converter and a switched feed via fuse
No8 to pin 2 of the converter. Both these incoming feeds are
24-volt.

The voltage is then reduced and gives out a permanent 12-

volt feed on pin 4 and a switched 12-volt supply on pin 5.

Pin 3 is the earth wire for the unit.

Radio
The radio has a permanent 12-volt supply from pin 4 of the
voltage converter to pin 5 of the radio. The permanent
supply is to retain the memory in the radio.

The 12-volt switched supply to power the radio is fed from

pin 5 of the voltage converter to pin 2 of the radio via a
rocker switch (Mute button) in the right hand console of the
cab. Operating the mute button simply turns off the power
supply to the radio.

Cigar lighter
The cigar lighter/phone charger, is fed from the switched
feed only.

9803/6510 Issue 1
 4
5 - 80
14

9803/6510
RADIO 20A C6
8 +24
Section C

IGN

GND
10A C5

BATTERY
IGNITION
9
and Cigar Lighter

+24
C39 6 5 4 3 2 1 Battery

Voltage
CAB HARNESS C224 Converter

C37 9 8 7 LG
24 to 12 Volt Converter, Radio

1 + 24V Battery

R
RY
RG
2 + 24V Ignition
B
3 GND
C159
Y R
4 + 12V Memory
C225 Y
C40 5 +12V Switched
Y 6
B
6 GND
RY 7
B

C41
Electrics

C180
Basic System Operation

B 4 B

RADIO MUTE SWITCH 58

C225 8

Y
Y

B
RY
A407030

Issue 1
5 - 80
Section C
Section C Electrics Section C
5 - 81 Basic System Operation 5 - 81

Service Required Warning

ECU1

Service Required
CAN
Data
JCB
Service
Tool Set Mode

ACK

Operation

The Service Required warning LED in the EMS will illuminate (no buzzer) when the next service is due, according to the
service schedule. The total elapsed time will be decided by the recorded hours on the hour meter.

At the 250 hour service intervals (marked †) the LED will flash until the ACK button is pressed on the EMS and then will
extinguish as a once only event. This is a reminder of a minor service only.

At the major (500 hour) service intervals, the LED will flash 20 hours before the preset 500 hour time has been reached. It will
illuminate continuously 20 hours after the 500 hour pre-set time has been reached since the previous service and can only be
re-set by one of the two methods as detailed below. If it reaches this point an error is written to the error log indicating that the
service has been missed.

The service warning can be cancelled in one of two ways :

a Through the JCB approved service tool.

b Through the EMS Set + Mode (20 sec) menu -

Warnings will be given at the following intervals:

1 † 250 hours 150 hours after 1st service actual hours

2 500 hours 250 hours after previous service actual hours
3 † 750 hours 250 hours after previous service actual hours
4 1000 hours 250 hours after previous service actual hours
5 † 1250 hours (250 hours after previous service actual hours
6 Every subsequent 250 hours after previous service actual hours

9803/6510 Issue 1
Section C Electrics Section C
5 - 82 Basic System Operation 5 - 82

Service Required Warning (cont’d)

Cancellation of the Service indicator.

JCB Service personnel will be able to cancel the main service indicator by entering the dealer code from the SET+ Mode menu
structure.

When the Service sub menu is reached and entered the dealer will be prompted to enter a four digit code by the use of the
"Up/Down" keys and the "ack" button. The required digit will flash until the ACK button is pressed, after which the next digit
will flash until all of the digits have been entered. Once the code is entered and the set button pressed the service warning is
cancelled and the code saved in memory. The saved data will be updated at the next service interval by the newly entered
dealer code.

Note: The dealer entered code can be accessed only by Factory service engineers with the service tool software.

SET + MODE SERVICE OFF ACK 0000

(20 seconds)

Press "Up/Down" to select digit

"ACK" to accept selection
Return to SET + Mode menu. & move to next digit

Repeat above until all five digits entered

Eg. 1 2 3 4

Press "Set" to enter and save code

Reset service warning & extinguish warning lamp.

9803/6510 Issue 1
Section C Electrics Section C
5 - 83 Basic System Operation 5 - 83

EMS Set Menu.

When the set button on the EMS is pressed a sub menu structure appears, enabling the operator to customise the machine
operations and confirm the local time/date. The following functions are available: The up/down arrows scroll through the menu
and the item is selected by pressing the "Ack" button. Pressing "set" at any time will return the operator to the normal display.

Clock : 12/24? 24 Clock format the arrow keys select 12/24 hour format. "Ack" to accept format then
the current time is displayed.

XX:XX Use the scroll keys to set the current time. "Ack" to accept value.

Hammer Hrs: XXXXX - - XXXX The total hours that the hammer pressure switch has been activated is displayed on
the left of the display (Up to 99,999 Max.) and the digits on the right which flashing
represent the hours accumulated since the last hammer service (up to 9,999 max.)
The four flashing digits can be reset by pressing the "Ack" button.
This Item will only be displayed if previously selected in set up tool

Reset Hrs? A further press of the "Ack" button will set the hours since service to
zero.

Auto Idle T: 5 Auto idle delay time. Scroll keys increase/decrease the delay time. "Ack" to accept
new delay time.

Language : Language can be changed between one and up to four preloaded languages, the
languages are installed at machine set up.

Int. Wiper S; Wiper SPD-1 Intermittent wiper speed. Scroll keys to increase/decrease the delay between
strokes time. "Ack" to accept new value.

Hammer Rpm: RPM XXXX The maximum hammer revs allowed. Use the scroll keys to set the desired rpm.
Increments/decrements in 50 rev/min. "Ack" to accept the new value.

Date: XX-XX-XXXX The current date. Use the scroll keys to increase the value. "Ack" to move to the
month section. Repeat until the year is entered "Ack" to return to menu.

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Section C Electrics Section C
5 - 84 Basic System Operation 5 - 84

EMS Set + Mode (5 Sec) Menu.

When the set and mode buttons on the EMS are pressed for 5 seconds a sub menu structure appears, enabling the operator
to view more detailed data on the machine and to set option configurations. The following functions are available:

The up / down arrows scrolls through the menu and the item is selected by pressing the "Ack" button. Pressing "set" at any
time will return the operator to the normal display.

Model : JXXXXX Displays the model type.

Serial No: XXXX Displays the serial number.
Sftware ver: Displays the software version.
Hrdware ver: Displays the hardware version
Pilot SW: XXXXX 0ff/On Displays the status of the pressure switches. Use the scroll keys to go through the
following switches, the current status will be displayed:
Boom ↓ Boom Down pressure switch status
Boom ↑ Boom Raise Pressure switch status
Hammer Hammer Pressure switch status
Slew Slew Pressure switch status
Travel Travel Pressure switch status
Upper Upper Pressure switch status
Boost Boost Pressure switch status
A-mode Auto mode Pressure switch status

Sense Pot : XX Displays the throttle lever feed back pot value in Ohms.
Throttle Pot: XX Displays the throttle volume dial value in Ohms
Sense Volts: XX Displays the sensor circuit voltage in volts.
AltVolts: XX Displays the alternator output voltage in volts.
Bat Volts: XX Displays the battery voltage in volts.
Fuel Level: XX Displays the fuel level sensor value in Ohms
Water Temp: XXX Displays the current engine coolant temperature in 0C
HYD Temp: XXX Displays the current hydraulic oil temperature in 0C
Throttl PWM: XXX Displays the current duty cycle of the throttle solenoid valve in %
PUMP AMPS: XXX Displays the current duty cycle of the pump control solenoid in %
RPM Value: XXXX Displays the current value of the engine speed in RPM.
Q/H enable? Up or down arrows enable/ disable function. "Ack" enters a configuration menu.
Q/H Type ? Up or down arrows change between type 1 or type 2. "Ack" to accept selection and return

LF + Track? Enables low flow priority valve to operate when tracking. "Ack" enters the configuration menu.
LF+TR OFF Up or down arrow keys change between ON and OFF. "Ack" to accept selection
and return.

Scrap Magnet The current status of the scrap magnet function is displayed. The up arrows changes the
status to “On” and the down arrows change it to “Off”. If “ack” is pressed the display shows
the scrap magnet rev/min. (see Scrap magnet Option in Basic System Operation)

Electrical Fault ACK, then scroll though current electrical error codes

9803/6510 Issue 1
Section C Electrics Section C
5 - 85 Basic System Operation 5 - 85

EMS Set+Mode (20 sec) Menu.

When the set and mode buttons on the EMS are pressed together for 20 seconds a sub menu structure appears, enabling
JCB trained personnel to cancel the intermediate service warning, calibrate the throttle and override the engine speed sensor
input to energise solenoids for testing purposes. The up/down arrows scrolls through the menu and the item is selected by
pressing the "Ack" button. Pressing "set" at any time will return the operator to the normal display.

Service off.
The intermediate service warning can be cancelled by entering this menu. To enter this menu the following procedure must be
followed:

Press and hold the "Set" and "Mode" buttons on the EMS together for 20 seconds, until the "Service off" is displayed.

Press the "Ack" button. You are now in the "service off" routine and four zeros will appear in the display and you will be
prompted to enter the JCB dealer code.

"0"000 Will be displayed and the left hand digit will be flashing. The up and down arrows are used to select the digit
value and "Ack" to enter/accept the value and move to the next digit. When all digits are entered the final press of "Ack'
followed by a press of the “Set” button will extinguish the service indicator and record the service event. (hours, time and
dealer code to the service history file).
Note: Information stored in the service history is available via the JCB Diagnostic tool.

Throttle calibration.
Throttle calibration is obtained via the Set + Mode (20 sec) menu on the EMS. The throttle calibration should be performed on
every new machine, when the throttle linkage parts are replaced or when the "No throttle" warning appears on the EMS.
To enter throttle calibration the following procedure must be followed:

The engine must be started, and warmed up to normal operating temperatures.

Press and hold the "Set" and "Mode" buttons on the EMS simultaneously for 20 seconds, until the "Service off" message
is displayed.

Use the scroll arrows until the "Calibrate" message is displayed.

Press the "Ack" button. You are now in the throttle calibration routine and the message "lower Limit" will appear in the
display.

Rotate the throttle volume dial to the minimum position.

Press "Ack". The "Upper Limit" message will then be displayed.

Rotate the throttle volume dial to the maximum position.

Press "Ack". The message "Working" will then be displayed and the engine will accelerate to maximum speed and slowly
reduce to idle speed. (This will take approximately 3 minutes).

When complete the engine will return to maximum revs and throttle control will be restored to the throttle volume dial. The
EMS will revert to the normal display.

Note: If the engine is stopped during the calibration, the "recalibrate" message is displayed and the procedure has to be
restarted. If the throttle volume dial minimum and maximum values are the same, or the wrong way round, then "recalibrate"
is also displayed.

9803/6510 Issue 1
Section C Electrics Section C
5 - 86 Basic System Operation 5 - 86

EMS Set+Mode (20 sec) Menu (cont’d)

Solenoid Override. Machine Controlled functions.
When the ignition is energised and the engine is not running, which the ECU can detect by either of the following inputs:
Engine Oil Pressure and/or engine speed sensor input. Then the following functions are allowed:

a Wiper
b Washer
c Horn
d Indicators
e Headlamp Flash
f Work lamps (Buzzer will sound but can be cancelled by "ACK")
g Side lights (Buzzer will sound but can be cancelled by "ACK".)
h Headlights (Buzzer will sound but can be cancelled by "ACK".)
i Beacon (Buzzer will sound but can be cancelled by "ACK".)

With the ignition on but the engine not started all solenoids with the exception of the Esos solenoids are de energised to
reduce battery drain and to reduce engine load whilst cranking.

For maintenance purposes an override facility is incorporated to safely operate the solenoid outputs whilst the engine is not
operating. This feature, once enabled, is automatically cancelled by switching the ignition off and then back on. To enter the
override facility the following procedure must be followed:

Press and hold the "Set" and "Mode" buttons on the EMS simultaneously for 20 seconds, until the "Service off" message
is displayed.

Use the scroll arrows until the "Over-ride?" message is displayed.

Press the "Ack" button. You are now in the solenoid over-ride function. This is confirmed by the message "Over-ride" and
internal buzzer will sound. The solenoids can now be operated as though the engine was running.

Horse Power Control Data Logging Facility

When selected this function will log information on engine speed, pump milliamps and mode over a selectable period up to 15
mins and display the data as a graph.

Press and hold the "Set" and "Mode" buttons on the EMS simultaneously for 20 seconds, until the "Service off" message
is displayed.

Use the scroll arrows until the "HRSEPWR MON" message is displayed.

Press the "Ack" button. You are now in the datalog function. This is confirmed by the message "MINUTES 1".

The time period for logging can now be adjusted from 1 to 15 minutes using the arrow keys.

Press 'ACK' to start recording , the EMS will display "RUNNING" When complete the display will return to normal.

The results of this test are then viewed through the Service Master, Data logging application using a laptop.

Kerosene Mode

Scroll to KEROSENE M
Press ACK.
Use the scroll buttons to turn either on and off.
Press ACK.

9803/6510 Issue 1
Section C Electrics Section C
9-1 JCB Service Master 9-1

JCB Service Master

Service Master is a gateway application allowing a large
number of Vehicle Support Applications to be linked using
one familiar interface. The interface acts as a graphical tool
for selecting the target vehicle from a database of Vehicle
Families and triggering the particular Service Tool Application
desired. This removes the need for a user to 'remember'
every individual service tool available and select which one is
intended for a particular machine.

The Service Master also provides several key features that

will accompany all JCB projects, a Multi Language editing
tool that provides a means of individual text string translation
for all JCB applicationsand the means to select a localised
language translation for each JCB application.

The contents of this document aim to explain to you, the

User, how to operate this application and to make most of its
functionality.

1 Using Service Master

The Service Master Application consists of a database of

records relating Vehicle Product Ranges and Service Tool
Applications. At most, any one product range has one
application for each of the Service Tool modules. In the image
adjacent, we see two JCB Product Ranges depicted,
currently the selected vehicle range is the 'Heavy Products'
range of excavators. The application buttons (or icons) visible
below the vehicle images are gateways to the individual
Service Tool Applications. The user need only to decide
which type of tool is required for the task at hand, click the
respective icon and the service tool will be opened.

Product Range Selectors Use the two arrow icons to

toggle through the database list
of 'Product Ranges supported by
Service Master.

Application Buttons These buttons access the

underlying service tool applications
available for the selected Product
Range

System Menus Functions are accessed by

clicking the right mouse button
anywhere on the main form.

2 Selecting Service Tool Applications

Service Tool Applications are selected by firstly locating and

selecting from the list of Product Ranges the range which
contains the vehicle that is to be worked on. The Service Tool
Applications which are available to the Product Range
selected are made accessible by clicking on one of the icons
that will be displayed on the lower portion of the main screen.

Only those applications which are supported by the CFE will

have a visible icon. As and when new applications are made
available by software vendors they can be included into the
product range by updating the Product Range database.

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Section C Electrics Section C
9-2 JCB Service Master 9-2

Vehicle Setup Operating Parameter settings, Option/Attachment control,

Alternative Language Support, Model/Serial Number Identification.

Data Logging Running Data Collection, Operating Data, Statistics, Device Error
Log Recording.

Service History Service/Engine Hour records, Service Dealership Codes.

Module Programming ECU Reprogramming and Software update/Revision capability.

Diagnostics ECU I/O (input and output) testing and diagnostics.

Technical Data Short cut to Technical data spread sheet for machine performance
and setting. CD3 needs to be installed.

JS Fault Finding Guide Short cut to JS fault finding guide. Fault finding guide on CD3 will
need to be installed.

Error Log Reset Tool Shortcut to reset. Double click the icon to access the reset screen.
Click on the send button to reset all error logs.

3 System Menus

System menu functions are accessed by pressing the right

mouse button anywhere on the main Service Master form.

Manage Applications Opens the Configure Applications

form which allows the User to add,
delete, update information relating to
the applications supported by
Product Ranges.

Multi Lingual Support Opens a text editing tool used to

control Application Text strings
which can be translated into almost
any WINDOWS supported language.

DLA Programmer Opens an application for the

reprogramming of the DLA module.

Properties Used to define various options and

settings used by the Service Master
Application.

About Box Shows software version, date,

developers information etc.

9803/6510 Issue 1
Section C Electrics Section C
9-3 JCB Service Master 9-3

HPSetup Overview
HPSetup is part of a suite of software modules designed for
the Advanced Management System (AMS) The task of
HPSetup is to ensure that the vehicle can be configured out
in the field or as it leaves the production line as per customer
requirements. It includes the ability to set various vehicle
attachment options for differing vehicle functions/design and
the programming of Alternative Languages into the EMS so
the operator can view information in his/her native tongue.

Features

Vehicle Profile Read and Write functionality, offering the

ability to modify the vehicles fitted options.

Data Link Adaptor (DLA) utilising the J1939 CAN Bus

Standard Interface.

Application Multi Language Support, options provided to

allow the PC application to operate in many different
languages. Note this is not the same as Alternative
Languages used in the EMS module. In this instance we
refer to the PC applications switching from a standard
English test to another language of choice.

Using HPSetup
In order to operate this software correctly it must have been
installed using the JCB Service Master Installation disk to
ensure the correct files, databases and resources have been
initialise.

1 Connecting to the vehicle

2 Starting HPSetup

3 Setting up a Vehicle Profile

4 Reading current Vehicle Profile

5 Options

6 Closing

7 Options

9803/6510 Issue 1
Section C Electrics Section C
9-4 JCB Service Master 9-4

1 Connecting the Data Link Adaptor (DLA)

The DLA supplied to JCB and related Dealerships is the only

tool required to connect to the vehicles onboard CAN data B
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network.

You will require a PC with Windows 95 and all JCB

applications installed and a free Parallel port or serial port

Connect the DLA to the Parallel Port fitted to your

computer using the 25 way cable supplied with the DLA.
A cable is supplied with the DLA and is specifically meant
for this application only.

Attach the second cable in between the DLA and the on

vehicle service connector, located in this diagram.

Power up the vehicle (optional, the power may be

permanent).

Ensure that the power on LED is illuminated.

A406130

2 Starting HPSetup

To open the HPSetup Application:

1 Boot PC into WINDOWS

2 Start the JCB Service Master CFE

3 Select the Heavy Products Range of Excavators

4 Click the icon to open the HPSetup application

The HPSetup tool when opened takes several seconds to

open because it must search the vehicle network and detect
the presence of each ECU attached and identify them by
means of analysis of the vehicles NAME field. As soon as
network analysis is complete then the main form will come
into view.

There are also many error checks made with respect to the
operation of the DLA, should any issues with DLA errors be
encountered you will need to read DLA Trouble Shooting.

HPSetup should now be ready for use. To verify the current

state of the DLA and network connections check each ECU
module Tab (ECU1, EMS, and ECW). The 'state' field should
indicate that the node is online and the CAN Name fields
contain what looks like valid settings. As long as the boxes
are not blank take it for granted that the information is
correct, it is not intended to give a detailed explanation of
Note: ECU1 and EMS nodes are fitted to every Heavy
each data item. This diagram below show the actual settings
Product machine.
read from a test vehicle.

9803/6510 Issue 1
Section C Electrics Section C
9-5 JCB Service Master 9-5

3 Setting Up A Vehicle Profile

The Vehicle Profile (VP) information sent to the machine
requires the user to select the following data fields,
Model Number Drop down list of currently
supported machines from which
the User is to select one particular
value. This selection in turn
controls the number and type of
options available (and some default
settings which cannot be changed)
for that particular model.
Serial Number Must be completed before the VP
can be written to the vehicle.
Build Date Date the machine was first
programmed.
Alternative Languages Predefined display text used on
EMS.
Models Options List of fitted Options on vehicle, as
required to complete customer
requirements. (see guidelines)
The Options installed on the vehicle may then be selected
using the check boxes (being checked defines the Option as
'Installed'). The "Custom Options" checkbox allows the User
to configure the options outside of the normal guidleines for
what devices are implemented on particular machines. In
general Wheeled and Tracked machines have several distinct
Options avaliable that are not always available on the other.
The Custom Options allows these to be overwritten on
demand, use of this option should only be made under
instruction from JCB Heavy Products Engineering.
Build date is once programmable only, on leaving the
production line (actual build) further writes will be ignored.
After setting up the VP, the user must now select the
Alternative Languages files which are to be sent to the EMS
module for storage. The EMS is able to select an alternative
operating language apart from English (the default language
in all JCB machines).
Click the left mouse button on the Languages Tabsheet. Use
the Country drop down list box to display the list of
Alternative Languages supported by HPSetup. The text boxes
below the Country list box display up to three alternative
languages that will be stored into the EMS. See Cross
Reference Table (C 6-9).
An option has been provided to program the languages
independently of programming the complete vehicle VP, this
way it is somewhat simpler to update language text when
moving the vehicle from one location to another.
The VP is now ready to be written. Select the DLA tabsheet.
Click on the Write button (or F12) to have the current VP
written to the machine. The diagnostics messages received
during read and write operations are displayed in the canvas
area provided. Verifying the write can be done by clicking the
Read button (F11). This reads the data back from the ECU1
(it does not however read the contents of the Alternative
Language tables). Check the values read back against your
original settings.

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Section C Electrics Section C
9-6 JCB Service Master 9-6

4 Writing Vehicle Profile <F12>

The User can program the vehicle connected using the Write
button at any time (or pressing F12 key). Several
programming checks are made to ensure all required values
are made (Model Type, Languages etc.) to ensure the data
written will not make any invalid conditions in the vehicle
system.

The Write button is disabled if the network connection is not

available, try the Connect button first if this is the case.

5 Reading Vehicle Profile <F11>

On occasion it may be necessary for the VP to be read back

from ECU1 to check settings or preload current settings
ready for updating because of new options being fitted to the
vehicle.

Connect vehicle to the PC via the DLA, power up the

vehicle and then run HPSetup.

From the main screen select DLA tabsheet and click the
Read button.

Monitor the progress of the read transaction in the status

window. When the PGN has been read from ECU1 the
data is stored back into the data entry boxes on the
Vehicle Setup and Languages tabsheets.

Note: It is not possible to extract the contents of the EMS

Language tables from the EMS.

6 Closing HPSetup

Closing HPSetup is performed using normal WINDOWS

based methods of menu selection and/or the clicking of the
'close' icon in the upper right corner of the window title bar.

7 Options - Multi Language Support

Use the Drop down list box to select the Language of the
country the visual text for the PC Application (HPSetup)
needs to be translated. This function allows HPSetup to be
operated by Users from many countries, thus reducing the
need to make many customised SetUp Service Tool
applications.

Any language files supplied as part of the HPSetup tool will

be automatically detected by the software and displayed in
the selection box. Representations are made by National Flag
and some text identifying (region or dialect) belonging to the
country selected. Typically this allows several regional
dialects of any single country to be selected.

As soon as a new Flag is selected all WINDOWS based text is

translated using the translation text files.

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Section C Electrics Section C
9-7 JCB Service Master 9-7

Guidelines for Setting up a Vehicle using the Set up Tool.

Select the options according to the following guidelines:

Travel Alarm: For all USA tracked machines or machines fitted with the option travel alarm.
Overload Caution: For all machines with Hose Burst Check Valves (HBCV) option.
Quick Hitch: Machines equiped with quick hitch option.
Lower Wiper: For all machines equiped with lower wiper option.
Grab Rotate: For wheeled machines with low flow pipework without priority valve.
Weed Cutter A/Bucket: For wheeled machines with low flow pipework with priority valve.
Low Flow: For tracked machines with low flow pipework (any spec).
Stabilisers: For all wheeled machines equiped with stabilisers.
Add. Work Lamps: Machines equiped with additional cab and counterweight lamps (including JS130HD).
Full Flow Lines: For all machines equiped with full flow pipework (breaker, auxiliary, combined or merged pump
circuits).
Boom priority: For machine equiped with boom priority option (future option).
Custom Options: This allows all above options to be specified for any machine.
This to be used for sales specials only.

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Section C Electrics Section C
9-8 JCB Service Master 9-8

Alternative Language Cross Reference

Language tables programmed into the EMS module are

selected using the following table. Predefined languages are
automatically loaded when the User selects the destination
Territory (Country). Up to three languages may be stored in
the EMS modules, each of which is Operator selectable using
EMS Menu functions.

Portuguese
Norwegian

Hungarian
Icelandic

Swedish

Croatain
Spanish
German
Flemish
English

Finnish

French
Danish
Czech

Polish
Dutch

Italian
Territory
Africa ! "

Austria ! "

Belgium ! " " "

Bosnia/Croatia ! " " "

Canada ! "

Czech Rep. ! " "

Denmark ! "

East Europe ! "

Finland ! "

France ! "

Germany ! "

Greece ! "

Iceland ! "

Ireland !

Israel ! "

Italy ! "

Latin America ! " "

Luxemburg ! "

Netherlands ! "

Norway ! "

Poland ! "

Portugal ! "

Russia ! "

Spain ! "

Sweden ! "

Switzerland ! " " "

Turkey ! "

UK !

USA ! "

Hungarian ! " " "

! Default language
" Alternative language

9803/6510 Issue 1
Section C Electrics Section C
9-9 JCB Service Master 9-9

Data Link Adaptor

The DLA is a universal device for connecting several data
communications mediums to the PC via a single piece of
hardware. HPSetup uses the J1939 CAN Specification for on
vehicle network and communications. Being one of the
cheapest methods to connect the PC to the vehicle bus the B
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DLA has proven its ability in applications such as Diagnostics,

Data Logging and Vehicle setup procedure tools like
HPSetup.
Power for the DLA is taken from the vehicle power supply via
the 15 way connector so it requires no internal source of
power and is self regulating up to +40V, giving great
protection and versatility because it can be connected to
most forms of automotive machinery operating between 5
and 40V DC.
Once connected to the PC the DLA is auto detected and
initialised by software eliminating any need for the user to
determine port settings, data transfer rates.

DLA Trouble Shooting

Failure of the software to initialise the DLA will prevent any
read/write operations. This section will help debug the error
and get the DLA working. Follow this list of checks to perform A406130
to help diagnose the problem.
1 Cables, ensure that the correct cables are used between
the PC/DLA/On-Vehicle connector.
2 Inspect cables for possible damage, replace if necessary.
3 Check that good firm connections have been made
between all devices.
4 Power up the vehicle and make sure the power LED on
the DLA is ON, if the LED is not illuminated there may be
a problem with the power supplied to the unit or the DLA
regulator system is not working. To check the power to
the DLA unplug the DLA from the vehicle, use a digital
multi-meter to check the voltage between pins 6 and 8.
There should be a minimum of 12 V DC (or IGNITION
Voltage, see vehicle specifications) between these two
pins. Suspect the vehicle power supply if there is not,
else the DLA should be replaced because of a problem
with it's internal circuitry.
5 With the Vehicle power ON, start HPSetup application
and visually observe the CAN activity LED and note the
error message displayed by the PC. If the LED does not
flash off/ON several times after it has been initialised by
the PC then there is probably a hardware problem with
the DLA. Replace the DLA. Error messages displayed by
the DLA driver software often indicates the origin of the
problem. It may help to power down the vehicle, wait a
few seconds and then retry establishing connection.

9803/6510 Issue 1
Section C Electrics Section C
9 - 10 JCB Service Master 9 - 10

HPDataLogs
HPDataLogs is an application designed to extract, compile
and present operating data taken from a JS Excavators
operating the Advanced Management System. The
application software connects a PC to the On-Vehicle
network via the DLA (Data Link Adapter) and provides a
simple means of requesting data from the network nodes
(ECU1, EMS and/or ECW1).

Data collected includes operating hours for particular vehicle

functions, hydraulic and coolant statistics. A secondary
function on the application is to download additional
information taken from 'run time' logging, here the Operator
places AMS into a mode to collect running information for 15
minutes at a time. The application allows this data to be
downloaded, displayed and printed.

Using HPDataLogs

Starting HPDatalogs

1 Connect DLA to vehicle On-Board Service connector

and to the Personal Computer that will run the
HPDataLogs application.

2 Open JCB Service Master

3 Select the Heavy Products Range of Excavators

4 Click the icon

5 The main HP Data Logging screen will open as shown

below.

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Section C Electrics Section C
9 - 11 JCB Service Master 9 - 11

User Functions

Allows the Operator to print the current selected Data

Logs

Allows the Operator to read the current Data logs from the
vehicle. After downloading AMS automatically clears old
records ready for next vehicle use. F11 is the shortcut key to
this function.

Running Data recorded during the operation of the vehicle

can be view, downloaded, printed using this feature.

Allows the Operator to close the application.

Change the language used for written text in the application

and return to the Service Master CFE.

View On-Vehicle network node status.

View help file.

View About box and application information.

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Section C Electrics Section C
9 - 12 JCB Service Master 9 - 12

Database Selection Criteria

Recordsets belonging to vehicle Data logs, past and present

can be selected using the following controls.

Allows the operator to select from the database the list of

records belonging to a specific vehicle using it's Serial
Number as the index field. Set this field first.

Data logs belonging to the selected Vehicle Serial Number

are further filtered by selecting the date on which the logs
were downloaded.

Tab Box Options

The TAB fields to select the Data Log information which you
wish to view.

Working Hours Shows accumulated operating hours for vehicle functions.

Engine Coolant Shows accumulated operating hours in several temperature ranges and data logs of critical
events.

Hydraulic Oil Shows accumulated operating hours in several temperature ranges and data logs of critical
events.

Error Logs View list of Error Logs reported during the selected period.

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Section C Electrics Section C
9 - 13 JCB Service Master 9 - 13

Working Hours
Details actual vehicle working hours accumulated for various
operating conditions.

Engine Coolant
Details Engine Coolant operating conditions and accumulated
operating hours within defined temperature ranges.

Date Date of the event.

Duration Time in minutes of the event.

Machine Hours Actual Engine Hours at which the event took

place.

Hydraulic Oil

Details Hydraulic Oil operating conditions since last service

and accumulated operating hours within defined temperature
ranges.

Date Date of the event.

Duration Time in minutes of the event.

Machine Hours Actual Engine Hours at which the event took

place.

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Section C Electrics Section C
9 - 14 JCB Service Master 9 - 14

Error Logs
Various error events are recorded and saved as logs for
future analysis by Service and Engineering personnel. Any
Error Logs detected and uploaded from the vehicle can be
displayed in the Error Log Tabsheet.

Error Type Details the type of error event logged.

Engine Hours Engine Hours at the time the error event

occurred.

Duration (min) Time in minutes of the error event. May be

blank or zero depending on the type of
error, some events do not require a duration
parameter.

Output Number Identifies the hardware Output using the

system/schematic circuit ID.

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Section C Electrics Section C
9 - 15 JCB Service Master 9 - 15

HP Control Monitoring

Horse Power Control Monitoring is used to record operating

conditions during the 15 minutes prior to the recording being
stopped by the vehicle operator. The graph displays the
Pump PWM and RPM against time.

The Running Data Logs are retained until the next time the
User requests Running Data to be recorded.

Downloading the Running Data

1 Select and open the Running Data form from the HPDLog
applications main menu bar.

2 Using the menu options on the Running Data form now

open, select the Read function, alternatively use the F11
key.

Exporting Data
The Running Data form may be exported to a string delimited
text file for importing into another Windows based
application.

Printing Reports
The Running Data form can be printed out as a document
suitable for distribution or fax purposes.

User Input
Zoom: The operator can use the left mouse button to drag on
an area of the graph, this are will be zoomed in when the left
button is released. To do this the User places the mouse
pointer to the upper left part of the area of the graphic which
is to be zoomed in, press and hold down the left mouse
button and drag the cursor over the area to be highlighted.
Keep dragging the mouse until you reach the bottom right of
the target area and release the left mouse button. The
selected are will then be zoomed into.

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9 - 16 JCB Service Master 9 - 16

Service History

The Service History tool is an application designed to retrieve

and display Service History records stored by AMS. Simple
functionality makes the tool ideal for quick referencing of
stored data, additionally Import, Export and Printing facilities
make information exchange between Service and JCB
Service Departments very easy.

Several forms of Service History events are recorded by the

EMS module,

Scheduled Service Events Where at pre defined intervals the Service LED on the EMS display is triggered and the
Service indicator is ACK'ed by the Operator. These events are generally for must do
service operations as specified in the service manual.

Unscheduled Service Events Are those events that may develop due to changes to the specification of the machine or
the repair of some system function, system or component. These unscheduled events are
'added' to the EMS list of Service History events by the Service Engineer responsible for
the service.

This application is responsible for reading, writing, printing,

import, export and control of the Service History records
taken from any HP vehicle.

Using HP Service
HP Service can be used as a standalone application or
through the JCB Service Master CFE.

1 Connect Vehicle/DLA/PC using the supplied cables.

2 Power up the vehicle.

3 Run HPSetup.

Open Using the ServiceMaster CFE.

Open Service Master CFE.

Click on the icon.

Opening Using Windows.

Click WINDOWS Start button on toolbar.

Select RUN... menu item.
Use the browse button to locate "HPService.exe".
Click OK after selecting the file.

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9 - 17 JCB Service Master 9 - 17

The HP Service application will open and look like that

shown.

Allows the User to select from the database the Service

History for any vehicle that has been connected to it and
downloaded.

Load Service History list from vehicle attached to PC.

Import Service History exported from another Service History

user.

Export Service History, exports the current Service History

recordset to file for another user to import.

Delete Service History, delets the current list of entries from

the Database.

Print Service Record the current Service History.

Add Service Record, allows the User to insert a record into

the current Vehicle Service History. A special option for
Services which are not preplanned.

Load Service History

Service History Records can be taken from the vehicle by

clicking on this button.

The list of Service History records are then stored in the local
database in a chronological order,as shown below.

In the example above four SH records have been saved from

the vehicle detailing the Service Interval, Current Engine
Hours at the time of service and the Dealer code of the
Service Centre who performed the service.

Should the module recording the SH ever be replaced the

Service History manager safely keeps this data and will
append the new records from the replaced module. But this
will only be true as long as the Serial Number of the vehicle is
not changed and Engine Hours are 'set' to approximately the
old number of Engine Hours prior to exchange.

9803/6510 Issue 1
Section C Electrics Section C
9 - 18 JCB Service Master 9 - 18

Import Service History

The Service History Manager provides tools for Importing and

Exporting individual SH records from one Personal Computer
to another, this makes the task of sharing information very
easy over a largely distributed computer system.

To import a file the User simply clicks on the button and

then use the dialog box below to locate the file that is to be
imported.

All Import/Export files have the .shi extension.

After importing the file it is displayed in the usual SH grid.

Export Service History

The currently displayed list of Service History records can be

exported to a file for distribution to other users who are
interested with any of the information stored in the records.

To export Service History records, select from the Vehicle

Serial Number List the Serial Number belonging to the vehicle
that is to be exported. Click the button to open the 'Save
as...' dialog box, (shown below). Enter or select a filename
(for overwriting) that is to receive the exported data.

The click the 'Save' button to have the table contents

exported.

Printing Service History

The Service History of any vehicle can be printed using the

default printer settings of the PC running the application.

How to Print Service History:

Use the Vehicle Serial Number selection box to select a set of

History Records.

Click the Print button.

9803/6510 Issue 1
Section C Electrics Section C
9 - 19 JCB Service Master 9 - 19

Delete Service History

The currently selected Vehicle Service History may be deleted

at any time.

How to Delete a Service History:

Use the Vehicle Serial Number selection box to select a set of

History Records.

Click the Delete button

Add Service History Record

At some point in time a vehicle may undergo some form of

service operation that is outside of the normal preset Service
Intervals. This option allows the Service Engineer to include
into the vehicles current Service History list an entry for a
non-scheduled service event. The special significance of this
event is two fold, firstly because the scheduled hours are
'unscheduled' then we must set the Service Interval to zero
and because we have the ability to enter text into the
comments field the Service Engineer can associate text with
the unscheduled service event.

To Add A Service History Record

Connect the vehicle, power up and make sure the PC has

logged onto the vehicle network.

Click the button.

In the form below enter the Dealership Code and a comment

(up to 30 characters maximum) relating to the nature of the
unscheduled service.

Click the OK button to send the record to the Vehicles

internal Service History table. The OK button is only enabled
when valid data is entered into the Dealer Code and
Comment fields.

Closing HPService

To Close HPService use the Exit menu item on the HPService

main window menu bar.

9803/6510 Issue 1
Section C Electrics Section C
9 - 20 JCB Service Master 9 - 20

FLASH Programming Application

"FLASHECU" Training Guide

This application is primarily based on a generic FLASH

Programming design which requires little information back
from the module that is to be programmed other than it's
source address (SA). FLASHECU utilises the DLA to link to
the On-Vehicle CAN network to obtain network node
information and to pass the FLASH program application
code.

To limit use to the JCB Heavy Products Application operator

selections have been limited to programming the ECU1, EMS
and the ECUW. Other Operator input is restricted to
supplying the filenames for applications that are to be written
to the individual network nodes.

Using FLASHECU

Preparation

1 Connect DLA to PC and to the On-Vehicle connector

using the DLA cables provided.

2 Power Up vehicle with engine off and check vehicle is

operational.

Opening FLASHECU application

1 Open the JCB Service Master CFE

2 Select the Heavy Products JS Excavator Product Range

3 Click on the icon.

4 The application should open as shown

Select FLASH Application

Use the Browse buttons or type into the text input box the
name of the file to be programmed into the ECU module.

9803/6510 Issue 1
Section C Electrics Section C
9 - 21 JCB Service Master 9 - 21

Programming FLASH

Only those ECU modules detected on the network can be

programmed. The Module program buttons are enabled if the
node they represent is identified on the network. After
selecting the application to program into FLASH click the
button that identifies the target ECU. FLASH programming
will begin immediately.

The progress bar indicates FLASH programming progress.

Stop Programming

The Stop button terminates programming at any time, the

side effect of this will be that any embedded code already
existing prior to reprogramming will be corrupted. The Stop
button is only to be used if the 'progress' of the FLASH
function stalls, then the FLASH program will be interrupted to
bring the target ECU into program mode once again.

9803/6510 Issue 1
Section C Electrics Section C
10 - 1 Fault Finding 10 - 1

Introduction to the Diagnostics Tool lights turn on when there are messages received or sent by
the diagnostic software.
The Diagnostics Window provides a framework for analysing
each functional section of the vehicle. It does this by
requesting and collecting data from the vehicle network
using the DLA (Data Link Adapter). The data after filtering
and interpretation is then used to display the current real
time state of I/O, running data values etc. of the particular
function control circuit under observation. Because the
Diagnostics tool adds little overhead to the CAN Bus or
loading on the ECU nodes it operates unnoticed, thus
retaining a high degree of real time efficiency.

For information on using this diagnostic tool see the

following sections:

1 Connecting to the Vehicle

2 Starting Diagnostic Mode

3 Analysing Circuits

4 Stopping Diagnostic Mode

5 Language Preferences

The status bar located at the bottom of the Diagnostic Tool

window shows some CAN Network information. The CAN
address of each of the modules (if present) are shown in the
Connecting to the Vehicle
ECU, ECUW and EMS sections. The red and green indicator The DLA supplied to JCB and related Dealerships is the only

9803/6510 Issue 1
Section C Electrics Section C
10 - 2 Fault Finding 10 - 2

Connecting to the Vehicle

The DLA supplied to JCB and related Dealerships is the only C D
B E

tool required to connect to the vehicle's onboard CAN

A
J F
H G

network.

You will require a PC with Windows 95/98 and a parallel

printer port. A cable is supplied with the DLA and is
specifically designed for this application.

Connect the DLA to your computer's Parallel Port using

the 25 pin cable supplied with the DLA.

Attach the second cable between the DLA and the on

vehicle service connector A.

Power up the vehicle.

Ensure that the power LED on the DLA is illuminated.

A406130

Starting Diagnostic Mode

To start the diagnostic mode, press the green button, or
select Start Diagnostics from the Options menu.

When the diagnostic mode is started:

the diagnostic software checks the vehicle model

number and installed options and displays only the
diagnostic functions that are available on the vehicle.

starts the real time monitoring of the vehicle's systems.

all of the circuit diagram windows are continuously

refreshed with the current values.

NOTE: If the DLA is not connected to the computer or it is

not powered, you will see an error message when starting
the diagnostics mode. You will be asked to Retry or Cancel. 416401

If you click Cancel, the diagnostic mode will start but will not
be able to show any real time information from the vehicle. If A
you press Retry, after connecting and turning on the DLA,
the diagnostic mode will start and the real time information
will be shown.

9803/6510 Issue 1
Section C Electrics Section C
10 - 3 Fault Finding 10 - 3

Circuit Diagrams
The circuit diagrams provide you with real time information
while the diagnostic software is running. The state or level of
all inputs and outputs of each functional circuit are shown
and continually updated as the conditions on the vehicle
change. This information allows for quick troubleshooting of
the vehicle. There are two example circuit diagrams below
showing the style of the diagnostic information.

The Horn diagram shows the state (on/off) of the horn

switches and the state of the output that drives the horn.

The Alternator diagram shows the current values for the

flywheel input and alternator voltage.

Indicator Lights (LEDs)

The indicator lights in the diagnostic circuit diagrams will

appear in one of the states (colors) below. This color key is
also visible in the lower left hand corner of the main HP
Diagnostics window.

Off (Dark Green)- the input or output is off or inactive.

On / Active (Light Green)- the input or output is on or activated.

Open Circuit (Light Blue) - the output is in an open circuit condition indicating that there is nothing
connected to the output (PWM and High Side outputs only).

Short Circuit (Red) - the output is in a short circuit condition indicating that the output is connected
directly to the battery or earth ground (PWM and High Side outputs only).

No Voltage (Yellow) - the output circuit does not have batter power indicating that a fuse may be
open (PWM and High Side outputs only).

Failed (Magenta) - the output is not functioning because of an undetermined fault which may be
open, shorted or no voltage applied (Low Side outputs only).

9803/6510 Issue 1
Section C Electrics Section C
10 - 4 Fault Finding 10 - 4

Stopping Diagnostic Mode

To stop the diagnostic mode, press the red button, or
select Stop Diagnostics from the Options menu.

Stopping diagnostic mode will stop the real time monitoring

of the vehicle and disengage the DLA from the CAN network.
The circuit diagram windows are not refreshed with new
values.

Language Setting
Select Preferences from the Options menu to view the
Preferences Dialog. To change the language used by the
Diagnostic Tool software, select the desired language from
the list of supported languages.

All language files supplied as part of the Diagnostic Tool will

be automatically detected by the software and displayed in
the selection box. Representations are made by national flag
and some text identifying (region or dialect) belonging to the
country. This allows several regional dialects of any single
country to be made available.

As soon as a new language is selected and the OK button is

pressed, all of the program's text is translated (changed)
using the selected language file.

9803/6510 Issue 1
Section C Electrics Section C
10 - 5 Text messages 10 - 5

List of Text Messages Displayed on the EMS.

Table 1: Error messages

MESSAGE DESCRIPTION

Air Filter Air Filter Blocked

Air Pressure Low Air Pressure
Alternator No / Low Charge
Brake Fail No Brake pressure
Comms Fault Can/ SPI network fault.
Coolant low Coolant level
Elec Fault ECUs / Harness Fault
Hyd oil low Hydraulic oil level
Oil Filter Oil filter blocked
Oil Press Engine Oil pressure
Over heat Engine/ Hydraulic temperature high.
Overload Overload caution reached
Low Fuel 2nd Low fuel warning
No Throttle Throttle system fault
Res Fuel 1st Low fuel warning

Table 2: Status messages

MESSAGE DESCRIPTION

Auto Idle Auto idle activated

Auto idleoff Auto idle deactivated
Auto warm Engine automatic warm up sequence
Beacon off Warning beacon status (Option)
Beacon on Warning beacon status (Option)
Boom Prior Boom Priority
Emer Stop Engine Emergency Stop activated
Grab CCW Grab rotation direction (Option)
Grab CW Grab rotation direction (Option)
Hammer Hammer selected (Option)
Hard Mode Cushion status
Isolator Hydraulic Isolator engaged
Lights on Side light status
Limp mode Limp mode system activated
Low idle Engine speed
Overload on Overload caution activated (option)
Power up One touch digging force up activated
Pre Heat Engine preheat activated
Q/H Discon Quick hitch status
Q/H Discon? Quick hitch disconnect
Service Rqd. Service required indicator
Slew Prior Slew priority
Soft mode Cushion status
Swing lock Swing Lock engaged
Wiper int Wiper intermittent
Wiper on Wiper continuous

9803/6510 Issue1
Section C Electrics Section C
10 - 6 Text messages 10 - 6

List of text messages displayed on the EMS (cont’d)

Table 3: Set Menu messages

MESSAGE DESCRIPTION

Auto idle T Delay time for Automatic idle

Clock Set current time
Date Set current date
Hammer RPM Set Hammer max revs.
Hammer Hrs Hammer Hour counter
Int Wiper S Set Intermittent wiper speed
Language Set language
RPM Engine Speed value (For hammer/ scrap
mag. options)
Scrap mag Set Scrap magnet min Rpm.
Scrp mg off Deactivate Scrap Mag. Rpm
Scrp mg on Activate Scrap Mag. Rpm.
Wiper SPD Wiper intermittent speed
12/24? Clock hour format
24 24 Hour format
12 12 Hour format

Table 4: Set + Mode (20 sec) Menu messages

MESSAGE DESCRIPTION

Calibrate Throttle calibration routine

Lower limit Throttle volume pot min. setting

Over-ride Solenoid override activated

Over-ride? Solenoid override request

9803/6510 Issue 1
Section C Electrics Section C
10 - 7 Text messages 10 - 7

List of text messages displayed on the EMS (cont’d)

Table 5: Set + Mode (5 sec.) Menu messages

MESSAGE DESCRIPTION

Alt Volts Alternator Output Volts

Boom off Boom pressure switch status
Boom on Boom pressure switch status
Boom up off Boom Raise Pressure switch status
Boom up on Boom Raise Pressure switch status
Deg C Degrees Celsius
Fuel level Fuel level
Hammer off Hammer pressure switch status
Hammer on Hammer pressure switch status
Hrdware Ver Hardware Version
Hyd Temp Hydraulic oil temperature
mA Hydraulic pump control current
Ohms Resistance value
Perc Percentage (Pwm Duty)
Pilot Swtch Pilot switch sub menu heading
Priority Variable swing priority (JS200W)
Pump Amps Hydraulic pump current
Pump pot Fuel lever potentiometer (Engine)
Q/H Enable? Quick Hitch option select
Q/H on Quick Hitch system activated
Q/H Type ? Quick Hitch type selection
Q/H type 1 Quick Hitch type
Q/H type 2 Quick Hitch type
Rpm value Engine speed
Serial No. Machine serial number
Slew/Boom Variable priority (JS200W)
Slew off Slew pressure switch status
Slew on Slew pressure switch status
Sftware ver Software version
Thrttle pot Throttle volume potentiometer
Throttl Pwm Throttle solenoid control signal
Travel off Travel pressure switch status
Travel on Travel pressure switch status
Upper off Upper pressure switch status
Upper on Upper pressure switch status
Volts Voltage
Water Temp Water Temperature

9803/6510 Issue 1*
Section C Electrics Section C
10 - 8 Text messages 10 - 8

List of text messages displayed on the EMS (cont’d)

Table 6: AMS System fault error code

Notes: 1 Open circuits can only be detected when the output has been turned off.
2 Short circuit conditions can only be detected when the output is turned on.
3 Open circuits, short circuitts and no voltage detections cannot be done on the low side drivers.
4 See Harness Data
5 The gaps in the the table below, are available outputs that are not used.
Error Type Error Function Error Type Error Function
No. No.
Open 1 Throttle Solenoid Short 50
Short 2 No Voltage 51
No Voltage 3 Open 52 CW Grab / Rotate Solenoid
Open 4 Boom Lower Speed Regulation- optional
Solenoid Short 53
Short 5 No Voltage 54
No Voltage 6 Open 55 CCW Grab / Rotate Solenoid -
Open 7 Max Flow Cut Solenoid optional
Short 8 Short 56
No Voltage 9 No Voltage 57
Open 10 Beacon Open 58 Low Flow Priority Solenoid
Short 11 optional
No Voltage 12 Short 59
Open 13 Boom Priority Solenoid optional No Voltage 60
Short 14 Open 61 Isolate Solenoid
No Voltage 15 Short 62
Open 16 Horn No Voltage 63
Short 17 Open 64 Emergency Stop Solenoid
No Voltage 18 Short 65
Open 19 Hydraulic Pump Solenoid No Voltage 66
Short 20 Open 67 Negative Flow Control Solenoid
No Voltage 21 Short 68
Open 22 Slew Lock 1 Solenoid No Voltage 69
Short 23 Open 70 2nd Stage Relief Solenoid
No Voltage 24 Short 71
Open 25 Slew Lock 2 Solenoid No Voltage 72
Short 26 Open 73 Quick Hitch Solenoid - optional
No Voltage 27 Short 74
Open 28 Slew Lock 3 Solenoid No Voltage 75
Short 29 Open 76 Travel Alarm - optional
No Voltage 30 Short 77
Open 31 Lower Wiper - optional No Voltage 78
Short 32 Open 79 Breaker Solenoid - optional
No Voltage 33 Short 80
Open 34 Wiper No Voltage 81
Short 35 Open 82 Soft / Hard Cushion Solenoid
No Voltage 36 Short 83
Open 37 Cab Work Light No Voltage 84
Short 38 Failed 85 Boom Work Light
No Voltage 39 Failed 86 Toolbox Work Light
Open 40 Cab Work Light Failed 87 Stop Relay
Short 41 Failed 88 Preheat Relay
No Voltage 42 Failed 89 Counter Weight Work Light
Open 43 Travel Change Solenoid Failed 90
Short 44 Failed 91
No Voltage 45 Failed 92
Open 46 Washer Open 93 Left Indicators
Short 47 Short 94
No Voltage 48 No Voltage 95
Open 49 Dozer Solenoid - optional Open 96 Left Sidelights

9803/6510 Issue 1
Section C Electrics Section C
10 - 9 Fault Finding 10 - 9

List of text messages displayed on the EMS (cont’d)

Table 6: AMS System fault error code (cont’d)

Error Type Error Function Error Type Error Function

No. No.
Short 97 Short 151
No Voltage 98 No Voltage 152
Open 99 Left Fog Lights Open 153 Stabilize Up Solenoid optional
Short 100 Short 154
No Voltage 101 No Voltage 155
Open 102 Left Main Beam Relay Open 156 Stabilizer Down Solenoid -
Short 103 optional
No Voltage 104 Short 157
Open 105 Left Dip Beam Relay No Voltage 158
Short 106 Open 159 Stabilizer Left Solenoid -
No Voltage 107 optional
Open 108 Short 160
Short 109 No Voltage 161
No Voltage 110 Open 162 Stabilizer Right Solenoid-
Open 111 Right Indicators optional
Short 112 Short 163
No Voltage 113 No Voltage 164
Open 114 Right Sidelight Open 165
Short 115 Short 166
No Voltage 116 No Voltage 167
Open 117 Right Fog Lights Open 168 Dig End Isolate - optional
Short 118 Short 169
No Voltage 119 No Voltage 170
Open 120 Right Main Beam Relay Open 171
Short 121 Short 172
No Voltage 122 No Voltage 173
Open 123 Right Dip Beam Relay Open 174 Park Brake
Short 124 Short 175
No Voltage 125 No Voltage 176
Open 126 Hazard Indicator LED Failed 177
Short 127 Failed 178
No Voltage 128 Failed 179
Open 129 Travel Flow 3 Solenoid Failed 180
Short 130 Failed 181
No Voltage 131 Failed 182
Open 132 Travel Flow 2 Solenoid Failed 183
Short 133 Failed 184
No Voltage 134
Open 135 Gear Change Solenoid
Short 136
No Voltage 137
Open 138
Short 139
No Voltage 140
Open 141
Short 142
No Voltage 143
Open 144
Short 145
No Voltage 146
Open 147
Short 148
No Voltage 149

9803/6510 Issue 1
Section C Electrics Section C
10 - 10 Fault Finding 10 - 10

Fault Finding Without using the JCB

Service Master Diagnostic Tool
B
Introduction
The AMS system is designed so that all of the components
that are connected to the system are able to communicate
with each other. This means not only are the machine hours
displayed on the Electronic Monitor (EMS) but also they are
recorded in the Electronic Control Unit 1 (ECU-1).
Changing Machine Components
Under such circumstances where fault diagnosis is not
possible by using the JCB Service Master Diagnostic Tool
then the following actions must be taken in circumstances
where a change of the Electronic Control Unit 1 (ECU-1)
and/or the Electronic Monitor System (EMS) is unavoidable.
C
1 If either a new ECU-1 or new EMS. is fitted to either a
new or old machine, the machines working hours will
pass automatically to the new units and upgrade them
when the machines ignition is switched on.
Note: This includes stock machines with over 1 hour
recorded by the AMS system.
2 Only under extreme circumstances should either the
ECU-1 or the EMS be transferred to a machine with
lower working hours than the donor machine. The effect The system comprises of the following main electronic
of this would be to automatically transfer the higher components:
hours information to the recipient machine. A Electronic Control Unit -1 (ECU-1)
B Electronic Monitoring System (EMS)
Note: This process is not reversible.
C Fascia switch panel (FSP).
3 When either an ECU-1. or EMS is changed on a
machine, the machine system must be set up again
using the Set Up Service Tool. Without this action some
options previously active would not function and the
throttle system would not be calibrated.
4 To remove the EMS unit, carefully pull the unit away
from the facia panel. The unit is held in place by a
retaining seal only and is a tight fit, do not attempt to
lever the unit out as this could cause damage to the the
E.MS and the facia panel. Reassembly is a reversal of
this procedure.
5 To access the ECU-1,remove the seven panel screws
from the panel behind the seat and remove panel.

6 To remove the ECU-1, remove the three Allen screws

which fasten the computers to a frame. To remove the
machine harnesses from the computers, undo the Allen
screw integral to each connector. Reassembly is a A
reversal of this procedure.

Note: On the ECU-1 the identification letters for the

individual harness connectors and the fixed harness
connections on the computer itself, are the cast letters
(A,B,C ) on the body of the computer.This is vital when
identifying connectors and pins during fault diagnosis.
A407730
7 The Facia Switch Panel (FSP) is not affected by any
changes of other components.

9803/6510 Issue 1
Section C Electrics Section C
10 - 11
10 - 11 Fault Finding

Fault Finding Without using the JCB

Service Master Diagnostic Tool (cont’d)
Fault Diagnosis (General)
Note: The method of testing the EMS, and ECU-1 input
and output voltages is shown in Section C Service
procedures.

Note: See Section C Harness Data for details of

Connectors

Permanent Battery Supply. ( Ignition Off )

ECU-1 permanent battery supply can be measured at
harness Connector B, Pin 6 ( 24 v+).
E.MS permanent battery supply can be measured at the
harness Connector, Pin 13 (24 v +).

Ignition On.
E.CU-1 ignition supply can be measured at harness
Connector B, Pin 5 (24 v +).
E.CU-1 output voltages can be measured at harness
Connector B, Pins 1, 2, 7, 8, 13, 14, 19, 20.
E.MS ignition supply can be measured at the harness
Connector, Pin 16 (24 v +).

Ground Tests.
A407730
E.CU-1 grounds can be tested at harness Connector B,
Pins 11,17, 23, and harness Connector C, Pins 9, 10.
E.MS grounds can be tested at the harness Connector,
Pins 14, 17, 18.

Can - Bus Network Tests.

If all 3 travel mode symbols flash together, this would

indicate a Can - Bus Network problem, use the Harness
Tests and the Unit Tests to identify the faulty component.

Harness Tests.

Check for continuity between:

EMS harness Connector Pin 6 and ECU1. harness
Connector B, Pin 21.

Check for continuity between

EMS harness Connector Pin 7 and ECU1 harness
Connector B, Pin 15.

Check the resistance between Pin 7 and Pin 8 at the -

Diagnostic Connector where the Data Link Adaptor Service
Tool connects to the machine B. The value should be 60
ohms, + / - 5 ohms.

9803/6510 Issue 1
Section C Electrics Section C
10 - 12 Fault Finding 10 - 12

Fault Finding Without using the JCB

Service Master Diagnostic Tool (cont’d)
Unit Tests.
Check the resistance between Pin 6 and Pin 7 on the EMS.
unit, the reading should be 120 ohms + / - 10 ohms.

Check the resistance between Pin 15 and Pin 21 on the

ECU-1 unit connector B, the reading should be 120 ohms +
/- 0 ohms.

Fault Diagnosis ECU-1

If the engine turns over but will not start, change to "Limp
Mode" and if the machine starts the ECU-1 may have failed.
This check assumes all other "Engine Failure To Start"
checks have been completed.
If there is a failure of the ECU-1 unit, the machine can be
moved by using the "LIMP MODE" Switch A located behind
the seat.

Note: The machine will only run at engine idle r.p.m. and
should only be operated in this mode to allow the machine to
be moved to a safe position for repairs. The machine does
not function in the same manner as earlier models fitted with
a Redundancy Switch.

To test the ECU-1, several individual circuits can be used to

identify ECU-1 failure. These are basic circuits which do not
require the use of solenoids but are actuated by the use of a
single switch.
B 416401
Horn circuit
Wiper circuit A
Washer circuit
Travel alarm circuit (American Machines Only)
Work lights circuit
The individual circuit can then be checked by testing the
ECU-1 input and output voltages. The method of testing the
input and output voltages is shown in, Section C Service
Procedures.

ECU-1. stores the following Data Log Information:

Hydraulic Overheating.
Engine Overheating.
No Throttle.
Throttle Recalibration.
Air Filter Blocked.
Low Air Pressure.
Low Engine Oil Pressure.

If the ECU-1 is changed the Data Log Information stored in it

will not be transferred to the new unit, therefore if possible
the Data Log Information must be downloaded before the
changes take place.

9803/6510 Issue 1
Section C Electrics Section C
10 - 13 Fault Finding 10 - 13

Fault Finding Without using the JCB

Service Master Diagnostic Tool (cont’d)

EMS Failure.

When the machine is started all 18 warning indicator lamps

should "flash" for approximately 1 second and the elements
within the monitors Liquid Crystal Display (LCD) should come
on for the same time period.
If there is a failure of the EMS unit, the machine can be
moved by using the "LIMP MODE" Switch located behind
the seat. B 416401

Note: The machine will only run at engine idle r.p.m. and A
should only be operated in this mode to allow the machine to
be moved to a safe position for repairs. The machine does
not function in the same manner as earlier models fitted with
a Redundancy Switch.
The EMS stores the following Data Log Information:
Limp Mode Use.
Alternator Low Charge Warning.
Circuit Driver Errors (Open Circuits, Short Circuits, No
Voltage.)
If the EMS is changed the Data Log Information stored in it
will not be transferred to the new unit, therefore if possible
the Data Log Information must be downloaded before the C
changes take place.

Fault Diagnosis - Facia Switch panel (F S P)

When the ignition is switched ON check all of the switch
buttons LED's function for 1 second.
If not, conduct tests using the JCB Service Master
Diagnostic Tool. ( Section C 6 )
Confirm +24v ignition supply is on pin 1 of the FSP
connector. Confirm earth on pin 2 of the FSP connector.
(See Harness data Section C 7 )
Carefully remove the Facica Switch panel C using a thin
bladed screw driver to lever out the unit from the cab panel.

9803/6510 Issue 1
Section C Electrics Section C
19 - 1 Service Procedures 19 - 1

Electrical Testing Methods

- Using a Multimeter

These instructions are intended to cover the use of the recommended multimeters.

OFF
V/A A
V/A

B
C
C

A171900
S153070

1 Make sure that the test leads are plugged into the correct sockets. The black test lead should be plugged into the black
socket (sometimes, this socket is also marked by a " – ", or "E" or marked as "COMMON" or "COM"). The red test lead
should be plugged into the red socket marked with "+", "V" or "Ω".

2 When making measurements ensure that the test probes have a good clean contact with bare metal, free from grease,
dirt, and corrosion as these can cause a false reading.

3 When measuring voltage:

Make sure that the correct range is selected, that is set the selector to a value equal to or greater than that you are about
to measure.
e.g. If asked to measure 12 Volts, set the selector to the 12V range. If there is no 12V range, set the selector to the next
range higher, 20V for instance.
If the meter is set to a range that is too low, it may be damaged.
e.g. setting to the 2V range to measure 12V.

9803/6510 Issue 1
Section C Electrics Section C
19 - 2 Service Procedures 19 - 2

Electrical Testing Methods

- Using a Multimeter (cont’d)

S153070

9803/6510 Issue 1
Section C Electrics Section C
19 - 3 Service Procedures 19 - 3

Electrical Testing Methods

- Using a Multimeter (cont’d)
1 Measuring DC Voltage

a On the FLUKE 85
Turn the switch to position B.

b On the AV0 2003

Move the right slider switch to position 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.

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.

2 Measuring Resistance

Make sure there is no power to the part of the circuit you are about to measure.

Connect one probe at one end of the component or wire to be checked and the other probe at the other end. It does not
matter which way round the two probes are placed.

a On the FLUKE 85
Turn the switch to position C and check that the Ω sign at the right hand side of the display window is on. If the F
sign is on instead, press the blue button G to change the reading to Ω.

Touch the meter lead probes together and press the REL ³ key on the meter to eliminate the lead resistance from the
meter reading.

b On the AV0 2003

Move the right hand slider switch to position B, and the left hand slider switch to the appropriate Ohms (Ω) range.

c On an analogue meter
Move the dial to the appropriate Ohms (Ω) range.

3 Measuring Continuity

Make sure there is no power to the part of the circuit you are checking for continuity.

Connect one probe to one end of the component or wire to be checked and the other probe to the other end. It does not
matter which way round the two probes are placed.

a On the FLUKE 85
Turn the switch to position C and check that the beeper symbol appears at the left hand side of the display window.
If the F sign is on instead, press the button labelled F in the meter drawing.

If there is continuity in the circuit, the beeper will sound. If there is no continuity (open circuit), the beeper will not
sound.

b On the AV0 2003

Move the right hand slider switch to position B, and the left hand slider switch to position 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.

9803/6510 Issue 1
Section C Electrics Section C
19 - 4 Service Procedures 19 - 4

Electrical Testing Methods

- Using a Multimeter (cont’d)

9803/6510 Issue 1
Section C Electrics Section C
19 - 5 Service Procedures 19 - 5

Electrical Testing Methods

- Using a Multimeter (cont’d)

4 Testing a Diode or a Diode Wire

A diode wire is a diode with male connector fitted on one end and a female connector fitted on the other end. The diode is
sealed in heatshrink sleeving.

a On the FLUKE 85
Turn the switch to position D.

Press the HOLD button and check that the H sign appears at the top right hand side of the display window.

Connect the black probe to the end of the diode with a band or to the male connector of the diode wire. Connect
the red probe to the other end of the diode or diode wire. If the beeper does not sound the diode or diode wire is
faulty.

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.

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

Move the right hand slider to position A, and the left hand slider switch to position C.

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.

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 On an analogue meter
Select the Ohms 1000s (1k) range.
Connect the black probe to the end of the diode marked with a band, or to the male connector of the diode wire, the
red probe should be connected to the other end of the diode or diode wire. The meter should read 20-400 KΩ, if it
reads more than this the diode is faulty.

Select the Ohms 100s range.

Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the
black probe should be connected to the other end of the diode or diode wire. The meter should read 300-400Ω, if it
reads less than this the diode is faulty.

9803/6510 Issue 1
Section C Electrics Section C
20 - 1 Fault Finding 20 - 1

Testing of ECU Inputs + Outputs

Remove panel behind drivers seat, for access to the ECU A.

Care should be taken when testing the inputs + outputs of

the ECU to ensure that correct test method is used to
determine if the ECU is functioning normally.

Note: Inputs/outputs should be checked with engine ECU

running or in solenoid overide mode (see Service Switch (rocker, momentary,
Procedures, set + mode menu 20 secs). pressure, level, etc.)

Input
Testing low side input Red lead

With the switch open the meter will read approximately 5v.
V
With the switch closed the meter will read 0v. Black lead

ECU Switch (lights, engine preheat,

etc.)
Testing High side input
With the switch open the meter will read 0v. Input
Red lead
With the switch closed the meter will read 24-28v.
V
Black lead
Testing low side output
With the output off the meter will read 0v.

With the output on the meter will read 24-28v.

Actuator; relay coils
ECU

Output

Red lead

Black lead +24

Testing high side output
With the output off the meter will read 0v.

With the output on the meter will read 24-28v.

Actuator (solenoid, motor,
bulb, horn relay)
ECU

Output
Red lead

Black lead

9803/6510 Issue 1
Section C Electrics Section C
20 - 2 Fault Finding 20 - 2

Testing high side outputs (cont’d)

The ECU is internally configured to give short circuit
protection and detection of short circuit / open circuit,
this is done by inter nal resistors. This inter nal
configuration can give some confusing results when ECU
testing the outputs on the ECU.

µ
Voltage at point A:

Output IN ST
Solenoid connected output off = 0.1 V approx.
supply +24v
Vbb OUT A
A
Solenoid connected output on = battery voltages
nominal.
Driver
Solenoid disconnected output off = reduced voltage
(15 V - 22 V).

Solenoid disconnected output on = battery voltage Pull up

Resistor 10kΩ
nominal. *
Shorted to ground = 0 V.

Shorted high (to positive) = battery voltage.

9803/6510 Issue 1
Section C Electrics Section C
23 - 1 Service Procedures 23 - 1

Wiring Harness

Introduction Tools Required

Instances do occur where it is necessary to incorporate 892/00350 Butane Heater assembly 1
auxiliary electrical components into existing electrical 892/00349 Crimp tool 1
circuits and, although unlikely with present wiring harnesses, 892/00351 Splice 0.5-1.5 mm (Red) 50
repair or replace specific individual wires within a harness. 892/00352 Splice 1.5-2.5 mm (Blue) 50
This will also apply to other machines in addition to those of 892/00353 Splice 3.0-6.0 mm (Yellow) 50
JCB manufacture.

To ensure that either the inclusion of an auxiliary electrical

component or a repair within a harness is completed to an Repair Procedure
acceptable standard it is strongly recommended that the
following tools, equipment and procedures are always used. 1 Cut the wire and remove the protective insulation for a
Note that JCB harnesses have an International Protection suitable distance dependent upon the size of wire and
rating of 67 (I.P.67). splice to be used. For the splices detailed above, the
dimension is 7mm.
The sheath covering of the recommended splice is heat
shrunk onto the original wire insulation. This results in a seal 2 Using the correct sized splice, attach the new section
and corresponding joint to IP 67 specifications. of wire required or auxiliary flying lead to the existing
harness and secure using the crimp tool X, part number
! CAUTION 892/00349.
When installing Auxiliary Electrical Components always
ensure that the additional load rating is suitable for that Note that each of the splices detailed is colour-coded
particular circuit. It is unacceptable to simply increase to make size and range readily visible. They are
the fuse rating as this can cause overloading and secured using the corresponding size and matching
consequential failure of wiring, along with failure of colour-coded jaws of the crimp tool to ensure joint
integral circuit components, which the fuse is protecting. security. This tool also incorporates a ratchet closing
ELEC 2 - 1 mechanism which will not release until the splice is
fully closed to the correct compression size.
! WARNING
In addition to the warnings incorporated into the 3 With the Butane heater assembly, 892/00350, seal the
procedure, extreme care should be taken when handling connection using the procedure on the next page.
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 ....continued
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 .
ELEC 2 - 2

7
!CAUTION
When the heater is in use, the reflector and the air
coming out are extremely hot. Keep away to avoid
accidental burns. Do not touch the reflector until it has
had time to cool down after switching off. If flame
reappears at the reflector when the heater is in use, the X
catalytic element is damaged or used up. Stop work
immediately and replace the heater.
ELEC 2-3

S189530

980/36510 Issue 1
Section C Electrics Section C
23 - 2 Service Procedures 23 - 2

Wiring Harness - Repair Procedure (cont'd)

With the Butane Heater assembly 892/00350, seal the
connection using the following procedure.
A
a Remove the cap A from the end of the disposable gas
cartridge B.

S189490/1

b Before assembling the gas cartridge to the reflector

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

S189490/2

c Position the tube hanging down from inside the reflector

assembly into the hole at the top of the gas cartridge.
Then press the gas cartridge up into the reflector
assembly as far as possible until the two elements are
clasped firmly together. A click will be heard.

S189490/3

d Turn the small ring E so that the air holes at F are

completely closed.

F
E

S189490/4

9803/6510 Issue 1
Section C Electrics Section C
23 - 3 Service Procedures 23 - 3

Wiring Harness - Repair Procedure (cont'd)

e Turn the red ring D to the right (in the direction of the
plus sign) in order to turn on the gas.

IMPORTANT: Before turning the heater on, make sure that

the cartridge is not hotter than the reflector element. This
may occur if the cartridge is held in the hand for a long time.
The temperature difference between the cartridge and the
reflector element may cause long yellow flames to appear on D
ignition.

S189490/5

f Hold the heater vertically and, using a match or

cigarette lighter, light the gas as shown.

Note: The fact that the sound of liquid cannot be heard when
the cartridge is shaken does not mean it is empty. No sound F
will be heard even when the cartridge is full.

Hold the heater vertically for 1 to 2 minutes until the

E
catalytic reaction occurs. This is indicated when the
blue flame fades and the ceramic element glows red.
Then turn the small ring E until the air holes at F are
completely open. The tool is ready for use.

S189490/6

The heater can be used in two modes:

g Side wings G down, reflector head completely open. In

this mode the infra-red heat waves are dominant
(recommended for the light coloured plastic splices). G
Side wings G up (see fig at step h), reflector head
opening reduced. In this mode the heating is done only
by the hot gas (use for dark coloured plastic splices).

S189490/7

h To switch off the heater, turn the red ring D to the left (in
the direction of the minus sign). G

S189490/8

9803/6510 Issue 1
Section C Electrics Section C
24 - 1 Service Procedures 24 - 1

Battery

Maintenance Safety
! WARNING
To ensure that the battery provides optimum performance
Batteries give off an explosive gas. Do not smoke when
the following steps should be observed:
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 prevent
Battery electrolyte contains sulphuric acid. It can burn you if
corrosion.
it touches your skin or eyes. Wear goggles. Handle the
battery carefully to prevent spillage. Keep metallic items
2 When applicable - never allow the electrolyte level to
(watches, rings, zips etc) away from the battery terminals.
fall below the recommended level - 6 mm (1/4 in) above
Such items could short the terminals and burn you.
the plates. Use only distilled water for topping up.
Set all switches in the cab to OFF before disconnecting and
3 Keep the battery at least three quarters charged,
connecting the battery. When disconnecting the battery,
otherwise the plates may become sulphated (hardened)
take off the earth (-) lead first.
- this condition makes recharging the battery very
difficult.
When reconnecting, fit the positive (+) lead first.
Extra precautions must be taken when bench charging
Re-charge the battery away from the machine, in a well
maintenance free batteries, they are more prone to damage
ventilated area. Switch the charging circuit off before
by overcharging than the standard type of battery:
connecting or disconnecting the battery. When you have
installed the battery in the machine, wait five minutes before
- NEVER boost-charge a maintenance free battery.
connecting it up.
- NEVER charge a maintenance free battery at a
voltage in excess of 15.8 Volts. First Aid - Electrolyte

- NEVER continue to charge a maintenance free Do the following if electrolyte:

battery after it begins to gas.
GETS INTO YOUR EYES

Immediately flush with water for 15 minutes, always get

medical help.

IS SWALLOWED

Do not induce vomiting. Drink large quantities of water or

milk. Then drink milk of magnesia, beaten egg or vegetable
oil. Get medical help.

GETS ONTO YOUR SKIN

Flush with water, remove affected clothing. Cover burns with

a sterile dressing then get medical help.
5-3-4-3/1

9803/6510 Issue 1
Section C Electrics Section C
24 - 2 Service Procedures 24 - 2

Battery (cont’d)

Testing
This test is to determine the electrical condition of the 5 Set the CHECK/LOAD switch A to LOAD and hold down
battery and to give an indication of the remaining useful for 5 - 10 seconds until the meter reading stabilises. The
‘life’. reading should be at least 9 volts.

Before testing ensure that the battery is at least 75% Note: Do not hold the switch in the LOAD position for more
charged (SG of 1.23 to 1.25 for ambient temperature up to than 10 seconds.
27°C).
6 If the foregoing tests are unsatisfactory, consult Fault
Ensure that the battery is completely disconnected from the Diagnosis below.
vehicle.

Connect up the battery tester (part no. 993/85700) as

follows:

1 Set the CHECK/LOAD switch A to OFF.

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

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

terminal and the black flying lead to the battery negative
(-) terminal.
B
4 Set the CHECK/LOAD switch A to CHECK to read the 239510
battery no-load voltage which should be at least 12.4
volts.

Fault Diagnosis

Battery Tester Readings Remedy

1 CHECK: 0 - 12.6 Volts

LOAD: less than 6 Volts Renew battery

2 CHECK: 6 - 12.4 Volts

LOAD: less than 9 Volts and falls steadily but remains Recharge and re-test. If tests still unsatisfactory renew
in yellow zone. battery.

3 CHECK: less than 10 Volts Indicates battery has been over-discharged and unlikely
LOAD: less than 3 Volts to recover. Renew battery.

4 CHECK: more than 11 Volts Charge battery which will probably recover.
LOAD: 6 - 10 Volts steady

Specific Gravity Testing

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

9803/6510 Issue 1
Section C Electrics Section C
150 - 1 Harness Data 150 - 1

Harness Location and

Interconnection Cab Sub Harness -
Main components con-
nected to this harness:
Radio

C37

Facia Link
C2
Harness -
Main components C1
connected to this C37
harness:
Electronic C225
Monitoring System
(EMS) C225
Cigar Lighter
Radio Mute Switch C180
Facia Switch Panel
HVAC Controller

C180

Main Harness -
Main components
connected to this C2
harness:
Slew Brake Valve
Main Control Valve
8 Spool Solenoid -
Shuttle Valve
Fuse link - Ignition
Battery
Glow Plugs C1
Alternator
Starter Motor
Throttle Control
Temperature -
Sensors C6
Work Lights

Cab Harness -
Main components C5
connected to this har-
ness:
Electronic Control
Unit -(ECU)
Fuses
Voltage Converter
Diagnostic Connector
Wiper motors
Control Lever
Switches
Ignition Switch
Throttle Dial
Interior Light Switch

A409471

9808/6510 Issue 1
Section C Electrics Electrics Section C
150 - 2 Harness Data 150 - 2

Main Harnes Connector Location

18
17
19

60

25, 63 9, 10, 11, 12, 57 55

56
13, 14, 15, 16

66 5
37, 44, 45 53
46, 47, 48
54
39
26 34, 49

36, 62
21
29, 31 40 51
33
20 52
32, 65 50
27
41
1, 2, 3, 4
42
60

30

28

64

22
23
24
A409631
67 7, 8

9808/6510 Issue 1
Section C Electrics Section C
150 - 3 Harness Data 150 - 3

Main Harness
Key to Connectors

Item Connector Function

Item Connector Function
43 C94 Travel Alarm
1 C1 Connector A
44 C95 Starter Relay S
2 C2 Connector B
45 C96 Starter Relay 1
3 C5 24V Supply (Battery)
46 C97 Alternator 3E
4 C6 24V Supply (Ignition)
47 C98 Alternator 1B
5 C28 CWT Lamp
48 C99 Alternator 2R
6 C54 Engine Stop Solenoid
49 C100 Glow Plug
7 C55 Slew Lock (Blue Marker Tape)
50 C101 Heat Relay 1
8 C56 Slew Brake (Yellow Marker Tape)
51 C102 Heat Relay 2
9 C58 High Speed Travel Change
52 C103 Heat Relay 3
Solenoid (Blue Marker Tape)
53 C104 Battery Relay 1
10 C59 2 Stage Relief Solenoid (Yellow -
54 C105 Battery Relay 2
Marker Tape)
55 C107 Battery Relay Coil 1
11 C60 Negative Flow Control Solenoid -
56 C108 Battery Relay Coil 2
(White Marker Tape)
57 C109 Battery Relay Earth
12 C61 Lever Lock Solenoid (Blue Marker
58 C110 Diode Washer
Tape)
59 C111 Diode Stop
13 C62 Slew Shut Off Solenoid (Green
60 C116 Earth Eyelet
Marker Tape)
61 C157 Quick Hitch (Optional)
14 C63 Soft/Hard Solenoid (Green Marker -
62 162 Over/Heat Switch Water
Tape)
63 C163 Hydraulic Oil Over Heat Switch
15 C64 Max Flow Control Solenoid
64 C165 Merged Pump Solenoid Valve -
16 C65 Boom Priority Solenoid (Pink -
(optional)
Marker Tape)
65 C166 Beacon
17 C66 Hydraulic Pump Proportional -
66 C220 Boost Pressure Switch (Blue Marker-
Solenoid Valve
Tape)
18 C67 Throttle Position Sensor
67 C221 Auto Mode Pilot Pressure Switch -
19 C68 Engine Control Solenoid Valve
(Green Marker Tape)
20 C69 Upper Pilot Pressure Switch
68 Earth Header
21 C70 Travel Pressure Switch (Yellow -
Marker Tape)
22 C71 Boom Up Pressure Switch (Yellow - Key To Wire Colours
Marker Tape)
23 C72 Boom Down Pilot Pressure Switch B Black
(Blue Marker Tape) R Red
24 C73 Slew Pilot Pressure Switch Red U Blue
Marker Tape) LG Light Green
25 C74 Hydraulic Oil Temperature Sensor G Green
Y Yellow
26 C75 Fuel Sensor
P Purple
27 C76 Reserve Tank Switch
W White
28 C77 Air Filter N Brown
29 C79 Washer Motor O Orange
30 C80 Electric Horn K Pink
31 C81 Tool Box Lamp S Grey
32 C82 Boom Lamp BR Black with Red
33 C83 Fuel Pump
34 C84 Oil Pressure Switch
35 C85 Oil Filter Switch
36 C86 Water Temperature Sensor
37 C87 Engine Speed Sensor
38 C88 Air Conditioner Binary Switch
39 C90 Air Conditioner Compressor Clutch
40 C91 Fuse Link Ignition 60A
41 C92 Fuse Link Battery 25A
42 C93 Over Load Switch

9803/6510 Issue 1
Section C Electrics Electrics Section C
150 - 4 Harness Data Harness Data 150 - 4

Main Harness A

A407310

51266964 Issue1

9808/6510 Issue 1
Section C Electrics Electrics Section C
150 - 5 Harness Data Harness Data 150 - 5

Main Harness B

A407320

51266964 Issue1
A

9808/6510 Issue 1
Section C Electrics Electrics Section C
150 -6 Harness Data Harness Data 150 - 6

Main Harness C

A407330

51266964 Issue1

9808/6510 Issue 1
Section C Electrics Electrics Section C
150 - 7 Harness Data Harness Data 150 - 7

Main Harness D

A407340
51266964 Issue1

9808/6510 Issue 1
Section C Electrics Section C
150 - 8 Main Harness 150 - 8

Main Harness Data

Wire Colour Connector Destination Wire Colour Connector Destination

Number Number
1 SB C60 C1 61 B CTAP A73 C93
2 UY C59 C1 62 - - -
3 OW C64 C1 63 WB C105 C92
4 LGW C58 C1 64 W C5 C92
5 UW C62 C1 65 W C91 C104
6 RG C94 C1 66 R C6 C91
7 BG C61 C1 67 B CTAP A83 C55
8 OG C61 C1 68 B CTAP A83 C56
9 UR C1 C56 69 R CTAP B66 C102
10 UB C1 C55 70 BW C100 C103
11 - - - 71 B S/JOINT 1 C116
12 SR C63 C1 72 B CTAP A73 C80
13 YU C1 C77 73 B ? C79
14 YW C1 C76 74 - - -
15 UB C1 C85 75 RG CTAP A31 C81
16 YG C1 C84 76 B CTAP A83 C77
17 NB C1 C66 77 SG CTAP A78 C74
18 O C1 C72 78 SG C2 C86
19 OB C1 C69 79 - - -
20 NY C1 C73 80 RG CTAP A31 C82
21 LG C1 C70 81 B Earth C69
22 YR C1 C79 Header
23 WR C1 C96 82 B CTAP A73 C70
24 RS C1 C82 83 B Earth Header C72
25 RW C1 C81 84 B CTAP A83 C73
26 GW C1 C80 85 B C1575 Earth Header
27 G C88 C1 86 B CTAP A83 C76
28 W C1 C90 87 B CTAP A83 C84
29 O C88 C1 88 SG CTAP A36 C87
30 RU C28 C1 89 - - -
31 RG C28 C1 90 - - -
32 NW C166 C1 91 - - -
33 R C68 C2 92 B S/JOINT 1 C54
34 U C54 C2 93 - - -
35 SG C67 C2 94 BU CTAP A39 C108
36 S C67 C2 95 WR CTAP A23 C99
37 WG C67 C2 96 B CTAP A73 C166
38 BR C2 C101 97 WR CTAP A23 C107
39 BU C2 C99 98 B Earth Header C97
40 BW C2 C95 99 R CTAP B66 C98
41 YB C2 C86 100 YR CTAP A22 C110
42 WY C2 C87 101 B CTAP A73 C110
43 - - - 102 U CTAP A34 C111
44 YR C2 C75 103 B CTAP A73 C111
45 NW C2 C74 104 B Earth Header C94
46 K C157 C2 105 B CTAP A73 C221
47 GU C93 C2 106 B CTAP A83 C71
48 G C2 C83 107 B S/JOINT 1 C220
49 R CTAP A66 C2
50 W C54 C2 151 GB C165 C1
51 B S/JOINT 1 C2 152 - - -
52 B CTAP A85 C65 153 UG C65 C1
53 B CTAP A85 C58 154 UO C71 C1
54 B CTAP A85 C59
55 B CTAP A85 C64 200 GW C221 C1
56 B CTAP A85 C62 201 GY C220 C1
57 B CTAP A85 C63
58 B CTAP A85 C60 289 B CTAP A83 C165
59 B CTAP A85 C66 290 B C164 Earth Header
60 B CTAP A85 C68 291 RG CTAP A31 C101
292 B S/JOINT 1 EarthHeader

9803/6510 Issue 1
Section C Electrics Section C
150 - 9 Main Harness 150 - 9

Main Harness Data (cont’d)

Wire Colour Connector Destination

Number
293 B S/JOINT 1 Earth Header
294 B Earth Header C109
295 - - -
296 - - -
297 SG CTAP A78 C163
298 NW CTAP A45 C163
299 RY C2 C162
300 SG CTAP A36 C75

Splice - Example: CTAP A31

Splice Wire Wire

Location No. Colour
A31 75 RG
A31 80 RG
A31 291 RG

CTAP A31
WIRE No. 31 WIRE No. 31

WIRE No. 75 WIRE No. 291

WIRE No. 80

A409870

Joint - Example: S/Joint 13

Joint Wire Wire

Location No. Colour
13 115 RY
13 150 RY

S/JOINT 13
WIRE No. 115 WIRE No. 150

A409880

9803/6150 Issue 1
Section C Electrics Section C
150 - 10 Harness Data 150 - 10

Facia Link Harness Connector Location

1
5, 6,8

3 11
4 7 12 13
9
10

A407770
Key to Connectors
Key To Wire Colours
Item Connector Function B Black
1 C14 Monitor EMS R Red
2 C15 Facia Switch Panel U Blue
3 C18 HVAC Controller (Air - LG Light Green
Conditioning) G Green
4 C24 Worklamp Switch Y Yellow
5 C40 Cigar Lighter P Purple
6 C41 Cigar Lighter W White
7 C49 Road Light Switch (Red Marker - N Brown
Tape) O Orange
8 C159 Cigar Lighter Ilumination K Pink
9 C180 Cab 1 (Cab Harness connection) S Grey
10 C181 Wheeled Harness BR Black with Red
11 C223 Radio Mute switch
12 C225 Cab 3 (Cab harness connectior)
13 C37 Cab Sub Harness (Radio and -
Upper Wiper)

9803/6510 Issue 1
Section C Electrics Section C
150 - 11 Harness Data 150 - 11

Facia Link Harness Connector Location -

(cont’d)

11

6 5
416411

See previous page for the description of the annotations

above.

9803/6510 Issue 1
Section C Electrics Electrics Section C
150 - 13 Harness Data Harness Data 150 - 13

Facia Link Harness B

A1

A2

A407560

51267172 Issue1

9808/6510 Issue 1
Section C Electrics Section C
150 - 14 Harness Data 150 - 14

Facia Link Harness Data

Wire Colour Connector Destination Splice - Example: CTAP A31

Number
Splice Wire Wire
Location No. Colour
1 P C18 C180
A31 75 RG
2 SR C180 C49
A31 80 RG
3 PU C14 C180
A31 291 RG
4 B C41 C180
5 R C14 C180
6 U C14 C180
7 SCR C180 C14 CTAP A31
WIRE No. 31 WIRE No. 31
8 U C180 C15
9 UK C180 C15
10 UO C18 C225
11 UW C18 C225
12 YR C18 C225
13 UY C225 C24 WIRE No. 75 WIRE No. 291
14 Y C225 C24
15 RS C181 C49 WIRE No. 80
16 RW C181 C49
A409870
17 SR CTAP A2 C14
18 B CTAP A4 C223
19 B CTAP A4 C49
20 P CTAP A1 C14
21 B CTAP A4 C14 Joint - Example: S/Joint 13
22 P CTAP A1 C24
23 P CTAP A1 C24 Joint Wire Wire
24 B CTAP A4 C24 Location No. Colour
25 P CTAP A1 C24 13 115 RY
26 P CTAP A1 C15 13 150 RY
27 B C14 C15
28 UG C14 C15
29 LG C14 C15 S/JOINT 13
30 RW C14 C15 WIRE No. 115 WIRE No. 150
31 OG C14 C15
32 - - -
33 - - -
34 U C18 C225 A409880

35 GW C18 C225
36 Y CTAP A38 C225
37 RY C223 C225
38 Y C159 C223
39 P CTAP A1 C49
40 Y C40 C223
41 SR CTAP A2 C49
42 B CTAP A4 C18

9803/6510 Issue 1
Section C Electrics Section C
150 - 15 Harness Data 150 - 15

Cab Harness Connector Location

44 33

24

28 27 25 26
35 29

34

18 19
20
47
40
45
43
17
32

401740

See following page for the description of the annotations Key To Wire Colours
above.
B Black
R Red
U Blue
LG Light Green
G Green
Y Yellow
P Purple
W White
N Brown
O Orange
K Pink
S Grey
BR Black with Red

9803/6510 Issue 1
Section C Electrics Section C
150 - 16 Harness Data 150 - 16

Cab Harness Connector Locations - (cont’d)

View from behind the drivers seat with panel 11 12 13 21

removed:

48
9,10
30 15

17 5
1, 2, 3, 4

22,23,50 16
14 To the left
hand
To the right console
hand Main Harness
console

42,49 46 33, 44
Facia Link Harness Under Front of Cab
8
Item Connector Function
Key to Connectors
27 C32 Lever Hammer Switch(wheeled only)
Item Connector Function 28 C33 Dozer On Switch (wheeled only)
1 Earth Header 29 C34 Horn Switch (Red Marker Tape)
2 Earth Header 30 C37 Cab Sub Harness
3 Earth Header 31 C42 Shut Down Relay (not used)
4 Earth Header 32 C43 Boom Priority Switch
5 C1 Connector A 33 C112 Breaker Pilot Switch
6 C2 Connector B 34 C113 Console Switch A
7 C3 Facia Link 3 35 C115 Console Switch B
8 C4 Wheeled Option Cab 36 C115 Lever Limit Switch
9 C5 24V Supply( Battery) 37 C117 Diode 1 Washer
10 C6 24V Supply( Ignition) 38 C155 Diode 3 Redundancy 1
11 C8 Electronic Controll Unit (ECU) A 39 C156 Diode 4 Redundancy 2
12 C9 Electronic Controll Unit (ECU) B 40 C160 Options Hydraulic Switch
13 C10 Electronic Controll Unit (ECU) C 41 C161 Diode 5
14 C11 Diagnostic Connector 42 C180 Facia Link 1
15 C12 Standard-Wheeled CAN Link 43 C200 Lower Wiper Switch(Green Marker -
16 C13 Redundancy Switch Tape)
17 C21 HVAC Unit Control (Air Con) 44 C201 Lower Wiper
18 C22 Throttle Dial 45 C202 Heated Seat Switch (Red Marker -
19 C23A Key Switch Tape)
20 C23B Key Switch 46 C203 Heated Seat
21 C25 Fuse Box 47 C222 Interior Lamp Switch
22 C26 Auxiliary 48 C224 Voltage Converter
23 C27 Auto Fan 49 C225 Facia Link 3
24 C29 2 Stage Travel 50 C226 Auxiliary 2
25 C30 Grab (Red Marker Tape) 51 C227 Wiper 2 (Diode)
26 C31 Right hand Lever Switch (option) 52 C228 Lower Wiper (Diode)

9803/6510 Issue 1
Section C Electrics Electrics Section C
150 - 17 150 - 17

Cab Harness A

51267171 Issue1
A407590
9808/6510 Issue 1
Section C Electrics Electrics Section C
150 - 18 Harness Data Harness Data 150 - 18

Cab Harness B

A407650

51267171 Issue1

9808/6510 Issue 1
Section C Electrics Electrics Section C
150 - 19 Harness Data Harness Data 150 - 19

Cab Harness C

A407600
51267171 Issue1

9808/6510 Issue 1
Section C Electrics Electrics Section C
150 - 20 Harness Data Harness Data 150 - 20

Cab Harness D

A407610

51267171 Issue1

9808/6510 Issue 1
Section C Electrics Electrics Section C
150 - 21 Harness Data Harness Data 150 - 21

Cab Harness E

9808/6510 Issue 1
Section C Electrics Electrics Section C
150 - 22 Harness Data Harness Data 150 - 22

Cab Harness F

A407630
51267171 Issue1

9808/6510 Issue 1
Section C Electrics Section C
150 - 23 Harness Data 150 - 23

Cab Harness Data

Wire Colour Connector Destination Wire Colour Connector Destination

Number Number
1 SB C1 C10 61 Y C4 C10
2 UY C1 C10 62 YG C4 C10
3 OW C1 C10 63 PS C4 C10
4 LGW C1 C10 64 - - -
5 UW C1 C10 65 - - -
6 RG C1 C10 66 UR C30 C8
7 BG C1 C115 67 SG CTAP A41 C8
8 OG C1 C10 68 LGR C8 C112
9 UR C1 C10 69 RB C23B C8
10 UB C1 C10 70 LGY C8 C29
11 G C37 C10 71 GR C34 C8
12 SR C1 C10 72 UW C30 C8
13 YU C1 C8 73 LG CTAP A25 C8
14 YW C1 C8 74 S CTAP A42 C8
15 UB C1 C8 75 NU C8 C32
16 YG C1 C8 76 PG C8 C33
17 GB C1 C168 77 GY C1 C8
18 NB C1 C10 78 UY C180 C8
19 SB C1 C8 79 SR C22 C8
20 UG C1 C10 80 U C8 C115
21 O C1 C8 81 PU C8 C33
22 UO C1 C8 82 BY C31 C8
23 OB C1 C8 83 Y C225 C8
24 NY C1 C8 84 O C25 C9
25 LG C1 C4 85 S C25 C9
26 YR C1 C10 86 - - -
27 WR C1 C8 87 PU C13 C9
28 RS C1 C10 88 SR S/JOINT 1 C9
29 RW C1 C10 89 RB S/JOINT 9 C9
30 GN C1 C10 90 RB S/JOINT 9 C9
31 G C1 C21 91 - - -
32 W C1 C21 92 B Earth Header 1 C9
33 O C1 C21 93 N S/JOINT 11 C9
34 GN C1 C8 94 - - -
35 RU C1 C10 95 - - -
36 RG C1 C224 96 - - -
37 NW C1 C10 97 B Earth Header 1 C9
38 GU C1 C160 98 GB S/JOINT 10 C9
39 R C2 C10 99 GB S/JOINT 10 C9
40 U C180 C2 100 - - -
41 SG C22 C2 101 B Earth Header 1 C9
42 S C22 C2 102 B Earth Header 1 C9
43 UR C160 C2 103 RB C37 C10
44 WG C2 C8 104 RY C37 C10
45 BR C2 C10 105 B Earth Header 1 C10
46 BU C23B C2 106 B Earth Header 1 C10
47 BW S/JOINT 14 C2 107 GR C37 C10
48 YB C2 C8 108 UK C180 C10
49 WY C2 C8 109 - - -
50 SG CTAP A41 C2 110 - - -
51 YR C2 C8 111 B C11 Earth Header 1
52 NW C2 C8 112 - - -
53 K C2 C10 113 - - -
54 GU C2 C8 114 BW S/JOINT 14 C23A
55 G C202 C2 115 RY S/JOINT 13 C23A
56 R C2 C42 116 - - -
57 W C2 C42 117 - - -
58 B Earth Header C2 118 PG C13 C156
59 YB C4 C10 119 - - -
60 YU C4 C10 120 - - -
121 - - -

9803/6510 Issue 1
Section C Electrics Section C
150 - 24 Cab Harness 150 - 24

Cab Harness Data (cont’d)

Wire Colour Connector Destination Wire Colour Connector Destination

Number Number
122 - - - 182 - - -
123 - - - 183 - - -
124 - - - 184 BW C200 Earth Header 3
125 SR S/JOINT 1 C180 185 - - -
126 B C180 Earth Header 1 186 BW C200 Earth Header 3
127 P C13 C180 187 - - -
128 PU CTAP A87 C180 188 - - -
129 - - - 189 BW C202 Earth Header 3
130 GW C227 C37 190 BG C13 C42
131 GR CTAP B107 C227 191 BW CTAP A47 C42
132 N C228 C201 192 NU CTAP A75 C43
133 GU CTAP A252 C228 193 BO Earth Header 4 C43
134 - - - 194 BO Earth Header 4 C43
135 UW C225 C21 195 RG CTAP A36 C43
136 - - - 196 - - -
137 UO C225 C21 197 WU C160 C112
138 - - - 198 BO Earth Header 4 C115
139 - - - 199 BG C115 C113
140 - - - 200 - - -
141 - - - 201 BO Earth Header 4 C117
142 - - - 202 GR CTAP A107 C117
143 UG C25 C21 203 - - -
144 - - - 204 - - -
145 BU C21 Earth Header 2 205 PG CTAP A118 C155
146 U C225 C21 206 UK CTAP A108 C155
147 - - - 207 - - -
148 - - - 208 OG CTAP A8 C156
149 - - - 209 - - -
150 RY S/JOINT 13 C25 210 GU CTAP A38 C161
151 - - - 211 GB CTAP A17 C161
152 - - - 212 LGR CTAP A68 C160
153 - - - 213 BO Earth Header 4 C160
154 - - - 214 - - -
155 - - - 215 - - -
156 - - - 216 RG CTAP A36 C160
157 - - - 217 R C25 C23B
158 N S/JOINT 11 C9 218 - - -
159 - - - 219 - - -
160 - - - 220 R S/JOINT 3 C12
161 - - - 221 U S/JOINT 4 C12
162 - - - 222 SCR S/JOINT 5 C12
163 - - - 223 R S/JOINT 6 C11
164 - - - 224 U S/JOINT 7 C11
165 BU Earth Header C26 225 SCR S/JOINT 8 C11
166 - - - 226 R S/JOINT 3 C9
167 UG CTAP A143 C27 227 U S/JOINT 4 C9
168 BU Earth Header 2 C29 228 SCR S/JOINT 5 C9
169 BU Earth Header 2 C30 229 R S/JOINT 6 C180
170 BU Earth Header 2 C30 230 U S/JOINT 7 C180
171 BU C201 Earth Header 2 231 SCR S/JOINT 8 C180
172 BW Earth Header 3 C31 232 - - -
173 - - - 233 - - -
174 BW Earth Header 3 C32 234 - - -
175 BW Earth Header 3 C33 235 R S/JOINT 6 S/JOINT 3
176 BW Earth Header 3 C33 236 U S/JOINT 7 S/JOINT 4
177 BW Earth Header 3 C34 237 SCR S/JOINT 8 S/JOINT 5
178 - - - 238 - - -
179 - - - 239 - - -
180 BW C37 Earth Header 3
181 - - -

9803/6510 Issue 1
Section C Electrics Section C
150 - 25 Cab Harness 150 - 25

Cab Harness Data (cont’d)

Wire Colour Connector Destination Wire Colour Connector Destination

Number Number
240 BW CTAP A47 C8 298 BO C203 Earth Header 4
241 BW C13 Earth Header 3 299 BO C224 Earth Header 4
242 YR C13 C10 300 - - -
243 - - -
244 - - -
245 BU CTAP A165 C226
246 - - -
247 - - - Splice - Example: CTAP A31
248 - - - Splice Wire Wire
249 - - - Location No. Colour
250 K C200 C8 A31 75 RG
251 RW C222 C8 A31 80 RG
252 GU C201 C10 A31 291 RG
253 - - -
254 W CTAP A259 C25
255 R S/JOINT 12 C25
CTAP A31
256 R S/JOINT 12 C25 WIRE No. 31 WIRE No. 31
257 R S/JOINT 12 C25
258 R S/JOINT 12 C25
259 W C25 C5
260 W CTAP A259 C25
261 R S/JOINT 12 C25
WIRE No. 75 WIRE No. 291
262 GB S/JOINT 10 C25
263 N S/JOINT 11 C25
264 RB S/JOINT 9 C25 WIRE No. 80
265 - - -
A409870
266 G CTAP A55 C25
267 RG CTAP A36 C25
268 LG CTAP A284 C25
269 SR S/JOINT 1 C25
270 UY C11 C25 Joint - Example: S/Joint 13
271 UR S/JOINT 2 C25
Joint Wire Wire
272 P CTAP A127 C25
Location No. Colour
273 - - -
13 115 RY
274 - - -
13 150 RY
275 R S/JOINT 12 C6
276 - - -
277 - - -
278 - - - S/JOINT 13
WIRE No. 115 WIRE No. 150
279 - - -
280 RG CTAP A36 C37
281 RG CTAP A36 C200
282 RY C2 C8
A409880
283 - - -
284 LG C224 C33
285 GW C225 C21
286 YR C180 C21
287 UR S/JOINT 2 C26
288 UR S/JOINT 2 C226
289 RY C225 C37
290 Y C224 C225
291 R C224 C37
292 G CTAP A 55 C201
293 - - -
294 Y C203 C202
295 G C202 C37
296 - - -
297 BO C224 Earth Header 4

9803/6510 Issue1
Section E Hydraulics Section E
i i

Contents Page No.

Service Tools 1-1

Technical Data 2-1

Basic System Operation

Hydraulic Component Location 3-1
Introduction to Hydraulic Schematic Symbols 4-1

Circuit Descriptions
Component Identification 5-1
Main Hydraulic Schematic 5-2
Servo Line 5-3
Servo Pressure and Return Line 5-5
Main Control Valve 5-7
Hydraulic Pump Operation 5 - 13
Hydraulic Pump Regulation 5 - 15
Neutral Circuit 5 - 17
Straight Line Travel 5 - 19
Travel - Middle Speed 5 - 21
Boom Up 5 - 23
Boom Down 5 - 25
Dipper Out 5 - 27
Dipper In 5 - 29
Bucket Opening 5 - 31
Bucket Closing 5 - 33
Priority Valves 5 - 35
Slew Motor Configuration 5 - 37
Slew Motor reduction Gear 5 - 37
Slew Circuit 5 - 38
Slew Brake 5 - 40
Auxiliary / Merged flow 5 - 42
Hammer 5 - 44
Remote Control Valve (Services) 5 - 46
Cushion Valve 5 - 47
Solenoid Valve (8 Spool) 5 - 50
Shuttle Valve 5 - 52
Rotary Coupling 5 - 53

Fault Finding
Main Control Valve 16 - 1
Relief Valve 16 - 2
Hydraulic System 16 - 2
Slew Motor 17 - 1
Hydraulic Pump 18 - 1
Hydraulic Rams 19 - 1
Fault Finding Tests 20 - 1

Service procedures Procedures

Hydraulic Contamination 21 - 1
- Test 001: Negative Control Signal 23 - 1
- Test 002: Max Flow Signal 23 - 2
- Test 003: Main Pump Pressure 23 - 3
- Test 004: Horse Power Control 23 - 5
- Test 005: Operation of Main Hydraulic Spool 23 - 7
- Test 006: Pressure Switches 23 - 8
- Test 007: Engine Speed Setting 23 - 9

9803/6510 Issue 1
Section E Hydraulics Section E
ii ii

Contents Page No.

Service Procedures cont’d
- Test 008: Machine Cycle Times 23 - 10
- Test 010: Hose Burst Check Valve 23 - 13
- Test 011: Slew Brake Pressure 23 - 14
- Test 012: Track Motor Relief Valve Setting 23 - 15
- Test 013: Track Motor Drain Line Flow Rate 23 - 16
- Test 014: Loss of High Speed Tracking 23 - 17
- Test 015: Machine Selects High Gear 23 - 18
- Test 016: Flow Testing Pumps 23 - 19
- Test 017: Testing Slew Bearing 23 - 21
- Ram Creep Tests - All Services 24 - 1
Pressure Testing General 26 - 1
- Pressure Testing Points 26 - 2
- Pressure Relief Valve Location 26 - 3
- Main Relief Valve Pressure 26 - 4
- Servo Relief Pressure 26 - 5
- Slew Motor Pressure Relief 26 - 6
- Auxiliary Relief Valves 26 - 8
- Travel Motor Relief Pressure 26 - 14

Hydraulic Pump
Removal and Replacement 31 - 1
Dismantling and Assembly 31 - 3

Remote Control Valve (Hand Control)

Removal and Replacement 35 - 1
Dismantling and Assembly 35 - 3

Direction Control Valve

Dismantling and Assembly 36 - 3

Solenoid Valve ( 8 spool)

Removal and Replacement 38 - 1
Dismantling and Assembly 38 - 2

Shuttle Valve
Removal and Replacement 40 - 1
Dismantling and Assembly 40 - 3

Cushion Valve
Removal and Replacement 42 - 1
Dismantling and Assembly 42 - 3

Slew Brake Valve

Removal and Replacement 44 - 1
Dismantling and Assembly 44 - 3

Slew Motor
Removal and Replacement 50 - 1
Dismantling and Assembly 50 - 2

Slew Motor Reduction Gear Assembly

Dismantling and Assembly 50 - 20

9803/6510 Issue 1
Section E Hydraulics Section E
iii iii

Contents Page No.

Rotary Coupling
Removal and Replacement 53 - 1
Dismantling and Assembly 53 - 5

Hydraulic Rams 55 - 1
Bucket Ram
- Removal and Replacement 55 - 2
Dipper Ram
- Removal and Replacement 55 - 6
Boom Ram
- Removal and Replacement 55 - 11
Hydraulic Rams
- Dismantling and Assembly 60 - 1
Piston Ram Nut
- Removal and Replacement 60 - 2
Hydraulic Rams
- Reconditioning 60 - 4

9803/6510 Issue 1
Section E Hydraulics Section E
1-1 Service Tools 1-1

Service Tools

SECTION E - Hydraulics

Hydraulic Pressure Test Gauges and Connections

1 892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in2)
2 892/00346 Pressure Gauge 0-70 bar (0-1000 lbf/in2)
3 892/00347 Connector
4 892/00254 Hose

3
4

1/2

Pressure Test ‘T’ Adapters Pressure Test Adapters

892/00262 1/4 in BSP x 1/4 in F BSP x Test Point 892/00255 1/4 in BSP x Test Point
816/55038 3/8 in BSP x 3/8 in F BSP x Test Point 892/00256 3/8 in BSP x Test Point
816/55040 1/2 in BSP x 1/2 in F BSP x Test Point 892/00257 1/2 in BSP x Test Point
892/00263 5/8 in BSP x 5/8 in F BSP x Test Point 892/00258 5/8 in BSP x Test Point
892/00264 3/4 in BSP x 3/4 in F BSP x Test Point 816/15118 3/4 in BSP x Test Point
892/00265 1 in M BSP x 1 in F BSP x Test Point 892/00259 1 in BSP x Test Point
892/00266 1,1/4 in M BSP x 1,1/4 in F BSP x Test Point 892/00260 1,1/4 in BSP x Test Point
892/00267 1,1/2 in M BSP x 1,1/2 in F BSP x Test Point 892/00261 5/8 in UNF x Test Point

9803/6510 Issue 1
Section E Hydraulics Section E
1-2 Service Tools 1-2

Service Tools (cont’d)

SECTION E - Hydraulics (cont’d)

Hand Pump Equipment

892/00223 Hand Pump
892/00137 Micro-bore Hose 1/4 in BSP x 5 metres
892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
892/00706 Test Probe
892/00278 Gauge 0 - 40 bar (0 - 600 lb/in2) 816/50005 1/2 in BSP (A) x 1/2 in BSP (B)
892/00279 Gauge 0 - 400 bar (0 - 6000 lb/in2) 816/60096 3/4 in BSP (A) x 3/4 in BSP (B)
892/00280 Gauge 0 - 600 bar (0 - 8500 lb/in2) 816/00018 1 in BSP (A) x 1 in BSP (B)

Female Cone Blanking Plug Male Cone Blanking Plug

892/00055 1/4 in BSP 816/00294 1/4 in BSP
892/00056 3/8 in BSP 816/00189 3/8 in BSP
892/00057 1/2 in BSP 816/00190 1/2 in BSP
892/00058 5/8 in BSP 816/00197 5/8 in BSP
892/00059 3/4 in BSP 816/00196 3/4 in BSP
892/00060 1 in BSP 816/00193 1 in BSP

9803/6510 Issue 1
Section E Hydraulics Section E
1-3 Service Tools 1-3

Service Tools (cont’d)

SECTION E - Hydraulics (cont’d)

Socket Box Wrench For disassembly and assembly of slew motor

gearbox.

A408900

Nut Adapter For disassembly and

assembly of slew motor
gearbox.

A408860

9803/6510 Issue 1
Section E Hydraulics Section E
1-4 Service Tools 1-4

Service Tools (cont’d)

SECTION E - Hydraulics (cont’d)

A408880
Seal Ring Tool for assembly and disassembly of slew motor
gearbox seal

Stopper for assembly of slew motor

gearbox.

A408890

9803/6510 Issue 1
Section E Hydraulics Section E
1-5 Service Tools 1-5

Service Tools (cont’d)

SECTION E - Hydraulics (cont’d)

Bearing Rig for removal of slew

motor bearing.

A408870

9803/6510 Issue 1
Section E Hydraulics Section E
1-6 Service Tools 1-6

Service Tools (cont’d)

SECTION E - Hydraulics (cont’d)

Ram Dismantling and Assembly

Ram Piston Head Nut

Item Part Number Description Quantity

1 993/99525 Rig assembly (not including spanners and ram) 1

2 993/99522 Anchor side plate (supplied loose unwelded) 1

3 993/99523 Anchor cross member (supplied loose unwelded) 1

4 993/99524 Ram eye end modification 1

5 556/43400 Lift ram 1

6 545/18000 Lynch pin 1

7 811/50232 11/4 in Pivot pin 1

Spanner Requirements
993/99518 Bucket ram 90 mm A/F Nut
SSP0047 Boom ram 95 mm A/F Nut
993/99519 Dipper ram 100 mm A/F Nut

Note: All spanners have operating centres of 500 mm.

9803/6510 Issue 1
Section E Hydraulics Section E
1-7 Service Tools 1-7

Service Tools (cont’d)

SECTION E - Hydraulics (cont’d)

Ram Dismantling and Assembly (cont’d)

Jig for inserting and correcting seal ring

WDB 2052 Bucket 120mm Cylinder inner diameter

WDB 2054 Boom 125mm Cylinder inner diameter

Jig for pulling out, press-fitting bushing

WDB 2166 Bucket 80mm Piston Rod diameter
WDB 2167 Boom 85mm Piston Rod diameter
WDB 2170 Arm 100mm Piston Rod diameter

Jig for press-fitting wiper ring

WDB 2166-1 Bucket 80mm Piston Rod diameter
WDB 2167-1 Boom 85mm Piston Rod diameter
WDB 2170-1 Arm 100mm Piston Rod diameter

Jig for inserting cylinder head

WDB 2174 Bucket 80mm Cylinder rod inner diameter
WDB 2175 Boom 85mm Cylinder rod inner diameter
WDB 2178 Arm 100mm Cylinder rod inner diameter

9803/6510 Issue 1
Section E Hydraulics Section E
1-8 Service Tools 1-8

Service Tools (cont’d)

SECTION E - Hydraulics (cont’d)

Ram Dismantling and Assembly (cont’d)

Seal Ring and Connector Jig

WDB 2052 Seal Ring insert and connection jig set
Note: The above Part no. is applicable to a tube diameter of 120mm.

Bush Removal Jig

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

Bush Fitting Jig

WDB 2166 Bush press fitting jig
WDB 2166-1 Retainer
Note: The above Part no. is applicable to a rod diameter of 80mm.

Wiper Ring fitting Jig

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

Wiper Ring fitting Jig

WDB 2174 Cylinder Head insertion guide jig
Note: The above Part no. is applicable to a rod diameter of 80mm.

9803/6510 Issue 1
Section E Hydraulics Section E
2-1 Technical Data 2 -1

Hydraulic Pump
Type Twin variable displacement piston pump
Displacement Volume 115 (cc/rev) x2
Working Pressure 350 kgf/cm2 (343 bar, 4977 lb/in2)
Maximum Output 215 litre/min (47.3 UK gal, 56.4 US gal)
Working Pressure 40 kgf/cm2 (39.2 bar, 569 lb/in2)
Minimum Output 40 litre/min (8.8 UK gal, 0.5 US gal)
Dry weight 132 kg (291 lb)

Servo (Pilot) Pump

Type Fixed Displacement Gear Pump
Displacement Volume (servo) 10 cc/rev
Working Pressure 37.7 - 49kgf/cm2 (37 - 43 bar, 536.5 - 623.5lb/in2)

Hydraulic Pump Regulator

Displacement 97.2 (96.5) cc/rev

Revolving Speed Range Rated 2070 (2200) rev/min

Rated 314 bar (320 kgf/cm , 4550 Ib in2) Max 343bar (350 kgf/cm , 4977Ib in2)
2 2
Pressure
MaximumFlow Rate 215 l /min(47 UK gal/min, 56 US gal/min) (Rated revolution load pressure
78.5 bar (80 Kgf/cm2, 1137 Ib in2)
Minimum Flow Rate 40 litres/min (8.8 UK gal, 10.5 US gal) (Rated revolution load pressure
78.6 bar (80 Kgf/cm2, 1137.6 Ib in2)
Input Horsepower 125 (154) PS
Maximum Input Torque 425 - 481.5 Nm (43.4 - 49.1 kgf-m, 314 - 355 Ibf ft)
Control Function Full horsepower control
Power shift control
Negative flow control
Q max cut control
Other KHI 10 cc/rev with gear pump

Proportional Pressure Reducing Valve

Max. primary pressure 39 bar (40 kgf/cm2, 569 Ib in2)
Max, back pressure (allowable pressure) 9.8 bar (10 kgf/cm2, 142 Ib in2)
Secondary pressure setting range 0 - 3.9 bar (0 - 40 kgf/cm, 0 - 568 Ib in2)
Max. flow rate 6 l/min (1.3 UK gal/min, 1.6 US gal/min)
Electrical specifications
1 Rated current 800 mA
2 Coil resistance (at 20°C) 13.5 ± 0.7 Ω
3 Recommended fluctuation of
proportional solenoid current 70 ~ 75 Hz, 400 ~ 600 mApp

9803/6510 Issue 1
Section E Hydraulics Section E
2-2 Technical Data 2 -2

Main Control Valve

Type Hydraulic Pilot System

Operating System Set pressure relief
Main Relief Pressure
Standard 343 bar (350kg cm2, 4975 lb/in2) at 138 litre/min (30.3UK gal, 36.4 US gal)
Pressure Raising 373 bar (380.5kg cm2,5410 lb/in2) at 155 litre/min (34 UK gal, 41 US gal)
Overload Relief Pressure
Bucket Open/closed 392 bar (400kg cm2, 5685 lb/in2) at 20 litre/min (4.4 UK gal, 5.3 US gal)
Dipper 392 bar (400kg cm2, 5685 lb/in2) at 20 litre/min (4.4 UK gal, 5.3 US gal)
Boom Raising 392 bar (400kg cm2, 5685 lb/in2) at 20 litre/min (4.4 UK gal, 5.3 US gal)
Boom Lowering Pressure 264 bar (269kg cm2, 3828 lb/in2) at 20 litre/min (4.4 UK gal, 5.3 US gal)
Function Travel priority, Slew or Boom priority and Dipper Load Holding Valve,
Boom and Dipper 2 Speed Confluence
Dry Weight 165 kg (364 lb)

Spool Stroke versus Pilot Pressure

Boom Ram

Cylinder Inside Diameter 125 mm (4.9 in)

Rod Diameter 85 mm (3.4 in)
Max Contracted Length 1790 mm +/-3 (70.5 in)
Stroke 1259 mm +/- 2 (49.6 in)
Dry Weight 176 kg (388 lb)

Dipper Ram

Cylinder Inside Diameter 130 mm (5.1 in)

Rod Diameter 95 mm (3.7 in)
Max Contracted Length 2150 mm +/- 3 (84.6 in)
Stroke 1578 mm +/- 2 (62 in)
Dry Weight 275 kg (606 lb)

9803/6510 Issue 1
Section 3 Hydraulics Section 3
2-3 Technical Data 2 -3

Bucket Ram

Cylinder Inside Diameter 115 mm (4.5 in)

Rod Diameter 85 mm (3.3 in)
Max Contracted Length 1583 mm +/- 3 (62. 3 in)
Stroke 1012 mm +/-2 (34.8 in)
Dry Weight 146 kg (322 lb)

Slew Equipment

Type Fixed displacement piston motor

Suction Capacity 151 cc/rev
Working Pressure 294.7 kgf/cm2 (289 bar, 4191.6 lb/in2)
Work Flow 198.7 litre/min (43.6 gal/min)
Set Pressure Relief 289 bar, 4191.6 lb/in2 at 155 litre/min (34 UK gal, 41 US gal)

Reduction Gear Ratio 16.757 : 1

Slew Brake
Brake Torque More than 739 Nm, 75 kgf m, 545 ft lbs (not including reduction gear)
Brake Pressure Release Min 29 bar, 29.5 kg cm2420 lb/in2
Dry Weight 197 kg (434 lb)

9803/6510 Issue 1
Section E Hydraulics Section E
3-1 Basic System Operation 3-1

Hydraulic Component Location

1 Hydraulic Pump

2 Drain Line Filter

3 Plexus Filter

4 Drain Line Filter

5 Servo Pump

6 Solenoid Valve (8 spool)

7 Dipper Ram

8 Slew Motor

9 Hydraulic Oil Tank

10 Tank Pressure Release/Air Breather

11 Hudraulic Oil Filler Cap

12 Main Control Valve -

Pressure Switches:
Excavator
Travel
Auto Boost

13 Oil Cooler

14 Cushion Valve

15 Slew Brake Valve

16 Shuttle Valve

17 Pressure Switches:
Slew
Boom Up
Boom Down
Auto Mode

18 Rotary Coupling

19 Boom Rams

20 Track Motor/Gearbox

21 Bucket Ram

9803/6510 Issue 1
Section E Hydraulics Section E
3-2 Basic System Operation 3-2

Hydraulic Component Location

11
12
10
9
7

3 4 5 6

19
18 13

21

20

A408100
17 16 15 14

9808/6510 Issue 1
Section E Hydraulics Section E
4-1 Basic System Operation 4-1

Introduction to Hydraulic Schematic

Pumps & Motors
Symbols
Complex hydraulic components and circuits can be
Variable capacity pump
described to the engineer by using graphical symbols. The two directions of flow
following pages illustrate and give a brief description for
some of the more common symbols used.

There are many symbols in use and it would be impossible

to include them all here. However it should be noted that Fixed capacity motor
most are only variations or refinements on the basic one direction of flow
principles explained here. If more detailed information is
required you are recommended to obtain a copy of BS2917
or IS01219.

Once familiar with the symbols, the engineer can use Fixed capacity motor
hydraulic circuit diagrams as an aid to fault finding. It will be two directions of flow
possible to see the complete hydraulic circuit and decipher
the relationship between hydraulic components.

General (Basic & Functional Symbols) Variable capacity motor

one direction of flow
Spring

Flow restriction
affected by viscosity Variable capacity motor
two directions of flow
Direction of flow

Indication of rotation

Indication of direction
and paths of flow

A189660
Variable control

Rams

Single acting

Double acting

Double ended

Double acting with

damping at rod area end
A189670 A189680

9803/6510 Issue 1
Section E Hydraulics Section E
4-2 Basic System Operation 4-2

Introduction to Hydraulic Schematic

Symbols (cont'd)
Control Valves

One way restrictor

Used to enclose several
valves indicating that they
are supplied as one unit

3-Position, 4-Port High pressure selector

spring centred pilot (shuttle valve)
operated valve

3-Position, 6-Port
spring centred hand Throttling orifice -
operated valve normally closed

3-Position, 4-Port
spring centred solenoid &
pilot pressure operated valve Throttling orifice -
normally open

3-Position, 4-Port
spring centred detent
hand operated valve

Relief valve

Non - return valve

Non - return valve with

back pressure spring
Variable restrictor

Pilot operated
non - return valve

A189690 A189700

9803/6510 Issue 1
Section E Hydraulics Section E
4-3 Basic System Operation 4-3

Introduction to Hydraulic Schematic

Symbols (cont'd)
Energy Transmissions and Conditioning
Working line, return or feed
Reservoir - return line
above fluid level

Pilot control

Reservoir - return line

Drain lines below fluid level

Flexible pipe Header tank

Pressure sealed tank

Line junction

Accumulator
Crossing lines

Filter or strainer

Air bleed Water trap

Line plugged, also

pressure test point Cooler - with no
indication of coolant flow

Line plugged with

take off line
Cooler - indicating
direction of coolant flow

Quick release
couplings - connected Heater

A189710 A189720
Quick release
couplings - disconnected

9803/6510 Issue 1
Section E Hydraulics Section E
4-4 Basic System Operation 4-4

Introduction to Hydraulic Schematic

Symbols (cont'd)
Control Mechanisms

Rotating shaft-one direction Solenoid one winding

Rotating shaft-two directions

Solenoid two winding

Detent
M Electric motor operated

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 separate pilot valve
Lever operated

Pressure gauge
Pedal operated

Stem operated Pressure switch

Spring operated

Roller operated

Roller trip operated

(one directional) S189730 S189740

9803/6510 Issue 1
Section E Hydraulics Section E
4-5 Basic System Operation 4-5

Introduction to Hydraulic Schematic

Symbols (cont'd) Position 1 Position 2 Position 3

Control Valves

Control valves are usually represented by one or more

square boxes.

Fig. 1 - shows a control valve represented by three boxes. FIG 2

The number of boxes indicates the number of possible valve
operating positions, (4 boxes - 4 positions etc).

Fig. 2 - In circuit diagrams the pipework is usually shown

connected to the box which represents the unoperated
condition. (Hydraulic circuit diagrams are usually shown in
the unoperated condition).

Fig. 3 - 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 Port 1 Port 3
all 4 ports are blocked.
FIG 3
If the valve spool was moved to Position 1, movement of the
spool would connect Port 1 to Port 2, and Port 3 to Port 4.

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

spool would connect Port 1 to Port 4, and Port 3 to Port 2.

It must be noted that not all spools are of the same type.
Their operating designs can be seen by following the path
the flow arrows take in their respective operating squares. Port 2 Port 4

Three typical JCB style spools are known as 'D' spools, 'F'
spools and 'N' spools.

The 'D' spools generally control rams because when in the

FIG 4
neutral position the outlet ports are blocked, preventing ram
movement. Fig 3 shows a 'D' type spool.

Fig 4 - 'F' spools are often shown as four position spools

with the three normal positions for neutral and service
control; and the forth position, which has a detent, connects
both sides of the ram together to allow the service to 'float'.

Fig 5 - '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 5

A189760

9803/6510 Issue 1
Section E Hydraulics Section E
4-6 Basic System Operation 4-6

Introduction to Hydraulic Schematic

Symbols (cont'd)
Example of Schematic Circuit

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

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 G. Notice that the fluid must first open
one way valve F before flowing to the ram.

A
B

C G
D
E
F

A189770

9803/6510 Issue 1
Section E Hydraulics Section E
5-1 Circuit Description 5-1

Component Identification
The item numbers in the following table are identified on the Hydraul;ic Schematic diagram.
Note: * denotes option.

Item Part number Description Location

1 20/925315 Slew motor Centre section of machine
2 2331/32713 Dipper ram On the boom
3 25/220996 Slew brake valve Battery bay on the bulkhead panel
4 20/925318 Track motors X2 Lower frame sprocket drive
5 45/920020 Rotary coupling Centre section of machine
6 331/32602 Bucket ram On the dipper
7&8 331/32714 Boom rams Boom to revolving frame
9* KHJ0579 Dipper In boost & merge if fitted Battery bay on the bulkhead panel
10 1025/220822 Main control valve Centre section of machine
11* JRV0139 Dipper ram hose burst check valve Dipper ram
12* JRV0227 Boom ram hose burst check valve Boom ram
13 KNJ0287 Return line filter Pump bay on side of hydraulic tank
14 KRJ3823 1 bar cooler return check valve Cooler return pipe
15 KRJ3515 3 bar cooler return check valve Cooler return pipe
16 30/925515 Oil cooler radiator Radiator bay
17 JRC0007 Slew gearbox Centre section of machine
18 KRJ4235 Hydraulic tank air breather On top of hydraulic tank
19 215/11191 Hydraulic tank. Right hand side of machine
20 KHJ0568 Cushion valve warm up filter Centre of machine on cooler pipe
21 32/925359 Hydraulic tank suction strainer Inside hydraulic tank
22 KRJ2246 1.03 bar main return filter relief valve On top of Main return filter
23 KRJ3836 Main return filter Inside Hydraulic tank
24 KHJ0897 Plexus filter stop valves Below Plexus filter
25 JRJ0238 Plexus filter. Rear side of pump bay
26* JNV0076 Merge valve shut off valve Centre section of machine
27* KHJ0979 Merge line check valve. Centre section of machine
28 701/80374 Upper Servo pressure switch On main control valve
29 220829 8 Spool Solenoid valve Front side of pump bay
30 928/60027 Throttle proportional solenoid Pump bay at side of hydraulic tank
31 JHJ0050 Servo circuit accumulator On 8 Spool Solenoid valve
32 331/14519 Throttle actuator Pump bay at side of hydraulic tank
33 32/925214 Servo filter Rear side of pump bay
34 20/925309 Hydraulic pump Centre of pump bay
35 KSJ2465 Travel pedal valve Under cab floor
36* 928/60209 Option pedal valve Under cab floor
37 25/220830 Servo control Shuttle block Battery bay on the bulkhead panel
38 701/80373 Slew pressure switch On servo control Shuttle block
39 25/220836 Left hand joystick Cab
40 25/220041 Cushion control valve Battery bay on the bulkhead panel
41* 701/80373 Option pressure switch. Under cab floor
42* JLV0535 Right hand side quick release coupling Right hand side of Dipper
43* JBJ0037 Hammer/Auxiliary change over valve Center of machine
44* JBJ0038 Hammer pressure relief valve Left hand side of centre section
45* JBJ0066 Hammer return filter Left hand side of centre section
46 701/80375 Travel pressure switch On main control valve
47* 25/220536 Merge solenoid valve Battery bay on the bulkhead panel
48 JHV0195 Left hand side quick release coupling Left hand side of Dipper
49 JRJ0132 Boom hose burst check valve manifold Centre of machine between Boom rams
50 701/80198 Overload warning pressure switch On rear of item 49
51 25/220837 Right hand joystick Cab
52 701/80371 Power boost pressure switch On main control valve
53 701/80372 Auto mode pressure switch On servo control Shuttle block

9803/6510 Issue 1
Section E Hydraulics Section E
5 -2 Schematics 5-2

331/31716 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Z=14 130- 95-1580

Z=92 MIN.L 2150 P a1 PS PS P a2
4 t=49.5 t=49.5 115- 85-1012 125- 85-1259
1 17 .. 153.5/89.1 cm /rev
3
MIN.L 1583 MIN.L 1790
A 2 11
.X
. 153.5/89.1 cm 3/rev 6 7 8 A

t=16.575 P .. ..
T
4 .X
. 12 12 .X
.

C2
C2 T1 T2
Dr
3 3 D D T
151cm/rev P1 P2 T

RED

RED
B P2 P1
C2 C2
C2 C2
P BL E V2
B 15 BAR B
i
A H-2
5 7
L-4 L-1
P a2 P a1 V2 E BL P P BL E V2

289 BAR at 155 l/min

5
T
P D
B A
Mu FC P C

C C
RIGHT B A LEFT

BACKWARD L.H BACKWARD R.H T P L L P T

..
.X
. 49
FORWARD L.H FORWARD R.H T
P

PSW

4 ..
.X ON 200 bar 6
J-5
. 50 E-2

D D
3 bar

6
D-13
P S1 T3 T1 D3 D1 D2 T2 P S2
10 9
15
.
13 16 m x
14 H-4 L-9

10u P C1
0.6 bar
A5
1 bar
3 B5
18
E ARM(1) ARM(2) 29 E
P b5 P b9 .

10u .
3
20
L-12
n P a9 T2 C8 .
B2 C6
31u J-4 C4
.
0.3 bar 0.05 bar 19 o P c2
CUSHION
J-4 .
P a5 A8 l
z H-4
I-2
P c3
B8 k NEG CONTROL .
H-3
BOOM(2) BOOM(1)
8 P b4 P b8
G-10
C3 C5 y
F-4
P a4 P a8 2-STAGE RELIEF
F 10u F
B7 p NOTES
1.03 bar
SWING A 7
J-5
1) UPPER CHARACTERS SHOW THE CONNECTION POINTS AND
y b a P b3 BUCKET BOOM
F-13 H-2 H-2
P b7 PRIORITY LOWER VALUES SHOW THE ZONE AREA OF THIS DRAWING.
150MESH
P a3
C2 2) X .ARE OPTIONAL ITEMS.
P i2 P a7 e C7
Dr4 P i1 K-2
SWING SHUT OFF
B2 B6
A2 A6 f
OPTION TRAVEL(R)
P b2 P b6 K-2
24 j MAX FLOW CUT
21 22 23 1 P4
H-3
K-11
2 P a2 P a6
K-11 C1
w B1 u 8
G K-9 v K-10 F-5 2 STAGE TRAVEL
G
K-9 A 1 TRAVEL(L) q
..
.X P b1 t J-5
. K-11

P a1 ISOLATOR
25 26 31 A
r s
..
.X
. K-10 K-9
P C9
i a b c j k d g l m h
B-4 F-4 F-4 L-5 G-10 F-11 L-5 L-4 F-11 E-11 L-4
27 32
C13 GAS PRESSURE
B1 B2 B3 C1 C2 B4 B5 C3 C4 B6 30
P1 PT PP PA PH P3 P2 15 bar
C11 C12 T1 C10 CAPACITY 33
ON 335 bar 300cm
3

OFF 330 bar

H C6 H
52 10u
C7
C8 RIGHT LEFT UP DOWN OUT IN
A1 S1 A2 A3 S2 S3 A4 A5 C9 C5 A6
SWING BOOM ARM
z 1.03 bar
F-5 37

38 38 38 53
ON 20 bar ON 12 bar
ON 5 bar ON 22 bar OFF 15 bar OFF 9 bar
OFF 3 bar OFF 20 bar 46
28 TRAVEL(L) TRAVEL(R) A1 Psv a3 A2
I ..
.X I
.

36 OPTION 35 BACKWARD FORWARD FORWARD BACKWARD 34

a1 a 2

(FRONT) (REAR)

5 n o 4 p q
B-4 E-5 E-5 d-12 F-10 G-10
1 3 P T 2 1 2 T P 4 3
J J

Pm 1 Pm 2

Pt 1 Pt 2
ISUZU
P T A1 C D E1 G H P T
BB-6BG1T-S
.. r s t u 102KW/1950rev/min
R .X
. 2 1 3
G-5 G-5 G-10 G-10 3 3 10cm
/rev
..
.X
F-4 F-4
110cm /rev 110cm /rev
..
42 43 .

M
.X
41 .

ON 12 bar
39 bar
v w
OFF 10 bar
K ARM
F-4 F-4
C A K
BUCKET BOOM SWING
OPEN CLOSE UP DOWN LEFT RIGHT OUT IN B a4
1 3 2 4 1 3 2 4
e A1
C1
J-11 39 1 3 .. Dr B1 B3 A3
.X
f 51 S
..
.X
B1 .
J-11 .
45
T 48
A ARM B E BOOM F 2 ..
.X
h g d c .
10u
H-4 H-4 H-3 H-3
40 ..
IN OUT DOWN UP
47 .X
.
x
7 9 3
C-4 x-x
E-12
44 E-3
L L

A409970 Issue 1 DRAWING NUMBER 331/31716

1 2 3 4 5 6 7 8 9 10 11 12 DRAWN ON CAD THIS DRAWING IS THE PROPERTY OF JCB HEAVY PRODUCTS LTD AND MAY NOT BE COPIED OR REPRODUCED WITHOUT WRITTEN CONSENT

9803/6510 Issue 1
Section E Hydraulics Section E
5-3 Circuit Description 5-3

Servo Line

Components
1 Cab Manifold
2 Left hand Joystick
3 Right hand Joystick
4 Shuttle Valve
5 Cushion Valve
6 Main Control Valve
a Dipper 2
b Boom
c Bucket
d Travel Right hand
e Dipper 1
f Boom
g Slew
h Option
i Travel Left hand
j Dipper Holding Valve
k Boom Holding Valve
l Swing Over Dipper Priority Valve
m Boom Over Bucket Priority Valve
7 Tank Manifold
8 Travel pedal

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

9803/6510 Issue 1
Section E Hydraulics Hydraulics Section E
5-4 Schematics 5-4

Servo Line

5
A1 E1
A C

3 B D
CUSHION
P T VALVE

4
1 E G
JOYSTICK

2 YG/P
RHS

3 F H GR/R
C5 R S T
4 C8
LB
LB

S3 C7
V
V

S2 C4 W/O

S1 C3
P
P

C9 C2
GR
10 C6 C1 G

SHUTTLE BLOCK
G

P
P P
P R
R
JOYSTICK

1 A6 B6
G/R
LHS

2 G/R

6
4
P T JRJ0124 G
G G
G
A5 B5
Pb9 Pb8 Pb7 Pb6 Pb5 Pb4 Pb3 Pb2 Pb1 Pc1 Pc2
R
R R
R j k

BOOM 1

BOOM 2
A4 B4

TRAVEL RH
a b c d e f g h i

OPTION
ARM 2

WING
1 l m
BL BL
7
BL BL Pa9 Pa8 Pa7 Pa6 Pa5 Pa4 Pa3 Pa2 Pa1 Pc3 Pi1
A3 B3 Pa9 Pa8 Pa7 Pa6 Pa5 Pa4 Pa3 Pa2 Pa1 Pc3 Pi1

W
W W O
O
P6
P2

8 A2 B2
K6
CL CL CL R/BR
T6
CAB MANIFOLD T2

JRJ0122 V
V BL BL T6
R/O 8 A1 B1
TANK
P5

627/10059 MANIFOLD
R/Y
R/Y
T5

Y
KTJ0812 BR BR
627/10075 G G
X X

8 O
627/10079 O
1 2
P JRJ0186 Y/YG Y/YG
TRAVEL
PEDAL W/R W/R
T
4 3
W/P

A406290

9808/6510 Issue 1
Section E Hydraulics Hydraulics Section E
5-5 Schematics 5-5

Servo Pressure and Return Line

5
X
6 7
CAB MANIFOLD
T 3 4 CUSHION T T7 T1 P1 TANK MANIFOLD
VALVE ASSY T
SLEW T1 T2 T3 T4 T5 T6 T7 T8
SLEW
B BRAKE T
MOTOR
VALVE R S T

P A P W/R W/W
1 R/LG

C5 YG
C8

CL W/Y W/BL
S3 C7

S2 C4
2 X
CENTRE
JOINT GR/GR
S1 C3
T
P
SHUTTLE BLOCK

C9 C2

Y/Y
C6 C1
X
A6 B6
R/R
P/P CL
A5 B5
BL/BL
X
A4 B4 8
O/O
A3 B3 C1 C2 C3 C4 C12 C11 C10

G/G
C13
A2 B2
T1
BL/P
SOLENOID VALVE ASSY T2
A1 B1
W/O
B2

BL/O
C6 C7 C5 P C8 C9

9
Ps1 Ps2 Pp Ph Pi2 Dr1 Dr2 Dr3 Dr4

MAIN CONTROL VALVE

Pt Pa Pr

14 LB
THROTTLE
SOLENOID
CL VALVE CL V/V
P T

A BR CL

CL 11 10

13 PILOT
PUMP
CL
Pt2 Pm2 Pm1 Pt1

THROTTLE
ACTUATOR Psv
ENGINE CONTROL GROUP PUMP ASSEMBLY

12

A406280

9808/6510 Issue 1
Section E Hydraulics Section E
5-6 Circuit Description 5-6

Servo Pressure and Return Line

Components
1. Shuttle Valve
2. Slew Motor
3. Rotary coupling
4. Swing Brake Valve
5. Cushion Valve
6. Cab Manifold
7. Tank Manifold
8. Solenoid Valve (8 Spool)
9. Main Control valve
10. Servo Pump
11. Servo Filter
12. Pump Assembly
13. Throttle Actuator
14. Throttle Solenoid 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

9803/6510 Issue 1
Section E Hydraulics Section E
5-7 5-7

Main Control Valve

P s1 T3 T1 D3 D1 D2 T2 P s2
B
A C A
C D
P C1 L1
A5
L1
B5 K7 N6
P b5
Dipper D DIPPER 2
P b9
N
K1
N M
E1
P a9 L1
M L2
P c2
E4 R L2 N1 E1
P a5 B A8
E
P c3
B8
N6
K1 K3
BOOM(2) N2 O K3 K5 BOOM(1)
N2 E2
P b4 P b8
L
P a4 E5 N7 P a8 N7
N3 K4 B7 N3 L2 F1
P b3
SWING
K6 BUCKET
A7 K2
P b7 F
N8
F2 K
P a3 N8 P a7
N4 E3
P i2
Dr4 P i1
K4
B2 F1 N9
B6
N9
A2
P b2
OPTION N4 K8 TRAVEL(R)
A6
P b6 Q1 N5 G
K2 N V1
V2 P4
Q
P a2 E6 E3 P a6 N10
B1
J1 J2 J3
E7 N10 I
A 1 TRAVEL(L) N5 P2
P b1
P a1

J2 I
J1 J3
P1 PT PP PA PH P3 P2

V1
H2 H3 H1

H1
KEY

A Negative Control Valve (Ps1)

B Restrictor
C Negative Control Valve (Ps2)
D Shuttle Valve
K
E Load Hold Check Valves ( x 7)
F Priority Valve
F1 Boom over Bucket, F2 Boom over Slew N6 R E
O
G Blank K5 E4
H Pressure Switch N1
N7
H1 Auto Power Boost, H2 Travel, H3 Excavator K7
K6 E5
I Main Relief Valve (MRV) N2
J Restrictors - J1 Travel, J2 Linear Travel, J3 Excavator Pressure Switch N8
F
K Auxiliary Relief Valves (ARV) N3 F2
K1 Dipper out, K2 Option, K3 Boom Up, K4 Bucket Open N9
K5 Boom Down, K6 Bucket Close, K7 Dipper In, K8 Option H2
N4 E6
L Load Holding Valve N10
K8 H3
L1 Dipper, L2 Boom
M Regeneration Valve N5 E7
N Spool (x 10) S
O Shuttle Valve V2
P1
P P1 Pump 1 pressure in, P2 Pump 2 pressure in
Q1, Q2 Blank (For option spool only when not used, to centralise the option spool) Q2
R Slew over Dipper Priority Valve
S End Cap A406670
V V1 Merge Out, V2 Merge in

9803/6510 Issue 1
Section E Hydraulics Section E
5-8 Circuit Description 5-8

Main Control Valve - (cont’d)

8 10
9
View on A 11
12
7
13

pb9 pb5 14
6

pb8 pb4
15

pb7 pb3
5

pb6 pb2
16
4

pb1
3
17

18
2
A405940
1
Port Identification-Note: the illustration above shows the Main Control Valve
as viewed from the rear of the machine

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 Boom Down
7. pb8 Boom Down Spool
8. pb9 Dipper (1) In Spool
9.
10. pc3 Slew over Dipper Priority Valve A
11. Shuttle Valve
B
12. pb5 Dipper (1) In Spool A406530

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

9803/6510 Issue 1
Section E Hydraulics Section E
5-9 Circuit Description 5-9

Main Control Valve - (cont’d)

View on B
25 26 27 28

29

T1 30
ps1
31
24

B5
A5

B4
32
23
33
B3 A3
22 Pi2

21
B2 P4 A2

B1 A1 PT
20
34
PA
P1
19

A405950

40 39 38 37 36 35

Port Identification-Note the illustration above shows the

Main Control Valve as viewed from the right of the machine.

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 A
26 Load Hold Check Valve B
27 ps1 Negative Control Port A406530

28 Load Hold Check Valve

29 A5 Dipper out
Item Port Function
30
35 PA Excavator Pressure Switch
31
36 A1 Travel Left
32 A3 Slew Right
37 Pi2 Boom Priority
33 A2 Option
38 P1 Pump 1
34 PT Travel Pressure Switch
39 Load Hold Check Valve (Travel)
40 P4 Merge In (if fitted)

9803/6510 Issue 1
Section E Hydraulics Section E
5 - 10 Circuit Description 5 - 10

Main Control Valve - (cont’d)

51 52
50 View on C
53

T3 54
49
55
48 DR1
pa5 pa9 56
pc1
47
57
pa4 pa8
pc2
46

45 pa3 pa7
58

pa2 pa6
59
44
60
pa1
43 PA PORT
PP 61
1
pr
42
PH 62

41
A405960
64 63
Port Identification-Note the illustration above shows the
Main Control Valve as viewed from the front of the machine.

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 ARV Dipper Out
48 pa4 Tank
49 pc1 Dipper Holding Valve
50 pa5 Dipper out Spool
51 Blank D
C
52 T3 Tank A406520

53 DR1 Boom Hold Drain

54 pa9 Dipper In Spool Item Port Function
55 ARV Boom Up 60 pa7 Bucket Open Spool
56 pa8 Boom Up Spool 61 pa6 Travel (R) Forward Spool
57 pc2 Boom Holding Valve 62 Linear Travel Spool
58 ARV Bucket Open 63 pr Auto Power Boost Pressure Switch
59 DR3 Drain (Boom Bucket) 64 PH MRV

9803/6510 Issue 1
Section E Hydraulics Section E
5 - 11 Circuit Description 5 - 11

Main Control Valve - (cont’d)

View on D

70 71 72
73
69

ps2 pc3
74
T2

68 75

76
67 A8 B8
pc2

A7 Pi1 B7

A6 B6
77

78

P3

P2
79
66

80
65
82 81
A405970
Port Identification- Note the illustration above shows the Main
Control Valve as viewed from the left of the machine.

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 Boom 1 Check Valve
74 pc3 Slew over Dipper Priority
75 B8 Boom Down C A406520
D
76 Pi1 Boom over Bucket Priority
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

9803/6510 Issue 1
Section E Hydraulics Section E
5 - 12 Circuit Description 5 - 12

Main Control Valve - (cont’d)

Port Identification-Note the illustration above shows the

Main Control Valve as viewed from above the machine. 87
86
Item Port Function
83 Blank
84 Ps1 Negative control Valve
85 Restrictor
86 Ps2 Negative control Valve 85
87 Shuttle Valve
88 DR4 Drain (Slew Over Dipper Priority
84
pc3 PORT
DR2

DR4

83 88

Port Identification-Note the illustration above shows the

Main Control Valve as viewed from below the machine B.

1
Item Port Function
89 DR3 Drain (Boom, Bucket)

DR3

89 A405980

9803/6510 Issue 1
Section E Hydraulics Section E
5 - 13 Circuit Description 5 - 13

Hydraulic Pump Operation

The rotary group consists of the drive shaft 7, cylinder rod
19, piston shoe 4, 5, press plate 11, spherical bush 12,
spacer 13 and cylinder spring 14. The drive shaft is
supported on both sides by the bearings 8, 16. The shoe is
caulked on the piston and forms the spherical coupler, and
because it slides slightly on the shoe plate 6, it has a pocket
to balance the oil pressure.

The subgroup, which is made up of the piston and shoe is

held down on the shoe plate by the cylinder spring through
the press plate and spherical bush. In the same way, the
cylinder block is held down on the valve plate 15 by the
cylinder spring.

The swash plate group consists of the swash plate 10, shoe
plate 6, swash plate support 9 bush 2 pin 3 and servo piston
1. The swash plate is supported by the swash plate support
at the cylindrical part formed by the side opposite to the
shoe sliding surface. The oil pressure controlled by the
regulator is guided to the hydraulic cavities on both sides of
the servo piston which moves the servo piston to the left
and right, causing the swash plate, through the spherical
portion of the pin, to press on the swash plate support and
changes the angle of the swash plate.

The valve cover group comprises of the valve block 17,

valve plate 13 and valve plate pin 18. The valve plate, which
has two oval shaped ports, is on the valve block and delivers
oil to and recovers oil from the cylinder block. The oil
directed by the valve plate flows through the valve block and
is connected to the outer piping.

When the drive shaft is driven by the engine, the cylinder

block rotates simultaneously with the spline coupling. When
the swash plate is leaning, the piston in the cylinder block
rotates simultaneously with the cylinder block and causes
reciprocal motion relative to the cylinder.

Therefore, during one rotation, the piston moves away from

the valve plate for 180° (enough for oil suction) and
approaches the valve plate for the remaining 180°. When
the swash plate leaning angle is at the minimum 5° the
piston does not stroke and does not deliver oil.
(Also see parts drawing in Removal and Replacement of
Hydraulic pump)

9803/6510 Issue 1
Section E Hydraulics Section E
5 - 14 Circuit Description 5 - 14

Hydraulic Pump

A406500
6
5

18
4

17
16
15
14
3

13
12
2

11
1

10
9
8
7

9803/6510 Issue 1
Section E Hydraulics Section E
5 - 15 Circuit Description 5 - 15

Hydraulic Pump Regulation

For this description pump A2 as been used.

On start up, the swash plate piston B is held in the

maximum flow position by the spring A and also by servo
pressure which enters via check valve H and is available to
the small area side of swash plate piston B to hold the pump
in the maximum flow position.

Once oil as passed through the valve block a 40 bar (580 Ib

in2) negative control signal enters port Pt2 and is available to
the negative control piston D. This acts against spring A to
move the spool across allowing pump pressure to cross the
spool and pressurise the large diameter side of the swash
plate piston B. Pressure is now available to both sides of the
swash piston B, but due to the difference in surface areas
the piston moves to the minimum flow position.

When a service is selected the negative control pressure

drops. Piston D now moves back due to the spring pressure.
This allows the oil in the larger area side of the swash plate
piston B to vent to tank, but pump pressure oil is still
available to the smaller diameter side so the pump moves
over to the maximum flow position.

As the pump pressure increases, the pressure seen at the

small diameter end of the swash plate piston B is also seen
at the piston E. At the same time any pressure generated at
pump A1 is also seen at pump A2 at the piston. As the
pressure increases at piston E via line F it starts to push
against spring A. When the pressure has increased to
approxmietley 200 bar (2900Ib in2 ) the spool will start to
select. This will now allow pump pressure to the large
diameter side of the swash plate piston B which will
proportionally start to select minimum flow.

When P mode is selected a 40 bar (580 Ib in2) secondary

pressure is also seen at piston G. This signal will add to the
force of the pump pressure at pistons E and G so that
minimum flow is selected earlier.

In A mode the secondary pressure drops to approximately

10 bar (145Ib in2). This reduction in secondary pressure at
piston G has to be made up for by higher pump pressure at
pistons "E" and F before the sumater spool starts to select,
hence more hydraulic horsepower.
The regulator on pump A1 works the same as above.

9803/6510 Issue 1
 Key to Oil Flow & Pressure Hydraulic Pump 5 - 16
Full Pressure

9803/6510
Pressure
Servo
Section E

Neutral
Exhaust A
H C
Cavitation
Lock Up

Psi

a 3
A1 Psv A2

a1 a2
E
(FRONT) (REAR)

D
Hydraulics
Circuit Description

Pm 1 Pm 2

Pt 1 Pt 2

Max
A1 A2
M
B

a4

Dr B1 B3 A3

A406300

Issue 1
5 - 16
Section E
Section E Hydraulics Section E
5 - 17 Circuit Description 5 - 17

Neutral Circuit

With all the controls in the neutral position, flow from pump
A1 enters the main control valve 10 at port P1 and flow from
pump A2 enters the main control valve 10 at port P2.
a Dipper (1) spool
Oil is allowed to flow across all of the spools via the neutral b Boom (2) spool
gallery when all controls are in the neutral position. Oil from c Slew spool
pump A1 exits port Ps1 and oil from pump A2, exits port d Option spool
Ps2 at the top of the main control valve. Both flows of oil e Travel (left) spool
meet a separate restrictor and relief valve. Some oil will pass f Dipper (2) spool
through the restrictor and back to tank, creating back g Boom (1) spool
pressure in the line. Oil is exhausted across the relief valves h Bucket spool
at 40 bar (580 Ib in2). The back pressure is sensed at ports i Travel (right) spool
Ps1 and Ps2 and ports Pt1 and Pt2 of the pumps, holding k Linear Travel spool
the pumps on minimum flow.

Flow from the servo pump enters the valve block at port Pp,
where it meets 3 restrictors. These maintains 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.

9803/6510 Issue 1
Section E Hydraulics Section E
5 - 18 5 - 18

Neutral Circuit

10
P S1 T3 T1 D3 D1 D2 T2 P S2

P C1
31
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
34 BOOM(1)
(FRONT) (REAR)
P b4
BOOM(2) b g P b8

P a4 P a8
B7
SWING
P b3 c BUCKET A 7
h P b7
Pm 1 Pm 2 P a3
P i2 P a7
Pt 1 Pt 2 Dr4 P i1
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

Key to Oil Flow & Pressure ON 335 bar

OFF 330 bar
Full Pressure
52
Pressure
Servo 46
Neutral 28
Exhaust
Cavitation
Lock Up

A405460

9803/6510 Issue 1
Section E Hydraulics Hydraulics Section E
5 - 19 Schematics 5 - 19

Straight Line Travel

P S1 T3 T1 D3 D1 D2 T2 P S2 10
6
Key to 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 P i1
B2 B6
A2 A6
P b2
OPTION d i P b6
P4
TRAVEL(R)
P a2 P a6
B1
A1 k
P b1 e
P a1 TRAVEL(L) LINEAR TRAVEL

P1 PT PP PA PH P3 P2

ON 335 bar
46 28 52 OFF 330 bar
4
A1 A2
P a1 PS PS P a2

T1 T2

P1 P2
RED

RED

P2 P1

P a2 P a1

D C
B A
FC P

A405530

9808/6510 Issue 1
Section E Hydraulics Section E
5 - 20 Circuit Description 5 - 20

Straight Line Travel

(Travel and exavator services selected)

Refer to Travel Middle Speed for servo function of travel

circuit and Boom Up for servo function of Boom up a Dipper (1) spool
function b Boom (2) spool
c Slew spool
Servo pressure entering at port Pp on the main control valve d Option spool
10 is blocked from tank by the Travel spools and the Boom e Travel (left) spool
(2) spool, this causes back pressure which selects the travel f Dipper (2) spool
and excavator pressure switches 46 and 28 and selects the g Boom (1) spool
Linear travel spool. h Bucket spool
i Travel (right) spool
Flow from pump A1 is available to the left hand Travel spool k Linear 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 10 via the parrallel
working gallery. If any excavator function is selected at slow
speed and does not require the full flow from pump A2, then
the extra flow is used in the travel circuit via (as long as the
travel circuit is at a lower pressure) the check valve at the
right hand travel spool, a restrictor gives low priority to the
travel circuit. If the Boom up is selected both Boom 1 and 2
spools are fed from the pump A2 through the left and right
hand parrallel working gallery.

When both Travel spools are selected, the loss of pressure in

the neutral gallery is sensed at the pumps through ports Ps1
and Ps2 on the main controll valve 10. The pumps come into
full flow.

9803/6510 Issue 1
Section E Hydraulics Section E
5 - 21 Circuit Description 5 - 21

Travel - Middle Speed

When both tracks are selected, servo pressure from port 2
(LH travel lever),and port 4 (RH travel lever) 35 enters the
main control valve 10 at Pa1 and Pa6 respectively, selecting
the left and right hand travel spools. a Dipper (1) spool
b Boom (2) spool
Flow from pump A1 is available at the LH travel spool and is c Slew spool
directed to the LH travel motor via port A1 of the Main d Option spool
control valve 10, through the rotary coupling and in to port e Travel (left) spool
P1 on the LH travel motor. Exhaust oil from the motor enters f Dipper (2) spool
the main control valve 10 at port B1 and is directed to the g Boom (1) spool
LH travel spool to the tank port. h Bucket spool
i Travel (right) spool
Flow from pump A2 is available at the RH travel spool and is k Linear Travel spool
directed to the RH travel motor via port A6 of the main
control valve 10, through the rotary coupling and in to port
P2 on the RH travel motor. Exhaust oil from the motor enters
the Main control valve 10 at port B6 and is directed to the
RH travel spool to the tank port.

The servo oil flowing over restrictors R1 and R2 is available

to tank causing the excavator pressure switch 28 to stay
open and the straight line travel spool to remain un-selected.

Pressure is lost on both negative control ports Ps1 and Ps2,

which is sensed at the pumps which come into full flow.

9803/6510 Issue 1
Section E Hydraulics Hydraulics Section E
5 - 22 Schematics 5 - 22

Travel Middle Speed

P S1 T3 T1 D3 D1 D2 T2 P S2
10

P C1

Key to 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 P i1
B2 A6
A2 OPTION P b6
P b2 d i
P4
TRAVEL(R)
P a2 P a6
B1
A1 k
P b1 e
P a1 TRAVEL(L)

R2

R3 R1
P1 PT PP PA PH P3 P2

ON 335 bar
46 28 52 OFF 330 bar

4
A1 A2
P a1 PS PS P a2 35

T1 T2

P1 P2
RED

RED

P2 P1

1 2 T P 4 3

P a2 P a1

D C
B A
FC P

A405520

9808/6510 Issue 1
Section E Hydraulics Hydraulics Section E
5 - 23 Schematics 5 - 23

Boom Up

7 8
10
P S1 T3 T1 D3 D1 D2 T2 P S2

C2 C2
C2 C2 12
P C1 12
A5
B5
ARM(2)
P b5
ARM(1) a f P b9
V2 E BL P P BL E V2

P a9

P c2
BHV
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 51 40
P i2 P a7 P T A1 C D E1 G H
Dr4 P i1
B2 B6
BBV R
A2
i TRAVEL(R) A 6
P b2
OPTION d P b6
P4
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

T
A B E F
P1 PT PP PA PH P3 P2

ON 335 bar
46 28 52 OFF 330 bar

A1 A2

37
B3 C1 C2 B4 B5 C3 C4 B6

Key to Oil Flow & Pressure

Full Pressure
Pressure
Servo
UP DOWN OUT IN
Neutral A3 S2 S3 A4 A5 C9 C5 A6
Exhaust BOOM ARM
Cavitation
Lock Up

38 38 53
A405540

9808/6510 Issue 1
Section E Hydraulics Section E
5 - 24 Circuit Description 5 - 24

Boom Up

Servo pressure from the handcontroller enters the servo

shuttle valve 37 at port A3 and is disributed to:
1. Boom up pressure switch 38a at port S2
2. Auto mode pressure switch 53 at port C9 a Dipper (1) spool
3. Port B3 through the Cushion control valve 40, the b Boom (2) spool
signal is divided between the Boom(1) spool valve at c Slew spool
port Pa8 and Boom(2) spool at port Pb4 on the main d Option spool
control valve 10 e Travel (left) spool
4. Port C1 to port Pi1 on the Main control 10 valve to f Dipper (2) spool
operate boom over bucket priority spool valve BBV. g Boom (1) spool
h Bucket spool
Flow from pump A2 is stopped by the Boom (1) spool and is i Travel (right) spool
diverted via the parallel working passage to the Boom (1) k Linear Travel spool
spool. The oil passes through the spool and merges with the
flow from pump A1. Flow from pump A1 is stopped by the
Boom (2) spool and is diverted via the parallel working
passage to the Boom (2) spool.The oil passes through the
spool and merges with the flow from pump A2.

The pressure lifts the Boom holding valve BHV off it’s seat
allowing oil to leave the main control valve at port B8 to
enter the Hose Burst Protection valve (HBPV) 12 (if fitted)
and the Boom rams 7 and 8.

Exhaust oil enters the Main control valve 10 at port B8 and

crosses the Boom (1) spool to tank.

Pressure is lost on both negative control ports Ps1 and Ps2,

which is sensed at the pumps, which comes into full flow.

The Excavator pressure switch 28 is closed by back

pressure resulting from Boom (2) spool closing the servo
route to tank. The travel pressure switch 46 remains open.

9803/6510 Issue 1
Section E Hydraulics Section E
5 - 25 Circuit Description 5 - 25

Boom Down
Servo pressure from the Handcontroller enters the Servo
Shuttle valve 37 at port A4 and is disributed to:
1. Port S3 to activate the Boom down pressure switch
38. a Dipper (1) spool
2. Port C9 to activate the Auto mode pressure switch b Boom (2) spool
53. c Slew spool
3. Port C2 to the Main control valve 10 at port Pc2. d Option spool
The Boom holding spool valve is moved across e Travel (left) spool
allowing pressure at the top of the Boom Holding f Dipper (2) spool
Valve BHV to exhaust to tank. g Boom (1) spool
4. Port B4 to port E of the Cushion control valve 40. h Bucket spool
The oil flows across the unrestricted part of the spool i Travel (right) spool
and out of port G to the main control valve 10 at port k Linear Travel spool
Pb8, moving the spool to the down position.
Note. If HBCV’s 12 are fitted a signal is also sent from
port E1 of the Cushion control valve 40 to the P ports
of the HBCV’s to move the HBCV spool over and allow
oil to return from the rams.

Flow from pump A2 travels through the neutral gallery to the

Boom (1) spool. The flow is restricted allowing a reduced
pressure at port Ps2 which is sensed at Pm2 of the pump A2
which increases flow (less than full flow). Oil flow also
passes through the parallel working gallery to the Boom (1)
spool and is directed to the Boom rams 7 and 8 via port B8.

Exhaust oil passes through the HBVC’s 12 (if fitted) to the

Main control valve 10 at port A8, lifts the Boom Holding
Valve BHV off it’s seat and passes through the Boom (1)
spool and exhausts to tank.

Exhaust oil passing through the spool can be regenerated

into the feed side of the rams. A check valve in the spool
(see Fig 1) 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. The restrictor creates back pressure so
causing the check valve to open.

9803/6510 Issue 1
Section E Hydraulics Hydraulics Section E
5 - 26 Schematics 5 - 26

Boom Down

7 8
10
T2 P S2

Fig 1
C2 C2

12 C2 C2

12
ARM(2)
f P b9 V2 E BL P P BL E V2

P a9

P c2
BHV
A8

B8

g BOOM(1)
P b8

P a8
B7
A7
h BUCKET
P b7

P a7
P i1
B6

Key to Oil Flow & Pressure i TRAVEL(R) AP 6

b6

Full Pressure P a6

Pressure
k 40
Servo 51
Neutral P T A1 C D E1 G H

Exhaust R
Cavitation
Lock Up
P3 P2

BUCKET BOOM
OPEN CLOSE UP DOWN
1 3 2 4

T
A ARM B E BOOM F
A1 A2

Pm2
37
B3 C1 C2 B4 B5 C3 C4 B6

UP DOWN OUT IN
A3 S2 S3 A4 A5 C9 C5 A6
BOOM ARM

53
38 38
A405510

9808/6510 Issue 1
Section E Hydraulics Hydraulics Section E
5 - 27 Schematics 5 - 27

Dipper Out

Key to Oil Flow & Pressure

T
Full Pressure
2 C2
C2
Pressure 11
Servo M
D D
Neutral
Exhaust
Cavitation 10
P BL E V2
Lock Up P S1 T3 T1 D3 D1 D2 T2 P S2

P C1 DHV

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

P a9

P c2
P a5 A8
P c3
B8
BOOM(1)
40 BOOM(2) b g
39 P b4 P b8
A1 C D E1 G H P T
R P a4 P a8
B7
SWING c A7
P b3 h BUCKET P b7

SWING ARM P a3
LEFT RIGHT IN OUT P i2 P a7
1 2 3 4
Dr4 P i1
B2 B6
A2 A6
P b2
OPTION
d i TRAVEL(R) P b6
S P4
T
P a2 P a6
A ARM B E BOOM F
B1
LINEAR TRAVEL
A 1 TRAVEL(L) k
B5 C3 C4 B6
P b1 e
P a1
37

OUT IN
A5 C9 C5 A6
ARM

P1 PT PP PA PH P3 P2

53 ON 335 bar
OFF 330 bar

46 28 52

A1 A2

A405490

9808/6510 Issue 1
Section E Hydraulics Section E
5 - 28 Circuit Description 5 - 28

Dipper Out

Servo pressure from the Handcontroller 39 is sent to port A5

of the shuttle valve 37 and is disributed to:
1. Port C9 to activate the Auto mode pressure switch
53. a Dipper (1) spool
2. Port C3 to port Pa9 of the Main control valve 10 to b Boom (2) spool
activate the Dipper (2) spool. c Slew spool
3. Port B5 to port B of the Cushion valve 40, through d Option spool
the valve leaving at port D. The signal is sent to port e Travel (left) spool
Pa5 on the Main contol valve 10 activating the Dipper f Dipper (2) spool
(1) spool. g Boom (1) spool
h Bucket spool
Flow from pump A1 is available at the Dipper (1) spool via i Travel (right) spool
the left hand neutral passage and the Linear travel spool via k Linear Travel spool
the parrallel working passage. Flow from pump A2 is
blocked at the Dipper (2) spool and joins the flow from pump
A1 just before the Dipper (1) spool.
Exhaust oil from the ram enters the Main control valve 10 at
port B5 and has a path to tank via the Dipper (1) and Dipper
(2) spools.

9803/6510 Issue 1
Section E Hydraulics Section E
5 - 29 Circuit Description 5 - 29

Dipper In

Servo pressure from the Hand controller 39 is sent to port A6

of the servo shuttle valve 37 and is dritributed to:
1 Port C9 to activate the Auto mode pressure switch 53.
2 Port C4 to port Pb9 on the Main controll valve 10
to the Dipper (2) spool (via a shuttle valve, if fitted with a Dipper (1) spool
a merged auxillary circuit). b Boom (2) spool
3 Port B6 to port A on the Cushion valve 40, through the c Slew spool
valve leaving at port C (if machine is fitted with HBCV d Option spool
11, pressure is also sent via port A1 to port P on the e Travel (left) spool
HBCV to allow trapped oil in the ram to exit). From port f Dipper (2) spool
C to port Pb5 and port Pc1 on the Main control valve g Boom (1) spool
10 to he Dipper (1) spool and the Dipper load hold h Bucket spool
check valve DHV. i Travel (right) spool
k Linear Travel spool

Flow from pump A1 is avaiable at the Dipper (1) spool via the
left hand neutral gallery or after passing over the straight line
travel spool via the parrallel working passage. At the Dipper
(1) spool the flow is diverted to the Dipper ram 2. Pressure is
sensed at the regeneration spool RGS and moves it to the
lesser restricted position (Fig 2).

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

joins the flow of pump A1 just before the Dipper (1) spool.
The pressure from both pumps is now cut off from the
negative control ports Ps1 and Ps2. This reduced pressure is
sensed at both pumps which now come into full flow.

Exhaust oil from the ram passes (through the HBCV 11 if

fitted) to the Main controll valve 10 at port A5 through the
Dipper hold check valve DHV (that has been released by
servo pressure) to the Dipper (1) spool.

Exhaust oil from the Dipper ram 2 can be at a hgher pressure

than the feed oil due to the effect of gravity on the dipper arm
when first selected. This causes the regeneration check valve
RG to open, feeding a proportion of exhaust oil into the feed
side. The remaining exhaust oil returns to tank passing over
the regeneration spool RGS. The regeneration spool has two
restrictors, one more restricted than the other. The restrictors
cause back pressure incouraging the regeneration check
valve to open. As the pressure drops the regeneration spool
moves across to the more retricted position. When the feed
pressure is greater than the exhaust pressure the
regeneration check valve will close.

Servo pressure from the Dipper (1) spool travels over

restrictors R2 and R3 and to tank via the unselected travel
spools. Oil passing over R1 has no passage to tank, creating
back pressure that selects the excavator pressure switch 46.

9803/6510 Issue 1
Section E Hydraulics Hydraulics Section E
5 - 30 Schematics 5 - 30

Dipper In

Key to Oil Flow & Pressure T

Full Pressure
2 C2
C2 11
Pressure
Servo M
D D
Neutral
10
Exhaust
P S1 T3 T1 D3 D1 D2 T2 P S2
Cavitation
Lock Up
P BL E V2

P C1

A5
B5

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

40 39 P a9
A1 C D E1 G H P T

P c2
R
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
S SWING
P a3
P i2 P a7
T Dr4 P i1
B2 B6
A B E F
A2 TRAVEL(R) A 6
P b2
OPTION d i P b6
B5 C3 C4 B6 37 P4
P a2 P a6
B1
A 1 TRAVEL(L) k
P b1 e
P a1
OUT IN
A5 C9 C5 A6
ARM
R2
PSW6
R3 R1
P1 PT PP PA PH P3 P2

ON 335 bar
OFF 330 bar
P C1
46 28 52
DHV
A5
B5 A1 A2

ARM(1)
P b5

RG
RGS

A405480
Fig 2

9808/6510 Issue 1
Section E Hydraulics Hydraulics Section E
5 - 31 Schematics 5 - 31

Bucket Opening

D3 D1 D2 T2 P S2
Key to Oil Flow & Pressure 10
Full Pressure
Pressure
Servo
Neutral
Exhaust
Cavitation
Lock Up
f ARM(2) P b9

P a9

P c2
6
A8

B8
BOOM(1)
g
P b8

P a8
B7
BUCKET A 7
h P b7

P a7 T
P i1
P
51
B6
BBV TRAVEL(R) A 6
i
P b6
BUCKET BOOM
CLOSE OPEN DOWN UP
1 2 3 4
P a6

PT PH P3 P2
PP

A2

28 52

A405500

9808/6510 Issue 1
Section E Hydraulics Section E
5 - 32 Circuit Description 5 - 32

Bucket Opening

Servo pressure from port 2 of the Handcontroller 51

selects the bucket spool open position via port Pa7 of the
Main control valve 10.
a Dipper (1) spool
Flow from pump A2 is avaiable to the Bucket spool via the b Boom (2) spool
parallel working gallery and Boom over Bucket priority c Slew spool
valve BBV. d Option spool
e Travel (left) spool
At the spool the flow is diverted to port B7 of the Main f Dipper (2) spool
control valve 10 to the Bucket ram 6. g Boom (1) spool
h Bucket spool
Returning oil enters the Main control valve 10 at port A7 i Travel (right) spool
and is diverted by the Bucket spool to the tank port. k Linear Travel spool

Pressure in the neutral circuit drops after the selected

Bucket spool, this is sensed at the port Ps2 and at the
pump bringing it into full flow.

Servo pressure entering the Main control valve at port Pp is

blocked by the bucket spool causing back pressure to the
restrictor which activates the Excavator pressure switch
46.

9803/6510 Issue 1
Section E Hydraulics Section E
5 - 33 Circuit Description 5 - 33

Bucket Closing
Servo pressure from the handcontroller is sent from port 1 to
port Pb7 of the Main control valve 10 and moves the Bucket
spool into the bucket close position.
a Dipper (1) spool
Flow from pump A2 is avaible at the Bucket spool via the b Boom (2) spool
parrallel working gallery and Boom over Bucket priority valve c Slew spool
BBV. d Option spool
Flow is diverted to port A7 of the Main control valve to the e Travel (left) spool
Bucket ram 6. f Dipper (2) spool
g Boom (1) spool
Returning oil from the Bucket ram enters the Main control h Bucket spool
valve at port B7 and is dirverted to tank by the Bucket spool. i Travel (right) spool
k Linear Travel spool
A regeneration valve is fitted in the Bucket spool (Fig 3).
When returning oil from the Bucket ram enters the spool it
crosses a restrictor which causes back pressure. If the
pressure in the return line is greater than that of the feed line,
the valve will open allowing return oil to be regenerated into
the feed line.

Servo pressure entering the main contol valve at port Pp is

blocked by the bucket spool causing back pressure to the
restrictor which activates the Excavator pressure switch 28.

9803/6510 Issue 1
Section E Hydraulics Hydraulics Section E
5 - 34 Schematics 5 - 34

Bucket Closing

Fig 3

10 BUCKET
P S1 T3 T1 D3 D1 D2 T2 P S2

P C1

A5
B5
Key to 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
6
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 P i1
B2 BBV 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

ON 335 bar
51
P T
OFF 330 bar

46 28 52

BUCKET BOOM
CLOSE OPEN DOWN UP
A1 A2 1 2 3 4

A406070

9808/6510 Issue 1
Section E Hydraulics Hydraulics Section E
5 - 35 Schematics 5 - 35

Priority Valves

Key to Oil Flow & Pressure

Full Pressure
Pressure
Servo
Neutral
Exhaust
Cavitation
B
Lock Up

B1 B2 B3 C1 C2 B4 B5 C3 C4 B6

C6
37
C7
C8

RIGHT LEFT UP DOWN OUT IN

A1 S1 A2 A3 S2 S3 A4 A5 C9 C5 A6

10
A P S1 T3 T1 D3 D1 D2 T2 P S2

P C1

A5
B5

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

P a9
29
P a5
P c2
A8
37
T2 B2 C8 C6
C4 P c3
B8
B1 B2 B3 C1 C2 B4 B5 C3 C4 B6
CUSHION
P b4
BOOM(2) b g BOOM(1) P b8

P a4 P a8
NEG CONTROL C6
B7
C7
C3 C5 P b3
SWING
c h BUCKET AP
7

b7
C8
2-STAGE RELIEF
P a3 RIGHT LEFT UP DOWN OUT IN
P i2 P a7
D r4
A1 S1 A2 A3 S2 S3 A4 A5 C9 C5 A6
P i1
BOOM
PRIORITY B2 B6
A2
i TRAVEL(R) AP
6

C2 C7 P b2
OPTION d b6

SWING SHUT OFF

P4
P a2 P a6
B1
MAX FLOW CUT
A 1 TRAVEL(L)
e k
P b1
C1 P a1
2 STAGE TRAVEL

ISOLATOR

P1 PT PP PA PH P3 P2
P C9

C13

C11 C12 T1 C10

A406110

9808/6510 Issue 1
Section E Hydraulics Section E
5 - 36 Circuit Description 5 - 36

Priority Valves

Boom over Slew Priority (A)

This is selected by the operator via EMS.

a Dipper (1) spool
When operated the Boom priority solenoid on the 8 spool b Boom (2) spool
block 29 is energised sending a signal via port C5 to the c Slew spool
Main control valve 10 at port Pi2. This selects the Boom over d Option spool
slew priority. Oil now being fed to the Slew spool is e Travel (left) spool
restricted to give priority to the boom. f Dipper (2) spool
g Boom (1) spool
Slew over Dipper Priority (B) h Bucket spool
i Travel (right) spool
This is a non-selectable function automatically carried out k Linear Travel spool
within the Main controll valve 10 when Slew and Dipper are
used together.

When Slew is selected a signal is sent from the servo Shuttle

valve 37 via port C8 to the Main control valve 10 at port Pc3.
This selects Slew over Dipper prioity valve B and limits the
flow to the Dipper from pump A1 only. This makes it possible
to have maximum swing torque with high swing pressure
when the Dipper is used at the same time.

Boom Priority Over Bucket (C)

This a non-selectable function automatically carried out

within the Main control valve 10 when Boom and Bucket are
used together.

When Boom up is selected a signal is sent from port C1 on

the servo Shuttle valve 37 to the main control valve port Pi1.
This selects the Boom over Bucket priority valve A . Oil now
flowing to the Bucket spool is restricted and gives priority to
Boom up.

9803/6510 Issue 1
Section E Hydraulics Section E
5 - 37 Circuit Description 5 - 37

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

Slew Motor Reduction Gear

Key

A A chamber
B B chamber
C Torque path

Reduction Gear Structure and Working Principles

Power transmitted by the hydraulic motor output shaft is transmitted to second sun gear 77 via first sun gear 66, planetary
gear 69 and holder 65. Power is then transmitted to output shaft 53 via second sun gear 77, planetary gear 72 and holder 76.
The output shaft is constructed with an integral pinion and is supported in gear case 58 by bearings 57 and 62.

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

9803/6510 Issue 1
Section E Hydraulics Section E
5 - 38 Circuit Description 5 - 38

Slew
Servo pressure from the Handcontroller 51 enters the Servo
shuttle valve 37 at port A2 and is disributed to:
a Dipper (1) spool
b Boom (2) spool
1. Port C7 to port A on Slew brake valve 3.
c Slew spool
2. Port C8 to port Pc3 on Slew over Dipper priority
d Option spool
spool SDV in the Main control valve.
e Travel (left) spool
3. Port S1 to the slew pressure switch 53.
f Dipper (2) spool
4. Port B2 to the slew spool at port Pa3 on the Main
g Boom (1) spool
control valve 10 to move spool across.
h Bucket spool
i Travel (right) spool
Flow from pump A1 is stopped in the neutral gallery by the
k Linear Travel spool
Slew spool. The flow passes through the Linear travel spool
into the parallel working passage over the un-restricted side
of the Boom priority spool BPV and to the Slew spool. the
flow is then directed via port A3 to the Slew motor 1.
Exhaust oil enters the Main control valve at B3 to the Slew
spool to the tank line.

9803/6510 Issue 1
Section E Hydraulics Hydraulics Section E
5 - 39 Schematics 5 - 39

Slew

Key to Oil Flow & Pressure

T2 B2 C8 Full Pressure
29 C4 C6

Pressure
1 CUSHION

Servo
P NEG CONTROL
Neutral
C3 C5
Exhaust
2-STAGE RELIEF
Dr Cavitation
BOOM
PRIORITY Lock Up
C2 C7
SWING SHUT OFF

10
MAX FLOW CUT P S1 T3 T1 D3 D1 D2 T2 P S2

C1
2 STAGE TRAVEL

ISOLATOR

P C1

P C9
Mu A5
C13 B5
RIGHT B A LEFT
C11 C12 T1 C10 ARM(1) ARM(2)
P b5 P b9

P a9

BPV P c2
P a5 SDV A8
P c3
B8
BOOM(2) BOOM(1)
P b4 P b8

P a4 P a8
B7
P b3 A7
BUCKET
P b7
B
3 P a3
SWING

P i2 P a7
Dr4 P i1
B2 B6
A A2 A6
OPTION TRAVEL(R)
A P b2 P b6
P4
P a2 P a6
B1
T T
A 1 TRAVEL(L)
P P b1
P a1

37 P1 PT PP PA PH P3 P2

39 46 ON 335 bar
OFF 330 bar
C6

C7

C8 SWING
28 52
LEFT RIGHT A1 A2
RIGHT LEFT
A1 S1 A2

53 A405550

9808/6510 Issue 1
Section E Hydraulics Hydraulics Section E
5 - 40 Schematics 5 - 40
Slew Brake Valve

Key to Oil Flow & Pressure

Full Pressure
Pressure
Servo
Neutral
A B C Exhaust
Cavitation
Lock Up

1 1 1
D D D
P P P

SL SL SL
3 3 3
B B B
SA SA SA

A A A
SB SB SB
C C C
1
T T T
P P P T2 B2 C8
C4 C6

CUSHION

SWING SWING SWING

NEG CONTROL
P b3 P b3 P b3
C3 C5
P a3 P a3 P a3
2-STAGE RELIEF

B1 B2 B1 B2 B1 B2
BOOM
PRIORITY

C6
37 C6 37 C 6

37 C2 C7
C7 C7 C7
SWING SHUT OFF

C8 C8 C8
RIGHT LEFT RIGHT LEFT RIGHT LEFT
A1 S1 A2 A1 S1 A2 A1 S1 A2 MAX FLOW CUT

SWING SWING SWING

C1
2 STAGE TRAVEL

38 38 38 ISOLATOR

P C9

C13

C11 C12 T1 C10

A406100

9808/6510 Issue 1
Section E Hydraulics Section E
5 - 41 Circuit Description 5 - 41

Slew Brake Valve C - Slew Brake at 100%

When the Slew lock button SL is operated in the cab:

Working Pressure 40bar (580 lb/in2)
Max rated flow 20 l/min(3.4UK gal/min ) 1. The Slew shut off solenoid on the 8 spool block 29
Pressure reducing valve 15bar (217lb/in2) energises and sends a signal to port C6 of the servo
Voltage 24v @ 14.5 watts shuttle valve 37. This diverts the pressure to ports B1
and B2, which is sent to opposite sides of the Slew
spool, this locks the spool hydraulically.
The valve is used to control the application and release of
the slew brake at either fully off, 50% on or 100% on. 2. 5 seconds after operation of the Slew spool button
the Slew lock solenoid SA energises. This allows any
The valve is operated by servo pressure from the Slew pressure in the Slew motor brakes to vent to tank and
control lever. The servo pressure is sensed by the Slew fully apply
pressure switch 38 which energises the Slew brake
solenoid, or by the selecting the Slew lock button SL in the
cab.

A - Slew Brake at 50%

C
50% Slew brake is applied when the machine is operating
and the Slew control has not been operated within 5 SB
seconds. Selecting the Slew lock switch SL in the cab
overides the 50% brake lock D. SA
Servo pressure is available at the slew pressure switch 38.
When the Slew has not been used the pressure switch
remains open. The ECU (see Section C, System
Overview) senses that the pressure switch is open 38, so
energies solenoid SB.
Servo pressure enters the Brake valve at P, the pressure
crosses the Pressure reducing cartridge C, which is forced
across to maintain a lower working pressure. The pressure
then crosses the shuttle valve and passes across the
swing lock solenoid SA to the Slew brake and partially lifts
the brake.

B - Slew Brake Fully Off

When Slew is selected on the hand controller the servo

pressure closes the pressure switch which is seen at the
ECU, which de-energises solenoid SB. Servo pressure
entering at port P can cross solenoid SB and act upon the
Pressure reducing cartridge C. Servo pressure also
crosses the Pressure reducing cartridge C which is now
held open. Full servo pressure crosses solenoid SA and
lifts the Slew brake completey off. A408140

Once the Slew service has been released, the Slew

pressure switch E will be open. After 5 seconds the ECU
will energise the Slew brake solenoid SB. This delay is to
prevent damage to the brakes and gearbox by allowing the
slew to come to a standstill by hydraulic breaking.

If the Slew brake solenoid SB remains energised, servo

pressure from port C7 of the Shuttle valve F enters Slew
brake valve at port A, crosses solenoid SA and lifts the
brake D. In this condition Slew will operate harshly on start
up and stop.

9803/6510 Issue 1
Section E Hydraulics Section E
5 - 42 Circuit Description 5 - 42

Auxiliary Flow

An auxiliary circuit gives a bi-directional flow to the

equipment being used.

The Option pedal 36 can be selected back or forward a Dipper (1) spool
depending on the direction the operator wants the b Boom (2) spool
equipment to move. c Slew spool
d Option spool
Servo pressure from the pedal, enters the main control valve e Travel (left) spool
at either port Pa2 or Pb2 depending on the direction the f Dipper (2) spool
pedal is selected. This in turn moves the spool in the g Boom (1) spool
selected direction. h Bucket spool
i Travel (right) spool
Oil from pump A1 is blocked at the option spool and is k Linear Travel spool
diverted to the parallel-working gallery via the linear travel
spool, where it is available to the now selected option spool.
Depending on the direction selected, the oil will exit the
valve block through ports A2 or B2.

In the example shown, oil flows from Port A2 to the direction

valve 43, which is set in the auxiliary position. The oil travels
across the valve and to the attachment fitted.

Returning oil again goes across the direction valve and back
to the option spool via port B2 were it is diverted to the tank
port.

In Auxiliary the oil from pump A2 is in a neutral state. (See

Neutral Circuit)

Merged Flow

This option allows the flow of both pumps to come together

where the attachment requires high oil flow.

The operation is similar to auxiliary except, a shuttle valve 9

is placed between the direction hoses, which allows
pressure from either side of the option pedal to be available
to the merge solenoid 47.

When the merged option is selected, using the auxiliary

switch in the cab, the merge solenoid 47 is energised.
Pressure from either side of the pedal crosses the solenoid
and selects the Dipper 2 spool, which blocks the flow of oil
to tank from pump A2. Oil from pump A2 is now forced
through the merge hose at port P3, over the non-return valve
27 and the shut off valve 26 and re-enters the valve block at
port P4 were it merges with the flow of oil from pump A1.

9803/6510 Issue 1
Section E Hydraulics Hydraulics Section E
5 - 43 Schematics 5 - 43

Merged

Key to Oil Flow & Pressure

Full Pressure
Pressure
Servo
Neutral
Exhaust
Cavitation
Lock Up
10
P S1 T3 T1 D3 D1 D2 T2 P S2

43
A P C1
C
B
A5
C1 A1 B5
B1 ARM(2)
ARM(1) a f
45 P b5 P b9

P a9

P c2
P a5 A8
44 P c3
B8

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

OPTION P a4 P a8
36 B7
SWING A7
P b3 c BUCKET
h P b7
P a3
P i2 P a7
Dr4 P i1
B2 B6
1 P T 2
A 2 OPTION A6
P b2 d
i TRAVEL(R) P b6
P4
P a2 P a6
B1
41 26 A 1 TRAVEL(L)
e
k
P b1
P a1

47 27
1 3

P1 PT PP PA PH P3 P2

2 ON 335 bar
OFF 330 bar

46 28
52

A1 A2

A405470

9808/6510 Issue 1
Section E Hydraulics Hydraulics Section E
5 - 44 Schematics 5 - 44

Hammer
Key to Oil Flow & Pressure

Full Pressure
Pressure
Servo
Neutral
Exhaust
Cavitation
Lock Up

P S1 T3 T1 D3 D1 D2 T2 P S2
10
43
A

C B

A1
P C1
C1 B1
A5
45 B5
f ARM(2)
P b5
ARM(1) a P b9

P a9
44 P c2
P a5 A8
P c3
B8
BOOM(1)
BOOM(2) b g
36 P b4 P b8

OPTION P a4 P a8
B7
SWING c BUCKET A 7
P b3 h P b7
P a3
P i2 P a7
Dr4 P i1
B2 B6
1 P T 2
A 2 OPTION TRAVEL(R) A 6
P b2 d i P b6
9 P4
P a2 P a6
B1

41 A 1 TRAVEL(L) k
P b1 e
P a1

1 3
47
P1 PT PP PA PH P3 P2

2 ON 335 bar
OFF 330 bar

46 28
52

A1 A2

A406120

9808/6510 Issue 1
Section E Hydraulics Section E
5 - 45 Circuit Description 5 - 45

Hammer Circuit
The hammer function only works when the hammer pedal 43
is pressed in a forward direction. In this position pressure
from the foot pedal is available to the hammer pressure
a Dipper (1) spool
switch 41, to reduce engine RPM to supply the required oil
b Boom (2) spool
flow for the hammer.
c Slew spool
d Option spool
Servo pressure from the foot pedal enters the main control
e Travel (left) spool
valve 10 at port Pa4 and selects the option spool.
f Dipper (2) spool
g Boom (1) spool
Oil from pump A1 is then blocked at the option spool and is
h Bucket spool
diverted through the linear travel spool and into the parallel
i Travel (right) spool
working gallery, where it is able to cross the now selected
k Linear Travel spool
option spool and exit the valve block at port A4.

On hammer only systems, the oil flow is will now go directly

to the hammer.

The pressure required to drive the hammer is set at the

option spool ARV on the main valve block.

Oil returning from the hammer flows through the hammer

filter 45 and direct to tank.

Note: When the machine is equipped for hammer only (not

auxiliary) the hose from Port2 of the hammer pedal will be
connected to the tank port of the cab manifold and the hose
from Port Pb4 of the main control valve 10 will be
connected to the tank manifold.

When a machine that is fitted with a hammer/auxiliary

combined option the ARV's in the valve block are set to the
pressure required for the auxiliary system and not the
hammer.

In hammer mode oil flowing from the main control valve 10,
has to cross the hammer /auxiliary change over valve 47.
At the valve the flow is diverted in 2 directions:
1. To feed the hammer.
2. To the hammer ARV 47, so pressure going to the hammer
can be regulated.

Returning oil from the hammer enters the change over valve
43 and is diverted direct to tank via the hammer filter 45.

The Hammer/auxiliary change over solenoid is de-energised

and allows a 40 bar (580 lb in2) servo pressure to cross and
hold the change over valve 47 in the hammer position.

9803/6510 Issue 1
Section E Hydraulics Section E
5 - 46 Circuit Description 5 - 46

Remote Control Valve (Services)

The remote control valve is a pressure reduction valve used
to control the servo pressure operated system. Four
pressure reduction valves used to control the servo pressure
are located in the main housing. Direction of the output
servo pressure is controlled by selective movement of the
control lever. The valves and control levers are mounted in
the arm rests on both sides of the operator’s seat.

The pressure reduction unit is comprised of spools 17,

pressure control springs , return springs, 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 retur n spring seats 13, 24
simultaneously compressing the pressure control springs
moving the spool, allowing hydraulic oil to flow to the
designated pilot port.
26
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, 11
2, 3 and 4.
25
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 11
applying pilot pressure to the opposite end. (In some cases,
pilot pressure is applied to both ends of the control valve
spool.) 13

Function 13 17

Oil supplied by the hydraulic servo pump enters at port P T

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 P
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
A409170
joint 26.
2,4
1,3
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 T P
return to their neutral (closed) positions. The springs also
provide a resistive force, giving the operator a ‘tactile feel’ of
the controls.

The control handles contain electrical push button and P

rocker switches which are used to operate auxiliary services
1 2 3 4

JS03240

9803/6510 Issue 1
Section E Hydraulics Section E
5 - 47 Circuit Description 5 - 47

Cushion Valve
Operation
The machine defaults to cushioned mode on start up. The
following describes only the “Dipper in” function but, Dipper
out, Boom in and Boom out circuits all operate in the same
way.
1. Cushioned Mode - Hand controller in neutral (Fig 1)
When the Hand control is in Neutral, hot oil is taken from the
pressurised oil cooler line, entering port R of the cushion
valve, through the outer spool and around the inner spool,
via the galleries E and F, around the middle of the outer, via
galleries G and H, returning to the tank via port T.
2. Cushioned Mode - Hand controller at Dipper in (Fig 2)
Pilot pressure enters port A of cushion valve from the left
hand controller. The left-hand inner and outer spools move
over to the right. Oil passes from A to C via gallery I and
flows on to the dipper spool in the main control valve.
Returning oil from the main control valve enters port D and
passes through gallery J to tank via port T. The movement
to the right, of the left hand inner and outer spool cuts off
galleries E, G and H. This allows hot oil from port R, to pass
through gallery F, through the central orifice Z, via port B to
the dipper hand controller, which then warms up.
A1 C D E1 G H
3. Cushioned Mode - Hand controller moved from dipper
R
in to neutral (Fig 3)
When the hand controller is released, the left hand inner and
the outer spools move over to the left, back into the neutral
position. Pilot return oil from the control valve enters via port
C, then passes through the restricted orifice Z through the
centre of the inner spool. Due to this restrictive effect, the
dipper control spool in the main control valve returns slower
than normal to the neutral/stop position.
Anticavitation
S
Anticavitation oil is supplied from the T port on the hand T
controller, through port B, through the centre of the right A B E F
hand spool and gallery K, via port D to the main control
valve. A406700

4. Cushion Control off (Fig 4)

When the cushion switch is illuminated, the cushion solenoid
is energised and pilot pressure is fed to port S on the
cushion valve. The two inner left and right cushion spools
are both pushed into the centre of the outer spool, so that
the unrestricted galleries X and the cushion valve spools are
open to allow the pilot outputs from the hand controller to
pass through the valve unrestricted, to the main control
valve. When the dipper hand controller is operated, pilot
pressure from the lever to port A, moves the outer spool to
the right and pilot pressure is fed to the dipper spool in the
control valve, via port C. At the conclusion of the hand
controller operation, the returning pilot oil, goes straight
back to the lever, with no restriction. There is no cushioning
effect. Hot oil from port R returns to tank via the dipper hand
controller, as it does in the warming circuit in the neutral
position.

9803/6510 Issue 1
Section E Hydraulics Section E
5 - 48 Circuit Description 5 - 48

Cushion Valves
1 Cushion valve - No Pressure applied

C D

G H

A B

E F
T
IN
R

A409220

2 Cushion valve -Pressure applied to A port (A to C and D to T)

C D

G H
I J

Y
A B

Z
F
E T

A409230

9803/6510 Issue 1
Section E Hydraulics Section E
5 - 49 Circuit Description 5 - 49

Cushion Valves
3 Cushion valve - Pressure applied to S port (Piloted Open)

C D

A B
Z

A409240

4 Cushion valve - No Pressure applied

C D

X Y
A B

A409250

9803/6510 Issue 1
Section E Hydraulics Section E
5 - 50 Circuit Description 5 - 50

Solenoid Valve (8 Spool)

T2 B2 C8 C6
C4

CUSHION NEG CONTROL

CT4 CT5

C3 C5
BOOM
2-STAGE RELIEF PRIORITY

CT3 CT6

C2 C7
SWING SHUT OFF
MAX FLOW CUT

CT2 CT7

C1
2 STAGE TRAVEL
ISOLATOR

A405830
CT1 CT8

P C9

C13

C11 C12 T1 C10

C11
A408610 C1 C2 C3 C4

C12
C10

A405760
CT1 CT2 CT3 CT4

B2 T2
T1
C9
CT1 CT2 CT3 CT4
CT6 CT7 CT8 CT5
CT10
CT9 C13

A405770 A405750
A405790
CT6 CT7 CT8 CT5

C6 C8

C5 C7
P

9803/6510 Issue 1
Section E Hydraulics Section E
5 - 51 Circuit Description 5 - 51

Solenoid Valve (8 spool)

8 Spool solenoid operation.

Solenoid Function Electrical Harness Tape Colour Hydraulic hose colour

CT1 2 Stage Travel Red Blue / Blue
CT2 Slew Shut Off Green Red / Red
CT3 2 Stage Relief Yellow Green / Green
CT4 Cushion Control Light Green Yellow / Yellow
CT5 Negative Control White Violet / Violet
CT6 Boom Priority Pink Orange / Orange
CT7 Max Flow Cut No Tape Light Blue
CT8 Servo Isolator Blue No Hose

The 8 spool solenoid valve distributes servo pressure to 2 By selecting "Lift mode" on the EMS panel. This will
activate machine function automatically or when selected by permanently energise the solenoid.
the operator. When energised by either of the above functions, servo
pressure acts on the MRV via port C3 and selects the
Isolator. (CT8) MRV to it's second stage.
The solenoid is energised when both the lever lock in the
cab is in the lowered position and the isolator button on the
right hand fascia switch panel is turned off. No further Cushion control. (CT4)
function will operate unless the isolator is energised. This function is operated by the cushion control button in the
cab. In the de-energised position the boom and dipper
Oil from the servo pump enters at port P which: services are cushioned when the servo levers are released to
1 Charges the servo pressure accumulator improve controllability.
2 Is available to the servo isolator spool. When the cushion control button is selected, servo pressure
Once the isolator solenoid is energised the pilot pressure via port C4 acts on the cushion spools within the cushion
crosses the isolator spool and becomes available to the valve and removes the cushioning on the boom and dipper
remaining 7 solenoid and exits at port B2 to feed the cab services. (See Cushion Valve Operation).
manifold which distributes servo pressure to the cab servo
controls.
Negative control (CT5)
The negative control solenoid acts as a boom down delay.
2 Stage travel. (CT1). When boom down is selected the boom down pressure
When high speed travel is selected in the cab (Hare) then switch is closed. The ECU1 then energises the negative
CTI solenoid is energised, which allow servo pressure to the control solenoid for 0.4 seconds. This sends a 40 bar (580 lb
track drive motors via port C1 to select high speed travel in in2) signal to the negative control port of pump2 and holds
the motors. See drive motor operation. the pump on minimum flow for the first 0.4 seconds of the
boom down operation to smooth the start up of the
operation.
Slew shut off (CT2)
When the Slew lock button in the cab is selected, the swing
shut off solenoid energises. This allows servo pressure via Boom priority (CT6)
port C2 to the servo shuttle valve (situated on the bulkhead The solenoid is only energised when both the boom priority
panel at the back of the cab), which diverts the pressure to switch in the cab is selected and the boom up pressure
each side of the swing spool in the main valve block and switch is closed. This then sends a 40 bar (580 lb in2) signal
holds the spool in the neutral position. to the boom priority spool in the main control valve via port
C6. See priority valves.

2 Stage relief. (CT3) Maximum flow cut. CT7)

This can be operated by two functions: The solenoid is energised when.
1 When the auto power boost pressure switch, on the 1 Slow speed travel is selected. (Tortoise).
main valve block, closes the 2 stage solenoid will 2 Lift mode is selected.
energise for 3 seconds, then de-energise for 9 When any of the above functions are selected then the max
seconds. This cycle will continue as long as the auto flow cut solenoid energises and sends a signal to both max
power boost pressure switch is closed. flow cut ports of the pump via port C7. This restricts the
maximum pump flow to 60%.

9803/6510 Issue 1
Section E Hydraulics Section E
5 - 52 Circuit Description 5 - 52

Shuttle Valve

Port Function Harness

Tape Colour
S1 Slew Pressure Switch Red
S2 Boom Up Pressure Switch Yellow
S3 Boom Down Pressure Switch Blue
C9 Auto Mode Pressure Switch Green

B1 B2 B3 C1 C2 B4 B5 C3 C4 B6

C6
C7
C8
OUT IN
A1 S1 A2 A3 S2 S3 A4 A5 C9 C5 A6

S1
S2
S3
C9
CT6

C5/ A6 A5 B5 C4 C3 B6
CT5
C9

A3 S2 S3 A4 B4 C2 C1 B3

CT4 CT1 C7
C6 B1 B2
A2 A1
CT2 S1 CT3
C8

CT1
CT2
CT3
Port Hose Colour A1Port
=V HoseC1 Colour
= GR/R CT4
A2 = O C2 = YG/P CT5
A1 Violet C1
A3 = BL
Grey/Red CT6
C3 = R/BR
A2 Orange A4C2
=R Yellow,Green/Pink
C4 = G/R
A3 Blue A5C3
=G Red/Brown
C5= GR/R
A4 Red A6C4
=P C6 = R/R
Green/Red
B1 = V C7 = CL
A5 Green C5 Gray/Red
B2 = 0 C8 = W/R
A6 Pink B3C6
= BL Red/Red
B1 Violet B5C7
=G -
B2 Orange B6C8
=P White/Red
B3 Blue A407821
B5 Green
B6 Pink

9803/6510 Issue 1
Section E Hydraulics Section E
5 - 53 Circuit Description 5 - 53

Rotary Coupling
The rotary coupling consists of the inner axle 11 and outer
rotor 13 with packing rings 15, 'O'-rings 14/18, thrust plate
16 and cover 19. In the axle and rotor, there are pairs of
ports and oil passages each pair being sealed from the
others by packing rings and 'O'-rings. Both the axle and
rotor can rotate and the oil can flow freely through the oil
grooves.

The coupling is located in the centre of the machine

between the lower and upper sections and rotates around
the slew centreline. It receives the supply and return
pressurised oil passing from the control valve to the traction
motor and is not affected by the rotation of the lower and
upper sections, allowing the machine to slew 360° in both
directions.

9803/6510 Issue 1
Section E Hydraulics Section E
16 - 1 Fault Finding 16 - 1

Control Valve in General

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 Check the torque.
too much
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 from 1. Foreign matter in load check valve Disassemble the check valve and clean.
neutral to raise position, the load
falls.
2. Check valve poppet or seat Replace the poppet or lap the poppet and
damaged seat part.

9803/6510 Issue 1
Section E Hydraulics Section E
16 - 2 Fault Finding 16 - 2

Relief Valve
Symptoms Possible Causes Countermeasures
Pressure does not rise at all 1. The main poppet, sleeve or pilot Check whether foreign matter is in each
poppets are sticking open or poppet.
foreign matter is in the valve seat.
Check whether each part is sliding
smoothly.

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 Remove the surface scratches.
poppet. 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 Check for scratches, cuts or foreign matter.
matter. Clean all the parts.

Hydraulic System

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 Disassemble the relief valve and clean.
relief 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.

9803/6510 Issue 1
Section E Hydraulics Section E
17 - 1 Fault Finding 17 - 1

Slew Motor
Table 1.

Symptom Cause External Inspection Countermeasure Repair

Internal damage to the Measure the oil drain High possibility of Refer to Table 2.
motor. volume. damage to the sliding
surfaces if the supply
volume is approximately
equal to the drain
volume. Dismantle and
Motor does not run

inspect.
Internal damage to the Open the motor inlet and High possibility of Renew damaged parts
motor. outlet ports and apply internal damage to the or renew the motor
20 kgf/cm2 (284 lbf/in2) motor if the supply shaft assembly.
pilot pressure to the does not rotate smoothly
brake release port. Try when this torque is
to rotate the shaft with applied. Dismantle and
a torque of approx. inspect.
39.32 Nm (29 lbf ft).
Relief valve in circuit not Measure pressure. Reset to the prescribed
set correctly. setting.
Wear or damage to the Measure the oil drain Leakage is too high if the Refer to table 2.
Excessive 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 Refer to table 2.
leakage in the motor. temperature. temperature.
Seizure of motor sliding Check for any metallic If metallic matter is Repair or renew the
parts or circuit. matter deposited in discovered or the supply damaged parts. Renew
Abnormal heating

motor drain oil or drain shaft does not rotate the motor assembly.
filter. Apply a 30 kgf/cm2 smoothly when torque is
(427 lbf/in2) pilot pressure applied, there is a high
to the brake release port possibility of internal
and try to rotate the shaft damage to the motor.
with a torque of approx. Dismantle and inspect.
39.32 Nm (29 lbf ft).
Damage or wear to oil Renew the oil seals.
seal lip.
Leakage from oil 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 damaged parts. Renew
and inspect if drain the motor assembly.
volume is excessive.

9803/6510 Issue 1
Section E Hydraulics Section E
17 - 2 Fault Finding 17 - 2

Slew (cont’d)

Symptom Cause External Inspection Countermeasure Repair

Wear or seizure of the Open motor inlet and High possibility of Inspect the parts and
motor sliding surfaces. outlet ports and apply 20 internal damage to the bearing according to
kgf/cm2 (284 lbf/in2) pilot motor if the supply shaft Table 2 a-e and renew
pressure to the brake does not rotate smoothly any defective parts.
release port.Try to rotate when this torque is
Insufficient torque

the shaft with a torque of applied. Dismantle and

approx. 39.32 Nm inspect.
(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 Repair or renew
motor. matter is deposited in the internal damage to the damaged parts. Renew
motor drain oil or drain motor if metallic matter the motor assembly.
filter. is discovered.
Dismantle and inspect.

Large amount of air Check the oil in the tank Thoroughly bleed the air.
Abnormal 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.
O-ring is damaged Renew O-rings.
Oil leakage from
mating surfaces

Seal face is damaged. Repair seal face or

renew.
Bolts are loose. Check the bolt tightness. Tighten the bolts to the
correct torque.

Table 2.

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.

9803/6510 Issue 1
Section E Hydraulics Section E
18 - 1 Fault Finding 18 - 1

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

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 Re-inspect regulator. Refer to regulator instructions.
high?

Seizure or damage of pumps internal Replace damaged parts. Check the filter or drain oil for signs
parts of abnormal wear.

Wrong regulator hose connection. Correct hose lines.

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 Replace damaged parts. Check filter, drain oil.
internal 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.

9803/6510 Issue 1
Section E Hydraulics Section E
18 - 2 Fault Finding 18 - 2

Hydraulic Pump cont’d

Abnormal Sound and Vibration

Cause Treatment Note

Cavitation. Prevent cavitation. Boost pressure is low

Check to see if hydraulic oil is Pump is broken.
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.

9803/6510 Issue 1
Section E Hydraulics Section E
19 - 1 Fault Finding 19 - 1

Hydraulic Rams
Hydraulic ram trouble and its remedies.
It is not easy to find the part causing the trouble. In the chart below, possible problems are listed. Repair is difficult, so refer
to the estimated cause and treatment listed in the chart. In the chart, the general phenomenon, estimated causes and treat-
ment are shown. However, machine trouble is most often caused, not by just one faulty part, but its relationship with other
parts. Not all of the possible causes and treatments are listed in the chart below, therefore, it may be necessary for the person
responsible for repairs to make further investigations to find the cause of the trouble.

Item Symptoms
1 Oil leakage from piston rod sliding part
2 Oil leakage from cylinder head meeting part
3 Oil leakage from pipe and cylinder tube welded part
4 Faulty operation

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.
Piston rod The plating is peeling. Re-plate or replace the piston rod.
1 sliding part Also inspect the seal and piston rod
oil leakage bearing member and replace if damaged.

Foreign matter is biting into the Remove foreign matter.

inner and outer surfaces of If there is damage to packing, replace it.
the packing.
There is a scratch on the inner Replace.
and outer surface of the packing.
Rod packing The lip and groove parts are Possibly due to burning caused by
(Buffer ring, locally carbonized (burned). adiabatic compression from air remaining
U-ring) inside the ram. After replacing the
packing, first operating the ram at
low-pressure, low speed to sufficiently
bleed the air.

9803/6510 Issue 1
Section E Hydraulics Section E
19 - 2 Fault Finding 19 - 2

Hydraulic Rams (cont’d)

Item Symptoms Related Parts Trouble Treatment

Packaging rubber elasticity is The packing life or hydraulic oil
gone and breaks into pieces. deterioration and high temperature are
possible reasons.
1. Renew hydraulic oil.
Rod packing 2. Check the hydraulic oil temperature.
(Buffer ring, (Below 80 C is advisable).
U-ring) 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.
The protrusion of the heel of the As a rule, replace the rod packing at the
Piston rod packing is excessive. same time. (It is desirable to replace parts
1 sliding part which are attached to the buffer ring at the
oil leakage Back up ring 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.
Wiper ring lip. The lip is damaged.
There are also other abnormal Replace.
damage.
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.
Scratches, rust on the seal Remove scratch, rust with oil stone. If it
Cylinder head attachment parts. cannot be repaired, replace the cylinder
head.

9803/6510 Issue 1
Section E Hydraulics Section E
19 - 3 Fault Finding 19 - 3

Hydraulic Rams (cont’d)

Item Symptoms Related Parts Trouble Treatment
Foreign matter biting on inner • Remove foreign matter.
and outer diameter. • Replace 'O'-ring if damaged.
• Inspect inside tube: if any scratches or
O-ring damaged. rust, make surface smooth with oil
stone.
O-ring • Inspect cylinder head 'O'-ring groove: if
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.
Back up ring Deformation, protrusion • Replace with 'O'-ring.
Oil leakage Looseness • Disassemble cylinder head and inspect
2 from cylinder 'O'-ring and back up ring.
head joint Cylinder head • Check tube and cylinder head thread for
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.

Crack in welding Replace with new parts.

Oil leakage • Cracks will develop into fractures.
from pipe Cylinder tube Fractures are very dangerous, so if any
3 and cylinder pipe (hollow cracks are found, stop work immediately
tube welded piston rod) and replace with new parts.
seam • Welding on top of cracks will have no
effect.

9803/6510 Issue 1
Section E Hydraulics Section E
19 - 4 Fault Finding 19 - 4

Hydraulic Rams (cont’d)

Item Symptoms Related Parts Trouble Treatment

Poor Bending is more than the • Replace with new part.
operation Piston rod specified limit. The seal and sliding part material may
cylinder tube (Bending distortion:Refer to be damaged too, so inspect. If abnor
maintenance standards) mal,replace.

Cylinder tube There is a recess • Replace with new part.

As above, inspect the seal and sliding
part material.
4-1 • Replace with new part.
Movement Piston rod Abnormal wear, damage of sliding As above, inspect the seal and sliding
not smooth cylinder rod parts. part material.
sliding part Foreign matter intruding on piston • Remove foreign material.
and cylinder head sliding area As above, inspect the seal and sliding
part material.

4-2 Piston seal Scratches, wear are preasent • Replace with new part.
Inpect the cylinder tube inner surface.
Inner oil leak-
age. Piston
rod extends Scratches, rust on the insidet • Remove the scratches/rust by honing
when work Cylinder tube or with an oil stone and make the sur-
stops or low- faces smooth
ers abnormally If the scratch is deep and cannot be
during work. repaired, replace the cylinder
Also, specified • Replace piston seal.
operating
speed is not Piston Nut Loose nut • Tighten to specified torque.
achieved.
Valves Leak from valve • Inspect the valve leakage amount and
service.

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.

9803/6510 Issue 1
Section E Hydraulics Section E
19 - 5 Fault Finding 19 - 5

Hydraulic Rams (cont’d)

Item Symptoms Related Parts Trouble Treatment

4-3 Air remaining inside ram • Bleed the air.
Operation is unsteady For rams that do not have an air
bleeder, operate back and forth several
times at low pressure and low speed to
bleed the air. For rams with an air
bleeder, remove the load to reduce the
Air 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
4-4 Pin bushing, Pin Gap between installation part and Measure the pin and pin bushing and
Heavy shock pin bushing is too large replace parts if measurements exceed
loading when the specifications.
changing from
extension to
retraction
and back
4-5 Oil supply Insufficient oil • Add oil.
Noisy
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.

9803/6510 Issue 1
Section E Hydraulics Section E
20 - 1 Fault Finding 20 - 1

Fault Finding Tests

Note: See Service Procedures, Section E for the following

Tests. Swap the two main hoses on the hydraulic pump. Does the
problem change direction?
Slow or Underpowered:
- boom up operation Poor Tractive Effort
- bucket service operation
- dipper service operation Carry out the following tests:
- slew service operation
Test 001 Testing negative control signal
Carry out the following tests: Test 003 Testing main pump pressures
Test 012 Testing track motor relief valve settings
Test 001 Testing negative control signal Test 013 Testing track motor drain line rates
Test 002 Testing max flow cut signal
Test 003 Testing main pump pressures Additional Information
Test 004 Testing horsepower control
Test 005 Testing operation of main hydraulic spool What travel gear is the machine operating in when the prob-
Test 006 Testing operation of pressure switches lem occurs?
Test 007 Testing engine speed settings
Test 008 Testing machine cycle times See: Machine Selects High Gear Even Though Monitor
Test 016 Testing Pump Flow Displays Another Travel Gear

Note: If Dipper cylinder has HBCV fitted then also carry

out :
Loss of Creep Speed
Test 010 Testing operation of arm HBCV
Carry outthe following tests:

Harsh Operation When Selecting: Test 012 Testing max flow cut signal
- boom down Test 008 Testing track motor speeds
- slew service Test 006 Testing pressure switches

Carry out the following tests: Additional information

When creep speed tracking is selected is ‘tortoise’ symbol
Test 001 Testing negative control signal (Boom displayed on monitor? yes / no
down only)
Test 011 Testing operation of Slew brake (Slew
only) Loss of High Speed
Test 006 Testing operation of pressure switches
Carry out the following tests:

Test 006 Testing operation of main hydraulic spool

Tracking Off Line Test 008 Testing engine speed settings
Test 012 Testing track motor relief valve settings
Carry out following tests: Test 014 Testing track Motor speeds and pressure
switches.
Test 001 Testing negative control signal
Test 003 Testing main pump pressures
Machine Selects High Speed Travel
Test 012 Testing track motor relief valve settings
Test 013 Testing track motor drain line rates
Test 008 Testing track motor speeds Carry out the following tests:

Additional information Test 015 Checking Servo pressure and solenoid

Measure the amount of deviation over a 20 metre (165.6 ft) voltage.
distance and record ground conditions.
Deviation limit = 1m (39.4 in) deviation in 20m (165.6 ft) of
travel Slew Bearing Faults

If machine is fitted with priority valve in pump line (this valve Carry out the following tests:
usually feeds low flow / weedcutter circuit) try connecting
the two main service hoses together that are connected to Test 017 Checking Slew Bearing Vertical Lift and
the valve. Does this change the fault? Backlash.

9803/6510 Issue 1
Section E Hydraulics Section E
21 - 1 Service Procedures 21 - 1

Hydraulic Contamination

Hydraulic Fluid Quality Contaminant Standards

Construction machinery uses a large volume of fluid in the Dirt that damages your system is in many cases too small to
hydraulic system for power transmission, equipment be seen with the eye. The particle size is measured in
lubrication, rust prevention and sealing. microns.

According to a survey conducted by a pump manufacturer, 1 micron= 0.001 mm (0.0000394 in)

seventy per cent of the causes of problems in hydraulic
equipment were attributable to inadequate maintenance of Listed below are a few typical comparisons:-
the quality of the hydraulic fluid.
Red Blood Cell = 8 microns (0.008 mm, 0.000315 in)
Therefore, it is obvious that control of the quality of the Human Hair = 70 microns (0.07 mm, 0.00275 in)
hydraulic fluid helps prevent hydraulic equipment problems Grain of Salt = 100 microns (0.1 mm, 0.00394 in)
and greatly improves safety and reliability. Furthermore from
an economic angle it extends the life of the hydraulic fluid if Smallest particle visible to the naked eye is 40 microns
quality is maintained. (0.00157) approximately.

Effects of Contamination Standards will often be quoted to ISO (International

Standards Organisation) for which literature can be
Once inside the system, hydraulic circuit contaminants obtained.
greatly effect the performance and life of hydraulic
equipment. For example, contaminants in a hydraulic pump Filters
develop internal wear to cause internal leakage and hence
lower discharges. Wear particles generated will circulate The filter assembly fitted to all product ranges is designed to
with the hydraulic fluid to cause further deterioration in the filter all the contamination that is generated through use to
performance of this and other equipment. the required level of cleanliness. The filter must be serviced
to the requirements of the machine Service Schedules.
Contaminants also enter principal sliding sections of the
equipment causing temporary malfunction, scuffing, sticking To ensure optimum performance and reliability it is
and leakage and can lead to major problems. important that the machines hydraulic system is serviced
periodicaly in accordance with the manufacturers
The main contaminants can be classified as follows:- requirements. For service schedules refer to Section 3
Routine Maintenance.
1 Solid Particles - sand, fibres, metallic particles,
welding scale, sealing materials and wear particles etc.

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
cleaning unit, as illustrated or similar. General Bulletin 011
also refers.

Procedure

Connect the cleaning unit in place of the hydraulic filter and

run the system for sufficient time to pump all the hydraulic
fluid through the unit. Disconnect the cleaning unit and
reconnect the filter. Top up the system with clean hydraulic
fluid as required.

S168050

9803/6510 Issue 1
Section E Service Procedures Section E
23 - 1 Service Procedures 23 - 1

Test 001: Testing Negative Control Signal

VIEW FROM REAR OF

HYDRAULIC PUMP

Port Pt2

A318950

Port Pt1

! Fit test gauges ( 0 - 60 bar, 10 - 1000lb in2 ) into hose connections to ports Pt1 + Pt2 with tee piece adapter

! Warm up machine hydraulic temperature to 50 °C (122 °F)

* This pressure will vary with oil temperature and engine speed. (Expected Pressures)

Port pt1 Port pt2

With max engine rpm’s and no services selected record negative control pressure 30 - 35 bar* (30 - 35 bar*)
435 - 507 lb in2 435 - 507 lb in2
Select and stall boom up service record pressure (0 - 3 bar) (0 - 3 bar)
43.5 - 145 lb in2 43.5 - 145 lb in2
Fully select boom down record pressure when service first selected (30 - 35 bar) (40 bar when first
selected for 0.5 sec
then 10 bar)
435 - 507 lb in2
Select and stall bucket open service record pressure (30 - 35 bar) (0 - 3 bar)
435 - 507 lb in 2
43.5 - 145 lb in2
Select and stall bucket close service record pressure (30 - 35 bar) (0 - 3 bar)
435 - 507 lb in 2
43.5 - 145 lb in2
Select and stall dipper open service record pressure (0 - 3 bar) (0 - 3 bar)
43.5 - 145 lb in 43.5 - 145 lb in2
2

Select and stall arm close service record pressure (0 - 3 bar) (0 - 3 bar)
43.5 - 145 lb in 43.5 - 145 lb in2
2

Select and stall swing left service record pressure (0 - 3 bar) (30 - 35 bar)
43.5 - 145 lb in2 435 - 507 lb in2
Select and stall swing right service record pressure (0 - 3 bar) (30 - 35 bar)
43.5 - 145 lb in2 435 - 507 lb in2
Select and stall left hand track forward record pressure (0 - 3 bar) (30 - 35 bar)
43.5 - 145 lb in 2
435 - 507 lb in2
Select and stall left hand track backwards record pressure (0 - 3 bar) (30 - 35 bar)
43.5 - 145 lb in 2
435 - 507 lb in2
Select and stall right hand track forwards record pressure (30 - 35 bar) (0 - 3 bar)
435 - 507 lb in 2
43.5 - 145 lb in2
Select and stall right hand track backwards record pressure (30 - 35 bar) (0 - 3 bar)
435 - 507 lb in 2
43.5 - 145 lb in2

9803/6510 Issue 1
Section E Service Procedures Section E
23 - 2 Service Procedures 23 - 2

Test 002: Test Max Flow Signal

Port Pm2
View from rear of
hydraulic pump

Port Pm1

A318950

! Fit test gauges 0 - 60 bar (10 - 1000 lb in2) into hose connections to ports Pm1 + Pm2 with tee piece adapter

! Warm up machine hydraulic temperature to 50 °C (122° F)

Port Pm1 Port Pm2

(Expected Pressures)

With max engine rpm’s and no services selected record max flow cut control pressure 0 - 1.5 bar 0 - 1.5 bar
in E mode

Select L mode and record pressure 40 bar 40 bar

Select standard mode, select low speed tracking (tortoise on monitor) then select 40 bar 40 bar
track service record pressure

Note: 40 bar = 80 lb in2

1.5 bar = 21.75lb in2

9803/6510 Issue 1
 Test 003: Testing Main Pump Pressure
23 - 3

9803/6510
FRONT VIEW OF
Section E

HYDRAULIC PUMP

Port G1
(nearest engine)

Port G2
Service Procedures
Service Procedures

Note: 28 bar = 406 lb in2

38 bar = 551 lb in2
! Fit test gauges 0 - 600 bar (8700 lb in2) into hose connections to ports G1 + G2. 289 bar = 4190.5 lb in2
343 bar = 4973.5 lb in2
! Warm up machine hydraulic temperature to 50 °C (122 °F). 373 bar = 5404.5 lb in2
374 bar = 5423 lb in2
Section E

Issue 1
23 - 3
 Testing Main Hydraulic Pump Pressures JS225
23 - 4

9803/6510
Expected value "A"-mode Expected value "E" mode Expected value "L" mode
Section E

Port G1 Port G2 Port G1 Port G2 Port G1 Port G2

Max Engine revs and no services selected 28 - 38 bar 28 - 38 bar 28 - 38 bar 28 - 38 bar 28 - 38 bar 28 - 38 bar

Select and stall Boom up 373 bar for 3 seconds 374 bar for 3 seconds 343 bar 343 bar 373 bar 373 bar
then 343 bar for then343 bar for
9 seconds(Repeating) 9 seconds (Repeating)

Select and stall Boom down. 28 - 38 bar 265 bar 28 - 38 bar 265 bar 28 - 38 bar 265 bar

Select and stall Bucket open 28 - 38 bar 374 bar for 3 seconds 28 - 38 bar 343 bar 28 - 38 bar 373 bar
then 343 bar for
9 seconds (Repeating)

Select and stall Bucket close 28 - 38 bar 374 bar for 3 seconds 28 - 38 bar 343 bar 28 - 38 bar 343 bar
then 343 bar for
9 seconds (Repeating)

Select and stall Dipper in 373 bar for 3 seconds 373 bar for 3 seconds 343 bar 343 bar 373 bar 373 bar
then 343 bar for then 343 bar for
9 seconds (Repeating) 9 seconds (Repeating)
Service Procedures
Service Procedures

Select and stall Dipper out 373 bar for 3 seconds 373 bar for 3 seconds 343 bar 343 bar 373 bar 373 bar
then 343 bar for then 343 bar for
9 seconds (Repeating) 9 seconds (Repeating)

Select and stall Slew Left 289 bar 28 - 38 bar 289 bar 28 - 38 bar 289 bar 28 - 38 bar

Select and stall Slew Right 289 bar 28 - 38 bar 289 bar 28 - 38 bar 289 bar 28 - 38 bar

Select and stall Left hand Track Forward 343 28 - 38 bar 343 bar 28 - 38 bar 343 28 - 38 bar

Select and stall Left hand Track reverse 343 28 - 38 bar 343 bar 28 - 38 bar 343 28 - 38 bar

Select and stall Right hand Track Forward 28 - 38 bar 343 bar 28 - 38 bar 343 28 - 38 bar 343

Select and stall Right hand Track reverse 28 - 38 bar 343 28 - 38 bar 343 28 - 38 bar 343
Section E

Issue 1
23 - 4
Section E Service Procedures Section E
23 - 5 Service Procedures 23 - 5

Test 004: Testing Horsepower Control

VIEW FROM Proportional solenoid secondary

UNDERSIDE pressure measurement port
OF
HYDRAULIC
PUMP

Brown/Black (BrB) Brown/Black (BrB)

! Fit gauge 0 - 60 bar (0 -1000lb in2 ) into proportional

+ -
solenoid secondary pressure measurement port using
suitable adapter (port thread is 1/4 BSP ‘O’ ring fitting).

! Separate proportional solenoid electrical connector.

Using service connector from electrical test kit
WDB0055 connect fluke meter in series as shown right.
Pump side
OR harness
+ -

! Using link wire, connect fluke meter in series as shown.

! Warm up machine hydraulic temperature to 50 °C

(122 °F)
Link wire
330470

Auto Power Boost Pressure

Switch
Note: The Harness Connector
should be labeled with a green
marker tape

A409200

9803/6510 Issue 1
Section E Service Procedures Section E
23 - 6 Service Procedures 23 - 6

Test 004: Testing Horsepower Control (cont’d)

Function Expected PSV Expected

Pressure Milliamps

With maximum engine RPM 9 bar (130lb in2) 540 M/A

selected on the throttle dial
and no service selected in "A" Mode.
Note: The auto pressure switch must
be shorted out during this test.

With the Auto pressure switch connected 9 bar (130lb in2) 540 M/A
and maximum engine RPM selected on the 13 bar (188lb in2) 490 M/A
throttle dial, stall the dipper service in "A" mode. 18 bar (261lb in2) 420 M/A
Note: M/A and PSV Pressure are not 25 bar (362lb in2) 320 M/A
constant in "A" mode has the pump horsepower
is always changing to absorb 100% of the
available engine power.

With maximum engine RPM and no services

operated, select "E" mode. 25 bar (362lb in2) 320 M/A
With maximum engine RPM and no services
operated, select "L" mode. 40 bar (580lb in2) 0 M/A

40

35

30

25
Pressure can
vary +/- 2bar
Pressure
(Bar) 20

15
.
10 .
5
.

100 200 300 400 500 600 700 800

Milliamps

To achieve the above values the following conditions have to be met A409360

1. Feed pressure in port "P" of the solenoid to be 39bar

2. Back pressure to be no more than 10 bar
3. Oil temperature to be 55 deg C +/- 10

9803/6510 Issue 1
Section E Service Procedures Section E
23 - 7 Service Procedures 23 - 7

Test 005: Checking the Operation of the Main Hydraulic Spool

Cylinder port B Cylinder port A

Sectional view of valve block

showing spool and pilot ports

Pilot port b
Pilot port
a

Valve block
Main spool

A325404

! Identify which is main directional spool for service being

tested, and which side of that spool is supplied pilot
27
pressure when service is operated in desired direction 25
Straight line travel
! Fit pressure gauges 0 - 60 bar (0 - 1000lb in2) to this port
and also to port on opposite end of spool

! Warm up hydraulic system to 50 °C (122°F) Pressure

Bar.
All Other Spools
! Remove the hose from the spool port that is not being 11
selected and plug the hose.

! Remove the hose from the spool end that is being 3.4

selected and plug the hose. Couple a hand pump (see

Service tools) with a pressure 60 bar (0 - 0 2 4 6 8 10
1000lbin2)gauge attached. (Instead of using a hand Spool stroke mm
pump, the pressure from the accumulator may be used A409210
by leaving the hose and Pressure gauge attached, but
will not be as accurate, and should only be used if only
full spool selection is being measured.)

! Insert a piece of stiff clean wire (Approximately 2 mm

(0.08 in) diameter)) through the adapter in the port not
being selected until the spool end is felt.

! Slowly select the spool from the selected end using the
portapower pack, measure the distance the spool
moves and check against the graph below. (If using the
accumulator pressure, turn on the machines ignition,
lower the lever lock and select the service.

Note:The accumulator may require recharging by running the

engine for a short period).

! Remove Spool cap from the main valve block and

withdraw the spool checking for any scratches/
imperfections, or any signs of sticking. Slide the spool in
and out of the valve block, rotating it at the same time
checking for smoothness.

9803/6510 Issue 1
Section E Service Procedures Section E
23 - 8 Service Procedures 23 - 8

Test 005: Checking the Operation of the Main Hydraulic Spool (cont’d)

Pressure at spool port which Pressure at spool port at

is being selected which is not being selected
(Expected Pressure) (Expected Pressure)
With max engine rpm’s and
no service selected 0 - 3 bar (43.5 lb in2) 0 - 3 bar (43.5 lb in2)

With service fully selected 36 - 40 bar* (522 - 580 lb in2) 0 - 3 bar (43.5 lb in2)

9803/6510 Issue 1
Section E Service Procedures Section E
23 - 9 Service Procedures 23 - 9

Test 006: Testing Pressure Switches

POWER
MODE

1 Start the engine. A335120

2 Press the set and mode buttons together for 5 seconds to access the Sub menu.

3 Use the Up & Down arrow buttons to until the Pilot SW appears on the screen.

4 Press ACK button.

5 Use the up & down buttons to scroll through the individual switches and check against the chart below.

Note: 22 bar = 319 lb in2

335 bar = 4857.5 lb in2

Function Boom Boom up Hammer Slew Travel Upper Boost A-mode

Boom up OFF ON OFF OFF OFF ON Only if main pump Only if servo pressure
pressure is above from Handcontroller
335 bar is above 22bar

Boom down ON OFF OFF OFF OFF ON OFF Only if servo pressure
from Handcontroller is
above 22bar

Dipper in OFF OFF OFF OFF OFF ON Only if main pump Only if servo pressure
pressure is above from Handcontroller
335 bar is above 22bar
Dipper out OFF OFF OFF OFF OFF ON Only if main pump Only if servo pressure
pressure is above from Handcontroller
335 bar is above 22bar

Bucket in & out OFF OFF OFF OFF OFF ON Only if main pump OFF
pressure is above
335bar

Slew left & right OFF OFF OFF ON OFF ON OFF OFF

Travel OFF OFF OFF OFF ON OFF OFF OFF

Hammer OFF OFF ON OFF OFF ON OFF OFF

9803/6510 Issue 1
Section E Service Procedures Section E
23 - 10 Service Procedures 23 - 10

Symptoms of Pressure Switch Failures

Pressure switches that need to be closed when selected, to avoid the issues described.

Upper pilot Travel Auto mode Boost Boom up Boom down Hammer Slew

In Auto /one
touch idle, engine Closed Closed Closed Closed
will not return to when when when when
full RPM when selected selected selected selected
service is
selected

In Auto mode the Closed

engine fails to rise when
to full engine selected
RPM when Boom
or Dipper are fully
selected.

Slow speed travel Closed

(Tortoise) does when
not work selected
2nd Stage MRV Check to Check
(Power boost) see it is closed
does not work in NOT when
Auto mode. (See closed selected
Test 003 for
testing Power
Boost)

Slew does not Closed

slow down when when
operating slew selected
and boom up in
boom priority
mode

Boom action Closed

violent when when
boom down is selected
first selected

Slew start up and Closed

slow down is very when
erratic and selected
juddering.

Note: See Main Control Valve and Shuttle Valve in Circuit

Descriptions for location of Pressure Switches.

9803/6510 Issue 1
Section E Service Procedures Section E
23 - 11 Service Procedures 23 - 11

Test 007: Testing Engine Speed Settings

! Warm Engine water temperature above 50 °C (122°F).

! Press Set + Mode for 5 seconds (On the EMS).

! Use the up and down arrows to scroll to the RPM

value.

! Press ACK to view engine speed.

POWER
MODE

Auto Power Boost Pressure

Switch
Note: The Harness Connector
should be labeled with a green
marker tape

Mode Expected RPM High idle Expected RPM Dipper In Expected RPM Bucket
(No service selected) stalled Close stalled
"A" mode with the 2145 +/- 50 RPM 2040 +/- 50 1970 +/- 50
auto pressure switch
shorted out
"A" mode with the 1945 +/- 50 RPM (Only for 3 2040 +/- 50 1950 +/- 50
auto pressure switch seconds after any service is
connected de-selected, then 1360 RPM
+/- 50RPM for X seconds
"E" mode. 2045 +/- 50RPM 1950 +/- 50 1950 +/- 50
"L" & "P" mode 1945 +/- 50RPM 1850 +/- 50 1870 +/- 50

2145 +/- 50 rpmA

1945 +/- 50 rpm B

1360 +/- 50 rpm C

Idle D
ON

OFF
Auto mode Pressure Switch
ON

Upper Pressure Switch OFF

F
ON

Travel Pressure Switch OFF

3s Xs 3s Xs 3s Xs

Time

9803/6510 Issue 1
Section E Service Procedures Section E
23 - 12 Service Procedures 23 - 12

Test 008: Testing Machine Cycle Times

! Warm up hydraulic system to 50 °C (122°F).

! Select E mode only
! Operate all services 10 times to ensure warm oil as been circulated through all the services.
! Use a stopwatch to measure the time is takes for the service to complete one cycle with the hand controller fully
selected.
! Repeat five times and take the average time.
! If the machine is fitted with HBCVs and any delay is felt when operating dipper in, then the HBCV must be bled of any
air and the test repeated.

Service operated Time. (Seconds)

Boom Up 3.0 - 3.7
Dipper In 3.0 - 3.6
Dipper Out 2.5 - 3.0
BucketOpen 2.0 - 2.5
Bucket Close 2.3 - 2.7
Slew. (1 revolution) 4.7 - 5.2

Track motor speed in E mode.

! Raise one track off the floor by slewing the machine through 90 degrees and lifting the machine using the boom and
dipper.
! Make a mark on the outside edge of the Track Gearbox.
! Operate the track motor in forward and reverse for 5 minutes, changing gear at regular intervals to distribute warm oil
through the system.

Speed selected Expected Gearbox RPM

Creep (Tortoise) 24 +/- 4
Middle 28 +/- 5
High (Rabbit) 46 +/- 6

9803/6510 Issue 1
Section E Service Procedures Section E
23 - 13 Service Procedures 23 - 13

Test 008: Testing Machine Cycle Times

(cont’d)
a Bucket Ram speed.
The conditions for checking are that the Dipper should
be level.
Measurement is of the time it takes the bucket to fully
open and close from each end of the stroke

b Dipper Ram speed

The conditions for checking are that the Dipper should
be level with the bucket open.
Measurement of the time it takes the Dipper to open and
close from each end of the stroke.

c Boom Ram speed A357571

The conditions for checking are that the Dipper and the
bucket are open.
Measurement of the time it takes for the boom to go from
a fully raised to fully lowered position.

Note: Place a wooden block where the Dipper would make

contact with the ground, so as to prevent a shock loading of
the Dipper, when it is lowered.

d Slew Speed
The conditions for checking are that the attachment is
facing forwards and that a vertical line is chalked on the
turn table bearing and lower ring, then place the attach-
ment in the minimum slew position.
Rotate the upper framework and after one complete
rotation, then measure the time it takes for the next
rotation.

e Travel Speed
The conditions for checking are that the main unit is
jacked up, then marks are made on the Traction Motor
and side frame. Rotate the sprocket two times or more
to warm the motor then, record the time it takes for the
motor to complete ten revolutions.
Measurement should be done with the machine in each
mode, low, medium and high speed and three
measurements in each direction in each mode should be
done to obtain an average.

9803/6510 Issue 1
Section E Service Procedures Section E
23 - 14 Service Procedures 23 - 14

Test 008: Testing Machine Cycle Times

(cont’d)
MEASUREMENT METHOD

a Travel Linearity.
The conditions for checking are that the machine should
have an approach of 5 metres (16.5 ft) and a travel
distance of 20 metres (65.62 ft); measurement is of the
amount of deviation after 20 metres (65.62 ft) between
the reference line and track shoe.

Approach the reference line and adjust the position of the

track shoe/travel direction against the reference line in
the first 5 metres (16.5 ft), then without adjusting, allow
the machine to travel 20 metres (65.62 ft), then measure MEASUREMENT METHOD
the deviation, then complete the same procedure in
reverse.

9803/6510 Issue 1
Section E Service Procedures Section E
23 - 15 Service Procedures 23 - 15

Test 010: Testing Hose Burst Check Valve - Dipper Ram

Port E

Port P

A409671

! Warm up hydraulic system to 50 °C (122° F)

! Set the Main Relief Valve (MRV) above the Auxiliary Relief Valve (ARV) - See Auxiliary Relief Valves in Service
Procedures.

! Set Dipper to fully extend position with bucket 300 mm (12in) above ground and operate the emergency stop button, to
stop the engine.

! Select Dipper in until the bucket rests on the ground, then fully select the lever for Dipper in, this will ensure that the
pressure in the Dipper circuit has been vented.

! Remove pilot hose from port P, plug hose and leave port open to atmosphere.

! Fit test gauge 0 - 600 bar (8700 lb in2) to port E using appropriate adapter.

! Start engine, lift boom to give clearance to move arm.

! Carefully select Dipper in and slowly build pressure until Dipper starts to move slowly and steadily.

! Record pressure at this point, this is relief setting of HBCV.

! To adjust this setting, remove cap from small cartridge A and adjust as necessary.

Note: - If the Dipper is selected too quickly a higher pressure will be seen at pressure gauge giving false reading of relief
setting.

Relief Valve Settings 370 - 390 bar (5365 - 5655 lb in2)

9803/6510 Issue 1
Section E Service Procedures Section E
23 - 16 Service Procedures 23 - 16

Test 011: Testing Slew Brake Pressure

Slew Brake Valve

Slew Motor
A405810

! Fit pressure test gauge 0 - 60 bar ( 1000 lb in2) into hose connection on hose A on the Slew Motor.

! Warm up hydraulic system to 50 °C

Pressure at port B
(Expected Pressure)
With engine at max rpm’s no services selected
record pressure 14 - 15 bar (203 -217.5 lb in2)

Select slew service

record pressure 40 bar (580 lb in2)

Deselect slew service 40 bar for 5 secs then 14 -15 bar

record pressure

Select 100% slew lock

record pressure after 5 secs 0 - 1.5 bar (21.75 lb in2)

9803/6510 Issue 1
Section E Service Procedures Section E
23 - 17 Service Procedures 23 - 17

Test 012: Testing Track Motor Relief Valve Settings

ARV

Alternative
pressure
measuring ports

ARV

A405820

! Fit pressure gauges 0 - 600 bar (8700 lb in2) to main pump test ports (see relevant test procedure for testing main
pump pressures).

! Warm up hydraulic system to 50 °C (122°F)

Testing Track Motor ARV Settings

! Disconnect the Travel Pressure Switch A on the Main Control Valve

! Select L mode

A406530

Expected relief valve setting

Select and stall left hand track motor forward 343 bar (4973.5 lb in2)

Select and stall left hand track motor reverse 343 bar (4973.5 lb in2)

Select and stall right hand track motor forward 343 bar (4973.5 lb in2)

Select and stall right hand track motor reverse 343 bar (4973.5 lb in2)

9803/6510 Issue 1
Section E Service Procedures Section E
23 - 18 Service Procedures 23 - 18

Testing 013: Testing Track Motor Drain Line Flow Rate

View of track motor

(cover removed)

Drain port D

A405820

! Warm up hydraulic system to 50 °C (122 °F).

! Remove tank hose from drain port D on left hand track motor.
! Plug hose.
! Fit hose between drain port D and measuring container.
! Set machine to max engine rpm’s in middle gear (arrow on monitor).

Expected drain line rate ltrs/min

Select and stall left hand track motor forward 3 - 4 litres (0.66 - 0.88 UK gal)
for 1 min

Select and stall left hand track motor reverse 3 - 4 litres (0.66 - 0.88 UK gal)
for 1 min

! Refit hose to track motor.

! Repeat above proceedure for right hand track motor.

Expected drain line rate ltrs/min

Refit Select
hose toand
track
stallmotor
right hand track motor forward 3 - 4 litres (0.66 - 0.88 UK gal)
for 1 min

Select and stall right hand track motor reverse 3 - 4 litres (0.66 - 0.88 UK gal)
for 1 min

! Refit hose to track motor

9803/6510 Issue 1
Section E Service Procedures Section E
23 - 19 Service Procedures 23 - 19

Test 014: Loss of High Speed Tracking

If experiencing loss of high speed tracking, carry out following checks:

Test 008 Testing track motor speeds

Test 006 Testing pressure switches

Additional information
When high speed tracking is selected is ‘hare’ symbol displayed on monitor? yes / no

When high speed tracking has been selected what pressure is seen at pilot port to select high gear on track motor (see
illustration below).

Pilot port X

A405820

High speed tracking Front view of 8

solenoid spool valve

When high speed tracking has been selected is electrical voltage seen at high speed tracking solenoid? yes / no ?

9803/6510 Issue 1
Section E Service Procedures Section E
23 - 20 Service Procedures 23 - 20

Test 015: Machine Selects High Gear Even Though Monitor Displays Another Travel Gear

If machine selects high tracking gear ‘by itself’ even though the operator has not selected high gear and the monitor display
has not changed carry out following checks :

What pressure is seen at pilot port X ( see below ) when :

1 Middle tracking gear is selected?

2 Middle tracking gear is selected and tracking service is stalled , forwards and backwards on both left and right
hand tracks?
3 High tracking gear is selected?

Pilot port X

A405820

High speed tracking Front view of 8

solenoid spool valve

A326403

What electrical voltage is seen at high speed tracking solenoid when :

1 Middle tracking gear is selected?

2 High tracking gear is selected?

9803/6510 Issue 1
Section E Service Procedures Section E
23 - 21 Service Procedures 23 - 21

Test 016: Flow Testing Hydraulic Pumps

! Install flow meter and load valve as close as possible to pump outlet in one of the pump lines.

! Fit pressure test gauges 0 - 600 bar (8700 lb in2) to main pump test points.

! Start engine and warm up hydraulic oil at least 50 °C (122 °F).

To Confirm Minimum Flow Setting

! Set machine to A mode.

! Stall boom up service and record pressure in each pump, flow on flow meter and engine rpm’s (record this on sheet
attached).

! Repeat this test for E mode, L mode and P mode.

To Confirm Maximum Flow Setting

! Disconnect negative control pilot hose from pump which is being tested, plug the hoses and leave ports on pump open
to atmosphere.

! Set machine to max engine rpm’s in A mode with the Auto Pressure Switch shorted out. Have the load valve the on flow
meter fully open and do not operate any services.

! Record the pressure on both pumps, the flow on flow meter and the engine rpm’s (record this on sheet attached).

! Repeat this test for E mode, L mode and P mode.

To Confirm Horse Power Control

! Disconnect negative control pilot hoses and max flow cut pilot hoses from both pumps.

! Plug the hoses and leave ports on pump open to atmosphere.

! Start the engine and set the machine to max engine rpm’s in A mode, make sure the load valve is fully open.

! Record the pressure on both pumps on the flow on flow meter, engine rpm’s and proportional solenoid current (record
this on sheet attached).

! SLOWLY increase the pressure using the load valve up to approx 100 bar (1450 lb in2).

! Record the pressure on both pumps, flow on flow meter, engine rpm’s and proportional solenoid current (record this on
sheet attached).

! Increase the pressure in steps of 25 bar (362.5 lb in2)each time recording the pressure on both pumps, flow on the meter,
engine rpm’s and proportional solenoid current (record this on sheet attached).

! DO NOT increase pressure above 350 bar (5075 lb in2).

! Reset the load valve to fully open.

! Repeat test for E mode and P mode (record all results on sheet attached).

Remove flow meter from pump being tested and fit into second pump carry out tests to confirm minimum flow, maximum flow
and horsepower control.

9803/6510 Issue 1
Section E Service Procedures Section E
23 - 22 Service Procedures 23 - 22

Test 016 - Flow Testing Hydraulic Pumps - Record Sheet

Minimum Flow Pump 1 Minimum Flow Pump 2
Mode Pressure in P1 Pressure in P2 Flow Rpm Mode Pressure in P1 Pressure in P2 Flow Rpm
A A
E E
L L
P P

Maximum Flow Pump 1 Maximum Flow Pump 2

Mode Pressure in P1 Pressure in P2 Flow Rpm Mode Pressure in P1 Pressure in P2 Flow Rpm
A A
E E
L L
P P

Horsepower Control Pump 1 A Mode Horsepower Control Pump 2 A Mode

Pressure in P1 Pressure in P2 Flow Rpm Pump Pressure in P1 Pressure in P2 Flow Rpm Pump Ma
Ma

Horsepower Control Pump 1 E Mode Horsepower Control Pump 2 E Mode

Pressure in P1 Pressure in P2 Flow Rpm Pump Ma Pressure in P1 Pressure in P2 Flow Rpm Pump Ma

Horsepower Control Pump 1 P Mode Horsepower Control Pump 2 P Mode

Pressure in P1 Pressure in P2 Flow Rpm Pump Ma Pressure in P1 Pressure in P2 Flow Rpm Pump Ma

9803/6510 Issue 1
Section E Service Procedures Section E
23 - 23 Service Procedures 23 - 23

Test 017: Testing Slew Bearing

Checking Slew Bearing Backlash

l Set bucket 1mtr (40 in) above ground with dipper fully extended.

l Attach dial test indicator to lower half of slew bearing and set needle to bolt head on top half of slew bearing.

l Stop the machine . By hand push bucket fully to one side and hold whilst dial test indicator is set to zero.

l By hand push bucket fully to other side and record measurement on dial test indicator.

Alternatively

l Set bucket 1mtr (40 in) above ground with dipper fully extended, stop machine.

l By hand push bucket fully to one side and hold whilst a mark is made across the two halves of slew bearing.

l By hand push bucket fully to other side and hold, make a further mark on bottom half of bearing (which is in line with
original mark on top half of bearing).

l Record measurementand check against limits below.

Slew Backlash Limits

New Machine Limit of Use

6mm (0.24 in) 12mm (0.48 in)

9803/6510 Issue 1
Section E Service Procedures Section E
23 - 24 Service Procedures 23 - 24

Test 017: Testing Slew Bearing (cont’d)

Checking Slew Bearing Vertical Lift

1 First set the Dipper in a perpendicular position and 2 Install a dial gauge and set the needle to the Zero Point.
position the bucket 200 mm (9 in) above the ground,
stop the engine.

3 Start the engine and lift the main body with the bucket, 4 Then rotate the main body 180° and repeat the
when the bottom of the shoe is 100 mm (4 in) above the procedure, this time the needle will rotate clockwise.
ground, note the reading on the dial gauge. The needle This value becomes L3.
will turn in the counter clockwise direction. This value
becomes L1, lower the body to the ground and confirm
the needle reads zero.

5 Next, place the dial gauge on the rear of the vehicle and 6 The average lateral movement is shown as the result of
repeat the two above procedures to obtain L2 and L4. the equation L1 + L2 + L3 + L4
2

Note: Always stop the engine when installing or removing the

dial gauge or reading the dial gauge.

New Machine Limit of Use

1.2 mm (0.05 in) 3.6 mm (0.15 in)

9803/6510 Issue 1
Section E Hydraulics Section E
24 - 1 Service Procedures 24 - 1

Ram Creep Tests - All Services

If ram creep is suspected the following procedures must be Bucket Service
carried out to define if the leakage is within tolerance. Ram 1 Operate the machine to bring the hydraulic oil to a
creep can be caused by a number of reasons: normal working temperature of 50°C (122°F) which can
Cylinder/Piston Leakage, Spool Leakage, ARV Leakage. be measured using a hydraulic oil temperature probe
(service tool 892/00285).
Note:This service procedure should be carried out with a 2 Raise the boom and move the dipper and the bucket to
standard empty bucket fitted the fully closed position.
3 Using a felt tip pen and ruler, make a mark 100mm from
Note: The procedures are not applicable for rams fitted with the edge of the wiper seal on the piston rod.
hose burst protection valves. 4 Repeat the test by raising the boom and move the dipper
and bucket to it’s fully open position.
5 Using a felt tip pen and ruler, make a mark 100mm from
! WARNING the edge of the wiper seal on the piston rod.
Hydraulic fluid at system pressure can injure you. Before 6 Measure the actual movement of the pistion rod over a
disconnecting or connecting hydraulic hoses, stop the period of 10 minutes
engine and operate the controls to release pressure 7 Refer the measured figure to the table, if measured figure
trapped in the hoses. Make sure the engine cannot be is outside the allowed tolerance then complete the basic
started while the hoses are open. checks at the end of this section.
INT-3-1-11/1

Note: The table indicates the MAXIMUM permitted ram

Test for Ram Creep movement.

Boom service Allowable ram creep rates

1 Operate the machine to bring the hydraulic oil to a
Boom 30 mm
normal working temperature of 50°C (122°F) which can
be measured using a hydraulic oil temperature probe Dipper 60 mm
(service tool 892/00285). Bucket 20mm
2 Raise the boom to it’s full height.
3 Using a felt tip pen and ruler, make a mark 100mm (4 in)
from the edge of the wiper seal on the piston rod. Basic Checks (after determining that the ram creep is
4 Measure the actual movement of the pistion rod over a outside of the allowable tolerance.)
period of 10 minutes
5 Refer the measured figure to the table, if measured figure
! WARNING
is outside the allowed tolerance then complete the basic
checks at the end of this section. Take care when disconnecting hydraulic hoses and
fittings as the oil will be HOT.
TRANS 1-2
Dipper service
1 Operate the machine to bring the hydraulic oil to a Ram seal bypass
normal working temperature of 50°C (122°F) which can If the ram creep is in only one direction of the ram then it is
be measured using a hydraulic oil temperature probe unlikely to be caused by failed ram seals, if however the
(service tool 892/00285). creep is excessive in both directions of the ram stroke then
2 Raise the boom and move the dipper to it’s fully closed it is possible that the seals have failed.
position.
3 Using a felt tip pen and ruler, make a mark 100mm (4 in) Check for seal bypass using the following procedure:
from the edge of the wiper seal on the piston rod. 1 Place a load in the bucket of the machine.
4 Repeat the test by raising the boom and move the dipper 2 Lower the attachment to the ground and vent all
to it’s fully open position. hydraulic pressure.
5 Using a felt tip pen and ruler, make a mark 100mm (4 in) 3 Blank off the port on the ram, which will be supporting
from the edge of the wiper seal on the piston rod. the attachment.
6 Measure the actual movement of the piston rod over a 4 Remove the hose from the otherr port on the ram, blank
period of 10 minutes the hose and leave the port on the ram open to
7 Refer the measured figure to the table, if measured figure atomosphere.
is outside the allowed tolerance then complete the basic 5 Raise the attachment off the ground
checks at the end of this section. 6 After intial movement, note the movement of the ram
over a 10 minute period.

After the intial movement of the ram when first raised from
the ground, a continual movement of the ram or continous
trickle of oil from the open port of the ram would indicate
that the ram seals require further inspection.

9803/6510 Issue 1
Section E Hydraulics Section E
24 - 2 Service Procedures 24 - 2

Ram Creep Tests - All Services (cont’d)

Basic Checks (after determining that the ram creep is

outside of the allowable tolerance.)

Port relief valve (ARV) failure

If the port relief valve itself had failed, if contaminattion was
stuck on the valve seat or if the valve seat itself was
damaged then this would allow oil to constantly bypass to
tank causing ram creep.
A visual check can be made by removing the port relief valve
and checking the condition of the valve seat and the seat in
the valve casing, any damage of either of these two items
would require rectification or replacement.
To check for failed port relief valve, loosen the adjuster
locknut and wind the adjuster of the port relief valve fully in,
until it locks the relief section. Re-check the ram rate, any
change in the creep rate would indicate that further
investigation of the port relief is required. If there is no
change in the creep rate the cause may be the ARV seat in
the valve block.

Quich hitch/ Auxiliary circuitss

It is common practice to take oil from the excavator service
to operate quick hitch and auxiliary circuits. If the excavator
service which is suffering from excessive ram creep has any
other services connected to it then the best policy is to
disconnect the quick hitch and auxiilary circuit and test
again the creep rate.

9803/6510 Issue 1
Section E Hydraulics Section E
26 - 1 Service Procedures 26 - 1

Pressure Testing - General

4 Operate the bucket control slowly until it reaches one
Confirmation of the oil Temperature
end of its travel and leave it there for 10 seconds.
Confirm the oil temperature is between 45° - 55° C using the 5 Operate the bucket control slowly to the other end of its
self check function. If the temperature is low use the follow- travel and leave it there for 10 seconds.
ing warm-up procedure.
6 Repeat steps 5 and 6 for 10 minutes to warm up the
Warming-up Procedure hydraulic circuit.

1 Turn the Throttle Control to mid-range and make sure 7 Now operate the excavating controls three to five times
the Work Mode Selection Switch is set to E. in each direction to distribute warm hydraulic oil around
the system.
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.

Pressure Measurement Measurement

Part Name bar (lb/in2) Method Port

Main Relief Standard: 343 bar (4975 lb/in2) Dipper Relief G1 (G2)
Power Boost: 373 bar (5410. lb/in2)

Boom Port Relief Raise 392 bar (5685 lb/in2) Boom Up Relief G2

Lower 264 bar (3829 lb/in2) Boom down Relief G2

Bucket Port Relief Open/Close 392 bar (5685 lb/in2) Bucket Relief G2

Dipper Port Relief Out/In 392 bar (5685 lb/in2) Dipper Relief G1

Swing Port Relief Left/Right 289 bar (4192 lb/in2) Swing Relief G1

Pilot Relief 37 - 43 bar (536.5 - 623.5 lb/in2) Lever Neutral G3

Accumulator 15 ± 5 bar (217 ± 72.5 lb/in2)

Track Motor Relief 343 bar (4975 lb/in2) G1 (G2)

9803/6510 Issue 1
Section E Hydraulics Section E
26 - 2 Service Procedures 26 - 2

A Pressure Testing Points

G1

G2

Key

G1 Main Pump P1
403610
G2 Main Pump P2
G3 Servo Pressure

G3

9803/6510 Issue 1
Section E Hydraulics Section E
26 - 3 Service Procedures 26 - 3

B Pressure Relief Valves

T3

DR1
pa5 pa9
pc1

pa4 pa8

4 pa3 pa7
pc2

2
pa2 pa6

pa1

8 PP
1
pr

PH

A406520

Key
1 Main Relief Valve (MRV)
2 Boom Up Relief Valve
3 Boom Down Relief Valve
4 Dipper Out Relief Valve
5 Dipper In Relief Valve 3
6 Bucket Open Relief Valve
7 Bucket Close Relief Valve
8 Option Relief Valve 5
9 Option Relief Valve

9803/6510 Issue 1
Section E Hydraulics Section E
26 - 4 Service Procedures 26 - 4

Main Relief Valve (MRV) Pressure

1 Prepare the Machine
a Put the operator levers into neutral and lower the
gate lock lever. Start the engine and park the
machine on level ground. Operate the dipper out
and lower the boom to set the bucket on the
ground. Stop the engine. Release the hydraulic oil
tank pressure. (See Releasing Tank Pressure). A296590

b Install a 0 - 400 bar (0 - 6000 lb/in 2 ) pressure

gauges at test points G1 and G2 (see Pressure
Measuring Points at start of Pressure Testing
Section).

c Start the engine, and confirm that the engine is at its

maximum no-load speed and it is in the E mode to
test standard pressure and L mode to test Power
Boost Pressure.

d Raise the boom and then operate the dipper out

control. Read the pressure gauges with the dipper
ram stalled at the end of its stroke.

e If it is outside the limits, stop engine and adjust the

MRV 1 as below.

Note: For accurate setting, the pressure should be adjusted C

up to the required level.
A
2 High Pressure Setting (Power Boost)
a Remove servo hose E and plug hose.

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

high pressure setting nut A clockwise all the way in. D
c Hold nut C and slacken nut D. Screw nut C in, to E B
increase pressure or out to decrease pressure.

d Once required pressure is achieved, hold nut C and

lock nut D back up. A406580

3 Low pressure setting (Standard)

a Hold nut C and slacken locknut B. Screw nut A out
to reduce pressure or in to increase pressure.

b The pressure gauges reading should be compared

to the technical data at the start of the section.

c Lock nut B against nut C.

d Stop engine and relieve the pressure in the

hydraulic oil tank (see Releasing Tank Pressure).

e Re-attach the servo hose to MRV 1.

5 Confirmation of the rated pressure

a Start the engine, raise the r.p.m to maximum in the E
mode, and check for leakage at the adjusted points.

b Operate the dipper, hold the service in the stalled

position, read pressure gauge (Standard pressure
setting).

c Select L mode. Operate the dipper, hold the service

in the stalled position, read pressure gauge (Power
Boost setting).

d If the pressure requires re-adjusting, repeat the

procedure from step 1d.

9803/6510 Issue 1
Section E Hydraulics Section E
26 - 5 Service Procedures 26 - 5

Servo Relief Pressure

G3
1 Prepare the Machine

Put the operator levers into neutral and lower the gate
lock lever. Start the engine and park the machine on
level ground. Operate the dipper out and lower the
A296590
boom to set the bucket on the ground. Stop the engine.

2 Before testing the Pilot Relief valve C, connect a 0-100

bar (0-1500 lb/in2) pressure gauge to test point G3.
G3
3 Start the engine and confirm that the engine is at its
maximum no-load speed and it is in the E mode. The
pressure gauge reading should be compared to the
technical data at the start of this section. If it is outside
the limits adjust the pilot relief valve as below.
C
4 Stop the engine.

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

6 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)).

7 Tighten lock nut B to 17 Nm (12. Ibf ft, 1.7 kgf m),

check the relief pressure again.
If it is not within the limits above, perform steps 3 to 6
again. A
8 Stop the engine, and then remove the pressure gauge.

A405800

9803/6510 Issue 1
Section E Hydraulics Section E
26 - 6 Service Procedures 26 - 6

Slew Motor Pressure Relief

1 Prepare the machine G1
Put the operators lever into neutral, lower the gate lock
lever. Start the engine and place the machine on level
ground, lower and open the dipper and set the bucket on
the ground. Stop the engine.
2 Release the hydraulic oil tank pressure. A296590

(See Releasing Tank Pressure).

3 Connect a 0-400 bar (0 - 6000 lb/in2) pressure gauge and
adapter to the port marked G1 on the pump.
4 Initiate slew lock procedures.
a Remove the water-proof connector on the slew lock
solenoid valve A.(Green )
b Press the slew lock switch which is on the right hand
console inside the cab, and confirm that the slew
(swing) lock symbol appears on the monitor. G1

c Start the engine,(error codes may appear for discon-

nected solenoid) and operate the engine at around
1000 r.p.m, then operate the slew lever slowly. Listen
to confirm that the relief sound is heard and that the
machine does not slew.
d Run the engine at maximum no-load speed and in the
E mode.
e Operate the slew lever.
5 The pressure gauge reading should be compared to the
technical data at the start of this section. If it is outside
the limits adjust the slew motor relief valve as below.
Note:
i If the water-proof slew lock solenoid valve is not A
removed. Full slew pressure can not to read.
ii Wire colour code to the solenoid is Dark Green.
iii Pressure measurement is also possible on the slew
motor, upper section. (C right, D left)
6 If the pressure is within the limits, stop engine release
A409800
tank pressure and remove the gauge and adaptor; If the
readings are outside the limits, continue as below.
7 Pressure Adjustment
a Confirm the present pressure reading.
b Stop engine, Remove relief valve to be adjusted
c The difference between the set pressure and the
present pressure determines the number of shims E
required for adjustment. C D

8 Remove the relief valve assembly from the slew motor.

Note: If both relief valves are removed at the same time,

mark them left and right to facilitate reassembly in the correct
position.

R L
A405810

9803/6400 Issue 2*
Section E Hydraulics Section E
26 - 7 Service Procedures 26 - 7

Slew Motor Pressure Relief (cont’d)

9 Disassemble
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
spring F. E
C
b Add shim to increase pressure. Remove shim to
decrease pressure.
c Re-assemble reif valve assembly
d Fix the sleeve into a vice and install the cap A with a F
torque of 156.9 Nm (115.17 lbft).
D
10 a Install the relief assembly in the slew motor unit, and
confirm the pressure. B
b If it is not within the setting pressure, repeat the A A405850
procedure from step 7.

9803/6510 Issue 1
Section E Hydraulics Section E
26 - 8 Service Procedures 26 - 8

Auxiliary Relief Valves

General

SOME auxiliary relief valves (ARV’s) are set to a higher

pressure than the main relief valve (MRV) 1. To permit
pressure testing of the ARV’s it is necessary to temporarily
adjust the MRV to a higher setting Proceed as follows: A296590

1 Prepare the machine

a Put the operator levers into neutral and lower the
gate lock lever. Start the engine and park the
machine on level ground. Operate the dipper out
and lower the boom to set the bucket on the
ground.

b Run the engine at maximum no-load speed in

the E mode.

2 Increase MRV Pressure

Remove servo hose E and plug hose
C
a. Hold nut C and slacken locknut B. Screw nut A,
all the way in to increase pressure. A

b. Lock nut B against nut C.

c. Hold nut C and slacken off locknut D, then screw
in nut C 180° then lock nut D back up. The MRV D
pressure should now be above all ARV’s. B
E
d. Re-attach the servo hose F to MRV 1.

A406580
3. Restore Original MRV Pressure
As described in Setting Main Relief Valve Section.

9803/6400 Issue 1
Section E Hydraulics Section E
26 - 9 Service Procedures 26 - 9

Auxiliary Relief Valves (cont’d)

Boom Ram

Boom Up
1 Prepare the machine
a Put the operator levers into neutral and lower the
gate lock lever. Start the engine and park the A296590

machine on level ground. Operate the dipper out

and lower the boom to set the bucket on the
ground. Stop the engine. Release the hydraulic oil
tank pressure. (See Releasing Tank Pressure).

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

gauge and adapter to port G2 on the hydraulic
pump (see Pressure Measuring Points at start of
Service Procedures, Section E).

2 If not already done, temporarily increase the pressure

setting of the MRV (see Auxiliary Relief Valves,
General, step 2). 2
3 Start the engine, lower the gate lock lever and run the
engine at maximum no-load speed in the E mode.

4 a Fully raise the boom and then continue to operate

the right control lever as at A.

b The pressure gauge reading should be compared to

the technical data at the start of the section. If it is
outside the limits, adjust ARV 2.

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.

9803/6510 Issue 1
Section E Hydraulics Section E
26 - 10 Service Procedures 26 - 10

Auxiliary Relief Valves (cont’d)

Boom Ram (continued)
Boom Down

5 Prepare the machine

a Put the operator levers into neutral and lower the
gate lock lever. Start the engine and park the
machine on level ground. Operate the dipper out A296590

and lower the boom to set the bucket on the

ground. Stop the engine. Release the hydraulic oil
tank pressure. (See Releasing Tank Pressure).

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

gauge and adapter to port G2 on the hydraulic
pump (see Pressure Measuring Points at start of
Pressure Testing Section).

6 It is not physically possible to fully close the boom ram, 3

without lifting the undercarriage of the ground.
Therefore the ARV’s 2 and 3 must be swapped over.

a Fully raise the boom and then continue to operate

the right control lever as at A.

b The pressure gauge reading (Boom down) should be

compared to the technical data at the start of the
section. If it is outside the limits, adjust ARV C.

7 Stop the engine and release the hydraulic pressure,

(see Releasing Tank Pressure). Remove the pressure
gauge and adaptor. The Relief Valves for Boom up and
Boom down must be swapped and returned to the
correct ports. A406530

8 If further ARV tests are necessary carry out the relevant

procedures detailed in this section. If no further ARV
tests are required restore the MRV pressure setting to
its original value (see Auxiliary Relief Valve, General,
step 3).

9 Stop the engine and release the hydraulic pressure,

(see Releasing Tank Pressure). Remove the pressure
gauge and adaptor.

X
Y

312460

9803/6510 Issue 1
Section E Hydraulics Section E
26 - 11 Service Procedures 26 - 11

Auxiliary Relief Valves (cont’d)

Dipper Ram

1 Prepare the Machine.

a Put the operator levers into neutral and lower the
gate lock lever. Start the engine and park the
machine on level ground. Operate the dipper out
A296590

and lower the boom to set the bucket on the

ground. Stop the engine. Release the hydraulic oil
tank pressure. (See Releasing Tank Pressure).

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

gauge and adapter to port G1 on the hydraulic
pump (see Pressure Measuring Points at start of
Pressure Testing Section).

2 If not already done, temporarily increase the pressure

4
setting of the MRV (see Auxiliary Relief Valves,
General, step 2). 5

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

4 Pressure Adjustment

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.
A406530

a Raise the boom enough to allow the Dipper to move

freely.

b Move the dipper fully out and then continue to A

operate the control lever, as at A.

c The pressure gauge reading (Dipper Out) should be B

compared to the technical data at the start of the
section. If it is outside the limits, adjust ARV 4.

d Move the dipper fully in and then continue to

operate the control lever, as at B.

e Compare the pressure gauge reading (Dipper In) to

that stated in the technical data section at the start
of the section. If it is outside the limits, adjust ARV
5.

5 If further ARV tests are necessary carry out the relevant

procedures detailed in this section. If no further ARV
tests are required, restore the MRV pressure setting to
its original value (see Auxiliary Relief Valve, General,
step 3). X
6 Stop the engine and release the hydraulic pressure (see
Releasing Tank Pressure). Remove the pressure gauge Y
and adaptor.

9803/6510 Issue 1
Section E Hydraulics Section E
26 - 12 Service Procedures 26 - 12

Auxiliary Relief Valves (cont’d)

Bucket Ram

1 Prepare the Machine

a Put the operator levers into neutral and lower the

gate lock lever. Start the engine and park the A296590

machine on level ground. Operate the dipper out

and lower the boom to set the bucket on the
ground. Stop the engine. Release the hydraulic oil
tank pressure. (See Releasing Tank Pressure).

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

gauge and adapter to port G2 on the hydraulic
pump ((see Pressure Measuring Points at start of
Pressure Testing Section).
7
2 If not already done, temporarily increase the pressure
setting of the MRV (see Auxiliary Relief Valves,
General, step 2).

3 Start the engine, lower the gate lock lever and run the
engine at maximum no-load speed in the E mode.
6
4 Pressure Adjustment

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.

a Raise the boom.

b Open the bucket fully and then continue to operate

the control lever at A.

c The pressure gauge reading (Bucket Open) should

be compared to the technical data at the start of the
section. If it is outside the limits, adjust ARV 6. B A
d Close the bucket fully and then continue to operate
the control lever, as at B.

e The pressure gauge reading (Bucket Closed) should

be compared to the technical data at the start of the
section. If it is outside the limits, adjust ARV 7.

5 If further ARV tests are necessary, carry out the relevant

procedures detailed in this section. If no further ARV
tests are required, restore the MRV pressure setting to
its original value (see Auxiliary Relief Valve, General,
step 3). X
6 Stop the engine and release the hydraulic pressure (see
Releasing Tank Pressure). Remove the pressure Y
gauge and adaptor.

9803/6510 Issue 1
Section E Hydraulics Section E
26 - 13 Service Procedures 26 - 13

Auxiliary Relief Valves (cont’d)

Option ARV (Monoboom)

1 Prepare the Machine.

a Put the operator levers into neutral and lower the
gate lock lever. Start the engine and park the
machine on level ground. Operate the dipper out
A296590
and lower the boom to set the hammer on the
ground. Stop the engine. Release the hydraulic oil
tank pressure. (See Releasing Tank Pressure).

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

c Connect a 0 - 400 bar (0-6000 lbf/in 2) pressure

gauge to test point G1 (see Pressure Measuring
Points at start of Pressure Testing Section).
B
2 Start the engine, lower the gate lock lever and run the
engine at maximum no-load speed in the E mode.

3 Operate the option by pressing the foot pedal. Check

the pressure on the gauge, adjust ARV 9.

4 Pressure Adjustment

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.

5 Stop the engine and release the hydraulic pressure (see

Releasing Tank Pressure). Remove the pressure gauge
and adapter.

A406530

X
Y

9803/6510 Issue 1
Section E Hydraulics Section E
26 - 14 Service Procedures 26 - 14

Travel Motor Relief Pressure

1 Prepare the Machine.
a Put the operator levers into neutral and lower the
gate lock lever. Start the engine and park the
machine on level ground. Operate the dipper out
and lower the boom to set the bucket on the
ground. Stop the engine. Release the hydraulic oil A296590

tank pressure. (See Releasing Tank Pressure).

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

gauge and adapter to port G1 and G2 on the
hydraulic pump (see view A Pressure Testing Point
at start of this Section).
P
c Disconnect the Travel Pressure Switch C on the
Main Control valve.

2 If not already done, temporarily increase the pressure

setting of the MRV (see Auxiliary Relief Valves,
General, step 2).

3 Insert a Lock Pin P between the drive sprocket to be

measured and the side frame.

4 Start the engine, lower the gate lock lever and run the
engine at maximum no-load speed in the L mode.

5 Slowly engage the locked travel motor and measure the

pressure in forward and reverse. B
6 Pressure Adjustment A
Note: For accurate setting, the pressure should be adjusted
up to the required level. Release lock nut A. Adjust setting
screw B to indicate a pressure below the required level and
then bring the pressure back up for final setting. Tighten lock
nut A.

a 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
A
pressure. B A405820

7 If further ARV tests are necessary carry out the relevant

procedures detailed in this section. If no further ARV
tests are required, restore the MRV pressure setting to
its original value (see Auxiliary Relief Valve, General,
step 3).

6 Stop the engine and release the hydraulic pressure (see

Releasing Tank Pressure). Remove the pressure gauge
and adapter.

ø35 P ø80

300 150
A406530

9803/6510 Issue 1
Section E Hydraulics Section E
31 - 1 Hydraulic Pump 31 - 1

Removal and Replacement

A406460

9803/6510 Issue 1
Section E Hydraulics Section E
31 - 2 Hydraulic Pump 31 - 2

Removal and Replacement cont’d)

Removal Replacement
! DANGER Replacement is the reversal of removal procedure but note
Hydraulic fluid at system pressure can injure you. Before the following:
disconnecting or connecting hydraulic hoses, stop the
engine and operate the controls to release pressure When fitting a new pump, the shaft end spline may be
trapped in the hoses. Make sure the engine cannot be coated with a anti-rust coating. Remove this coating
started while the hoses are open. with a suitable cleaning agent and apply a lubricant to
INT-3-1-11/1 the shaft being careful not to get either on to the oil seal
! CAUTION of the pump.
The hydraulic pump is heavy. Do not attempt to remove
the pump unless its weight is held by a sling. Make sure The beveled edge of the pump coupling 3 must be
that the sling is attached to a suitable lifting appliance. fitted facing the pump.
HYD 2-3
Locate the rubber flange 6 of the pump into the four
1 Lower dipper and place bucket on the ground engine studs 7.

2 Turn off engine. Before fastening pump flange 4 to engine, make sure
the mating surfaces are fully together.
3. Attach lifting eyes to the pump at 1. Support weight of
the pump 2 with a suitable lifting aparatus (see Pump Apply JCB Threadlocker to bolts 5 and 8.
Weight in Technical data).
Fill the pump casing inside fully with oil and operate at
4 Operate both control joysticks back and forth and side low engine revs with no services selected for 3 minutes.
to side to vent residual pressure.

5 Drain the hydraulic fluid from the hydraulic tank.

! WARNING
Fine jets of hydraulic fluid at high pressure can penetrate
6 Disconnect all hydraulic hoses and pipes from the the skin. Do not use your fingers to check for hydraulic
hydraulic pump and plug all orifices to prevent ingress fluid leaks. Do not put your face close to suspected
of dirt.Label each hose before disconnecting, this will leaks. Hold a piece of cardboard close to suspected
ensure correct position when refitting. leaks and then inspect the cardboard for signs of
hydraulic fluid. If hydraulic fluid penetrates your skin, get
7 Disconnect electrical connection to Proportion solenoid medical help immediately.
INT-3-1-10/1
on Hydraulic pump.
If there is any air left in the circuit or pump, this may cause
8 Remove engine exhaust muffler bracket from pump
faulty operation or damage so be sure to bleed the air
flange 4 by removing three set pins 8. Remove the
remaining nine set pins 8 and washers from pump completely.
flange 4.
It is not desirable to leave the pump motor unused for a
9 Withdraw the pump clear of the engine. When clear of long period of time (more than one year.) At intervals, start
engine, lift pump clear of machine. the engine even if for short periods of time. When left
unused by itself, rotating the shaft end by hand can be
10 Remove rubber flange 6 from pump coupling 3 by effective. If left unused for an extended period of time,
removing the two retaining bolts. inspection for overhaul will become necessary.

11 Loosen the two grub screws on the pump coupling 3.

Withdraw pump coupling 3 from the pump’s splined
shaft.

12 Support the weight of the pump flange 4. Remove four

cap screws 5 from the flange and pump. Remove
flange from pump.

13 Remove the four studs 7 from the engine.

9803/6510 Issue 1
Section E Hydraulics Section E
31 - 3 Hydraulic Pump 31 - 3

9803/6510 Issue 1
Section E Hydraulics Section E
31 - 4 Hydraulic Pump 31 - 4

Dismantling
Refer to the drawing on the previous pages of the pump and Adjusting screws should only be moved when absolutely
associated components. necessary. Moving the adjusting screws will alter the power
output settings. If the adjusting screws must be moved,
Note: Before attempting to dismantle the hydraulic pump, measure and record the dimensions and positions.
drain all oil, blank all inlet and outlet ports and wash the
outer surfaces with a suitable solvent to remove all dirt and The pump contains two rotary groups and control systems;
dust. Dry using compressed air. the No.1 (subsidiary) pump and the No.2 (drive) pump. Take
care not to confuse parts between the two.
Make different alignment marks across each sub-assembly
joint face as an aid to assembly. During disassembly, record the number and dimensions of
shims. Take care to reassemble in the same manner.
The rotary groups, servo pump, relief valve and proportional
pressure reduction valve must be replaced as entire
assemblies.

1 Remove the drain port plugs and drain the oil from both
the front and rear pump.

3
2 As an aid to re-assembly, match mark the mating
flanges of regulator and pump casing. Remove socket
head screws 2 and 3 (2 off each) and lift off the 2
regulator. Put the regulator to one side in readiness for
dismantling if required (see Regulator, Dismantling).

3 Loosen cap screws 435. Remove the gear pump

assembly 4..
Loosen the hexagonal socket head bolt 401 which
connects the swash plate suppor 251, pump casing 217
and valve block 312.

379380

4 Place the pump so that the regulator installation side is

down and place level on the work bench. Match mark
the mating flanges of pump casing 271 and valve block
312.Separate the pump casing 271 and valve block 312.

379540

9803/6510 Issue 1
Section E Hydraulics Section E
31 - 5 Hydraulic Pump 31 - 5

Dismantling (cont’d)
5 Pull out the cylinder 141 (keeping it straight in relation to
the drive shaft 111) from the pump casing 271 and also
pull out the piston 151, press plate 153, spherical bush
156 and cylinder spring 157 at the same time.

Take care not to damage the sliding surfaces of the

components.

379550

6 Remove the hexagonal socket head bolt 406 and

remove the seal cover 261.

This is an oil seal on the seal cover 261 be careful not to

damage it when removing the cover 261. This task can
be simplified by inserting a pull-out bolt into the tapped
hole in the cover.

379560

7 Remove the hexagonal socket head bolt 408 and

remove the rear cover 263.

8 Match mark the mating flanges of swash plate support

251 and pump casing. Lightly tap the installation flange
part of the swash plate support 251 from the pump
casing side and separate them.

379570

9803/6510 Issue 1
Section E Hydraulics Section E
31 - 6 Hydraulic Pump 31 - 6

Dismantling (cont’d)
9 Remove the shoe plate 211 and swash plate 212 from
the pump casing 271.

379580

10 Pump 1
Remove snap ring 824 and bearing spacer 127. Using a
plastic hammer, gently tap shaft 113 out of its support
bearing 123 to remove it from swash plate support 251.

Pump 2 (right)
Gently tap shaft 111, at the end nearest the mating
flange of valve block 312, to separate it from swash
plate support bearing 774.

379590

11 Remove the valve plate 313, 314 from the valve block
312. It may be removed in step 4.

12 If necessary, remove the stopper 534, stopper 535,

servo piston 532, tilting pin 531 from the pump casing
271 and also the needle bearing 124 and spline coupling
116 from the valve block 312.

Use a jig to remove tilting pin 531 take care not to

damage the fitting part of the tilting pin 531 and servo
piston 532 because it is coated with JCB Threadseal.
Do not remove the needle bearing 124 unless the life of
the bearing is in question.
Note: Do not loosen the hexagonal nuts of the valve block
and swash plate support because the flow setting will
change.

9803/6510 Issue 1
Section E Hydraulics Section E
31 - 7 Hydraulic Pump 31 - 7

Inpection
Main body wear limit
If the wear of the parts exceeds the standards below, replace or readjust. However, if they are extremely damaged judging
from the external appearance, replace with the appropriate part.

Standard Dimensions/
Part Name and Recommended Replacement Value Treatment
Inspection Item
Pump Model K3V112 / K5V140
Clearance between 0.039 - 0.067mm Replace piston or
piston and cylinder cylinder
bore (D-d)

Backlash of piston 0~0.1 - 0.3mm Replace piston

and shoe caulking shoe assembly
part(δ)

Shoe thickness(t) 4.9 - 4.7mm Replace piston

shoe assembly

Cylinder spring free 41.1- 40.3mm Replace cylinder

height (L) spring

Assembled height of 9.8 - 8.8mm Replacepress

press plate and plate or spherical
spherical bush bush

9803/6510 Issue 1
Section E Hydraulics Section E
31 - 8 Hydraulic Pump 31 - 8

Inspection (cont’d)
Main body wear limit (cont’d)
Cylinder, Valve Plate, Swash Plate (Shoe Plate)
Modification Standards

Valve Plate (sliding part) Surface roughness 3-Z

requiring modification
Swash Plate (shoe plate part)

Cylinder (sliding part) Roughness of each surface Standard surface roughness Less than 0.4mm (lapping)
(modification value)

9803/6510 Issue 1
Section E Hydraulics Section E
31 - 9 Hydraulic Pump 31 - 9

Assembly
Clean each part in a suitable solvent and dry using All tapped holes and gasket faces should be thoroughly
compressed air. degreased by washing as liquid packing and adhesive is
used on all gasket surfaces and threads.
Inspect all parts and replace as required.
Apply adhesive to the final few threads of a bolt or screw. Do
Care must be taken not to let dust or dirt adhere to parts not apply excessive amounts of adhesive. Wipe off any
after cleaning and that parts do not become dented, surplus.
scratched or damaged.
Leave the pump for at least twelve hours after assembly to
Fit new 'O' rings, plugs, packing, oil seals and fastener allow the adhesive to fully dry.
seals.
Ensure that the pump controllers are fitted to the positions
Apply grease to all new oil seals and 'O' rings, and clean from which they were removed.
hydraulic fluid to all sliding parts before installation.

1 By lightly tapping, install the swash plate support 251 to

the pump casing 271.

When the servo piston 532, tilting pin 531 stopper 534,
stopper 544 are removed, install them in the pump
casing in advance.

Use a jig when tightening the servo piston 532 and

tilting pin 531 so as not to damage the tilting pin head
and feedback pin. Also, coat JCB Threadlock on the
screw threads when assembling.

379610

2 Place the pump casing with the regulator installation

surface facing down. Fit the swash plate tilting bush to
the tilting pin 531 and then mate the swash plate 212 to
the swash plate support 251.
Note: Check with the fingertips that the swash plate moves
smoothly.

Apply grease to the moving parts of the swash plate 212

and swash plate support 25 to aid the installation of the
drive shaft 113, 111.

379620

9803/6510 Issue 1
Section E Hydraulics Section E
31 - 10 Hydraulic Pump 31 - 10

Assembly (cont’d)
3 Pump 1
From inside pump casing 271a install shaft 113 through
its support bearing 123 and secure with bearing spacer
127 and snap ring 824.

Pump 2 (right)
From outside pump casing 217b, install shaft 111, small
splined end first, through its support bearing 774 as far
as it will go.

Note: Do not hit the drive shaft with the hammer. Tap the
outer ring of the bearing with a plastic hammer to install it
and use a steel bar to fit it securely.

379630

4 Install the seal cover 261 to the pump casing 271 and fix
with hexagonal socket head bolt 406.

Coat the oil seal inside the seal cover 261 with a thin
coat of grease.

Install the oil seal taking care not to damage it.

Attach the rear cover 263 and the seal cover 262 in the
same way if it is a tandem pump.

379640

5 Assemble the piston cylinder sub-assembly (cylinder

141, piston shoe 151, 152, press plate 153, spherical
bush 156, spacer 158, cylinder spring 157, align the
spherical bush and cylinder spline and insert into the
pump casing.

Insert the piston/cylinder sub-assembly into pump

casing 312.

379650

9803/6510 Issue 1
Section E Hydraulics Section E
31 - 11 Hydraulic Pump 31 - 11

Assembly (cont’d)
6 Aligning the pin, install the valve plate 313 into the valve
block 312.
Note: Be careful not to mistake the valve plate suction and
delivery directions.

7 Install the valve block 312 to the pump casing 271 and
tighten the hexagonal socket head bolt 401.
Note:
a The work would be easier if the rear of the pump is
assembled first.
b Take care not to mistake the direction of the valve
block. When looking from the front side, the 3
regulator is on the top and the delivery flange is on
the left.
2

8 Insert the feedback pin of the tilting pin into the

feedback lever of the regulator and install the regulator,
tightening the hexagonal socket head bolts 2,3..
Note: Take care not to mistake the front and rear of the
regulator.

379380

9 Replace servo pump 4, and tighten cap screws 435

9803/6510 Issue 1
 14
31 - 12

9803/6510
13
Regulator
Section E

15

12

42
D
41 B 36
40
F 35
34 16
32 17 5
37A 18
39 A 11
26 G
10
22 E 6
24 C
25 33A
23 10
7
8
38 3 2
9
Hydraulics
Hydraulic Pump

37

3
F 29
G
28A
20 A
B 28
C

31
19
4 30A
21 30
379670

Issue 1
31 - 12
Section E
Section E Hydraulics Section E
31 - 13 Hydraulic Pump 31 - 13

Regulator (cont’d)
Dismantling and Assembly

The working environment must be clean and the workbench

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

The item numbers called up in the following procedures

correspond with those in the exploded view opposite.

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

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

379380

2 Remove the four socket head screws 5 and lift off cover
6 complete with adjusters 7/8, adjusting screw 9, two 5
locking nuts 10, mounting nut 11 and adjusting ring 12. 6
Do not interfere with the settings of any of these
components as this could alter the pre-set flow settings.

9803/6510 Issue 1
Section E Hydraulics Section E
31 - 14 Hydraulic Pump 31 - 14

Regulator (cont’d)
Dismantling and Assembly (cont’d)

Dismantling (cont’d)

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

spring 14 and spring seat 15. Also withdraw adjusting 13
ring 16 (see Note 1), pilot spring 17 and spring seat 18. 14
15
Note 1: Use an M4 screw Z attached to the end of adjusting 16
ring 16 to facilitate its easy removal. 1

18 17
Z

379400

4 Remove socket head screws 19 and 20 and lift off pilot

cover 21. Take out set spring 22.

22

20

21
19
379410

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.

25
23

26

1
24
379420

9803/6510 Issue 1
Section E Hydraulics Section E
31 - 15 Hydraulic Pump 31 - 15

Regulator (cont’d)
Dismantling and Assembly (cont’d)

Dismantling (cont’d)

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

complete with pin 33. Remove snap ring 30 and take out 1
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.
33
29
28

31
30

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

32

37944

8 Knock out pin 34 (4 mm dia.) using a suitable metal rod

X and a plastic hammer.

37945

9803/6510 Issue 1
Section E Hydraulics Section E
31 - 16 Hydraulic Pump 31 - 16

Regulator (cont’d)
Dismantling and Assembly (cont’d)

Dismantling (cont’d)

9 Withdraw feedback lever 35.

35

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.

Note 3: Piston case 40 can be removed by pressing

compensating rod 42 from the opposite side of regulator
body 1.

9803/6510 Issue 1
Section E Hydraulics Section E
31 - 17 Hydraulic Pump 31 - 17

Regulator (cont’d)
Dismantling and Assembly (cont’d)

Assembly

Before assembling:

a Thoroughly clean all components with clean hydraulic oil

and dry with compressed air.

b Apply clean hydraulic oil to all sliding surfaces, bearings,

etc.

c Renew any damaged components.

d Renew all O-rings and other seals.

1 Insert compensating rod 42 into hole B of regulator

body 1.

2 Locate pin 37A in lever 36 in the groove of

compensating rod 42. Locate lever 36 on pin 37 in
regulator body 1.

3 Fit spool 39 and sleeve 26 into hole A of regulator body

1. Check that the spool and the sleeve slide smoothly in
the body without binding. Check the orientation of the
spool with respect to feedback lever 35 (see right).

Spool 35
Feedback Leve
39

379470

4 Install feedback lever 35, orientating it as shown right

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

Lever(1)side
36 32
Lever(2)side
(Fulcrum plug of
adjusting plug si

35

379480

5 Insert pilot piston 38 into hole C of regulator body 1.

Check that the piston slides freely without binding.

9803/6510 Issue 1
Section E Hydraulics Section E
31 - 18 Hydraulic Pump 31 - 18

Regulator (cont’d)
Dismantling and Assembly (cont’d)

Assembly (cont’d)

6 Locate pin 33A in lever 32 in the groove of pilot piston

38. Position lever 32 in regulator body 1.

7 Fit fulcrum plug 29 so that integral pin 33 locates with

lever 32. Fit a new seal 28A and install snap ring 28.

29

379490

8 Insert adjusting plug 31. Fit a new seal 30A and install
snap ring 30.

Check that feedback lever 35 moves freely but does not

have excessive play.

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.

23

24

25

379500

9803/6510 Issue 1
Section E Hydraulics Section E
31 - 19 Hydraulic Pump 31 - 19

Regulator (cont’d)
Dismantling and Assembly (cont’d)

Assembly (cont’d)

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

1
Insert compensating piston 41 and piston case 40 into
hole B of regulator body 1.
22
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).

41

40

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

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

16

17
18

379520

12 Install the cover 6 assembly comprising adjusting 5

screws 7/8, adjusting ring 12, mounting nut 11, two
locking nuts 10 and adjusting screw 9. 5

Secure the cover using socket head screws 5 tightened

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

379530

9803/6510 Issue 1
Section E Hydraulics Section E
35 -1 Remote Control Valve (Hand Control) 35 - 1

Removal and Replacement

E
F
G

B
D

A407780

A
C

Right hand Control Valve Left hand Control Valve

Port Hose Colour Port Hose Colour

1 Yellow 1 Orange
2 Blue 2 Green
3 Green 3 Violet
4 Red 4 Pink
P White P White
T - T -

9803/6510 Issue 1
Section E Hydraulics Section E
35 -2 Remote Control Valve (Hand Control) 35 - 2

Removal and Replacement (cont’d)

! DANGER
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop the
engine and operate the controls to release pressure
trapped in the hoses. Make sure the engine cannot be
started while the hoses are open.
INT-3-1-11/1

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.

Remove the two screws A from each side, and loosen

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

Disconnect electrical connection to Remote Control

Valve.

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.

Remove the two screws D, two screws E and loosen

the two screws F. Remove panel G.

Lift up gaiter H and remove the fours bolts holding the

valve to the arm rest .

Lift the remote contol valve clear of the arm rest.

Note: Care should be taken when removing right arm rest,

remove switches, using a thin flat bladed screw driver and
discounect electrical connections.

Replacement

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

Replacement is the reversal of the removal sequence.

Note: All hydraulic adapters that are installed together with a

bonded sealing washer must also have JCB Threadseal
applied to the threads of the adapter.

9803/6510 Issue 1
Section E Hydraulics Section E
35 -3 Remote Control Valve (Hand Control) 35 - 3

21

26

18

8
19

10

2 11

12
20
3
23
13
4
5
14
22 1
15

24
16

25 7

17
6

30

29

28

27

A408130

Item Description Qty. Item Description Qty. Item Description Qty.

1 Lower body 1 13 Spring seat 4 22 Locknut 1

2 Upper body 1 14 Compression spring 4 23 Mounting knuckle 1
3 ‘O’-ring 1 15 Return spring 4 24 Joint nut 1
4 ‘O’-ring 1 16 Shims - 25 Rocker plate 1
5 Dowel pin 2 17 Spool 4 26 Knuckle joint 1
6 Body assembly screw 1 18 Retaining plate 1 27 Hex Bolt 2
7 ‘O’-ring 1 16 Shims - 28 Washer 2
8 Plunger guide 4 17 Spool 4 29 Base plate 1
9 Seal 4 19 Gaiter 1 30 ‘O’- ring 1
10 Seal 4 20 Roll pin 1
11 Plunger 4 21 Control handle 1
12 Split Washer 4

9803/6510 Issue 1
Section E Hydraulics Section E
35 -4 Remote Control Valve (Hand Control) 35 - 4

Dismantling and Assembly

Dismantling 8 If the return springs 15 are weak, the sliding resistance
of the seal 9 will cause the guides 8 to stick in the
Notes: casing. Using a screw driver, carefully ease out the
All parts are precision made and require the utmost care guides 8 and plungers 11.
when being handled.
Note: Care must be taken to prevent damage to the guides
During dismantling, do not use excessive force to separate when removing. Ensure the guides do not fly out due to the
components which could cause scratches or burrs on force of the return springs.
bearing surfaces. Failure to observe this instruction will
cause oil leaks leading to poor performance. 9 Remove spring seats 13, split washers 12, return
springs 15, pressure control springs 14 and spools 17.
Label all parts during dismantling, to ensure correct
assembly. Note: Identify each set of parts and their locations for
assembly.
Storing the valve when dismantled could cause rusting of
parts. Ensure they are suitably protected by anti-rust 10 Loosen the two hex bolts 27 on the base of the valve.
treatment. Remove the base plate and O-ring 30 from the valve
casing.
Note: For part number identification for the Remote Control
Valve assembly, see illustration. 11 Slacken and remove body assembly screw 6. Remove
and discard ‘O’-ring 7.
1 Push down upper section of gaiter 19 and remove roll
pin 20. 12 Separate upper and lower body sections 1 and 2 and
remove dowel pins 5.
2 Remove control handle from mounting knuckle 23.
13 Remove and discard ‘O’-rings 3 and 4.
Note: Take care when removing handle to avoid damage to
wiring loom and switches. These should be removed by Note: The surface of spool 17 and spring 13 can be
separating the line connectors in the control handle and damaged by mis-handling. Take care not to damage the
below the valve body. suface of the spool during removal and do not push the
spring seat down more than 6mm (0.24 in).
3 Remove gaiter 19 from valve housing.
14 Hold spools 17 firmly on the work bench and depress
4 Slacken locknut 22 and remove mounting knuckle 23. spring seat 13 and remove split washers 12.

5 Slacken and remove joint nut 24 and rocker plate 25. Note: Avoid scratching the surface of the spools. Do not
depress the spring seats more than 6 mm (0.24 in).
! WARNING
Always wear safety glasses when dismantling 15 Separate spools 17, spring seats 13, springs 14 and 15
assemblies containing components under pressure from and shims 16.
springs. This will protect against eye injury from
components accidently flying out. 16 Remove plungers 11 from guides 8.
GEN 6-2
17 Remove seals 9 and 10 from guide 8 and discard.
Note: The return spring 15, retaining plate 18 and plunger 11
will rise when knuckle joint 26 is loosened. Note: Leave all parts to soak in suitable solvent until dirt is
loosened. Using clean solvent wash all parts and allow to air
6 Using a jig, slacken and unscrew knuckle joint 26, dry. Apply rust inhibitor to all parts.
releasing retaining plate 18.

Note: Ensure retaining plate moves freely to prevent sudden

release due to spring pressure beneath.

7 Clean the valve exterior using approved solvent and

using soft metal pads for protection, clamp the valve
body into a vice.

9803/6510 Issue 1
Section E Hydraulics Section E
35 -5 Remote Control Valve (Hand Control) 35 - 5

Dismantling and Assembly (cont’d)

Inspection

Before assembling the Remote control valve make sure that

a thorough inpection 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.

2 Carefully inpect all components for signs of excessive

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

Note: O-rings 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 undamaged.

9803/6510 Issue 1
Section E Hydraulics Section E
35 - 6 Remote Control Valve (Hand Control) 35 - 6

Dismantling and Assembly (cont’d)

Assembly

Note:During assembly, ensure all parts are clean and free

from burrs and scratches. Remove minor damage by
lapping.

Renew all ‘O’-rings, seals and back-up rings. Take care to

install seals the correct way around.

During assembly apply hydraulic oil to ‘O’-rings and seals.

Ensure all screws and bolts are tightened to the torque

settings given. 24

The numerical sequence given previously is a guide to

dismantling. For assembly the sequence should be reversed 25
noting the following details:

1 Locate retaining plate 18 onto plunger guides 8 and

using the jig, screw knuckle joint into position.
26
2 Locate rocker plate 25 and tighten until it makes
contact with the plungers 11. Ensure the plungers are
not depressed at this stage.
18
3 Holding the rocker plate 25 in its position, screw down
joint nut 24.

4 Ensure the switch cable is free from obstruction and the

line connectors are securely fastened.
1

Torque Settings

Item Nm kgf m lbf ft

6 40 4 29.5
P
24 68 7 50
25 30 3 22
26 30 3 22
27 20 2 4.7 6,7

JS03250

9803/6510 Issue 1
 36 - 3

9803/6510
Section E

311 311
214

324 324
214
501
217 217
271 313 313
224
472

420 224
336 301 301
414

413
471 336
271 218
335 335

225
218

211 211
225
414 201
213
Hydraulics

252
Direction Control Valve

203
102

101
210
203

261
210 251
202

202
212

212

A406310

Issue 1
36 - 3
Section E
Section E Hydraulics Section E
36 - 4 Direction Control Valve 36 - 4

Dismantling and Assembly

Note: Parts can be damaged by use of excessive force. 15 For disassembly of the pressure reduction valve, press
Parts can be damaged by corrosion caused by humidity and in spring washer 311, slide the spring washer sideways,
dust if left in un-assembled. bending secondary pressure spring 324, then remove
spool 301 from the larger hole.
Dismantling
16 Separate spool 301, secondary pressure setting spring
1 Clean the valve exterior using an de-greasing agent and 324, shim 217 and washer 313.
using soft metal pads for protection, clamp the valve
body into a vice. 17 Remove grease cap 203 from plug 202.
Remove packing 210 from plug 202 using a small flat
2 Remove the gaiter 501 from the cover 201.. screw driver being careful not to scratch the plug.
Remove O-ring 212 from plug 202.
3 Loosen the 5mm hex screw 472.
18 Wash all parts:
! WARNING a Place all parts in container with clean de-greasing
Always wear safety glasses when dismantling agent (first washing).
assemblies containing components under pressure from b Place all parts in a finishing wash container with
springs. This will protect against eye injury from clean de-greasing agent and rotate slowly to ensure
components accidently flying out. complete washing. (finish wash).
GEN 6-2 c Wipe clean de-greasing agent from all parts using a
lint-free cloth.
Note: Take care that push rod 214 does not fly out under
spring tension.
Note: Adhered dirt and grease may cause damage during
4 Remove pin 413 using a 7mm punch and.remove cam the first washing; soak well to loosen and float these off.
420. Dirty de-greasing agent may cause damage to the parts.
Monitor the cleanness of the de-greasing agent up to re-
Note:Take care that push rod 214 and plug 202 are not assembly. Do not dry with compressed air as the dust and
thrown out by damping spring 336 pressure. moisture carried by the air may damage the parts or cause
corrosion
5 Loosen hex bolt 271 and remove cover. Making a note
of the relative positions of the cover 201 and the casing
102. The plug 202 will remain in casing 102 due to
friction of the O-ring 212.

6 Remove casing 102 and fix in vice using soft metal pads
for protection.

7 Pull push rod 214 from plug 202 noting the relative
postions of plugs and push rods to the casing 102.

8 Remove plug 202 with the grease cap 203, packer 210
and O ring attached.

9 Remove piston 224 and damping spring 336 from the

casing.

10 Remove spring washer 218 from the casing 102 using

tweezers etc.
Jig 1 May have central hole
11 Remove steel balls 225 using a magnet. ( 2 mm maximum)
10mm -0.3
-0.4

12 Fix the lower casing assembly in a vice and remove the

8mm-0.2
-0.3

O-rings 211, 213 from casing 101.

13 Remove pressure reduction valve assembly and return

30

spring 335 from casing 101.

14 Place cover 201 flat on a flat bench, apply special jig 1

20 mm 2
to bush 414 and tap with a hammer to remove the bush.
30mm

A406320

9803/6510 Issue 1
Section E Hydraulics Section E
36 - 5 Direction Control Valve 36 - 5

Dismantling and Assembly (cont’d)

Inspection

Before assembling the Directional control valve make sure

that a thorough inpection 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.

2 Carefully inpect all components for signs of excessive

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

Note: O-rings 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 undamaged.

9803/6510 Issue 1
Section E Hydraulics Section E
36 - 6 Direction Control Valve 36 - 6

Dismantling and Assembly (cont’d)

Assembly Torque Setting

Note: O-rings rings and other sealing materials should Item Nm kgf m Ibf ft
preferably be replaced each time the valve is 125 20.5 2 15
disassembled but they may be re-used provided a 312 68.5 7 50.5
careful check is made that they are undamaged. 301 47 5 35

Note: When hexagonal socket (hex) bolts 125 are

loosened the seal washers 121 must be replaced.

Note: Fit all components in the same positions as before

disassembly

! WARNING
Always wear safety glasses when dismantling
assemblies containing components under pressure from
springs. This will protect against eye injury from
components accidently flying out.
GEN 6-2

1 Assemble washer 313, shim 217, secondary pressure

setting spring 324 and spring washer, in that order, onto
spool 301

2 Push spool 301 through the larger hole of spring washer

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

3 Fix casing 101 in a vice. Fit return spring 335 into

casing. A

4 Fit the pressure reduction valve sub-assembly,

assembled in 1 and 2 above, into casing 101. When
fitting the pressure reduction valve subassembly, take
care not to hit the lower end of the spool against the Be careful of
edge of the casing (see A) the casing edge

5 Fit O-rings 211,213 into the casing.

6 Fix upper casing 102 in a vice and fit steel balls 225.

7 Fit spring washer 218 into casing 102 using tweezers

etc.
A406350

8 Fit damping spring 336 into casing 102.

9 Fit piston 224 into casing 102.

10 Fit O-ring 212 to plug 202.

11 Fit packing 210 to plug 202. Be careful of the direction B

when fitting the packing. (See B). Apply a light coating
Packing
of grease before fitting packing.

12 Fit grease cap 203 to plug 202.

13 Fit push-rod 214 to plug 202. Apply working oil to

surfaces before fitting push-rod.There is a risk of
damage to the rib part of packing 210 do not use A406370
excessive force when fitting.

14 Fit the push-rod subassembly, assembled in No. 10, 11,

12 and 13, into casing 102.

9803/6510 Issue 1
Section E Hydraulics Section E
36 - 7 Direction Control Valve 36 - 7

Dismantling and Assembly (cont’d)

Assembly (cont’d) Jig 1 May have central hole
( 2 mm maximum)
15 Place cover 201 flat on a flat bench, push on bush 414

10mm -0.3
-0.4
using the special Jig 1 and insert by tapping with a

8mm-0.2
-0.3
hammer.

16 Fix the lower cover assembly, as assembled in No. 1 to

30
5, in a vice and attach upper assembly, as assembled in
No. 6 to 14.
20 mm 2
17 Fit cover 201 to casing 102.
30mm
18 Tighten the hexagonal socket bolt 271 to the specified A406320
torque.

19 Fit cam 420 to cover 201. Press down cam 420 and
insert cam shaft 413 from the outside. Torque Setting
Item Nm kgf m Ibf ft
20 Apply JCB Threadlock or equivalent to the surfaces of 125 20.5 2 15
hexagonal socket screws 472. 312 68.5 7 50.5
301 47 5 35
21 Tighten hexagonal socket screw 472 to specified torque.

22 Tilt cam 420, apply grease to the top of push-rod 214

and inject grease into grease cap 203 of plug 202.
Grease is to be applied and injected using a spatula
made of soft material and care it to be taken that the
surfaces of the push-rod and plug are not damaged.

23 Fit the top of bellows 501 into cam 420 and then the
bottom into the groove in cover 201.

24 Before fitting the bottom edge of the bellows into the

groove in the cover, apply anticorrosion oil inside the
bellows.Please note that if the bellows do not fit
precisely into the groove and are loose, resistance to
dust and water will deteriorate.

9803/6510 Issue 1
Section E Hydraulics Section E
38 - 1 Solenoid Valve (8 spool) 38 - 1

Removal and Replacement

A405830

C11
C1 C2 C3 C4

C12
C10

A405760
CT1 CT2 CT3 CT4

B2 T2
T1
C9
CT1 CT2 CT3 CT4
CT6 CT7 CT8 CT5
CT10
CT9 C13

A405770 A405750
A405790
CT6 CT7 CT8 CT5

C6 C8

C5 C7
P

Solenoid Function Electrical Harness Tape Colour Hydraulic hose colour

CT1 2 Stage Travel Red Blue / Blue
CT2 Swing Shut Off Green Red / Red
CT3 2 Stage Relief Yellow Green / Green
CT4 Cushion Control Light Green Yellow / Yellow
CT5 Negative Control White Violet / Violet
CT6 Boom Priority Pink Orange / Orange
CT7 Max Flow Cut No Tape Light Blue
CT8 Servo Isolator Blue No Hose

9803/6510 Issue 1
Section E Hydraulics Section E
38 - 2 Solenoid Valve (8 spool) 38 - 2

Removal and Replacement (cont’d)

! DANGER
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop the
engine and operate the controls to release pressure
trapped in the hoses. Make sure the engine cannot be
started while the hoses are open.
INT-3-1-11/1

Removal

1 Turn off engine. Operate the control joysticks back and

forth and side to side to vent residual pressure.

2 Disconnect all the electrical connections to the solenoids

3, labeling which connector goes to which solenoid.

3 Disconnect all hydraulic pilot hoses from the valve block

and plug all orifices to prevent ingress of dirt. The hoses
should be labelled, if not label each hose before
disconnecting, this will ensure correct position when
refitting.

4 Remove the four M8 bolts from rear of valve and remove

valve from machine.

Replacement

Replacement is a reversal of the removal sequence.

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

Note: All hydraulic adapters that are installed together with a

bonded sealing washer must also have JCB Threadseal
applied to the threads of the adapter.

9803/6510 Issue 1
Section E Hydraulics Section E
38 - 3 Solenoid Valve (8 spool) 38 - 3

Dismantling and Assembly

3
13
2

8 12
7
11
6 10

9
1

A406560

9803/6510 Issue 1
Section E Hydraulics Section E
38 - 4 Solenoid Valve (8 spool) 38 - 4

Dismantling and Assembly (cont’d)

Dismantling Assembly

1 Remove nut 1 from solenoid valve. Assembly is a reversal of the dismantling sequence.

2 Carefully slide seal 2, solenoid 3, and seal 4 away from 1 Lubricate spool 5, spring 7 and balls 8 and 12 with clean
the valve block. hydraulic oil.

3 Loosen spool 5 and extract spool from the valve block. 2 Tighten components to specified torque.

4 Repeat steps 1 to 3 to remove all solenoid valves from 3 Apply JCB Threadseal to hex plug 10.
the valve block.

5 Remove plug 6 and extract spring 7 and ball 8. Torque Settings

6 Unscrew accumulator 9 and remove from valve block. Item Nm kgf m lbf ft

7 Remove hex pug 10. 1 3.4 2.5 0.36

5 30 22 3
8 Using a 5mm allen key remove valve 11, ball 12 and seat 6 10 7 1
13. 9 15 11 1.5
10 10 7 1
Inspection 11 10 7 1

Before assembling the solenoid 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.

2 Carefully inspect all components for signs of excessive

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

Note: Seals 2 and 4 should be replaced before assembly.

9803/6510 Issue 1
Section E Hydraulics Section E
40 - 1 Shuttle Valve 40 - 1

Port Function Harness

Tape Colour
S1 Slew Pressure Switch Red
S2 Boom Up Pressure Switch Yellow
S3 Boom Down Pressure Switch Blue
C9 Auto Mode Pressure Switch Green

S1
S2
S3
C9

CT6

C5/ A6 A5 B5 C4 C3 B6
CT5
C9

A3 S2 S3 A4 B4 C2 C1 B3

CT4 CT1 C7
C6 B1 B2
A2 A1
CT2 S1 CT3
C8

Port Hose Colour Port Hose Colour

A1 Violet C1 Grey/Red
A2 Orange C2 Yellow,Green/Pink
A3 Blue C3 Red/Brown CT1
A4 Red C4 Green/Red CT2
A5 Green C5 Gray/Red CT3
A6 Pink C6 Red/Red CT4
B1 Violet CT5
A1 = C7
V - = GR/R
C1 CT6
B2 Orange A2 = C8
O White/Red
C2 = YG/P 3
B3 Blue A3 = BL C3 = R/BR
B5 Green A4 = R C4 = G/R
B6 Pink A5 = G C5= GR/R 5 2
A6 = P C6 = R/R
4
B1 = V C7 = CL
B2 = 0 C8 = W/R
B3 = BL

9803/6510 Issue 1
Section E Hydraulics Section E
40 - 2 Shuttle Valve 40 - 2

Removal and Replacement

! DANGER
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop the
engine and operate the controls to release pressure
trapped in the hoses. Make sure the engine cannot be
started while the hoses are open.
INT-3-1-11/1

Removal

1 Turn off engine. Operate the control joysticks back and

forth and side to side to vent residual pressure.

2 Disconnect the electrical connections to the four

pressure switches. Label each connector to ensure
correct position when refitting.

3 Disconnect all hydraulic hoses from the valve block and

plug all orifices to prevent ingress of dirt. The hoses
should be labelled, if not, label each hose before
disconnecting, this will ensure correct position when
refitting.

4 Remove the four M10 bolts from rear of valve and

remove valve from machine.

Replacement

Replacement is a reversal of the removal sequence.

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

Note: All hydraulic adapters that are installed together with a

bonded sealing washer must also have JCB Threadseal
applied to the threads of the adapter.

9803/6510 Issue 1
Section E Hydraulics Section E
40 - 3 Shuttle Valve 40 - 3

Dismantling and Assembly

Dismantling Assembly

1 Remove the four pressure switches 1 and plug all Assembly is a reversal of the dismantling sequence.
orifices to prevent ingress of dirt
1 Lubricate valve 3, ball 4 and seat 5 with clean hydraulic
2 Remove plug 2 from valve. oil.

3 Using a 5mm allen key remove valve 3, ball 4 and seat 5. 2 Tighten components to specified torque.

4 Repeat steps 2 to 3 to remove the remaining three 3 Apply JCB Threadseal to plugs 2.
shuttle valves.

Torque Settings
Inspection
Item Nm kgf m lbf ft
Before assembling the solenoid valve make sure that a
thorough inspection of all the components is carried out. 2, 3 10 7 1
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.

2 Carefully inspect all components for signs of excessive

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

Note: Check condition of O-rings before assembly.

9803/6510 Issue 1
Section E Hydraulics Section E
42 - 1 Cushion Valve 42 - 1

4
2 3
1

F B

H D
R

G C

S
E1 A1

A = P
B = G
C = P
E A
D = G
F = BL
H = BL
R = Y/G
S = Y/Y
T = W/R A407750

9803/6510 Issue 1
Section E Hydraulics Section E
42 - 2 Cushion Valve 42 - 2

Removal and Replacement

! DANGER
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop the Hose Colour Key:
engine and operate the controls to release pressure
trapped in the hoses. Make sure the engine cannot be BL = Blue
started while the hoses are open. BR = Brown
INT-3-1-11/1
CL = Colourless
Removal
G = Green
GR = Gray
1 Turn off engine. Operate the control joysticks back and LB = Light Blue
forth and side to side to vent residual pressure. O = Orange
P = Pink
2 Disconnect all hydraulic hoses from the valve block and R = Red
plug all orifices to prevent ingress of dirt. The hoses V = Violet
should be labelled, if not, label each hose before W = White
disconnecting, this will ensure correct position when
Y = Yellow
refitting.
LG = Light Green
3 Remove the four M8 bolts from rear of valve and remove
valve from machine.

Replacement

Replacement is a reversal of the removal sequence.

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

Note: All hydraulic adapters that are installed together with a

bonded sealing washer must also have JCB Threadseal
applied to the threads of the adapter.

9803/6510 Issue 1
Section E Hydraulics Section E
42 - 3 Cushion Valve 42 - 3

Dismantling and Assembly

Dismantling Assembly

1 Remove adapter 1 and O-ring 2 from valve. Assembly is a reversal of the dismantling sequence.

2 Extract spring 3, spool 4 and spring 5. 1 Lubricate spool 4, springs 3 and 5 with clean hydraulic
oil.
3 Remove adapter 6 from valve and repeat step 2

Inspection

Before assembling the solenoid 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.

2 Carefully insect all components for signs of excessive

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

9803/6510 Issue 1
Section E Hydraulics Section E
44 - 1 Slew Brake Valve 44 - 1

10
9
8
7

5
3 4

2
1

A407670
A

BL

Port Hose Colour

A -
B Red/Light Green
P Gray/Gray
T White/Yellow

T
B

A408170

9803/6510 Issue 1
Section E Hydraulics Section E
44 - 2 Slew Brake Valve 44 - 2

Removal and Replacement

! DANGER
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop the
engine and operate the controls to release pressure
trapped in the hoses. Make sure the engine cannot be
started while the hoses are open.
INT-3-1-11/1

Removal

1 Turn off engine. Operate the control joysticks back and

forth and side to side to vent residual pressure.

2 Disconnect all the electrical connections to the solenoids

3, labeling which connector goes to which solenoid, if
not already labeled.

Note: Connector labeling, Y = Yellow, BL = Blue

3 Disconnect all hydraulic hoses from the valve block and

plug all orifices to prevent ingress of dirt.

The hoses should be labeled, if not label each hose

before disconnecting, this will ensure correct position
when refitting.

4 Remove the two M10 bolts from rear of valve and

remove valve from machine.

Replacement

Replacement is a reversal of the removal sequence.

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

Note: All hydraulic adapters that are installed together with a

bonded sealing washer must also have JCB Threadseal
applied to the threads of the adapter.

9803/6510 Issue 1
Section E Hydraulics Section E
44 - 3 Slew Brake Valve 44 - 3

Dismantling and Assembly

Dismantling Assembly

1 Remove nut 1 from Slew Brake valve. Assembly is a reversal of the dismantling sequence.

2 Carefully slide seal 2, solenoid 3, and seal 4 away from 1 Lubricate spool 5, 8 and ball 9 with clean hydraulic oil.
the valve block.
2 Tighten components to specified torque.
3 Loosen spool 5 and extract spool from the valve block.
3 Apply JCB threadlocker to hex plug 7.
4 Repeat steps 1 to 3 to remove all solenoid valves from
the valve block.
Torque Settings
5 Unscrew relief valve 6 and remove from valve
Item Nm kgf m lbf ft
6 Remove hex pug 7.
1 3.4 2.5 0.36
7 Using a 5mm allen key remove valve 8, ball 9 and seat 5 30 22 3
10. 6 60 44 6
7 10 7 1
Inspection
8 10 7 1
Before assembling the Slew Brake 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.

2 Carefully inspect all components for signs of excessive

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

Note: Seals 2 and 4 should be replaced before assembly.

9803/6510 Issue 1
Section E Hydraulics Section E
50 - 1 Slew Motor 50 - 1

Removal and Replacement

X
n Y

Removal Replacement

1 Turn off engine. Operate the slew control joystick back Replacement is a reversal of the removal sequence.
and forth to vent residual pressure.
1 Position Slew motor on frame by reference pin Y
2 Disconnect all hydraulic hoses from the slew motor and
plug all orifices to prevent ingress of dirt.Label each hose 2 Check Slew motor oil level
before disconnecting, this will ensure correct position
when refitting. ! WARNING
Fine jets of hydraulic fluid at high pressure can penetrate
3 Remove bolts X and reference pin Y.
the skin. Do not use your fingers to check for hydraulic
fluid leaks. Do not put your face close to suspected leaks.
4 Using suitable lifting equipment,(see Weights in
Hold a piece of cardboard close to suspected leaks and
Technical Data) carefully lift slew motor until clear of
then inspect the cardboard for signs of hydraulic fluid. If
machine.
hydraulic fluid penetrates your skin, get medical help
immediately.
! DANGER INT-3-1-10/1

Hydraulic fluid at system pressure can injure you. Before

After replacement check the main relief valve (M.R.V.) and
disconnecting or connecting hydraulic hoses, stop the
auxiliary relief valve (A.R.V.) pressure settings.
engine and operate the controls to release pressure
trapped in the hoses. Make sure the engine cannot be Torque Setting
started while the hoses are open.
INT-3-1-11/1
Item Nm kgf m Ibf ft

X 415 42 306

9803/6510 Issue 1
Section E Hydraulics Section E
50 - 2 Slew Motor 50 - 2

Hydraulic Motor Components

Key

a Drain port
a1
Pilot port
b1
A
a2
Pilot hole
a3
b
c
Flow paths
d
e
f Piston bore
g
h Flow paths
i
j By pass valve
A Inlet port
B Outlet port
C Anti-cavitation check valve
D Mechanical brake
J Cross-line relief valve
K A side cavity
L B side cavity
M Intermediate cavity
N A side seat
P B side seat
R Anti-pendulum valve
S Anti-pendulum valve
T Pilot hole
U Spring chamber
V Make-up port
W Piston
X Mechanical brake release
port
Y Motor output shaft
Z Slipper foot
JS00960

Note: Item numbers are referred to on the following pages.

9803/6510 Issue 1
Section E Hydraulics Section E
50 - 5 Slew Motor 50 - 5

Dismantling
Refer to the sectional drawing at start of this section as a
guide to dismantling and assembly.

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.

JS06100

2 Remove plug 26 with an 8 mm Allen key and drain the

gear oil.

26

JS06110

9803/6510 Issue 1
Section E Hydraulics Section E
50 - 6 Slew Motor 50 - 6

Dismantling (cont’d)
3 Remove screws B with a 19 mm socket wrench and
remove the motor.

Note: Before removing the motor from the reduction gear, it B
is advisable to make an alignment mark on the mating faces
to facilitate reassembly.

JS06120

4 Remove the caps 37 with 14 mm A/F hexagonal key 30

and remove relief valves 34 from the motor.
17
31
Note: Record the position of relief valves 34 to ensure
29
correct reassembly.
28
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.
29 34
Note: Record the relative positions of the parts to ensure
correct reassembly.

6 It is advisable to make alignment marks on cover 17

and housing 25 with white paint, etc. to facilitate
reassembly. 34 37
31
30 25

JS06130

7 Remove screws 27 attaching cover 17 to housing 25

with a 12 mm hexagonal key. 27
8 Place the motor with the main shaft downwards and lift
off cover 17.

17

25

JS05670

9803/6510 Issue 1
Section E Hydraulics Section E
50 - 7 Slew Motor 50 - 7

Dismantling (cont’d)
9 Remove snap ring 23 and remove the inner ring of
needle bearing 22. 23
10 Remove 'O'-ring 13.

11 Remove balance plate 21. Remove the pins 15 from the 22

balance plate.
13
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. 21
Before removing the balance plate, note the correct
15
relationship with cover 17.) 20
15
12 Remove the bushings 20 with Teflon rings 19 and the 19
plate springs 18.
18

17

JS05680

13 Remove the springs 14 from brake piston 12.

14
Note: Keep the springs in the order in which they are to be
reinserted. 13
14 It may be difficult to remove brake piston 12 from 12
housing 25 due to resistance caused by ‘O’-rings 11
and 13. Therefore remove brake piston 12 using the
tapped M6 holes X as shown in the illustration. 11
15 Remove ‘O’-ring 11 from housing 25 and ‘O’-ring 13 25
from brake piston 12.

25

12

JS05700

9803/6510 Issue 1
Section E Hydraulics Section E
50 - 8 Slew Motor 50 - 8

Dismantling (cont’d)
16 Remove friction plate 9 and mating plate 10.
9
17 Hold the end of cylinder 24 by hand and pull out the
cylinder assembly from housing 25. 10
9
Note: The oil seal 2 and the outer ring of taper roller bearing 10
3 remain in the housing. 9
The end face of the cylinder should be protected by clean 10
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. 24
18 Remove the outer ring of taper roller bearing 3 from the
housing.

25
3

JS05710

19 Tap oil seal 2 with a screwdriver and hammer to remove

it from housing 25.

Note: The oil seal cannot be reused.

JS06170

9803/6510 Issue 1
Section E Hydraulics Section E
50 - 9 Slew Motor 50 - 9

Dismantling (cont’d)
20 Attach a puller to the inner ring of taper roller bearing 3
at two places and on the end of cylinder 24 spline, then 1
extract bearing inner ring 1. Take out collar 53.
53
21 Remove swash plate 6, piston assemblies 8 and
6
retainer plate 7 together from cylinder 24.

24

JS06160

22 Slide swash plate 6 from the sliding faces of the piston

assemblies.

Note: Take care not to damage the swash plate during

handling.
6

JS06150

23 Remove spring 5 from cylinder 24.

5

24

JS06140

9803/6510 Issue 1
Section E Hydraulics Section E
50 - 10 Slew Motor 50 - 10

Inspection
1 Clean each part in a suitable solvent and dry using
compressed air. ! WARNING
Hydraulic Pressure
2 Inspect all parts and act in accordance with the Hydraulic fluid at system pressure can injure you. Before
following table. disconnecting or connecting hydraulic hoses, stop the
engine and operate the controls to release pressure
3 Discard all used seals and ‘O’ rings and fit new ones trapped in the hoses. Make sure the engine cannot be
during assembly. started while the hoses are open.
! CAUTION
INT-3-1-11/1

If the machine is operated at full load, before its initial

! WARNING
run-in procedure is complete, it may cause scuffing and Hydraulic Fluid
seizing which can adversely effect the service life of the Fine jets of hydraulic fluid at high pressure can penetrate
machine. the skin. Do not use your fingers to check for hydraulic
8-3-1-5 fluid leaks. Do not put your face close to suspected
leaks. Hold a piece of cardboard close to suspected
leaks and then inspect the cardboard for signs of
hydraulic fluid. If hydraulic fluid penetrates your skin, get
medical help immediately.
INT-3-1-10/1

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.
Balance Plate 21 Any seizure of the sliding 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
Piston assembly 8 slipper feet emery 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.

Piston assembly 8 pistons The external surfaces of the piston assemblies should be practically unworn. The
motor should be renewed if a piston assembly shows any sign of seizure.

Cylinder assembly 24 piston bores The piston bores should be practically unworn. The motor should be renewed if
the bores show any sign of seizure or are badly damaged.

HYDRAULIC MOTOR The bearings should be renewed if any slight damage is noticed on the contact
Taper roller bearing 3 surfaces of the rollers or needles.
Needle bearing 22 It is recommended that all bearings be renewed on reassembly of the motor
REDUCTION GEAR because bearings can be damaged when the motor is dismantled.
Self-aligning roller bearing 57
Roller Bearing 62

HYDRAULIC MOTOR Renew any oil seal if damage to the lip is apparent.
Oil seal 2 New seals must be used when reassembling the motor.
REDUCTION GEAR
Oil seal 61

HYDRAULIC MOTOR Renew any 'O'-ring that appears to be damaged.

O-rings 11, 13, 33, 36, 41, 45, 52 New 'O'-rings must be used when reassembling the motor.

HYDRAULIC MOTOR The back-up rings must be renewed when reassembling the motor.
Back-up ring 32, 35, 46

9803/6510 Issue 1
Section E Hydraulics Section E
50 - 12 Slew Motor 50 - 12

Assembly
Refer to the sectional drawing at start of this section as a ! CAUTION
guide to dismantling and assembly.
Cleaning
Cleaning metal parts with incorrect solvents can cause
Check all parts before assembly and remove any scratches
corrosion. Use only recommended cleaning agents and
with a fine oil stone or carborundum paper. Wash with a
solvents.
suitable solvent and blow dry. INT-3-2-11
! CAUTION
Replace all seals with new ones.
‘O’-rings, Seals and Gaskets
Badly fitted, damaged or rotted ‘O’-rings, seals and
Apply clean hydraulic oil to all sliding faces during assembly.
gaskets can cause leakages and possible accidents.
Renew whenever disturbed unless otherwise instructed.
Do not use Trichloroethane or paint thinners near ‘O’-
rings and seals.
INT-3-2-12

1 Lap the sliding contact faces of piston assemblies 8,

balance plate 21 and swash plate 6 with very fine paste
on a flat surface.

JS06180

JS06190

JS06200

9803/6510 Issue 1
Section E Hydraulics Section E
50 - 13 Slew Motor 50 - 13

Assembly (cont’d)
2 Apply grease to the curved part of cylinder 24 (contact
1
face with spring 5) and mount spring 5. 53

3 Position the piston assemblies 8 into the holes of 6

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 8
which they were removed.
Apply clean hydraulic oil to all cylinder 24 bores before 7
reassembling.

5 Apply clean hydraulic oil to piston assembly 8 shoe 5

sliding surface and mount the swash plate 6.

6 Mount collar 53 and inner ring of taper roller bearing 1

on motor output shaft.

7 Apply a thin coat of JCB Retainer where the inner ring is

mounted on motor output shaft.

24

JS05720

8 Using a jig, (see Special Tools, Section 1) press inner

ring 1 on output shaft.

24

JS05730

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

JS05740

9803/6510 Issue 1
Section E Hydraulics Section E
50 - 14 Slew Motor 50 - 14

Assembly (cont’d)
10 Mount the outer ring of the taper roller bearing into
housing 25. 14
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. 13

Note: The splines of the cylinder assembly protrude beyond 12

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.
9
12 Mount friction plate 9 and mating plate 10.
10
Note: Apply hydraulic oil to both faces before mounting the 9
plates. 10
9
13 Mount 'O'-ring 11 in housing 25 and 'O'-ring 13 on
piston 12. 10

Note: Grease the 'O'-rings before mounting. 11

14 Apply hydraulic oil to the sliding surface around piston

12 and slide it into housing 25.

Note: It is difficult to insert piston 12 into the housing due to 24

O'-rings 11 and 13. Hold the piston horizontally and push it
into the housing with one movement.

15 Insert the brake unit springs 14 back into brake piston 7, 5

12.

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

found during dismantling.

25

JS05690

9803/6510 Issue 1
Section E Hydraulics Section E
50 - 15 Slew Motor 50 - 15

Assembly (cont’d)
16 Mount the bushings 20 with Teflon rings 19 and the
23
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 22
before mounting them, as this helps prevent them from
falling out when the cover is mounted onto the housing. 13
17 Generously grease the pins 15 and insert into cover 17.
21
18 Mount balance plate 21 onto cover 17. 15
20
19 Press needle bearing 22 inner ring into cover 17 and 15
attach snap ring 23.
19
20 Apply grease to the 'O'-ring and install 'O'-ring 13 to
18
cover 17.
17

JS05680

21 To prevent oil leakage from the cover bolt holes apply

JCB Multi-gasket to the surface.

JS05650

22 Lift cover 17 and balance plate 21 by hand and mount

them carefully on housing 25. 27
Take care that balance plate 21 and bushings 20 do not
fall out while mounting cover 17. Align housing 25 and
cover 17 alignment marks which were made before
dismantling. 17

23 Tighten the cap screws 27 (with a 12 mm A/F hexagonal

key) which attach cover 17 to housing 25 to a torque of
157 Nm (116 lbf ft). 25

JS05660

9803/6510 Issue 1
Section E Hydraulics Section E
50 - 16 Slew Motor 50 - 16

Assembly (cont’d)
24 Assembling the Make-up and by-pass valves.
30
Assemble the check valves 29 and springs 31 in cover 17
17 and tighten the caps 30 (14 mm A/F hexagonal
31
sockets) to a torque of 137 Nm (101 lbf ft). 29

Assemble by-pass valve assembly 28 to cover 17 and 28

tighten the caps (10 mm A/F hexagonal sockets) to a
torque of 78.65 Nm (58 lbf ft).

29 34
25 Insert the relief valve assemblies 34 into cover 17 and
tighten the caps 37 (14 mm A/F hexagonal sockets) to a
torque of 78.65 Nm (58 lbf ft).

Note: Ensure that the relief valves are replaced in their

original positions.
34 37
31
30 25

JS06130

26 Final checks after assembling.

Open the inlet and outlet ports and apply 30 kgf/cm2

(427 lbf/in2) pilot pressure to the brake release port.
(Take care as oil will be discharged from the drain port).
Check that the drive shaft can be rotated smoothly for
at least one full revolution by applying a torque of
approx. 39.32 Nm (29 lbf ft).

Note: If the shaft does not turn, the unit has not been
assembled correctly so dismantle again and inspect.

27 Degrease the mating faces of the gear unit ring gear 64

and motor housing 25 and apply Multi-gasket to the
ring gear.

25

64

JS06220

9803/6510 Issue 1
Section E Hydraulics Section E
50 - 17 Slew Motor 50 - 17

Assembly (cont’d)
28 Attach the motor with hexagonal bolts and spring
washers.

Size: 19 mm
Tightening torque: 103 Nm (76 lbf ft).
B

JS06120

29 Attach the level gauge A with a pipe wrench, setting the

height as shown.

JS06210

30 Fill with gear oil through the filler port.

Insert plug 26 with an 8 mm Allen key and tighten to

torque of 39.32 Nm (29 lbf ft). 26

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.

JS06110

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
Torque Setting
damage the oil seal.
Item Nm kgf m Ibf ft
B 103 76 16
After the unit is filled, run it for around 10-15 minutes at zero
26 39 29 4
load, and at low speed and verify that there is no abnormal
27 157 116 16
noise or vibration. Gradually bring the system into high
28 78.5 58 8
speed and loaded operation.
30 137 101 14

9803/6510 Issue 1
Section E Hydraulics Section E
50 - 18 Slew Motor 50 - 18

Relief Valves
Dismantling
Refer to the sectional drawing as a guide to dismantling and
assembling.

Take steps during dismantling to ensure that all the parts are
returned to their original positions.

Clean the parts with a suitable solvent and blow them dry.
Replace all used 'O'-rings

34
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.
40

43 38

42
51

37 JS06230

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

using a soft object, taking care not to scratch the seat
face.
39

44

JS06240

9803/6510 Issue 1
Section E Hydraulics Section E
50 - 19 Slew Motor 50 - 19

Relief Valves
Assembly

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

41.
41
2 Mount poppet 43, spring 42, shim 40, piston 38, liner
51 onto sleeve 39. 39

3 Screw cap 37 (with a 14 mm A/F hexagonal socket) 44

with 'O'-ring 36 and back-up 35 mounted, on to sleeve
40
39 and tighten to a torque of 157 Nm (116 lbf ft).
43 38
Check the relief set pressure. 35
42
The correlation between the set pressure of the relief 51
valve and the adjusting shims is shown below.
However, adjustment must not be attempted if the 36
pressure cannot be checked. 37

JS06250
A 0.1 mm (0.003 in) shim equals 5 kgf/cm2 (71 lbf/in2)
approximately.

9803/6510 Issue 1
Section E Hydraulics Section E
50 - 20 Slew Motor 50 - 20

Slew Reduction Gear

2 1

10
3

11

4
12

13

14

7
15

16

17

Component Identification

1 1st Reduction Sun Gear 10 Ring nut

2 1st Reduction Planet gear assembly 11 Bearing
3 Bolt 12 Seal
4 Cover 13 Gearbox housing
5 2nd Reduction Sun Gear 14 Bearing
6 O-ring seal 15 Nylon ring
7 Ring gear 16 Spacer
8 O-ring seal 17 Pinion shaft
9 2nd Reduction Planet gear assembly

9803/6510 Issue 1
Section E Hydraulics Section E
50 - 21 Slew Motor 50 - 21

Slew Reduction Gear (cont’d)

Dismantling

Cleanliness is the utmost importance when servicing the

gearbox. All precautions to prevent any ingress of dirt, grit
etc must be taken

Note: For details of service tools referred to, see Service

Tools at the front of this section

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

gear and gear box cover 13.
Lift out 1st Reduction Sun Gear 1.
Lift out 1st Reduction Planet gear assembly 2
Lift out 2nd Reduction Sun Gear 5.
Remove cover 4.
Remove O-ring 6 from the ring gear.
Lift out 2nd Reduction Planet gear assembly 9.
Remove ring gear 7.
Remove O-ring 8 from the ring gear.

2 Assemble the Socket Box Wrench and Nut Adapter (see

Services Tools, Section 1) on the ring nut 10.
A406450

By using a torque multiplier (1:25) loosen the ring nut 10.

Remove the ring nut.

A406380

A406430

9803/6510 Issue 1
Section E Hydraulics Section E
50 - 22 Slew Motor 50 - 22

Slew Reduction Gear (cont’d)

Dismantling (cont’d)

4 Use a 3 leg puller to release gear box housing 13 from

Pinion shaft 17 and bearing. Using suitable lifting
equipment , remove gearbox housing 13.

A406420

5 Assemble the Bearing Rig (see Service Tools, Section

1) between the pinion shaft 17 and the bearing 14. Using
suitable lifting equipment place the unit in the tube
provided with the service tool. By using a press, push on
the pinion shaft 17 to separate it from the bearing 14.
Remove bearing 14 and nylon ring 15 from pinion shaft.

A406410

6 Turn gearbox housing 13 upside down. Place Seal Ring

tool (see Service Tools, Section 1) on the seal 12, using
a soft faced hammer, tap service tool to remove seal 12.
Remove bearing 11 from gearbox housing 13.

A406390

9803/6510 Issue 1
Section E Hydraulics Section E
50 - 23 Slew Motor 50 - 23

Slew Reduction Gear (cont’d)

Inspection

Before assembling the gear box 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 gearbox.

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 signs

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

3 In the case of damaged gears, for example a planetary

gear, do not proceed to replace the individual gears but
the entire assembly.

9803/6510 Issue 1
Section E Hydraulics Section E
50 - 24 Slew Motor 50 - 24

Slew Reduction Gear (cont’d)

Assembly (cont’d)

Note: Apply clean hydraulic fluid to all sliding contact faces

during assembly. New seals must be used on assembly.

1 Place seal 12 on to it’s seat in the gearbox housing 13.

2 Using the Seal Ring Tool (see Service Tools, Section 1)

and a soft faced hammer, push the seal 12 against it’s
seat.

3 Turn the gear box housing 13 upside down and apply

with grease.

4 Place the nylon ring 15 over the pinion shaft 17.

Apply a coat of grease to the nylon ring 15.

5 Place bearing 14 on the pinion shaft 17.

6 Using the Stopper Tool (see Service Tools, Section 1)

and a press, push the bearing against the pinion shaft
shoulder.

7 Apply grease to the bearing 14.

8 Using suitable lifting equipment, lift the pinion shaft 17

into the tube of the Bearing Rig (see Service Tools,
Section 1)

9 Using suitable lifting equipment, place the gearbox

housing 13 onto the pinion shaft 17.
Using the Stopper Tool (see Service Tools, Section
1)and a press, push the gearbox housing 13 against the
pinion shaft shoulder 17.

10 Insert bearing 11 onto the pinion shaft 17 and using the A406400
Stopper Tool (see Service Tools, Section 1) and a
press, assemble the output unit.

11 Apply JCB Threadlocker to the thread of a NEW ring

nut 10.

Assemble the Socket Box Wrench and Nut Adapter

(see Services Tools, Section 1) on the ring nut 10.
Tighten the ring nut 10 (see Torque Settings at end of
this section)

A406450

9803/6510 Issue 1
Section E Hydraulics Section E
50 - 25 Slew Motor 50 - 25

Slew Reduction Gear (cont’d)

Assembly (cont’d)

12 Place 2nd Reduction planetary gear assembly 9 over

the pinion shaft 17.

13 Replace O-ring 8 into it’s seat in the ring gear 7.

14 Place ring gear 7 onto the gear box housing 13, making
sure bolt holes are aligned.

15 Replace O-ring 6 into it’s seat in the ring gear 7.

16 Insert 2nd Reduction Sun Gear 5 in the 2nd Reduction

planetary gear assembly 9.

17 Assemble the cover 4 onto the gear ring 7. Insert bolts A406380
3 and tighten to 205 Nm torque.

18 Insert 1st Reduction planet gear assembly 2.

Torque Settings
19 Insert 1st Reduction Sun Gear 1.
Item Nm kgf m Ibf ft

10 1400 1032 143

3 205 21 151

9803/6510 Issue 1
Section E Hydraulics Section E
53 - 1 Rotary Coupling 53 - 1

Rotary Coupling

Item Part Name

11 Axle
12 V-ring
13 Rotor
14 O-ring
15 Packing ring
16 Thrust plate
17 Hexagonal socket head
bolt
18 O-ring
19 Cover
20 Plug
21 Plug

9803/6510 Issue 1
Section E Hydraulics Section E
53 - 2 Rotary Coupling 53 - 2

Rotary Coupling (cont’d)

Item Part Name

1 High strength bolt
2 High strength washer
3 Loctite 262
4 Lock bar
5 Seal washer
6 Seal cap
7 Rubber packing
8 Seal ring
9 Rotating joint assmebly
The unit weighs 35kg.

9803/6510 Issue 1
Section E Hydraulics Section E
53 - 3 Rotary Coupling 53 - 3

Removal

Refer to the sectional illustration on the previous page as a

guide to the dismantling and assembly procedures.

Details of the service tools used in the dismantling and

assembly procedures are given in Section 1, Service Tools.

1. Prepare the machine.

a. Stop the machine and release the hydraulic pressure
(See Releasing Tank Pressure).
b. Jack up the machine and insert wooden blocks
under the tracks.

2. Remove the access panel.

3. Attach identification tags to the rotary coupling hoses

for reconnection purposes. Remove the hoses and
install blind plugs and caps to prevent contamination.

4. Remove the Coupling.

Remove the lock bar (4), remove the rotary coupling
installation bolt (1).
Lift out the rotary coupling.

9803/6510 Issue 1
Section E Hydraulics Section E
53 - 4 Rotary Coupling 53 - 4

Replacement

1 Align the coupling (9) to the lower frame and tighten the
rotating joint installation bolt (1) and.

Tighten the lock bar installation bolt (1) and washer (2) to
the specified torque, 109-127 Nm (11.1-12.9 Kgf/m,
80.28-93.28 lb/ft) and install the lock bar.

2 Reconnect the hoses, and install the access cover,

remove the wooden block, lower the machine to the
ground.
Start the machine and check for leaks.

9803/6510 Issue 1
Section E Hydraulics Section E
53 - 5 Rotary Coupling 53 - 5

Dismantling (cont’d)

1. Remove the cover 19 with the bolt 17.

2. Remove the 'O'-ring 18.

Do not reuse the 'O'-ring 18.

3. Remove the thrust plate 16 with the bolt 17.

4. Using a jig push off the axle 11 from the rotor 13.
Do not hit with a hammer.

9803/6510 Issue 1
Section E Hydraulics Section E
53 - 6 Rotary Coupling 53 - 6

Dismantling (cont’d)
5. Remove the V-ring 12 from the axle 11.

Note: Do not reuse the V-ring 12.

6. Remove the 'O'-ring 14, and packing ring from the rotor
13.

Note: Do not reuse the packing ring 15.

9803/6510 Issue 1
Section E Hydraulics Section E
53 - 7 Rotary Coupling 53 - 7

Assembly
Inspect the parts for signs of wear, pitting,
scratching,discolouration etc. Polish out scratches
using a fine grade oil stone.
Before assembly, thoroughly clean all parts using a suitable
solvent: Do NOT use solvents on 'O'-rings, backup rings and
seals.
Fit new 'O'-rings, backup rings and seals.
Lubricate all 'O'-rings, backup rings and seals, with clean
hydraulic fluid before fitting.

1. a. Clean the rotor 13 with cleaning fluid or compressed

air.
b. After cleaning, check to see if there are any
scratches or roughness on the inner side of the rotor
or grooves.

2. Check the number of packing rings 15 and 'O'-rings 14.

Coat with Vaseline and install in the order below.
a. Set one packing ring in each groove starting from the
2nd groove from the top.
b. Set the 'O'-ring in the top groove.

9803/6510 Issue 1
Section E Hydraulics Section E
53 - 8 Rotary Coupling 53 - 8

Assembly (cont’d)
3. After installing the 'O'-ring, packing ring and packing,
check with a mirror to see if they are installed correctly.
After checking, coat with grease then check once more
for any protrusion, twisting, etc.

4. Install the V-ring 12 on the axle 11 and grease

adequately.
Take care to prevent contamination of the grease by
water or dirt.

5. Install the axle 11 to the rotor 13.

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

6. Install the thrust plate. 17

16

11

9803/6510 Issue 1
Section E Hydraulics Section E
53 - 9 Rotary Coupling 53 - 9

Assembly (cont’d)
7. Install the 'O'-ring.

8. Install the cover.

9803/6510 Issue 1
Section E Hydraulics Section E
55 - 1 Hydraulic Rams 55 - 1

Precautions During Use

1 Precautions when installing the ram on the machine The oil inside the ram may leak and due to the
temperature change in the hydraulic oil, the hydraulic oil
When installing and removing from the machine, volume changes. For that reason, the ram expands and
suspend the ram safely. contracts, causing unexpected movement to the
Suspending the ram by the piping is not only machine which is dangerous. Stop or store the
dangerous, but can also cause damage to the cylinder. machine in a safe and fixed position.

Secure the rod with a band. It is very dangerous if the 3 Maintenance, Inspection Points
rod should fly out unexpectedly. Also, the rod can be
damaged and become unusable. Carry out daily maintenance and inspection.
The key point for correct long-term ram function is daily
Welding after installing the ram may result in maintenance and inspection. Carry out maintenance
damage. and inspection so that the ram functions fully at all
If electric welding is done even at a point away from the times
ram, there may be sparking inside the ram and it will .
become necessary to replace the ram with a new one. Always remove any mud, water, dust or oil film adhering
to the rod and keep it in normal condition. However,
When painting the machine, mask the ram. when cleaning the wiper ring and seals, do not get
If paint adheres to the rod surface or to the wiper ring them wet with water but wipe clean with a rag. If
and the ram is worked, the wiper ring cannot function leaving for more than one week, apply anti-rust oil to
properly and foreign matter from the outside and paint the rod surface.
can easily enter the ram and cause damage to the
seals, drastically shortening the life of the ram. Use genuine JCB parts when replacing parts.
If parts other than genuine JCB parts are used, the
Note: Install the ram only when it is clean. desired results may not be obtained. Use only genuine
JCB parts.
2 Caution During Use
Caution during disassembly and reassemble.
Use only under designated conditions. Disassembling the ram while it is still installed on the
If hydraulic oil other than the designated oil is used, the machine can be dangerous as unexpected movements
seals quickly degenerate and become damaged. If the of the machine can occur. Remove the ram from the
relief valve is set at a value higher than specified, it may machine and then disassemble.
cause ram damage and is dangerous.
If reassembled with dirty hands, foreign matter can
In high temperature environments (Approx. 90°C and enter the ram causing a shorter life span and also the
above) or low temperature environments (Below -20°C), other hydraulic equipment may be damaged.
seals quickly become damaged. Special seal materials Reassemble in a clean state.
are necessary so check to see if the ram that you are
using is suitable or not. Follow the instructions in the diagrams regarding torque
tightening for screwed parts. If the torque is too high or
The number one cause of ram oil leakage is due to rod too low, it can cause damage.
damage. Be careful not to damage the rod.

Warm up sufficiently before beginning work.

In cold conditions the rod seals may be frozen so if the
ram is operated at maximum pressure and maximum
speed, the seals will be damaged.

There is a large amount of air in a new ram or one

which has been left for a long time, so the ram will not
operate smoothly. Also, if pressure is applied suddenly
without bleeding the air, high temperature will be
generated due to adiabatic compression and the seals
may burn.

Before beginning work, always move the ram at full

stroke with no load and expel air from the cylinder.

When stopping or storing, do it at a safe and fixed

position.
The installed ram cannot maintain the same position for
a long period of time.

9803/6510 Issue 1
Section E Hydraulics Section E
55 - 2 Hydraulic Rams 55 - 2

Bucket Ram

Removal
! WARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop the
engine and operate the controls to release pressure
trapped in the hoses. Make sure the engine cannot be
started while the hoses are open.
INT-3-1-11/1

! WARNING
Lifting Equipment
You can be injured if you use faulty lifting equipment.
Make sure that lifting equipment is in good condition.
Make sure that lifting tackle complies with all local
regulations and is suitable for the job. Make sure that
lifting equipment is strong enough for the job.
INT-1-3-7

1 Prepare the Machine, and lower the attachment to the

ground.

A296590

2 Place a wooden block under the bucket ram.

3 Stop the engine, remove the key.

Release the Tank pressure, see Releasing the Tank Cap nut of breather
Pressure.

9803/6510 Issue 1
Section E Hydraulics Section E
55 - 3 Hydraulic Rams 55 - 3

Bucket Ram (cont’d)

Removal (cont’d)

4 Remove nuts and bolts.

5 Push the pin out using a bar and hammer.

6 Restrain the eye end of the bucket ram rod to the ram
cylinder to prevent the ram rod from extending.

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

to prevent contamination.

9803/6510 Issue 1
Section E Hydraulics Section E
55 - 4 Hydraulic Rams 55 - 4

Bucket Ram (cont’d)

Removal (cont’d)

8 Attach a sling and lift the bucket ram.

9 Remove the nuts and bolts. Push out the pin using a bar
and hammer.

Installation

1 Attach a sling to the bucket ram and lift it into the

dipper.

2 Install the pin, bolt and nuts.

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

3mm A409820

9803/6510 Issue 1
Section E Hydraulics Section E
55 - 5 Hydraulic Rams 55 - 5

Bucket Ram (cont’d)

Installation (cont’d)

3 Connect the hose to the bucket ram.

4 Hoist the bucket ram to align with the link.

5 Install the pin, bolt and nuts.

Note: Stroke the ram to release entrapped air. After releasing

the air, check for oil leakage

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

3mm A409820

9803/6510 Issue 1
Section E Hydraulics Section E
55 - 6 Hydraulic Rams 55 - 6

Dipper Ram
Removal
! WARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop the
engine and operate the controls to release pressure
trapped in the hoses. Make sure the engine cannot be
started while the hoses are open.
INT-3-1-11/1

! WARNING
Lifting Equipment
You can be injured if you use faulty lifting equipment.
Make sure that lifting equipment is in good condition.
Make sure that lifting tackle complies with all local
regulations and is suitable for the job. Make sure that
lifting equipment is strong enough for the job.
INT-1-3-7

1 Prepare the Machine, and lower the attachment to the

ground.

A296590

2 Place a wooden block under the dipper ram.

3 Stop the engine, remove the key.

Release the Tank Pressure (see Releasing Tank

Pressure).

9803/6510 Issue 1
Section E Hydraulics Section E
55 - 7 Hydraulic Rams 55 - 7

Dipper Ram (cont’d)

Removal (cont’d)

4 Remove the nuts and bolts.

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

6 Restrain the eye end of the Dipper ram rod to the ram
cylinder to prevent the rod from extending.

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

to prevent contamination.

9803/6510 Issue 1
Section E Hydraulics Section E
55 - 8 Hydraulic Rams 55 - 8

Dipper Ram (cont’d)

Removal (cont’d)

8 Remove the grease tube, from the Dipper ram.

9 Attach a sling and lift the Dipper ram.

10 Remove the nuts and bolts, push out the pin using a bar
and hammer. Lift the ram from the boom.

Installation

1 Attach a sling and lift the Dipper ram onto the boom.

9803/6510 Issue 1
Section E Hydraulics Section E
55 - 9 Hydraulic Rams 55 - 9

Dipper Ram (cont’d)

Installation (cont’d)

2 Install the pin, bolts and nuts.

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

3mm A409820

3 Install the grease tube to the Dipper ram.

4 Connect the hoses to the Dipper ram.

5 Hoist the Dipper ram to align the ram eye end with the
dipper pin position.

9803/6510 Issue 1
Section E Hydraulics Section E
55 - 10 Hydraulic Rams 55 - 10

Dipper Ram (cont’d)

Installation (cont’d)

6 Install the pin, bolt and nuts.

Note: Stroke the ram to release entrapped air. After releasing

the air, check for oil leakage.
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

3mm A409820

9803/6510 Issue 1
Section E Hydraulics Section E
55 - 11 Hydraulic Rams 55 - 11

Boom Ram
Removal
! WARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop the
engine and operate the controls to release pressure
trapped in the hoses. Make sure the engine cannot be
started while the hoses are open.
INT-3-1-11/1
! WARNING
Lifting Equipment
You can be injured if you use faulty lifting equipment.
Make sure that lifting equipment is in good condition.
Make sure that lifting tackle complies with all local
regulations and is suitable for the job. Make sure that
lifting equipment is strong enough for the job.
INT-1-3-7

1 Prepare the Machine, and lower the attachment to the

ground.

Stop the engine, remove the key.

A296590

2 Remove the greasing tube.

3 Attach a sling for lifting the boom ram.

9803/6510 Issue 1
Section E Hydraulics Section E
55 - 12 Hydraulic Rams 55 - 12

Boom Ram (cont’d)

Removal (cont’d)

4 a Remove the nuts, bolt and collar.

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

5 Lower the Boom ram and place it on a stand.

6 Restrain the eye end of the Boom ram rod to the ram
cylinder, to prevent movement of the rod.

7 Release the Tank Pressure (see Releasing Tank

Pressure).

9803/6510 Issue 1
Section E Hydraulics Section E
55 - 13 Hydraulic Rams 55 - 13

Boom Ram (cont’d)

Removal (cont’d)

8 Remove the boom ram hoses, and install plugs or caps

to prevent contamination.

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

10 Lift the boom ram away from the unit.

Installation

1 Attach a sling to lift the boom ram.

Align the main frame to the installation position.

9803/6510 Issue 1
Section E Hydraulics Section E
55 - 14 Hydraulic Rams 55 - 14

Boom Ram (cont’d)

Installation (cont’d)

2 Install the pin and then the bolt and nuts.

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

3mm A409820

3 Install the hoses to the boom ram.

4 Lift the boom ram and align the rod eye end with boom
pin position.

5 Install the pin with a bar and hammer.

9803/6510 Issue 1
Section E Hydraulics Section E
55 - 15 Hydraulic Rams 55 - 15

Boom Ram (cont’d)

Installation (cont’d)

6 Install the collar and then the bolt and nuts.

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

3mm A409820

7 Connect the greasing tube.

Note: Stroke the ram and release entrapped air. After

releasing the air, check for oil leakage.

9803/6510 Issue 1
Section E Hydraulics Section E
56 - 1 Hydraulic Rams 56 - 1

Dismantling the Piston Rod from the Cylinder

Tube

Necessary equipment
Assembly bench
Overhead crane
Cleaning facilities
Socket wrench Fig. 1
Note: Disassembly should be done vertically.

1 Clean the cylinder carefully. Use high-pressure cleaning

and solvent (Fig. 1). Empty the oil from the cylinder.

2 Unfasten the cylinder head screws. Keep screws in

place (Fig. 2).

3 Position the cylinder vertically (Fig. 3).

4 Release the end cover and pull out the piston rod pack.

Note: Handle the piston rod with care to avoid damage. Put
some soft material between piston rod and shims during Fig. 2
transport and at storage. Fasten the covers for the end
flange.

Fig. 3

9803/6510 Issue 1
Section E Hydraulics Section E
56 - 2 Hydraulic Rams 56 - 2

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 (Fig. 4).

Fig. 4

2 Unfasten and remove the stop screw X. Remove the X

steel ball Y (Fig. 5).
Y

Fig. 5
3 Unfasten the nut (Fig. 6).

Fig. 6

4 Dismantle the snap ring (Fig 7).

Fig. 7
5 Press the cushion ring against the piston (Fig. 8).

Fig. 8

9803/6510 Issue 1
Section E Hydraulics Section E
56 - 3 Hydraulic Rams 56 - 3

Dismantling the Piston Rod (cont’d)

6 Dismantle the lock halves (Fig. 9).

Fig. 9

7 Remove the cushion ring (Fig. 10).

Fig. 10

8 Remove the seal (Fig. 11).

Fig. 11

9 Remove the shims A, the piston B, the cushion ring C

and disassemble the cushion ring seal D (Fig.12). C D B A

Fig. 12

10 Dismantle the cylinder head (Fig 13).

Note: Protect the threads.

Fig. 13

9803/6510 Issue 1
Section E Hydraulics Section E
56 - 4 Hydraulic Rams 56 - 4

Dismantling the Piston Rod (cont’d)

Note: Never reuse seals.

While dismantling, handle the piston very carefully.

1 Remove the four slotted guiding rings and the two back
up rings from the piston (Fig. 14).
Fig. 14

2 Turn the sharp edge of the scalpel against the slide ring
and press it down into the small gap between piston and
slide ring (Fig. 15). Lift the O-ring with a chisel and cut it
off.
Note: Take care not to damage the surface.

Fig. 15

Removing the Cylinder Head Seals

1 The cylinder head wiper is disassembled by deforming it
with a hammer and chisel according to (Fig. 16).

Fig. 16

2 Press a sharp object into the back up ring (Pos. 1) at its

slit, bend out and pull away the back up ring with pliers
(Fig. 17).
1

Fig. 17

3 The secondary seal (Pos. 2) is removed using a chisel.

Put the chisel into the small gap where the back up ring
was earlier, bend out (Fig. 18).
Note: Do not put the chisel in too far, the surfaces of the 2
head are galvanised.

Fig. 18

4 Cut the primary seal with a scalpel (Fig. 19). After that,
the chisel may be used to remove the back up ring.
Note: Do not cut through, the surfaces of the cylinder head
are easily damaged.

Fig. 19

9803/6510 Issue 1
Section E Hydraulics Section E
56 - 5 Hydraulic Rams 56 - 5

Removing the Cylinder Head Seals

(cont’d)
5 Remove the O-ring using a sharp tool. Press the tool
through the square ring and bend out (Fig. 20).

3
Fig. 20

6 Turn the cylinder head and remove the snap ring with a
chisel (Fig. 21).

Fig. 21

7 Remove the O-ring and back up ring for the external

seal. Use a chisel (Fig. 22).

Fig. 22

9803/6510 Issue 1
Section E Hydraulics Section E
56 - 6 Hydraulic Rams 56 - 6

Removing the Cylinder Head Seals (cont’d)

D C A B

Fig. 23

8 To remove the bush in the cylinder head, an expander

tool is required. Fit the expander tool A in the cylinder
head B according to Fig. 23. Please note the direction!
Press the tool in far enough, so that the rifled part is
opposite the bush.
Assemble the guide jig C and the screw D.
Extend the flutes in the expander tool using the Allen
key.
9 Put the cylinder head on the press rod (Fig. 24). Press
out the expander tool which will then remove the bush.

Fig. 24

9803/6510 Issue 1
Section E Hydraulics Section E
56 - 7 Hydraulic Rams 56 -7

Assembly of Piston Seals

Before assembly

1 To assemble the piston seals use a seal insertion tool.

Make sure the tool is free from defects. Burrs or marks
may damage the seals and cause leakage. Check the
outside of the tool carefully.
One part of the seal insertion tool is thin-walled, make
sure it is not damaged (Fig. 1).

Fig. 1

2 Carefully place seal insertion tool on the piston and roll

on the O-ring until it is placed in the middle groove of
the piston.
Make sure the O-ring is not twisted after assembly (Fig.
2)

Fig. 2

3 Assembly of slide ring

Set up according to Fig. 3.

A Plate A
B Outer guide jig
C Slide ring.
D Inner guide jig,(heated to approximately 60ºC,
140 ºF).
E Piston.
B

D
E

Fig. 3

9803/6510 Issue 1
Section E Hydraulics Section E
56 - 8 Hydraulic Rams 56 -8

Assembling the Piston Seals (cont’d)

4 Pressing of slide ring
Use the press to press the slide ring down into the
middle groove of the piston (where the O-ring already
is). During pressing, the outer guide jig must be held
together with one hand (Fig. 4). The slide ring will open
out at this stage.

Fig. 4
5 Assembling the back up rings.
Attach the green back up rings, make sure that their slits
are not aligned (Fig. 5).

Fig. 5
6 Use the correction jig to calibrate the seals. Please note
the direction of the jig! (Fig. 6)

Fig. 6

7 Check the piston seal.

Press the piston through the correction jig (Fig. 7).

Fig. 7

9803/6510 Issue 1
Section E Hydraulics Section E
56 - 9 Hydraulic Rams 56 -9

Assembling the Piston Seals (cont’d)

8 Fit slotted guiding rings.

Note: Guiding ring slits must not be aligned! (Fig. 8).

Fig. 8

Assembling the Cylinder Head Seals

Before assembly
Check that assembly tools are free from defect. Clean
tools before starting the set. Pre-heat the U-ring to
approximately. 60ºC (140ºF). Clean cylinder head before
assembly. Check that grooves are clean and not
damaged.
1 Fitting of bushing and snap ring.
Set up according to Fig. 9. Press in the bush using the
press rod. Attach snap ring.

Fig. 9
2 Fit O-ring and back up ring (Fig. 10).

Fig. 10
3 Fitting of primary seal and U-ring.(Fig 11)
Turn the head to get the wiper end up and clean. Attach
the Buffer ring.

Fig. 11

9803/6510 Issue 1
Section E Hydraulics Section E
56 - 10 Hydraulic Rams 56 -10

Assembling the Cylinder Head Seals

(cont’d)

Bend the slide ring to a loose curve before fitting,

(Fig.12). Please note the right direction! Soft transition
No breaking
Fit back up ring after putting the slide ring in place.
4 Attach the back up ring first.
Bend the U-ring according to Fig. 12.

Fig. 12

BACK
BACKUP
UPRING
RING

Insert the U-ring under the back up ring.

U-RING
U-RING
Fig. 13

5 Fitting of wiper.
Plate for
Use the plate to press in the wiper (Fig. 14).
mounting
wiper

WIPER

Fig. 14

6 Complete pre-assembled head (Fig. 15).

A Wiper
B Back-up ring A
C Secondary seal
D Buffer ring
E Bushing
B
F Snap ring C
G Back-up ring
H O-Ring D

G
H

Fig. 15 A373531

9803/6510 Issue 1
Section E Hydraulics Section E
56 - 11 Hydraulic Rams 56 -11

Assembly of Piston Rod with Cushion Ring

on the Piston Rod Side
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.

3 6
1 4

Fig. 16

Piston rod (Fig.16)

Fig. 17

Fig. 18

9803/6510 Issue 1
Section E Hydraulics Section E
56 - 12 Hydraulic Rams 56 -12

Assembly of the Piston Rod with Cushion

Ring on the Piston Rod Side (cont’d) 1
1 Fit the cylinder head on (Fig. 19).

Fig. 19

2 Fit the seal under the cushion ring (Fig. 20).

Please note the direction!

Fig. 20

3 Put the cushion ring on (Fig. 21).

Please note the direction! Turn the arrow point towards
the piston.

Fig. 21

4 Put the piston on. Please note the direction! (Fig. 22).

Fig. 22

5 Fit shims (reduction of friction) (Fig. 23).

Fig. 23

9803/6510 Issue 1
Section E Hydraulics Section E
56 - 13 Hydraulic Rams 56 -13

Assembly of the Piston Rod with Cushion

Ring on the Piston Rod Side (cont’d)

6 Assemble and tighten the nut A to torque value

according (Fig. 24).

Ram Torque
Boom non HBCV 3770 Nm (2780 lbf ft) (384 kgf m)
Bucket 4310 Nm (3178 lbf ft) (439 kgf m)
Arm 7090 Nm (5229 lbf ft) (723 kgf m)
Boom with HBCV 3770 Nm (2780 lbf ft) (384 kgf m)

7 Fit the steel ball B.

8 Fit the stop screw E Tighten to 46.9 to 66.9 Nm (34.6 to

49.3 lbf ft) (4.8 to 6.8 kgf m).

Make two punch marks by the stop screw so that the

material is clearly indented.

A
E
B

9803/6510 Issue 1
Section E Hydraulics Section E
56 - 14 Hydraulic Rams 56 -14

Assembly of Piston Rod with Cushion Ring

on the Piston Rod and Cylinder Bottom
Side
Cylinder components must be cleaned before assembly.
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.

Fully assembled piston rod

7 6

8
9

5 10 11 12

Turn the notch

and arrows
towards the
piston

Turn the notch and arrows

towards the piston

1 3 4
Fig. 28 A409130

Piston rod (Fig.29)

Fig. 29

Put the guide jig on 683035 (Fig. 30)

Fig. 30

9803/6510 Issue 1
Section E Hydraulics Section E
56 - 15 Hydraulic Rams 56 -15

Assembly of Piston Rod with Cushion Ring

on the Piston Rod and Cylinder Bottom
Side (cont’d) 1

1 Put the cylinder head on (Fig. 31).

Fig. 31

2 Fit the seal for the front cushion ring (Fig. 32).
2
Please note the direction!

Fig. 32

3 Put the front cushion ring on. Please note the direction!
Warning! Turn arrow point towards the piston (Fig. 33)
3

Fig. 33

4 Fit the piston (Fig. 34). Please note the direction!

4

Fig. 34

5 Fit shims (Fig. 35).

5

Fig. 35
6 Fit the seal for the rear cushion ring (Fig. 36).
Please note the direction!
6

Fig. 36

9803/6510 Issue 1
Section E Hydraulics Section E
56 - 16 Hydraulic Rams 56 -16

Assembly of Piston Rod with Cushion Ring

on the Piston Rod and Cylinder Bottom
Side

7 Fit the rear cushion ring. Please note the direction! (Fig.
37)
Note: Turn arrow point towards the piston

Fig. 37

8 Press in the rear cushion ring as far as possible (Fig. 38).

Fig. 38

Assemble the two lock halves and hold them with your
fingers. Use the other hand to put the rear cushion ring
over the two halves (Fig. 39).

Fig. 39

The rear cushion ring keeps the lock halves in place (Fig.
40).

Fig. 40

9 Carefully knock the snap ring in place.

Use a plastic hammer (Fig. 41).

Fig. 41

10 Fit and tighten the nut to stated torque value as follows:

(Fig. 42).
Note: Do not use oil!
Ram Torque
Boom 3770 Nm (2780 lbf ft) (384 kgf m)
(non HBCV)
Bucket 4310 Nm (3178 lbf ft) (439 kgf m)
Dipper 7090 Nm (5229 lbf ft) (723 kgf m) Fig. 42
Boom 3770 Nm (2780 lbf ft) (384 kgf m)
(with HBCV)

9803/6510 Issue 1
Section E Hydraulics Section E
56 - 17 Hydraulic Rams 56 -17

Assembly of Piston Rod with Cushion Ring

on the Piston Rod and Cylinder Bottom
Side

11 Fit the steel ball (Fig. 43).

Fig. 43

12 Fit stop screw (Fig. 44). Tighten the screw to 46.9 to

66.9 Nm (34.6 to 49.3 lbf ft) (4.8 to 6.8 kgf m).
Make two punch marks on each side of the stop screw
so that the material is clearly bent

Fig. 44

Assembly of Piston Rod in the Cylinder

Tube
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 (Fig. 45) and bring the end of
the piston rod to the cylinder tube opening.

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.

Fig. 45
2 Before assembly, make sure that guiding slits on the
piston are not aligned (Fig. 46).

Fig. 46

9803/6510 Issue 1
Section E Hydraulics Section E
56 - 18 Hydraulic Rams 56 -18

Assembly of Piston Rod in the Cylinder

Tube (cont’d)
3 Put the piston rod pack into the cylinder tube. Make
sure that the piston guiding ring does not get jammed
during assembly.

Clean hydraulic oil will help, but do not use a brush as

hairs may come off.

When running the piston rod in, turn the cylinder head
into the right position. Finish doing this before the
cylinder head O-ring has reached the cylinder tube (Fig.
47). Do not use assembly grease.

Fasten the cover.

Fasten cylinder head screws and torque tighten to the

following values:

Ram Torque

Boom (non HBCV) 267 Nm (197 lbf ft) (27.2 kgf m)

Bucket 171 Nm(126 lbf ft) (17.4 kgf m)

Arm 267 Nm (197 lbf ft) (27.2 kgf m)

Boom (with HBCV) 267 Nm (197 lbf ft) (27.2 kgf m)

Fig. 47

4 Tighten in order according to Fig. 48.

Note: Be careful not to damage the piston rod!

Fig. 48

9803/6510 Issue 1
Section E Hydraulics Section E
60 - 1 Hydraulic Rams 60 - 1

Ram Piston Head Nut

JS00980

9803/6510 Issue 1
Section E Hydraulics Section E
60 - 2 Hydraulic Rams 60 - 2

Ram Piston Head Nut (cont’d)

Due to the high piston nut tightening torques used on the Nut Fitting
rams, it is necessary to use a special rig (see opposite) for
ram piston head nut fitting and removal (see Service Tools) Before assembly ensure that all components have been
thoroughly cleaned and all new seals, backing rings and ‘O’-
As shown in illustrations A and B, the rig uses a modified lift rings are available. Smear all seals, etc. with hydraulic fluid.
ram C acting on a heavy-duty ring spanner D to loosen or
tighten the piston nut. Hydraulic power to operate the rig 1 Assemble the piston rod components as detailed earlier
may be obtained from a suitable hydraulic power pack for individual rams.
(maximum pressure required 150 bar (2175 lb/in2) or from
the auxiliary circuit of a JCB machine equipped with quick- 2 Install the piston rod assembly in the nut removal/fitting
release couplings. In either case, small bore hoses E (Part rig with the piston rod supported by block J.
No. 892/00137 - 2 off) must be used to connect the rig to
the power source to limit the speed of operation of ram C. In 3 Secure the eye end of the piston rod to the rig at
addition F, test point (Part No. 892/00262) and pressure position G, using a suitable pivot pin.
gauge (Part No. 892/00279) should be fitted in the line to the
piston side of the ram C to measure the tightening pressure 4 Fit a ring spanner to the piston nut and connect it to the
being applied. eye end of ram C at position K.

See the Nut Fitting table for details of the pressure 5 Using the rig, tighten the piston head nut H to the
necessary to achieve the required tightening torques. torque specified for individual rams by powering the
ram slowly downwards. The torque being applied is
Nut Removal indicated by gauge F (see table )

It is assumed that the ram has been removed from the 6 Remove the piston rod assembly from the rig and insert
machine, hydraulic piping removed and the piston rod into the ram cylinder as detailed earlier for individual
assembly separated from the cylinder. rams.

Note: Before using the nut removal/fitting rig, operate the rig
cylinder over its full range for 5 or 6 strokes to remove all air
from the cylinder.

1 Install the piston rod assembly in the

dismantling/assembly rig with the piston rod supported
by block J.

2 Secure the eye end of the piston rod to the rig at

position G, using a suitable pivot pin.

3 Fit a ring spanner to the piston nut and connect it to the

eye end of ram C at position H.

4 Power the ram slowly downwards, noting the pressure

at which the piston nut first moves on the piston rod.
(The pressure should be 1.0 to 1.5 times the tightening
pressure for the particular size).

5 Remove the piston nut.

6 Remove the piston rod assembly from the rig and then
proceed with dismantling as detailed earlier for
individual rams.

9803/6510 Issue 1
Section E Hydraulics Section E
60 - 3 Hydraulic Rams 60 - 3

Ram Piston Head Nut (cont’d)

Nut Fitting (cont’d)

Ram Location Gland Bolts Piston Nuts Piston nut Grub Screw Gauge Pressure

Nm, Ibf ft, kgf m Nm, Ibf ft, kgf m Nm, Ibf ft, kgf m Bar, Ib in2, kg cm2

Boom 268, 198, 27 5470, 4035, 558 60, 44, 6 38, 551, 39

Dipper 367, 270, 37 9560, 7051, 975 60, 44, 6 67, 972, 68

Bucket 267, 197, 27 6690, 4935, 682 60, 44, 6 47, 682, 48

Note: The gauge pressures in the above table assume that

the rig is used with spanners having 500 mm centres (see
Service Tools, Hydraulics, Ram Dismantling and
Assembly, Spanner Requirements).

9803/6510 Issue 1
Section E Hydraulics Section E
60 - 4 Hydraulic Rams 60 - 4

Reconditioning
Structure and Characteristics of Special Jigs for Repair of Rams
Inserting seal ring and correction jig.
a Jig components

Part no Part Name Qty Note

WDB 2052 Seal ring inserting and correction jig set 1
Inner Guide (1)
Outer Guide (1)
Plate (1)
Collection (1)

Note: For the above Part No. the tube diameter is 120 mm.

b Special characteristics

Because the seal ring is hard, it requires a lot of time to insert it without a special jig. By using the special jig, anyone can
insert the seal ring on the piston quickly, easily and accurately without damaging the seal ring.

Bushing removal jig

a Jig components

Part no Part Name Qty Note

WDB 2166 Jig set for pulling out bushing 1 Also to be used for press-fitting bushing
Chuck assembly 1
WDB 2166-1 Retainer 1 Also to be used for press-fitting wiper ring
Block 1 Prepare locally
Lever 1 Prepare locally
Allen wrench 1

Note: For the above Part No. the tube diameter is 120 mm.

b Special characteristics

Because the bushing is press-fitted by the hydraulic press at the central part of the cylinder head, it requires a lot of time
and work in order to remove the bushing from the cylinder head quickly, easily and accurately without damaging the
inside of the cylinder head.

9803/6510 Issue 1
Section E Hydraulics Section E
60 - 5 Hydraulic Rams 60 - 5

Reconditioning (cont’d)
Structure and Characteristics of Special Jigs for Repair of Rams (cont’d)
Bushing press-fitting jig
a Jig components

Part no Part Name Qty Note

WDB 2166 Bushing press-fitting jig set 1 Also to be used for removing bushing
Chuck assembly 1
WDB 2166-1 Retainer 1 Also to be used for press-fitting wiper ring

Note: The above Part No. indicates those for rod diameter 80 mm.

b Special characteristics

If this special jig is used, anyone can press-fit the bushing into cylinder head quickly, easily and accurately without
damaging the cylinder head.

Wiper ring press-fitting jig

a Jig components

Part no Part Name Qty Note

WDB 2166-1 Jig for press-fitting wiper ring 1 Also to be used for removing bushing
(Retainer)

Note: The above Part No. indicates those for rod diameter 80 mm.

b Special characteristics

By using this special jig, anyone can press-fit the wiper ring easily, quickly and accurately into the specified groove of the
cylinder head evenly without deforming or damaging it.

Cylinder head insertion guide jig

a Jig components

Part no Part Name Qty Note

WDB 2174 Cylinder head insertion guide jig 1

Note: The above Part No. indicates those for rod diameter 80 mm.

b Special characteristics

By using this special jig, anyone can slide the cylinder head assembly onto the piston rod quickly, easily and accurately
without damaging any of the seals.

9803/6510 Issue 1
Section E Hydraulics Section E
60 - 6 Hydraulic Rams 60 - 6

Reconditioning (cont’d)
Jig Table

For inserting and correcting seal ring

Cylinder inner diameter Unit: mm
80 90 95 100 105 110 115 120 125 130 135 140 150 160
Boom O
Dipper O
Bucket O
WDB 2163

WDB 2049

WDB 2120

WDB 2050

WDB 2051

WDB 2052

WDB 2054

WDB 2164

WDB 2055

WDB 2056

WDB 2057
WSB 2162

Jig No.

For pulling out and press-fitting bushing

Piston rod diameter Unit: mm

50 55 60 65 70 75 80 85 90 95 100 105 110
Boom O
Dipper O
Bucket O
WDB 2165

WDB 2166

WDB 2167

WDB 2168

WDB 2169

WDB 2170

WDB 2171

WDB 2172

Jig No.

9803/6510 Issue 1
Section E Hydraulics Section E
60 - 7 Hydraulic Rams 60 - 7

Reconditioning (cont’d)
For press-fitting wiper ring (Can be used for pulling out and press-fitting bushing)
Note: The mark O in the table below indicates KCH type.

Piston rod diameter Unit: mm

50 55 60 65 70 75 80 85 90 95 100 105 110
Boom O
Dipper O
Bucket O

WDB 2165-1

WDB 2166-1

WDB 2167-1

WDB 2168-1

WDB 2169-1

WDB 2170-1

WDB 2171-1

WDB 2172-1
Jig No.

Jig for inserting cylinder head

Piston rod diameter Unit: mm

50 55 60 65 70 75 80 85 90 95 100 105 110
Boom O
Dipper O
Bucket O
WDB 2173

WDB 2174

WDB 2175

WDB 2176

WDB 2177

WDB 2178

WDB 2179

WDB 2180
Jig No.

9803/6510 Issue 1
Section E Hydraulics Section E
60 - 8 Hydraulic Rams 60 - 8

Reconditioning (cont’d)
Jig Usage
Note: The special jigs are different, according to the cylinder diameter, so choose the appropriate jig from the table. The lower
part of the inner guide jig is very thin, so be careful with handling and storage.
Procedures for inserting, correcting the seal ring.

1 O-ring installation Stretch the 'O'-ring by hand and fit it into the piston
groove.

Be sure not to twist the 'O'-ring. A twisted 'O'-ring may

cause oil leakage.

2 Attaching the inner guide jig Fit the inner guide jig on the upper section of the piston.

Carefully fit the thinner end of the inner-guide jig on the

upper section of the piston.

3 Seal ring installation Apply a thin coat of lubricant to the inner guide jig
periphery and then set the seal ring on the inner guide jig.

Make sure that any foreign matter like dust, chipped

metal and lint do not adhere to the outer surface of the
inner guide jig.

9803/6510 Issue 1
Section E Hydraulics Section E
60 - 9 Hydraulic Rams 60 - 9

Reconditioning (cont’d)
Jig Usage (cont’d)

4 Outer guide jig fitting Put the plate on the outer guide jig and then continue to
push the plate by hand until the seal ring touches the
outer guide jig.

Be sure to set the seal ring straight on the inner guide jig.

5 Press-fitting Continue to press the plate on the outer guide jig by

hydraulic press until the seal ring fits into the groove.

Be sure to press the plate carefully so that the seal ring

will fit straight on the inner guide jig and into the groove.

Finish this work quickly.

6 Removal of jig After confirming that the seal ring is completely fitted into
the piston groove, remove the jigs in the following order.

1 Remove the press rod.

2 Remove the plate.
3 Remove the outer guide jig.
4 Remove the inner guide jig.
The fitting of the seal ring is completed at this stage.
Next, correct the fitting of the seal ring using the
correction jig.

9803/6510 Issue 1
Section E Hydraulics Section E
60 - 10 Hydraulic Rams 60 - 10

Reconditioning (cont’d)
Jig Usage (cont’d)

7 Correction jig preparation Set the correction jig underneath the press.

Apply a thin coat of lubricant to the tapered section of the

correction jig and place the jig with the tapered section
facing up.

Be careful that no dust, chipped metal and lint adheres to

the jig.

8 Inserting the piston Slowly insert the piston, with the seal ring fitted, into the
correction jig.

Insert the piston evenly inside the correction jig.

9 Press fit Press the piston slowly using a press rod, which is
smaller in diameter than the piston, so that the seal
ring may fit properly in a groove.

Note: Stop pressing temporarily for three to five

seconds when the piston reaches the point of
correction and then re-press the piston to the end.

9803/6510 Issue 1
Section E Hydraulics Section E
60 - 11 Hydraulic Rams 60 - 11

Reconditioning (cont’d)
Jig Usage (cont’d)

10 Removal of correction jig After completion of the correction of the seal ring, remove
the jig in the following order.

1 Remove the press rod.

2 Remove the correction jig.
This completes the fitting and correction of the seal ring.

9803/6510 Issue 1
Section E Hydraulics Section E
60 - 12 Hydraulic Rams 60 - 12

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

Annually
Monthly
Inspection, Inspection,

Daily
Maintenance Point Maintenance Contents Note

Is the ram kept clean (especially the rod sliding part)? O

Appearance Is there oil leakage from piping installation and fixing points? O
Is there any peeling paint, separation or rust? O

Are the movements smooth and are there any abnormal sounds? O
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 normal? O

Is the hydraulic oil dirty or deteriorated? O

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

Is the pin greasing sufficient? O

Is there any abnormal sound at the pins or seizure? 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

When the rod

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

Are the bolts, nuts loose? O

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

9803/6510 Issue 1
Section E Hydraulics Section E
60 - 13 Hydraulic Rams 60 - 13

Maintenance Specifications (cont’d)

Use Limit
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

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

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

9803/6510 Issue 1
Section F Transmission Section F
i i

Contents Page No.

Service Tools 1-1

Technical Data 2-1

Basic System Operation

Travel Motor Operation
- Middle Speed 5-1
- Slow Speed 5-1
- Creep 5-1
- High Speed 5-3

Fault Finding 15 -1

Track Motor
Removal and Replacement 20 - 1
Dismantling and Assembly 20 - 9

9803/6510 Issue 1
Section F Transmission Section F
1-1 Service Tools 1-1

Service Tools
SECTION F - Transmission

Track Gearbox Jig

SST0037 Re-sealing Tool
(All dimensions are in mm.)

ø315
ø270

21
24

ø304

14
SST0037 ø306

Stopper for the assembly of

Hydraulic motor on track
gearbox A409010

9803/6510 Issue 1
Section F Transmission Section F
1-2 Service Tools 1-2

Service Tools (cont’d)

SECTION F - Transmission (cont’d)

Track Gearbox Jig

SST0040 Ring Nut Tool
(All dimensions are in mm.)

38.1sq
1x45°

30
ø9.7

90
M4x4 no.4 screw

ø9.5 no.4 dowel

30
11

SST0040 1.5x45°
8

ø233.5
ø248

ø265

9803/6510 Issue 1
Section F Transmission Section F
2-1 Technical Data 2-1

Travel Equipment

Type Fixed Displacement Piston Motor (automatic 2-speed change)

Motor Displacement 153-4 cc/rev
Working Pressure 343 bar, 4975 lb/in2
Working Flow 214 litre/min (47 UK gal)
Reduction Gears
Deceleration Ratio 49.5
Parking Brake
Brake Torque-static 47 kN/m including reduction gear
dynamic 3773 kgf/m (37 kN/m) including reduction gear
Brake Pressure Release >14 bar, 203 lb/in2
Brake Valve Pressure Relief 353 bar, 5119 lb/in2 at 40 litre/min (8.8 UK gal)
Dry Weight 270 kg (595 lb)

9803/6510 Issue 1
Section F Transmission Section F
5-1 Basic Operation 5-1

Travel Motor Operation (Middle Speed) Slow Speed Travel (Creep)

Note: Second stage MRV is not selected during travel on When slow travel speed is selected the electronic control
this machine. unit (ECU1) controller sends a signal to the max flow cut
solenoid CT7 on the 8-spool solenoid block. This then
Oil from the valve block enters the motor at either P1 or P2. allows servo pressure to the ports Pm1 and Pm2 of the main
In this case the oil enters at P2. hydraulic pump (See pump operation) and reduces the
pump flow to the drive motors.
Pressure entering the motor crosses the counterbalance The drive motors work in exactly the same way as in middle
spool 1 and directed to the travel motor and the auxiliary speed travel. Only the pump flow is reduced to achieve
relief valve (ARV) ports. At this point the motor cannot move slow-speed travel.
as the brakes B are applied.

The pressure also travels to the end of the counterbalance

via:

1 The restricter which restricts the flow to the spool

2 The check valve which will allow full flow to the spool
end. This is the normal path for the oil to take.

The counterbalance spool 1 is selected at 6 - 13bar (87- 188

lb in2) which in turns diverts the flow of oil to the Travel motor
in 2 directions:

1 Oil can flow over the spool and direct to the motor.
This is also available to the motor ARV and the 2 speed
travel spool that is in the neutral position. Once the
brake is lifted the motor will start to turn.

2 Also diverted to the travel motor brake via a restrictor.

Once the pressure in the brake rises to 14bar (203lb in2) the
brake is released. This flow of oil also crosses the brake
piston and is available at the end of the two speed travel
spool and along with the assistance of a spring, holds the
two speed spool in the low speed position. With the two
speed spool in this position the swash plate angle piston
head is vented to the tank port and the motor stays on
maximum displacement. (Low speed).

Once the pressure rises to 353 bar (5118.5 lb in2) the motor’s
ARVs will open and allow excess pressure to be exhausted
to the return side. The ARV's are of the shockless type to
reduce harsh starting and stopping. When travel is de-
selected by the driver the P2 port loses pressure. Pressure is
also lost to the end of the counterbalance spool 1 which is
cushioned to reduce the shock when stopping. The
cushioning is achieved by the check valve trapping the
pressure at the spool end and only allows it to vent through
the restrictor, allowing the counterbalance spool to return
slowly. Returning oil from the motor is slowly blocked in its
path to tank and as the back pressure rises, braking occurs.

Once the counterbalance spool is in the neutral position any

additional pressure within the motor due to inertia (motor
pumping function) above 353bar (5118.5 lb in2) is relieved
through the ARV and is fed back to the opposite side to
prevent cavitation. The pressure in the brake piston is also
released slowly due the restrictor in the brake line restricting
the flow, so the brake remains off initially to allow the motor
to stop by hydraulic breaking, to protect the brakes
components from damage.

9803/6510 Issue 1
Section F Transmission Section F
5-2 Basic Operation 5-2

Travel Motor Operation (Middle Speed) (cont’d)

Key to Oil Flow & Pressure

Full Pressure
Pressure
Servo
Neutral
Exhaust
Cavitation
Lock Up

P a1 PS

T1

P1
RED

P2

1
P a2

A406360

9803/6510 Issue 1
Section F Transmission Section F
5-3 Basic Operation 5-3

Travel Motor Operation (High Speed)

Key to Oil Flow & Pressure

Full Pressure
Pressure
Servo
Neutral
Exhaust
Cavitation
Lock Up

P a1 PS

2
T1

P1
RED

P2

B B

1
P a2

A406340

9803/6510 Issue 1
Section F Transmission Section F
5-4 Basic Operation 5-4

Travel motor operation (High speed)

(cont’d)
When high-speed travel is selected, the electronic control
unit (ECU1) controller sends a signal to solenoid CT1 on the
8-spool solenoid block. The solenoid energises, allowing
servo pressure to cross the solenoid and sends a signal to
port Ps of the drive motor, which moves the two speed travel
spool 2 to the high-speed position. Pressure that is available
to the drive motor now crosses the two speed spool and
acts on the swash plate piston to move the motor to
minimum displacement (High speed).

The pressure in the system is also seen at the opposite side

of two speed spool 2 via the brake piston and acts against
the servo pressure. Due to the larger surface area that the
servo pressure acts against, the servo pressure can hold the
two speed spool in the high-speed position until the system
pressure rises to 258bar (3741 lb in2). (This is based on the
servo pressure being 39bar (565.5 lb in2)). At this point the
system pressure can overcome the servo pressure and
moves the two speed spool 2 back into the low speed
position. This releases the pressure acting on the swash
plate piston and allows the swash plate to return to
maximum displacement to increase the torque of the motor.

If the system pressure then falls back below 258 bar (3741 lb
in2)the servo pressure can overcome the system pressure
and move the 2-speed spool back into the high-speed
position.

9803/6510 Issue 1
Section F Transmission Section F
15 - 1 Fault Finding 15 - 1

Under Normal operating conditions, no routine maintenance

is required, except routine oil checks and oil changes.

Unusual operating characteristics, such as noise or over-

heating, should indicate further investigation.

For correct maintenance of the gear box, the following

checks and actions are required:

Inspection Frequency Action

Tightening of bolts After first 50 hours of operation Check torque of bolts
Oil Level Every 100 hours of operation Refill oil if necessary
First Oil Change At 150 hours of operation Drain and Replace Oil
Next Oil Change Every 1000 hours of operation Drain and Replace Oil
or at least once a year
Fault Finding

External Oil Leakage:

Related Part Cause Remedy

From Life time seal Lifetime seal damaged Replace lifetime seal
From the end cover O-ring seal damaged Replace O-ring
From the plugs on cover Plug seal damaged Replace plug seal
Plugs loose Tighten the plug
From hydraulic motor O-ring seals damaged Relplace O-ring seals
Plugs/ bolts loose Tighten the plugs/bolts
Internal motor parts damaged Check the hydraulic motor

Excessive Noise:

Related Parts Cause Remedy

Mechanical noise inside Internal motor parts damaged Check hydraulic motor
hydraulic motor

Hydraulic noise (during slowing Internal Motor parts damaged Check hydraulic motor
down of hydraulic motor speed) Hydraulic circuit malfunctioning Check pressure to motor ports > 3bar (43.5
lb in2)
Verify hydraulic circuit.
Inside the gearbox Internal damage Check gearbox

Other Faults Cause Remedy

Overheating Low oil level Check oil level and refill is necessary
Hydraulic oil over heating Check the hydraulic circuit
Brake not fully released Check brake release pressure

Insufficient power Internal motor parts damaged Check the hydraulic motor
Malfunctioning relief valves Check relief valves

Insufficient speed Fault in hydraulic circuit Check the hydraulic circuit

Low volumetric efficiency Check hydraulic motor

Insufficient braking torque Internal motor damaged Check hydraulic motor

Brake discs worn Replace brake disc pack
Damaged parts Check brake components

Sprocket locked Hydraulic motor locked Check hydraulic motor

Parking brake locked Check the complete brake release.
Mechanical components Replace damaged parts
damaged

9803/6510 Issue 1
Section F Transmission Section F
20 - 1 Track Motor 20 - 1

Removal
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.

2 Slacken the check valve to bleed out the grease.

! WARNING
Slacken the check valve slowly and stop when grease is
released. The grease and valve are under extremely high
pressure and could cause injury if suddenly released.
TRANS 6-2

3 Disconnect the track link by removing the locking pin

and knocking out the master pin.

a Remove bolts and lift off the track shoes adjacent to

the master pin.

b Position a suitable hydraulic press so that its ram

aligns with the master pin.

c Insert the spacer bar between the master pin and the
hydraulic ram.

d Slowly operate the hydraulic ram and press out the

JS02780
master pin.

! WARNING
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.
TRACK 1-1

e Remove the seal rings from each side of the chain

link.

JS02790

9803/6510 Issue 1
Section F Transmission Section F
20 - 2 Track Motor 20 - 2

Removal (cont’d)
4 Operate the traction motor to remove the track.

5 Lift the side of the undercarriage high enough to

permit drive sprocket removal. Support with wooden
blocks.

6 Stop the engine and operate the control lever to

relieve pressure in the hydraulic system.

Release pressure in the hydraulic tank (See Releasing

Tank Pressure in Routine Maintenance, Section 3).

7 Remove the motor cover, attach identification tags to

the motor hoses, disconnect the hoses from the
motor and install plugs and caps.

9803/6510 Issue 1
Section F Transmission Section F
20 - 3 Track Motor 20 - 3

Removal (cont’d)
8 Support the motor so that the cables are in tension,
then remove the motor installation bolts.

9803/6510 Issue 1
Section F Transmission Section F
20 - 4 Track Motor 20 - 4

Precautions During Installation

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

Rotation Direction
The relationship between the flow direction of the hydraulic oil and the rotation direction is as shown below.

Arrow Oil input port Oil output port Rotation direction (viewed from output shaft end of motor)

P1 P2 Rotation to right (clockwise)

P2 P1 Rotation to left (counterclockwise)

P1

P2

A408273

Rotational Direction

9803/6510 Issue 1
Section F Transmission Section F
20 - 5 Track Motor 20 - 5

Precautions During Installation (cont’d)

Install the new or repaired and inspected traction motor on the machine and perform the inspection and starting preparations
described below.
a Fully fill the piston motor case with clean hydraulic oil at B. Also bleed air from each part of the piping.
Fill gearbox casing to level A.

A408274

Note: When using a hand pump or small capacity electric pump for filling with hydraulic oil, be careful that the inner case
pressure does not exceed 0.3 MPa (3 kgf/cm2). Oil Capacity is 400CC (0.88 UK gal)
b Initial Operation
First run at low speed, repeating the operations. At this time, air remaining in the circuit may cause abnormal sounds in
the valve, so continue running at low speed. Also check for oil leakage from the equipment.
After air bleeding and checking for oil leakage is completed, confirm that abnormal noise or vibration does not occur in
the traction motor due to running with a load on the motor.

9803/6510 Issue 1
Section F Transmission Section F
20 - 6 Track Motor 20 - 6

Replacement
1 Before fitting, clean the gearbox and bleed air out as
follows:
A B
Turn the gearbox so that the hydraulic oil ports are
facing upwards.
Remove plugs from ports A and B. Fill the motor
through port A with the specified hydraulic oil. Fit
plugs to ports A and B.

A408300

2 Lift the gearbox and position it on the undercarriage.

Install the bolts and washers, using JCB Threalseal on
the bolt threads. Tighten the bolts in a diagonal
sequence.

Torque Settings
Item Nm Ibf ft kgf m
1 300 221 30.6
2 300 221 30.6

3 Remove plugs and install the hoses to the motor.

1
2

2
1

A408272

9803/6510 Issue 1
Section F Transmission Section F
20 - 7 Track Motor 20 - 7

Replacement (cont’d)
4 a Install the covers over the motor.
b Check the amount of oil in the gearbox.
c Bleed air from the motor (see Motor Bleeding).
d If the traction motor has been dismantled and
serviced, carry out the functional tests detailed
under Testing later in this section.
e Install the drive sprocket (see Drive Sprocket,
Replacement, Section J).
f Remove the wooden blocks.
g Position the lower frame on the track.
h Move the track link by reversing step 1 of Removal.
i Clean the seal ring housings in the chain link. Insert
the seal rings and clamp into position.
j 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.
k Insert the pointed guide pin from the inner face and
tap through its full length.
l. Position a suitable hydraulic press so that its ram
aligns with the guide pin.
m Insert the master pin into its locating hole.
n Slowly operate the hydraulic ram and press the JS02800

master pin into position.

o Re-locate the track shoes and tighten the bolts (see
Checking Shoe Plate, Routine Maintenance,
Section 3).

JS02810

JS02820

9803/6510 Issue 1
Section F Transmission Section F
20 - 8 Track Motor 20 - 8

Replacement (cont’d)
5 Apply grease through the check valve to adjust the
track tension (see Tracks and Running Gear,
Checking/Adjusting the Track Tension, Section 3).

Motor Bleeding
Bleeding must be done whenever a track motor is being
fitted.
Note: If a track gearbox assembly is being fitted to the
machine with the motor attached, follow the procedure given
under Track Gearbox Removal and Replacement.
When the motor is being fitted to a gearbox already fitted to
the machine, bleed the air from the motor by one of the three
methods detailed below.
Note: Method 1 will take considerable time as air in the motor
is very difficult to purge. Methods 2 or 3 may be quicker.

Method 1
After fitting the motor but before connecting the pipework,
remove plug from upper drain port A but make sure that a
plug is fitted to lower drain port B.
Fill the motor with specified hydraulic oil through port A.
Connect the pipes.

Method 2
Fit the motor and connect all pipes except the two drains.
Remove plug from port A. Make sure that a steel plug is
fitted to bottom drain port B.
Run the engine and operate the track control lever slightly so
that the sprocket does not turn. If necessary, prevent the
sprocket from turning by means of a steel bar or tube
jammed in the track. Return the lever to neutral when air-free
oil flows from port A. Connect the drain pipes.

Method 3
Fit the motor and connect all pipes. Prevent the sprocket
from turning by means of a steel bar or tube jammed in the
track. Run the engine and fully select the track control lever
for about 1 minute. This will fill the motor case with oil.

9803/6510 Issue 1
Section F Transmission Section F
20 - 9 Track Gearbox 20 - 9

Dismantling and Assembly

9803/6510 Issue 1
Section F Transmission Section F
20 - 10 Track Gearbox 20 - 10

Dismantling and Assembly (cont’d)

Dismantling
1 Unscrew and remove the two plugs 3, from the end of the
cover 2.

2 Remove the socket head screws 2.

3 Remove the end cover 2.

Note: Screws M22 x 1.5 can be inserted in the two open oil
plug holes to aid the cover removal.

4 Remove the ‘O’-ring 5, from its groove in the end

cover 4.

9803/6510 Issue 1
Section F Transmission Section F
20 - 11 Track Gearbox 20 - 11

Dismantling and Assembly (cont’d)

Dismantling (cont’d)
5 Remove the first stage sun gear 7.

6 Remove the first reduction assembly 8.

7 Remove the second reduction assembly 9.

8 Remove the circlip 10, from the planet assembly

of the third reduction assembly.

9803/6510 Issue 1
Section F Transmission Section F
20 - 12 Track Gearbox 20 - 12

Dismantling and Assembly (cont’d)

Dismantling (cont’d)
9 Use a puller and remove the five planet gears 11 off
the third reduction assembly.

10 Remove the spacers 12, positioned on the back of the

planet gears of the third reduction assembly.

11 Using a drill, remove the two deformed sections of the

ring nut 13. Using Service tool SST0040 and a torque
multiplier, unscrew the ring nut 13.

12 Remove the centring ring 16, from the hydraulic motor

17.
Note: This operation must be carried out only when the
hydraulic motor is to be removed.

9803/6510 Issue 1
Section F Transmission Section F
20 - 13 Track Gearbox 20 - 13

Dismantling and Assembly (cont’d)

Dismantling (cont’d)
13 Using a press and a drift, remove the hydraulic motor
17.from the gearbox housing 14.
Note: To prevent the gearbox housing 14 coming out of the
hydraulic motor 17, use a M16 x 120 bolt and a flat plate to
secure the two parts together when repositioning unit.

M16 x 120

10 mm

55mm 20mm A408310

Note: To prevent oil leaks it is advisable to replace the lifetime

seals, (both the metal ring and ‘O’-rings) at this time. Seal
replacement can only be done with the gearbox removed
from the machine.

14 Remove the spacer from the hydraulic motor 17.

15 Using a flat bladed screw driver, remove the seal 15 from

the hydraulic motor.

16 Using a puller, remove the inner bearing race from the

hydraulic motor 17.

A408590

9803/6510 Issue 1
Section F Transmission Section F
20 - 14 Track Gearbox 20 - 14

Dismantling and Assembly (cont’d)

Dismantling (cont’d)
17 Take out the bearing race from the gearbox housing 14.
Remove the bearings from the gear box housing.

A408600

9803/6510 Issue 1
Section F Transmission Section F
20 - 15 Track Gearbox 20 - 15

Dismantling and Assembly (cont’d)

Inspection
Before assembling the Track Motor gearbox 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.

2 Carefully insect all components for signs of excessive

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

Note: O-rings 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 undamaged.

9803/6510 Issue 1
Section F Transmission Section F
20 - 16 Track Gearbox 20 - 16

Dismantling and Assembly (cont’d)

Assembly
Assembly is a reversal of the Dismantling procedure.
Note:
1 Exchange or repair all parts that are found to be
damaged. In the case of a damaged planet gear, do not
replace the single gear but the whole reduction stage.
2 Ensure that all the parts are cleaned in the appropriate
solvent and dried with compressed air.
3 Apply a thin film of hydraulic fluid to all sliding parts,
bearings and other contact surfaces before assembly.
4 Replace all O-rings and seals and thoroughly clean the
grooves that they sit in. Cover the O-rings and seals with
petroleum jelly.

1 Fit the lower ball bearing sets in the housing, holding the
inner raceway in position with the spacer tools a
and b.

13 5
a
b
2 Remove spacer a. Place the bearing spacer e into
position and drop the upper ball bearing sets into
20

position. Then fit the inner race.

Ø2 44,5
20 Ø2 60,5

a
b

9803/6510 Issue 1
Section F Transmission Section F
20 - 17 Track Gearbox 20 - 17

Dismantling and Assembly (cont’d)

Assembly (cont’d)

Half Seal Installation

The half seals used in re-assembly require a specific
technique to install. Follow the instructions detailed below.
A Carefully clean the seats 1 and 2 using a small wire brush
or solvent if necessary. The surfaces in contact with the 1 2
O-ring 3 must be perfectly clean and dry.
B Make sure that the sealing surfaces 4 of the metal rings
are free from scratches and abrasions and foreign 6 6
substances and are clean and dry.

C Carefully clean the contact surface of the metal rings 5 3 3

and remove dust and fingerprints. Lubricate them with a
thin film of oil. Take care not to oil the other components 5 5
4 4
A408370

3 Fit half seal 15, on service tool SST0037

9803/6510 Issue 1
Section F Transmission Section F
20 - 18 Track Gearbox 20 - 18

Dismantling and Assembly (cont’d)

Assembly (cont’d)
4 Fit the half seal 15, inside the gearbox housing 14.

3 Assemble, the half seal, on the hydraulic motor 17 by

using service tool SST0037. Carefully clean the metal
faces of the half seals.

4 Lubricate the metallic face of the half seal with a thin film
of oil.

5 Fit a lifting eye on to the hydraulic motor 17 and using

suit able lifting equipment, position the hydraulic motor
17 inside the gearbox housing.

9803/6510 Issue 1
Section F Transmission Section F
20 - 19 Track Gearbox 20 - 19

Dismantling and Assembly (cont’d)

Assembly (cont’d)
5 Using a press and a Stopper (see Service tools at start of
this section), push the hydraulic motor 17 against the
shoulder of the gearbox housing.

6 By using a press and a drift, assemble the centering ring

16 in it’s seat on the hydraulic motor 17.

Øi = 72±1
Øe = 80±1
Øe
Øi

L = ~60

A408380

7 Using a torque multiplier and service tool SST0040

tighten the new ring nut13.

Torque Multiplier

Item Nm Ibf ft kgf m

Input 210 155 21.5

Output 6500 4795 663

8 Deform the ring nut 13 to a depth of 1-1.5mm, at a

position next to a space on the flanged hub on the
hydraulic motor 17 using a 4 - 5mm punch.

Ø4-5mm

A408390

9803/6510 Issue 1
Section F Transmission Section F
20 - 20 Track Gearbox 20 - 20

Dismantling and Assembly (cont’d)

Assembly (cont’d)
9 Place the spacers 12, on the pins of the hydraulic motor
17. Make sure that the spacers are the correct way up.

A408400

10 Place the five planet gears 11 of the third reduction

assembly onto the flanged hub of the hydraulic motor 17.

A408410

11 Using a rubber hammer and a drift, tap the planet gear

assemblies 11 against the pins of the hydraulic motor 17.

Using circlip pliers, place the circlip 10, into

its groove.

9803/6510 Issue 1
Section F Transmission Section F
20 - 21 Track Gearbox 20 - 21

Dismantling and Assembly (cont’d)

Assembly (cont’d)
12 Insert the second reduction assembly 9.

13 Insert the first reduction assemble 8.

14 Insert the first stage sun gear 7.

15 Position the O ring seal 5 into it’s seat in the end cover 2.

9803/6510 Issue 1
Section F Transmission Section F
20 - 22 Track Gearbox 20 - 22

Dismantling and Assembly (cont’d)

Assembly (cont’d)

16 Fit the end cover 2, on the gearbox housing 14.

17 Fix the end cover 2, with the socket screws 1.

Torque Setting

Item Nm Ibf ft kgf m

1 75 53 7.6

16 Fill the gear box with oil Tighten the two plugs 3 using a
hex head torque wrench.

Torque Setting

Item Nm Ibf ft kgf m

1 35 26 3.5

A408275

9803/6510 Issue 1
Section F Transmission Section F
20 - 23 Track Motor 20 - 23

Dismantling and Assembly

9803/6510 Issue 1
Section F Transmission Section F
20 - 24 Track Motor 20 - 24

Dismantling and Assembly (cont’d)

9803/6510 Issue 1
Section F Transmission Section F
20 - 25 Track Motor 20 - 25

Dismantling and Assembly (cont’d)

Note: The numbers in the following section refer to the 16 Remove the restrictor 75.
illustrations at the start of this section.
Note: The restrictor may be secured by a deformed thread,
Before starting the dismantling, drain the oil, clean all the a M5 tap will be require to reform the thread before the
surfaces with a suitable solvent and dry with compressed air. restrictor can be removed.
Discard all 'O'-rings and seals which are disturbed during
dismantling. ! WARNING
Always wear safety glasses when dismantling assemblies
Dismantling containing components under pressure from springs.
This will protect against eye injury from components
Two Speed Spool accidentally flying out.
GEN 6-2
1 Unscrew the plug 2 from the base plate 66. Remove the
O-ring seal 3 from it’s seat on the plug. 17 Unscrew the nine socket head screws (M14) 16 from the
Take out the spring seat 4 and the spring 6. Unscrew the base plate. Carefully lift the base plate until all the pins
plug 26 and remove the O- ring 25. 69 are completely out,making sure none of the springs
fly out.
2 Slide out the two speed spool 17 to 24.
18 Remove pin 69 and the valve plate 66.
Relief Valve
19 Using a puller, remove the bearing 1-9 from the base
3 Unscrew the relief valve 1. plate 66.

4 Take out the free piston 33 from the relief valve 1. Motor Shaft and Cylinder Block
Remove the backup rings from their seats in the free
piston 33. 20 Remove the O-ring 1-23 and the O-rings 1-22 from their
seats in the flanged hub 1-1.
5 Remove the O-ring 41 from the relief valve 1.
21 Remove the eight springs 70 from the brake piston 1-15.
6 Repeat the same steps for the second relief valve
disassembly. 22 Mark the position of the brake piston 1-15 to the
flanged hub 1-1, as a reference for assembly.
Counter Balance Valve
23 Lift out the brake piston 1-15 from the flanged hub 1-1.
7 Unscrew the four socket head screws (M12) 88 of the
first flanged plug assembly. Take out flanged plug 24 Remove the O-ring seals 1-16/17 from their seats in the
assembly 87 then remove the first spring seat 82 and brake piston 1-15.
the O-ring 86. Unscrew the plug 83 and remove the O-
ring. 25 Take out the brake discs 1-13 and the steel discs 1-14
.
8 Remove the the first spring 81 and take out the first 26 Lift out the cylinder block 1-4-1 and remove the
spring seat 80 from the counterbalance valve spool. spherical retainer plate holder 1-4-4.

9 Remove the first spring 73, remove the O ring seal 74 27 Take out the three pins 1-4-9 from their seats in the
and the check valve 72. cylinder block 1-4-1.

10 Repeat the same steps for the second check valve 45 to 28 Take out the pistons and the retainer plate 1-4-2/3.
47. Remove the pistons 1-4-2 from the retainer plate 1-4-3.

11 Unscrew the four socket head screws (M12) 48 of the 29 Remove the swash plate 1-5 from the flanged hub 1-1.
second flanged plug assembly. Take out the second
flanged plug assembly 52 then remove the second 30 Take out the two steel balls 1-6, the two 2-speed control
spring seat 54 and the O-ring 53. Unscrew the plug 50 pistons 1-7 and the two 2-speed control springs 1-20.
and remove the O-ring.
31 Using a punch from the gearbox side of the flanged hub
12 Remove the the first spring 55 and take out the second 1-1, take out the motor shaft 1-3 and the bearing 1-8.
spring seat 56 from the counterbalance valve spool.
Note: To remove the shaft 1-3 and the bearing 1- 8 the gear
13 Remove the counterbalance valve spool 57 to 61. box must first be removed. See Gear Box Dismantling

Base Plate 32 By using a puller, take out the bearing 1-8 from the
motor shaft 1-3.
14 Unscrew the plugs 15 from the base plate 66 and
remove the O-ring. 33 By using a screwdriver, remove the seal 1-12 from it’s
seat in the flanged hub 1-1.
15 Unscrew the conical plugs 7 and 12 from the base plate
66 and remove the restrictors 8 and 9. Note: Only remove the seal if replacement is required, as
removal will damage the seal.

9803/6510 Issue 1
Section F Transmission Section F
20 - 26 Track Motor 20 - 26

Dismantling and Assembly (cont’d)

Inspection

Before assembling the Track Motor 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 motor.

1 Carefully clean all components using a suitable

degreasing agent.

2 Carefully insect all components for signs of excessive

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

Note: O-rings 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 undamaged.

9803/6510 Issue 1
Section F Transmission Section F
20 - 27 Track Motor 20 - 27

Dismantling and Assembly (cont’d) 13 Assemble the brake piston 1-15 respecting the
markings set out previously and being careful not to
Note: The numbers in the following section refer to the damage the seals already fitted.
illustrations at the start of this section.
Note: It is important that the brake piston is aligned correctly
Assembly with the marking made during Dismantling.
Motor Shaft and cylinder Block 14 Assemble the O-ring 1-23 into it’s seat on the flanged
1 Place the seal ring 1-12 into it’s seat in the flanged hub hub 1-1.
1-1. 15 Assemble the O-rings 1-22 into their seats on the
Note: Before inserting the bearing and shaft, make sure that flanged hub 1-1.
the seal is greased. 16 Insert the springs in their seats in the brake piston 1-15.

2 Using a rubber hammer and drift, push the bearing 1-8 17 Using a rubber hammer and drift tap the bearing 1-9
against the motor shaft shoulder 1-3. Place the bearing onto it’s seat in the base plate 66.
and shaft inside the flanged hub 1-1 and push up 18 Place the valve plate 1-21 on to the base plate 66.
against the flanged hub shoulder.
Note: The bronze layer surface must be upwards.
3 Assemble the 2 steel balls 1-6 into their seats.
19 Insert the pins 69 into the base plate 66.
4 Assemble the two 2-speed springs into their seats in the
two 2-speed pistons 1-7, then place into their seats 20 Place the base plate 66 on the flanged hub 1-1.
inside the flanged hub 1-1. Note: The base plate is centered by the two pins and the
Note: Make sure that the pistons can move freely into the second speed oil passages must match.
seats. 21 Fix the base plate 66 to the flanged hub 1-1 by the nine
5 Insert the swash plate 1-5 inside the flanged hub 1-1 socket head screws (M14) 16. See torque settings .
being careful that the spherical housings matches with 22 Assemble the O-rings 14 in their seats in the plugs 15,
the steel balls 1-6. taking care not damage the O-ring on the thread of the
6 Assemble the three pins 1-49 in their seats in the plug. Tighten the plugs into the base plate 66. See
cylinder block 1-4-1. Torque Settings .

7 Assemble the spherical retainer holder 1-4-4 on the 23 Tighten the retrictors 9, 64, 65 into the base plate 66.
cylinder block 1-4-1. See Torque Settings .

Note: The two splines must be aligned together. 24 Tighten the restrictor plugs 7, 63 and seal with teflon
tape. See Torque Settings.
8 Assemble the nine pistons 1-4-2 in the retainer plate 1-
4-3.. 25 Tighten the restrictors 62, 75 in the base plate 66. See
torque settings. Using a punch, deform the thread to
secure the restrictor.
27 Assemble the O-rings 49 in their seats in the plugs 50,
taking care not damage the O-ring on the thread of the
A plug. Tighten the plugs into the base plate 66. See
Torque Settings .
28 Assemble the O-ring 53 in it’s seat in the flanged plug
52.
A408540
Counterbalance Spool Valve
Note: The orifice A in the piston must be open and free of 29 Insert the counterbalance spool 61 to 57
dust or dirt.
30 Assemble the check valve 45 into it’s seat, the O-ring 47
9 Assemble the pistons-retainer plate unit 1-4-2/3 in the into it’s seat and insert the spring 46. Repeat the same
cylinder block 1-4-1. steps for the second check valve assembly 72 -74.
10 Position the flanged hub on it’s side to aid assembly. 31 Insert the first spring seat 56 on the counterbalance
Assemble the cylinder block unit into the flanged hub 1- spool valve 61 to 57.
1 on the motor shaft spine 1-3.
32 Insert the first spring 55 on the counterbalance valve
11 Assemble the brake disc package according to the
spool.
following order: Insert one brake disk with internal
toothing 1-13, then insert a steel disc 1-14. Repeat the 33 Assemble the first spring seat 54 into the flanged plug
operation until all discs have been assembled. assemble 52.
12 Assemble the O-ring 1-16/17 into their seats in the 34 Assemble the flanged plug assembly on the base plate
brake piston 1-15. 66 and tighten the four socket head screws 48. See
Torque Settings.

9803/6510 Issue 1
Section F Transmission Section F
20 - 28 Track Motor 20 - 28

Dismantling and Assembly (cont’d)

Assembly (cont’d) Torque Setting
35 Insert the second spring seat 80 on the counterbalance Item Nm kgf m lbf ft
spool valve 61.
16 205 21 151
36 Insert the second spring 81 on the counterbalance valve
15 10 1 7.3
spool 61.
9, 64, 65 2.5 1.8 0.25
37 Assemble the second spring seat 82 into the flanged
plug assemble 87. 63 10 1 7.3
38 Assemble the second flanged plug assembly on the 50, 83 20.5 2.1 15
base plate 66 and tighten the four socket head screws
48, 88 108 18 133
88. See torque settings.
1 373 38 275
2, 26 118 12 87
Relief Valve Assembly
39 Assemble the O-ring 41 in it’s seat in it’s seat in the relief
valve 1.
40 Assemble the first backup ring A 36 into it’s seat in the
free piston 33 followed by the O-ring B 35 and then the
second backup ring C 34 as shown below:

A
B

C
D
A408550

41 Insert the free piston 33 in the relief valve 1 checking

that the groove D is towards the inside of the motor.
42 Insert the relief valve 1 into the base plate 60 and tighten
to the specified torque. See Torque Settings.
Two Speed Spool
43 Assemble the O-ring 3 and 24 in it’s seat in the plugs 2
and 26.
44 Insert the 2-speed spool 17 to 24 in the base plate 66.
45 Insert the 2-speed spool springs 6 and 23 and their
seats 4 into each end of the spool.
46 Tighten the plugs 2 and 26 into the base plate. See
Torque Settings.

9803/6510 Issue 1
Section J Track and Running Gear Section J
i i

Contents Page No.

Torque Specifications 1-1

Idler Wheel and Recoil Unit

Removal 2-1
Replacement 2-2

Idler Wheel
Dismantling 3-1
Assembly 3-2
Wear Limits 4-1

Grease Cylinder
Removal 5-1
Replacement 5-2
Dismantling 6-1
Assembly 6-2

Drive Sprocket
Removal 7-1
Replacement 7-2
Wear Limits 8-1

Top Roller
Removal 9-1
Replacement 9-2
Dismantling 10 - 1
Assembly 10 - 3
Wear Limits 11 - 1

Bottom Roller
Removal 12 - 1
Replacement 12 - 2
Dismantling 13 - 1
Assembly 13 - 3
Wear Limits 14 - 1

9803/6510 Issue 1
Section J Track and Running Gear Section J
1-1 Torque Specifications 1-1

Torque Specifications

Component Nm kgf m lb/ft Remarks

Drive sprocket
fastening bolts 267-312 27.2-31.8 196.65-229.91 JCB Threadseal
Idler wheel
installation bolts 267-312 27.2-31.8 196.65-229.91 JCB Threadseal
Top roller
installation bolts 521-608 53.1-62 383.91-448.26 JCB Threadseal

Bottom roller
installation bolts 371-432 37.8-44.1 273.29-318.84 JCB Threadseal

Recoil unit
installation bolts 380-443 38.7-45.2 279.8-326.79 JCB Threadseal

Track shoe bolt 775.1-931.6 77-95 556.71-686.85 JCB Threadseal

Note: Install the drive sprocket with the chamfer to the body side.

9803/6510 Issue 1
Section J Track and Running Gear Section J
2-1 Idler Wheel and Recoil Unit 2-1

Removal

1 Slacken the check valve to bleed out grease.

! WARNING
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

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.

! WARNING
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.
TRACK 1-1

3 Fasten a sling around the idler wheel and recoil

assembly and remove it from the undercarriage.

4 Remove the bolts and remove the idler wheel from the
recoil unit.

! WARNING
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 Removal, Grease Cylinder, for Recoil Spring

dismantling details.

9803/6510 Issue 1
Section J Track and Running Gear Section J
2-2 Idler Wheel and Recoil Unit 2-2

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.

2 Fasten a sling around the idler wheel and recoil

assembly and enter it into the undercarriage.

3 Position the idler wheel in the undercarriage using a bar.

4 Connect the track link (see Track Motor/Reduction

Gearbox, Removal and Replacement, Section F).

9803/6510 Issue 1
Section J Track and Running Gear Section J
3-1 Idler Wheel 3-1

Dismantling

1 Clean the idler wheel with a suitable solvent. Remove

the plug A from hub B and drain the oil.

2 On one side of the unit only, remove the wire clip E or

roll pin F and separate the hub C from shaft D.

* G F

C
E
H

3 Remove 'O'-ring I from shaft D. Pull out the shaft D from

the idler wheel G.

D
I C

4 Remove the wire clip E or roll pin F and separate hub C

from shaft D. Remove 'O'-ring I from shaft D.
F
D

I
C

9803/6510 Issue 1
Section J Track and Running Gear Section J
3-2 Idler Wheel 3-2

Dismantling (cont’d)

5 Remove floating seal J from each hub C using a pry bar. C

6 Remove floating seal J from each side of idler wheel G J G

using a pry bar.

7 If badly worn or damaged, remove the bushes K from

idler wheel G using a press or puller. K
G
Protect parts from moisture and dust if left dismantled
for some time.

Assembly

1 Clean all parts thoroughly in a suitable solvent. Dry shaft

and bore of idler wheel using compressed air in a place
free of dust and moisture.
L
K
Check components for wear as detailed under Wear
Limits. Polish out scratches and roughness using an oil
stone. Then apply a coat of engine oil to all parts. G
Carefully drive the new bushes K into the idler wheel G,
using a suitable dolly L.

9803/6510 Issue 1
Section J Track and Running Gear Section J
3-3 Idler Wheel 3-3

Assembly (cont’d)

2 Apply a coating of grease and install a new floating seal

J G
J into each side of the idler wheel G.

J
J

3 Apply a coating of grease and install a new floating seal C

J into hub C. J

4 Grease a new 'O'-ring I and install on one end only of

shaft D. Install shaft D into hub C. Fit new wire clip E or
roll pin F. F

I
C

5 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.

9803/6510 Issue 1
Section J Track and Running Gear Section J
3-4 Idler Wheel 3-4

Assembly (cont’d)

6 Apply grease to a new 'O'-ring I and install it on the

shaft D.
F
Clean the metallic face of the seal, coat the metallic face
with engine oil and install the hub C onto the shaft D. Fit G
new wire clip E or roll pin F.
D
Wrap sealing tape around the plug A with one thread I
remaining uncovered. Insert this plug but leave the other C
one out until after testing.
E
A

7 Using extreme care to prevent water entering the

assembly, lower it into a tank of water. Connect
compressed air at M and apply pressure of 1.9 bar (28
M
lbf/in2). Check for air bubbles.

8 Remove the assembly from the tank. Dry with

compressed air. Add the specified oil (see Section 3).
Install plug using an appropriate pipe sealant.

9803/6510 Issue 1
Section J Track and Running Gear Section J
4-1 Idler Wheel 4-1

Wear Limits

Item Dimension Standard Size Service Limit Action

mm in mm in
Wheel Diameter A 494 19.4 490 19.29 Build up or renew
B 21 0.8 Build up or renew
Wheel Width C 84 3.3 80 3.14 Build up or renew
Shaft Diameter D 65 2.55 64.5 2.53
Bush Bore D 65 2.55 65.0 2.59 Renew
Length over Bush/Seal E 69 2.71 68.6 2.7 Renew
Hub F 12.4 .48 11.9 .46 Renew
B

C
A

E F
D

JS03780

9803/6510 Issue1
Section J Track and Running Gear Section J
5-1 Grease Cylinder 5-1

Removal
1 Slacken the check valve to bleed out grease.

! WARNING
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

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.

! WARNING
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.
TRACK 1-1

3 Fasten a sling around the idler wheel and recoil

assembly and remove it from the undercarriage.

4 Remove the bolts and remove the idler wheel from the
recoil unit.

9803/6510 Issue 1
Section J Track and Running Gear Section J
5-2 Grease Cylinder 5-2

Removal (cont’d)

! WARNING
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 B
releasing the pressure.
TRACK 1-10
A
Note: If it becomes necessary to dismantle the recoil spring
assembly, the following procedure should be used.

5 Prepare the jig for Recoil Spring Disassembly.

Place the re-coil spring unit as shown.

Jack up the hydraulic jack A and compress the Recoil

Spring B.

6 Remove the Recoil Spring.

Pull out the Spring Pin C and remove the castellated nut
D. Let the jack A down to relieve the pressure on the
recoil spring B.

Remove the components from the jig, firstly the yoke E,

spring B and finally, the grease cylinder F.

Replacement

1 Reassembly of Components.
a Set the components in the jig, firstly the grease
cylinder F, then place the spring B on top, and
finally, the yoke E.

b Extend jack A and compress recoil spring B. B

c Install the castellated nut D on the threaded

section of the grease cylinder F which protrudes
through the yoke E. Tighten nut D, aligning the
castellations with the pin hole.
E
d Remove the recoil spring assembly from the jig.
See "Recoil Spring Installation".

e Renew and install spring pin C.

f Release jack A carefully and allow recoil spring B

to expand. Remove assembly from the jig.

D
C

9803/6510 Issue 1
Section J Track and Running Gear Section J
6-1 Grease Cylinder 6-1

Dismantling
1 Clean the grease cylinder A with an appropriate
detergent. B
Remove bolt B and washer C, remove the bracket D. A
Remove the check valve E, together with the grease C
nipple F from the cylinder A.

2 Pull out the Piston Rod G from the grease cylinder A.

A G

3 Remove the Dust Seal H from the grease cylinder A.

H

4 Remove the Back-up ring I and 'O'-ring J from the

grease cylinder.
I

9803/6510 Issue 1
Section J Track and Running Gear Section J
6-2 Grease Cylinder 6-2

Assembly
1 Install a new greased 'O'-ring J, to the grease
cylinder A.
Install a new back-up ring I. I
J

2 Install the dust seal H using a suitable jig and hammer

to the grease cylinder A.
H

3 Coat the piston rod G with grease.

Insert the piston rod G into the grease cylinder A.

A G

4 Install the check valve E, with the grease nipple F, to

the grease cylinder A torque to 58.84 Nm (43.4 lb/ft).
B
A
Fasten the bracket D to the grease cylinder A using the C
bolt B and washer C.

9803/6510 Issue 1
Section J Track and Running Gear Section J
7-1 Drive Sprocket 7-1

Removal

1 Slacken the check valve to bleed out grease.

! WARNING
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

2 Disconnect the track link.

! WARNING
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.
TRACK 1-1

3 Lift the side of the undercarriage high enough to permit

drive sprocket removal. Support with wooden blocks.

4 Support the drive sprocket, remove the bolts and lever it

away from the gearbox unit.

9803/6510 Issue 1
Section J Track and Running Gear Section J
7-2 Drive Sprocket 7-2

Replacement

1 Support the sprocket and position it on the gearbox.

Install the bolts and washers, using Loctite 262 on the

bolt threads. Tighten the bolts in a diagonal sequence.

Torque Settings

Nm lbf ft kgf m
267-312 196-230 27-32

2 Remove the wooden blocks. Connect the track link.

3 Apply grease through the check valve to adjust the track

tension (see Section 3).

9803/6510 Issue 1
Section J Track and Running Gear Section J
8-1 Drive Sprocket 8-1

Wear Limits

Item Dimension Standard Size Service Limit Action

mm in mm in
Width A 66 2.59 60 2.59 Renew
Diameter B 582.5 22.93 576.5 22.69 Renew
Diameter C 659 25.9 65.3 25.7 Renew
Diameter D 644.6 25.37 Renew
Centres E 190 7.4 Renew

9803/6510 Issue 1
Section J Track and Running Gear Section J
9-1 Top Roller 9-1

Removal

Note: The following procedure is applicable to all top rollers

but as there are visual differences, the illustrations show only
a typical unit.
1 Slacken the check valve to bleed out grease.

! WARNING
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

2 Jack up the track high enough to permit roller removal.

Put wooden blocks between track link and side frame.

3 Remove the mounting bolts, and tap the upper roller

with a copper mallet to separate it from the side frame.

4 Fasten a sling to the upper roller, and completely

remove the upper roller bolt and remove the upper roller.

9803/6510 Issue 1
Section J Track and Running Gear Section J
9-2 Top Roller 9-2

Replacement

1 Before fitting the roller, add the specified oil (see Section
3). Install plug using an appropriate pipe thread sealant.

2 With the track supported as shown under Removal,

install the roller. Apply Loctite 262 to the threads and fit
the mounting bolts.

3 Remove the wooden blocks and jack.

4 Apply grease through the check valve to adjust the track

tension (see "Checking/Adjusting the Track Tension).

9803/6510 Issue 1
Section J Track and Running Gear Section J
10 - 1 Top Roller 10 - 1

Item Part Name

1 Roller

2 Shaft

5 3 Bushing

4 4 Floating seal

5 Bracket
3

1 6 Thrust plate

7 Hexagonal bolt
12
8 O-ring

9 Cover

10 Snap ring

11 Plug

12 Bushing

6 10

11

9803/6510 Issue 1
Section J Track and Running Gear Section J
10 - 2 Top Roller 10 - 2

Dismantling (Two and Four Bolt Pedestal)

1 Clean the upper roller A with an appropriate detergent.

Remove the plug B from the cover and drain the oil.
A

2 Remove the retaining ring C, and remove cover D. A

From cover D, remove 'O'-ring E and discard.

D
C

3 Remove bolt F, and the thrust plate G from the end of

G
the shaft. A

4 Pull the upper roller A from the shaft H.

A

9803/6510 Issue 1
Section J Track and Running Gear Section J
10 - 3 Top Roller 10 - 3

Dismantling (Two and Four Bolt Pedestal)

(cont’d)
5 Remove the floating seal I from the upper roller A.
A

6 If badly worn or damaged, remove the bushes J and K,

from the roller A. K

7 Remove seal I from bracket L using a pry bar. I

H
Protect parts from moisture and dust if left dismantled L
for some time.

H I
L

Assembly (Two and Four Bolt Pedestal) L

1 Clean all parts thoroughly in a suitable solvent. Dry shaft

and bore of roller using compressed air in a place free of
dust and moisture.
Check components for wear as detailed under (Wear H
Limits). Polish out scratches and roughness using an oil
stone. Then apply a coat of engine oil to all parts.
If a new shaft or bracket are required, press-fit shaft H
into bracket L, taking care to protect the threads of the
tapped holes in the end of the shaft.

9803/6510 Issue 1
Section J Track and Running Gear Section J
10 - 4 Top Roller 10 - 4

Assembly (Two and Four Bolt Pedestal)

(cont’d)
N
2 Using a jig M, and hammer, insert the bushing N, and P A
into the roller A. M
P

3 Install the new floating seal I into the roller A coat oil
onto the floating seal surface.
A

4 Install the new seal I into the bracket L. I

H
Coat the metallic face of the seal with engine oil.
L
I

5 Coat the shaft H with grease. Install the roller A onto the
shaft H. A

9803/6510 Issue 1
Section J Track and Running Gear Section J
10 - 5 Top Roller 10 - 5

Assembly (Two and Four Bolt Pedestal)

(cont’d)
Q
6 Apply grease to the inside face of the thrust plate Q and A
install it on the shaft using bolt R and washer S.
R
S

7 Apply grease to a new 'O'-ring T and install it onto cover

D. Install the cover D to the roller A. Retain with the
T
retaining ring C.
C
A

8 Using extreme care to prevent water entering the

assembly, lower it into a tank of water. Connect a
compressed air pipe V to the port N, check for air
bubbles. V

Apply a pressure of 1.9 bar , 1.9kg cm2, 28 lb/in2 .

9 Remove the assembly from the tank.

Dry with compressed air. Add the specified oil (see

Routine Maintenance).

Install plug B using an appropriate pipe thread sealant.

9803/6510 Issue 1
Section J Track and Running Gear Section J
11 - 1 Top Roller 11 - 1

Wear Limits

Item Dimension Standard Size Service Limit Action

mm in mm in
Carrier Roller A 120 4.72 112 4.40 Renew
B 0 .39 Renew
C 85 3.34 79 3.11 Renew
Inner Flange width D 46 1.81 45.5 1.79 Renew
Outer Flange width D 46 1.81 46.8 1.84 Renew
Shaft Diameter E 83 3.26 82.6 3.25 Renew
Length F 5.5 .21 5 .19 Renew
Collar G 23 .90 22.5 .88 Renew

9803/6510 Issue 1
Section J Track and Running Gear Section J
12 - 1 Bottom Roller 12 - 1

Removal

Note: The following procedure is applicable to all bottom

rollers, but as there are visual differences, the illustrations
show only a typical unit.

1 Slacken the check valve to bleed out grease.

! WARNING
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

2 Lift the side of the undercarriage high enough to permit

bottom roller removal. Support with wooden blocks.

3 Remove the mounting bolts, and tap the bottom roller

with a copper mallet to separate it from the side frame.

4 Remove the roller.

9803/6510 Issue 1
Section J Track and Running Gear Section J
12 - 2 Bottom Roller 12 - 2

Replacement

1 Before fitting the roller, add the specified oil (see Section
3). Install plug A using an appropriate pipe thread
sealant.
With the undercarriage lifted and supported as shown
under Removal, position the roller on the track link as
shown.
Align the holes in the brackets with the tapped holes in
the undercarriage.

2 Lower the undercarriage sufficient to allow the mounting

bolts to be installed.

3 Apply Loctite 262 to the threads and install the

mounting bolts.

4 Apply grease through the check valve to adjust the track

tension (see Section 3).

9803/6510 Issue 1
Section J Track and Running Gear Section J
13 - 1 Bottom Roller 13 - 1

Item Part Name

Roller assembly(outer flange)

1 Roller (outer flange)

Roller assembly (inner flange)

2 Roller (inner flange)

8 3 Shaft

9 4 Collar

10 5 Bushing
6
6 Floating seal
7
5 7 O-ring
3
8 Wire clip
1
9 Plug

10 Collar

5
7
6
4
8
9
2

9803/6510 Issue 1
Section J Track and Running Gear Section J
13 - 2 Bottom Roller 13 - 2

Dismantling
Note: The following procedure is applicable to all bottom
rollers, but as there are visual differences, the illustrations
show only a typical unit.
1 Clean the roller with a suitable solvent. Remove the plug
A and drain the oil.

2 Remove locking wire B from each end of the shaft C.

E
Remove brackets D and E from shaft C. B

3 Remove seal F from brackets D and E, using a pry bar.

D, E

4 Remove 'O'-rings G from shaft C.

G
Pull out shaft C from roller H or J.
C
J

9803/6510 Issue 1
Section J Track and Running Gear Section J
13 - 3 Bottom Roller 13 - 3

Dismantling (cont’d)

5 Remove seals F from roller J or H using a pry bar.

6 If badly worn or damaged, remove the bushes from

roller J or H, using a press or puller.
Protect parts from moisture and dust if left dismantled
for some time.
J

H
K

Assembly

1 Clean all parts thoroughly in a suitable solvent. Dry shaft

and bore of roller using compressed air in a place free of J
dust and moisture.

Check components for wear as detailed under Wear

Limits. Polish out scratches and roughness using an oil
stone. Then apply a coat of engine oil to all parts.
K

Drive bushes K into roller J or H, using a dolly and H

hammer.
K

2 Install new seals F into roller J or H.

9803/6510 Issue 1
Section J Track and Running Gear Section J
13 - 4 Bottom Roller 13 - 4

Assembly (cont’d)
3 Coat shaft C with grease. Insert the shaft into roller J or
H.

Apply grease to new 'O'-rings G and install them on G

shaft C.
C J

4 Install a new seal F into brackets D and E. Coat the

metallic face of each seal with engine oil.
D,E

5 Press brackets D and E onto shaft C and insert new

locking wires B.
B E
Wrap sealing tape around one plug A with one thread
remaining uncovered. Insert this plug, but leave the
other one out until after testing.
B

D
A

6 Using extreme care to prevent water entering the

assembly, lower it into a tank of water. Connect
compressed air at A and apply pressure of 1.9 bar (28
lbf/in 2). Check for air bubbles. A

9803/6510 Issue 1
Section J Track and Running Gear Section J
13 - 5 Bottom Roller 13 - 5

Assembly (cont’d)
7 Hammer in locking wires B.

8 Add the specified oil (see Section 3). Install plug A

using an appropriate pipe thread sealant.

9803/6510 Issue 1
Section J Track and Running Gear Section J
14 - 1 Bottom Roller 14 - 1

Wear Limits

Item Dimension Standard Size Service Limit Action

mm in mm in
Roller Diameter A 150 5.9 142 5.5 Renew
A 160 6.3 152 5.98 Renew
B 150 5.9 Renew
Inner Flange width C 86 3.38 80 3.14 Renew
Outer Flange width D 173 6.8 170 6.7 Renew
Shaft Diameter E 65 2.5 64.5 2.53 Renew
Length F 69 2.7 68.6 2.7 Renew
Collar G 28.8 1.13 28.3 1.11 Renew

Lower Roller (inside)

Lower Roller (outside)

9803/6510 Issue 1
Section K Engine Section K
i i

Contents Page No.

Technical Data 1-1

9803/6510 Issue 1
Section K Engine Section K
1-1 1 -1

Technical Data JS200, JS210, JS220

Type Isuzu 6BG1, 6 cylinder turbo charged
Model BB-6BG1T
Bore 105 mm (4.13 in)
Stroke 125 mm (4.92 in)
Swept volume 6494 cm3 (396 in2)
Compression Ratio 18.0 : 1
Compression Pressure at 200 rev/min 30 bar (441 lbf/in2)
Firing Order 1, 5, 3, 6, 2, 4
Valve Clearance (cold)
- Inlet 0.4 mm (0.016 in)
- Exhaust 0.4 mm (0.016 in)
Dry Weight (approximately) 484 kg (1067 lb)
Fuel System
Max. Speed (No Load) 2250 ± 50 rev/min
Injection Timing (static) 8° BTDC
Injector Opening Pressure 181 bar (2630 lbf/in2)
Induction system
Air Cleaner Type 2 stage, dry element

For further details, see JS200, JS210, JS220 Tier 2 Engine Service Manual, Publication No. 9806/2210

9803/6510 Issue 1