190-1110 probsolv

RROOBBOOTT119900,, 119900HHFF,, 11111100,, 11111100HHFF

Problem SolvingClick the problem on the contents list to

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Fred H Wild

Fred H Wild

Problem Solving

9803/8530 Issue 1

Contents

The following pages are extracted from the Robot 190, 1110 Service Manual 9803/8530.For more information, refer to the Service Manual.

Click on the appropriate title to go to the page. Start with Transmission or Loader Problems and Causes.

Transmission Problems Loader Problems

Transmission Problems and Causes Loader Problems and Causes

Checking for Faulty Pump or Motor CPPV Flow/Pressure Check

Checking Wheel Speed Levelling Circuit Problem Solving

Machine Veers to One Side When Travelling Main Relief Valve Pressure Test

Transmission Pump Neutral Adjustment Hydraulic Fluid Level

Checking Motor Leakage Rate Changing Hydraulic Filter

Pump High Pressure Relief Valves Changing High-flow Hydraulic Filter

Checking Joystick Hydraulic Lines Changing Hydraulic Tank Breather

Tyres and Wheels High-flow Circuit Flow/Pressure Check

CPPV Flow/Pressure Check

Pump/Engine Coupling

Drive Chain Removal and Replacement

Adjusting Drive Chain Tension

Wheel Hub Assembly

10 - 1

Section E Hydraulics

9803/8530

Section E

10 - 1

Issue 2*

Problem Solving CONTENTS

*

Hydrostatic Transmission

Before carrying out any problem solving or any tests on the machine, make sure that the hydraulic system is filled to the correctlevel with the correct grade of hydraulic oil (see Section 3) and that the system is at the correct working temperature.

PROBLEM CAUSE

No drive in any direction 1, 2, 4, 5, 10, 16, 22, 23, 24

No drive in either forward or reverse 6, 8, 11, 18, 24

No spin turn either left or right 3, 4, 5, 11, 16, 18, 21, 24

No drive on one side 5, 6, 9, 11, 18, 21, 22, 24

Machine will not travel in straight line 3, 8, 9, 11, 16, 18, 19, 20, 21

No brakes 13, 14, 15, 17

Brakes on all the time 12, 13, 14, 15, 17

No tractive effort 4, 5, 6

Machine creeps in neutral 7

KEY TO CAUSE REMEDY PAGE REF.

1 No oil in hydrostatic system Check supply of oil to pump.

2 Restraint not in correct position Ensure restraint is in operating position,check electrical wiring and switch as required.

3 Tyres worn or pressure incorrect Check tyre pressures and condition. 3/9-2

4 Charge pressure incorrect Charge pressure is controlled by the Priority Valve.Carry out flow check. E22-1Check that transmission pump charge valve is disabled.

5 No or low pump output Check pump - carry out wheel speed check. E10-5If one pump suspect, swop motor feed hoses and noticeif problem changes sides - if yes, pump related fault;if no, motor related fault. E10-4

6 A high pressure loop relief valve/tow valve Replace relief valve and re-check. E10-9open/set incorrectly

7 Pump neutral position set incorrectly Adjust servo neutral position. E10-7

8 Pump servos incorrectly set Adjust servos. E10-6, E10-7

9 Feed hose failure Check motor feed hoses.

10 No hydraulic feed to joystick Check for feed to joystick. E10-10

11 No hydraulic feed from joystick to pump Check for feed from joystick to pump. E10-10

12 Brake hose failure Inspect brake hoses.

13 Brake release pressure incorrect Check charge/brake pressure. E22-1

14 Electrical failure (brake valve circuit) Check brake valve electrical circuit.

15 Brake valve inoperative Check valve (sticking spool, etc.)

16 Brakes not released Inspect motor brakes for seal damage. Repair as required.

CONTENTS10 - 2


17 Mechanical brake failure Check brake components(worn plates, spring damage, etc.).

18 Motor seal leakage Check motor case drain for confirmation of internal leakage E10-8(compare one motor with the other). Check for shaft sealleakage by checking chain case oil level.

19 Joystick inoperative Check joystick (plunger movement, leaking seals, etc.)

20 Chain tension Check chain tension. F3-2

21 Motor failure Inspect motor for damage. Repair as required.

22 Chain/sprocket damage Inspect chain and sprocket. Repair as required. F4-2

23 Pump/engine drive coupling failure Check coupling. E26-1

24 Mechanical linkage maladjusted Check linkage and adjust as required.(manual machine)


9803/8530

Section E

10 - 2

Issue 2*

Problem Solving

*

10 - 3


9803/8530

Section E

10 - 3

Issue 1


T

M4

T

CT1

REAR PUMP

A

REV

C

E

CT2

LEFT

SP1

SP2

FWD

LH MOTOR

REV

RH MOTOR

B

A

M4

P

SOFTSHIFTVALVE

P

SP4

A

F

D

FRONT PUMP

RIGHT

Z

CT3

T

M5

C

OIL COOLER

SP3

X

D

FWD

REV

M5

SERVO CONTROL VALVE

FWD

T

B

B

P1 P2M2

M1c

M1b

M1a

M2c

M2b

M2a

10

10a

10b

10c

10d

X1

F1

FILTER

6 7

X2

T

TANK

C

P3GEARPUMP

19

S

M1

382590

TTANK

X1

382770

X2

382780

10 - 4

Checking for Faulty Pump or Motor

If the transmission operates or is faulty on one side only thenswop the motor feed hoses to check if the fault is with thepump or motor. If, after the hose swop, the suspect motorthen operates the fault lies in the relevant pump unit. If themotor still does not operate then the motor itself is faulty.

Proceed as follows:

1 Stop the engine.

2 Remove the seat and floorplate to expose the pump.

3 To ensure correct replacement after the test iscomplete, mark the motor feed hoses A and B for theleft hand motor, C and D for the right hand motor.

4 Swop the motor feed hoses from one side to the otheras indicated in the illustration, i.e. swop hoses A and Cthen swop hoses B and D.

Note: It may be found more convenient to use separateadditional hoses to extend the existing feed hoses.

5 Restart the engine and re-check the operation of leftand right motors. Note that when the left motor isselected the right motor should now drive and the leftmotor should drive when the right motor is selected. Ifthe previously faulty motor now functions then the faultlies in the relevant pump unit. If the motor still does notoperate then the motor itself is faulty.

!!WARNINGHydraulic Fluid

Fine jets of hydraulic fluid at high pressure can penetratethe skin. Do not use your fingers to check for hydraulicfluid leaks. Do not put your face close to suspectedleaks. Hold a piece of cardboard close to suspectedleaks and then inspect the cardboard for signs ofhydraulic fluid. If hydraulic fluid penetrates your skin, getmedical help immediately.INT-3-1-10/1


9803/8530

Section E

10 - 4

Issue 1


382790

A

B

C

D

CONTENTS

Maximum Displacement Adjustment

If necessary the appropriate adjusting screws should bescrewed in 1/4 turn at a time until the correct wheel speed isachieved. Stop the engine while adjustment is carried out.

1 Remove the seat and floorplate to expose the pump.

2 If the left hand wheels are rotating too fast, screw inadjusters A (forward) or B (reverse) to achieve thecorrect speed. If the right hand wheels are rotating toofast, screw in adjusters C (forward) or D (reverse).

If all four wheels rotate slowly and cannot be corrected byadjustment, the most likely cause would be internal wear ofthe hydrostatic pump.

If the wheel speed is slow on one side only, the cause couldbe a faulty servo or a faulty motor. Carry out procedure onpage E10-4 to determine which is faulty.

Following this procedure, further small adjustments may berequired to achieve correct straight line travel (see followingpage).

Manual Machines

If the correct wheel speed cannot be achieved, check thatthe control linkage is correctly adjusted and giving maximumpump swash.

10 - 5

Checking Wheel Speed

The pump output and general efficiency of the drive systemmay be checked by raising the machine off the ground andchecking the wheel speeds.

!!WARNINGThe following procedure requires the machine to bedisabled (wheels raised off the ground, attachmentdisconnected etc.) while the work is carried out.HYD 8-1/2

Place the machine safely onto blocks, so that all four wheelsare clear of the ground. Ensure that the machine is stable.

Stick a piece of reflective tape on a wheel rim. Start theengine and run at maximum speed then operate the drivecontrol. Using a stroboscopic meter, measure the speed ofwheel rotation in each direction which should be as follows:

Single Speed 70-75 rev/min.2 Speed Low 60-66 rev/min.2 Speed High 120-130 rev/min.Track Sprocket 95-100 rev/min.

Check the speed of the wheels on the opposite side of themachine.

Note that excessive wheel speed may result in coolingproblems due to overheating of the hydraulic oil.


9803/8530

Section E

10 - 5

Issue 1

Problem Solving

382800

B

AC

D

10 - 6


9803/8530

Section E

10 - 6

Issue 1


Machine veers to one side when travelling.

Adjustment

If the machine does not travel in a straight line, proceed asfollows:

Refer to illustration on previous page.

Fault

1 Machine veers excessively to left in forward travel

2 Machine veers excessively to right in forward travel

3 Machine veers excessively to left in reverse travel

4 Machine veers excessively to right in reverse travel

Loosen locknut on adjuster screw C, screw in adjuster screw1/4 turn and tighten locknut. Try machine. Keep adjusting 1/4turn at a time until straight line travel is achieved.

Proceed as for fault 1 but adjust screw A.

Proceed as for fault 2 but adjust screw D.

Proceed as for fault 3 but adjust screw B.

This condition may be corrected by adjusting the pump servo units or manual controls but before attempting this, carry out thefollowing preliminary checks.

Check tyre pressures The pressure of one tyre may be low or one or both tyres on one side of the machine may be and condition new and the other tyres worn. In both these cases the rolling circumference of the tyres will be

unequal causing the machine to veer to one side.

Check chain tension Chains which are tensioned unequally will cause the machine to veer to one side. Always adjustthe tension on all four chains, never just one.

Check the servo joystick Check that the joystick spools are not sticking and are correctly operated by the lever.

Check the manual controls Check that the manual control linkage is not sticking. Lubricate if necessary.

Note: If the fault cannot be rectified by any of the above checks or adjustment, then either the pump or motor could be faulty.To identify which, swop the motor feed hoses at the pump as described on page E10-4. If the machine now veers in theopposite direction then the pump is faulty. If the machine continues to veer in the same direction the motor is faulty.

10 - 7

Transmission Pump Neutral Adjustment

This procedure may be carried out if the machine creepswhen the drive control is in the neutral position.

Adjustment

This fault may be due to an incorrect neutral setting of theservo piston.

1 Identify which pump section requires adjustment.

If the machine veers to the left this could be caused byeither the right hand wheels moving forward or the lefthand wheels moving in reverse. Remember that pumpP1 drives the left hand motor and pump P2 drives theright hand motor.

If the machine moves either straight ahead or behindthen both pump servos must be adjusted equally.

2 Stop the engine.

3 Remove the seat, seat base and pump cover.

4 If pump P1 requires adjusting, loosen locknut A and turnthe neutral adjusting screw B 1/10 of a turn in therequired direction then re-tighten the locknut.

If pump P2 is to be adjusted, loosen locknut C and turnadjusting screw D.

If the wheels are creeping forward, turn the adjustingscrews in an anti-clockwise direction (out). If the wheelsare creeping in reverse, turn the screws clockwise (in).

Note: This adjustment is very sensitive. Turn the adjustingscrew 1/10 of a turn at a time and re-check. A slightmovement when the wheels are raised is acceptableprovided that no movement occurs when the machine isresting on the ground.

5 Start the engine and check that the wheels arestationary.

6 Finally tighten locknuts A and C taking care to retain theset position of adjusting screws.

7 Re-check for wheel movement.

Manual Machines

Check that the control linkage is correctly adjusted and notsticking.


9803/8530

Section E

10 - 7

Issue 1


382810

P1

P2

A

B

D

C

10 - 8

Checking Motor Leakage Rate

If the motor speed is low and the pump output is normal, thecause could be excessive internal wear in the motor whichwould result in high leakage of oil into the motor casing. Bymeasuring the amount of oil leaking from the motor casingback to tank, it is possible to determine if the motor is worn.

1 Stop the engine.

2 Remove the seat and floorplate to expose the motors.

3 Connect a flowmeter into the motor drain hose at themotor.

4 Install a 0 - 400 bar (0 - 6000 lb/in2, 0 - 422 kg/cm2)pressure gauge into the appropriate point on the pumpto measure the pressure generated in the motor feedline (see next page for pressure test points).

5 Start the engine and drive the machine forward againsta solid, immovable object as shown at C. Measure theamount of oil expelled from the motor during oneminutes operation.

At the maximum pressure of 414 bar (6000 lbf/in2) thenormal oil leakage should be approx. 17 l/min (3.75 UKgal/min, 4.5 US gal/min).

Note: The motor leakage at zero pressure is much less thanthe rate at higher pressures. This is because at higherpressures the motor flushing spool is actuated causing theoil flow through the motor casing to increase. The figurequoted above is the combined leakage and flushing flows.

If the flow rate is higher than normal, the motor should bedismantled for repair.


9803/8530

Section E

10 - 8

Issue 1


382830

C

10 - 9

Pump High Pressure Relief Valves

The upper illustration shows the right hand side of the pump,the lower illustration shows the left hand side of the pump.

A Left motor forward portB Left motor reverse portC Right motor reverse portD Right motor forward port

!!WARNINGHydraulic Fluid

Fine jets of hydraulic fluid at high pressure can penetratethe skin. Do not use your fingers to check for hydraulicfluid leaks. Do not put your face close to suspectedleaks. Hold a piece of cardboard close to suspectedleaks and then inspect the cardboard for signs ofhydraulic fluid. If hydraulic fluid penetrates your skin, getmedical help immediately.INT-3-1-10/1

Testing High Pressure Relief Valves

To carry out a dynamic test of the high pressure relief valveswould require the wheels to be prevented from moving.Because of the difficulty of doing this it is recommended thatthe valves are tested by swopping them from one drive sideto the other.

DO NOT attempt to blank off the drive to activate the reliefvalves as the pump could be severely damaged.

Identify which drive circuit is faulty then proceed as follows:

1 Remove the seat and seat base.

2 Check for dirt trapped under the valve poppet byunscrewing the faulty valve by four turns then startingthe engine and operating the transmission control toselect the appropriate drive. Retighten the valve.

3 Operate the transmission to see if the problem persists.

4 If the problem is still present, swop the valves from leftside to right side and recheck. If the problem changessides then the valve is faulty. If the problem remains onthe same side the fault lies elsewhere.

The valves are not adjustable. The faulty valve should beremoved and a new one fitted.


9803/8530

Section E

10 - 9

Issue 2


B

A

C

D

327490

10 - 10

Checking the Joystick Hydraulic Lines

If the machine does not respond to joystick movements,check the hydraulic supply to and from the joystick asfollows:

1 Remove the seat and floorplate to access the hoseconnections A and B.

2 Insert a tee piece and 0 - 40 bar (0 - 600 lb/in2, 0 - 42kg/cm2) pressure gauge into the joystick supply hose atthe brake valve at position A.

3 Start the engine and observe the gauge reading whichshould show the transmission pump charge pressure(see Hydraulics Technical Data).

4 If the gauge shows no or little pressure it could indicatea fault in the charge pressure priority valve.

5 If the supply pressure is correct, check the feed hose tothe joystick for blockage.

6 Remove the tee piece and gauge.

7 Disconnect each servo feed line in turn from the pumpand connect the gauge to the end of the hose, as shownat B.

8 Start the engine and move the joystick lever topressurise the relevant hose. The lever should be movedfully diagonally as shown below.

9 The pressure gauge should show transmission pumpcharge pressure with full joystick travel (see HydraulicsTechnical Data).

10 If any readings are not correct, check the hoses forblockage. If the hoses are clear the joystick should bedismantled for repair.


9803/8530

Section E

10 - 10

Issue 2


FWD

REV

B

382841

CT1CT2 SOFTSHIFTVALVE

P

CT3

6 7

TT

BRAKEVALVE

382850

21

3 4

4

2

3

1

A

CONTENTS11 - 1


9803/8530

Section E

11 - 1

Issue 1

Problem Solving

Loader Circuit

The purpose of this section is to help you trace hydraulic problems to a faulty unit (valve, actuator, ram etc). Once you havetraced the faulty unit, refer to the appropriate dismantling, inspecting and test instructions given elsewhere in the manual.

To help identify circuits, valves, rams etc. mentioned in the problem solving procedures, refer to hydraulic schematic diagrams.

* Before you begin problem solving, read the Safety Information at the beginning of this manual.

* Make simple checks before say, stripping a major component.

* Make sure that the hydraulic fluid is at correct working temperature (50 C, 122 F).

* Whatever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary.

* Be sure to remove ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in thecircuit.

PROBLEM CAUSE (standard machines) CAUSE (High-flow machines)

Lack of power in all loader functions. 1, 2, 3, 4, 6, 18 1, 2, 3, 4, 6, 7, 18

All hydraulic rams slow to operate. 3, 4, 10 3, 4, 7 (servo only), 10

One hydraulic service fails to operate or 12, 13, 15, 15, 17 12, 13, 14, 15, 17is slow to operate.

Engine tends to stall when hydraulics are under load. 3, 18 3, 7, 18

Valve spool sticking. 3, 19, 21, 22, 23, 24, 25, 26, 27, 28 3, 19, 21, 22, 23, 24, 25, 26, 27, 28

Ram creep. 15, 16 15, 16

Hydraulic oil becomes too hot. 5, 6, 11, 20 5, 6, 11, 20

Boom judders when used while machine is moving. 8 (servo only) 10


1 Insufficient hydraulic fluid. Check for leaks and top up as required.

2 Hydraulic leaks in system. Check hoses, replace as required.

3 Main relief valve (MRV) setting incorrect. Check and adjust as required. E21-1

4 Low loader pump flow. Check pump flow, if necessary service or replace pump.

5 Hydraulic filter clogged. Change hydraulic filter. 3/8-1

6 Charge filter by-pass valve leaking. Check condition of hydraulic filter. 3/8-1Check operation of by-pass valve.

7 Charge pressure priority valve pressure Check pressure setting of charge pressure priority valve. E22-1setting incorrect.

8 Servo pressure low Carry out charge pressure priority valve check. E22-1Check for blocked service feed hose or faulty joystick.

..... continued

11 - 2


9803/8530

Section E

11 - 2

Issue 1



9 Non priority pressure/flow low. Carry out charge pressure priority valve flow check. E22-1

10 Neutral circuit or low pressure lines leaking, Check pipe lines and replace as required.damaged, trapped or kinked.

11 Restriction in neutral circuit lines. Check hoses and pipes, replace as necessary.

12 Service pipe lines leaking, damaged, Check hoses and pipes, replace as required.trapped or kinked.

13 Ram or pipe lines from ram leaking. Check and rectify as required.

14 Valve spool not operating. Check for leaks, rectify as required.Make sure that spool lock-out is operating (check forfaulty wiring, solenoid sticking, burr on spool, etc.)Make sure that associated load holdcheck valve is operating.

On servo machines, check operation ofjoystick and feed hoses.On manual machines, check that control leverand associated linkage is operating the spool,rectify as required.

15 Valve spool not moving fully from Spool movement should be 5.5 mm (0.22 in)neutral to full selection. On servo machines, check servo (charge) pressure. E26-3

16 Valve spool leaking Rectify, check for contamination.

17 Piston rod bent. Replace piston rod. Check pressure setting of MRV.Check that associated pivot pins are adequately greased.

18 Poor engine performance. Check engine performance.

19 Manual control linkage bent. Disconnect linkage. Repair linkage or renew.

20 Oil cooler obstructed. Remove debris from cooler fins.

21 Oil temperature abnormally high. Check for correct fluid, see Lubricants andCapacities. Check oil cooler and grille for blockage.

22 Hydraulic fluid dirty. Clean tank strainer. If strainer badly clogged, drain andflush hydraulic system then fill with clean hydraulic fluid.

23 Service pipe connection over tightened. Check tightness.

24 Valve housing twisted during installation. Loosen retaining bolts and tighten to correct torque.

25 Bent spool. Dismantle control valve. Renew spool as necessary.

26 Spool return spring broken. Renew as necessary.

27 Spool return spring or cap out of alignment. Remove cap, check that spring is in correct position.Refit cap and torque tighten bolts.

28 Temperature distribution within Warm up entire system before using service.control valve not uniform.

12 - 1


9803/8530

Section E

12 - 1

Issue 2


Levelling Circuit

PROBLEM PROBABLE CAUSE REMEDY

1 Boom delay at start of self-level A Air in system A Cycle boom and bucket slowlyor unstable self-level to rid system of air

2 Loaded bucket dumps or raises A Unloading spool is leaking A Remove and inspect unloadingwhen control valve is in neutral spool for damage

3 Insufficient self-level A Pin X is out of adjustment A Re-adjust pin to achieve properflow split

B Broken unloading spool spring B Replace unloading spool spring

C Flow divider spool stuck C Remove flow divider spool andtowards port B check for damage

4 Bucket dumps faster than boom A Pin X out of adjustment A Re-adjust pin to achieve properraises. Too much self-level flow split

B Flow divider spool stuck B Remove flow divider spool andtowards port B check for damage

C Flow divider spool installed C Remove spool and install withincorrectly internal orifice towards port B

5 With bucket dumped, boom is A Dampening orifice in the A Remove unloading spool andslow in starting to raise unloading spool is blocked clean dampening orifice

6 Bucket does not move in self-level A Pin X is screwed in all the way A Re-adjust pin to achieve properflow split

B Dampening orifice in the B Remove unloading spool andunloading spool is blocked clean dampening orifice

C Ports A and B cross connected C Reverse hoses to ports A and B

7 Bucket raises in self-level A Ports A and B cross connected A Reverse hoses to ports A and B

8 External leakage A Damaged O ring A Replace O ring

X

382881

13 - 1


9803/8530

Section E

13 - 1

Issue 1


382900

A

B

CONTENTS

If poor attachment performance is still experienced afterresetting the High-flow valve and the flow rates and pressureare correct, then the problem is with the attachment.Consult the attachment service manual for corrective action.

An example of a problem may be excessive back pressure.No more than 12 bar (175 lbf /in2) should be seen at theHigh-flow valve block. To check this insert a tee piece and a40 bar (600 lbf /in2) pressure gauge into the return line at B.Check the pressure recorded by the gauge with theattachment running.


9803/8530

Section E

Issue 2

Problem Solving13 - 2

High-flow Circuit

In the event of poor attachment performance or hydraulicoverheating when using the High-flow circuit, the followingprocedure should be followed to ensure optimum machineand attachment performance.

Checking Flow and Pressure

1 Check the flow requirement of the attachment fittedand compare it to the machine specification. Note thatthe flow at the High-flow circuit is a combination of thehigh flow pump and the auxil iary pump. If theattachment flow rate requirement exceeds the totalmachine flow then the attachment is unsuitable for use.

2 Check the pressure requirement of the attachment. Ifthis exceeds the machine specification then theattachment is unsuitable.

3 Only when attachment suitability has been confirmedcan the cause of the problem be established.

4 Check the flow and pressure setting of the High-flowcircuit as detailed below:

4.1 Connect a flow meter, 400 bar (6000 lbf /in2) pressuregauge and load valve between the high flow couplingson the loader arm as shown.

4.2 With the hydraulic oil at 50 C (122 F), the engine atmaximum speed and the load valve fully open, operatethe High-flow circuit and check that the flow reading isas specified in the table below. Progressively close theload valve and check the flow and pressure against thefigures in the table.

4.3 If necessary, adjust the High-flow relief valve A so thatthe correct specified pressure is achieved.

Flow Rates - L/min (UK gal/min) [US gal/min]

13 - 2

Max. flow, no pressure 120 - 130 (26.4 - 28.6) [31.7 - 34.3]100 bar (1450 lbf /in2) 115 - 125 (25.3 - 27.5) [30.4 - 33.0]120 bar (1740 lbf /in2) 115 - 125 (25.3 - 27.5) [30.4 - 33.0]140 bar (1740 lbf /in2) 115 - 120 (25.3 - 26.4) [30.4 - 31.7]

21 - 1

Main Relief Valve (M.R.V.)

Remove the seat and seat base.

Connect a 0 - 400 bar (0 - 6000 lb/in2, 0 - 422 kg/cm2)pressure gauge to test connector A located on the chargepressure priority valve.

With the engine running at maximum speed, check theM.R.V. setting by raising or lowering the loader arm until therams are fully open or closed and noting the maximumgauge reading. Keep clear of the loader arm. Themaximum pressure should be as stated in Technical Data.

If the pressure is incorrect, remove cap B from the M.R.V.Slacken lock nut C and turn adjusting screw D clockwise toincrease the pressure or anti-clockwise to decrease thepressure. Tighten lock nut C and recheck the pressure.When the pressure is correct, refit cap B.

Remove the pressure gauge and refit the seat and seatbase.


9803/8530

Section E

21 - 1

Issue 2*

Pressure Testing CONTENTS

385021

382780

A

B

D C

*

22 - 1

1 Install a flow meter and 0 - 40 bar (0 - 600 lb/in2, 0 - 42kg/cm2) pressure gauge into the priority line from theCharge Pressure Priority Valve (CPPV) right hand port tothe transmission pump.

!!WARNINGThe following procedure requires the machine to beraised off the ground while the work is carried out.Support the machine safely on blocks. Keep clear ofrotating wheels.0082

2 Place the machine safely onto blocks so that all fourwheels are clear of the ground. Ensure that the machineis stable.

3 Start the engine and run at max. revs. then select drive.Observe the reading on the pressure gauge then, usingthe graph below, plot a horizontal line from the pressurereading and check that the flow recorded on theflowmeter is as indicated on the graph for that pressure.

4 If the flow is higher than indicated on the graph suspectexcessive leakage within the hydrostatic system. Checkthat the hydraulic filter element is not blocked causingthe by-pass valve to open.

5 Lower the machine to the ground and repeat test inparagraph 3 whilst driving the machine against a solidimmovable object.

6 If the flow is higher than indicated on the graph suspectexcessive leakage within the motors.

7 Operate a loader service and check that the priority linepressure is not affected.

8 If the priority line pressure is below 20 bar (290 lb/in2;20kg/cm2) or the pressure is affected by loaderoperation the CPPV or the gear pump could be faulty.To check which unit is faulty proceed as follows.

9 Connect a flow meter and load valve into the non-priority line from the CPPV left hand port to the valveblock. Alternatively the flow meter and load valve can beconnected across the quick release couplings.

Note: The machine must remain static during the followingtests. If the transmission control levers are moved the motorflushing flow will increase and the non priority rate will drop.

10 With the load valve open and the engine at max. revs,the flow reading should be above 85 litres/min (18.7 UKgal/min; 22.5 US gal/min). If the flow reading is belowthis figure the gear pump is faulty.

11 Using the load valve, gradually increase the pressure inthe non-priority line. The flow and pressure readingsshould be as indicated in the table below.DO NOT EXCEED 180 Bar (2610 lb/in2, 184 kg/cm2).


9803/8530

Section E

22 - 1

Issue 2

Pressure Testing CONTENTS

Charge Pressure Priority Valve Flow/Pressure Check

30

25

20

150 15

Litres/Min

Bar

0 3.9US gal/min

5 25

1.3 5.3

10 20 30 35 40

2.6 6.4 7.9 9.2 10.5

390080

Table of Non-priority flow/Pressure

Pressure Flowbar lb/in2 kg/cm2 l/min UK gal/min US gal/min

100 1450 102 81-83 17.8-18.3 21.4-21.9150 2175 153 78-80 17.2-17.6 20.6-21.1180 2610 184 77-79 16.9-17.4 20.3-20.9

26 - 1

Pump/Engine Coupling

This is a flexible coupling comprising an outer coupling A,bolted to the engine flywheel, and an inner coupling Bclamped to the input shaft of the pump unit.

The outer coupling A is bolted to the engine flywheel with sixsetscrews C. The inner section B is tightened onto the pumpshaft spline with grub screws D.

When fitting the outer coupling to the flywheel insert mandrelX (see service tools) before fitting setscrews C.

Coat threads of setscrews C with JCB Threadlocker andSealer and torque tighten to 28 Nm (21 lbf ft, 2.8 kgf m).

Slide inner coupling B fully onto the pump input shaft. Coatthreads of grub screws D with JCB Threadlocker and Sealerand torque tighten to 70 Nm (52 lbf ft, 7.1 kgf m).


9803/8530

Section E

26 - 1

Issue 1

Pumps CONTENTS

385040382920

C

X

AD

B

3 - 2

Section F Transmission

9803/8530

Section F

3 - 2

Issue 1

Wheel Hubs CONTENTS

12

5

87

13

64

2

31

9

11

10

5 5

8 7

1313

64

4

23

1

385490

YX

3 - 3

Wheel Hub Assembly

Dismantling

Remove bolt 1, plain washer 2 and preload washer 3.Remove drive sprocket 4.

Support the casing assembly on its outer flange with thewheel hub facing downwards and press out the axle shaftassembly 5. Bearing 6 will remain in the casing 13 and canbe removed separately if necessary. The outer race ofbearing 7 will also be left in the casing and can be removedif necessary. Shaft seal 8 should be removed and discarded.

If fitted and if necessary, remove bolts 9 with washers 10and remove twine cutter 11.

Inspection

Thoroughly clean and dry all components. Examine thebearings, axle shaft and casing for wear or damage. Renewas necessary.

Assembly

Assemble the twine cutter, if previously removed, andtighten bolts 9 to the correct torque.

Lubricate outer bearing 7 and seal 8 with JCB Special HPGrease before assembly. Inner bearing 6 should beassembled without grease.

Press bearing 7 into casing 13 ensuring that the outer race ispressed fully home.

Assemble outer race of bearing 6 into casing 13. Ensure it ispressed fully home.

Fit the two halves of the oil seal installer A (825/10003)around the axle shaft 5 and position a new oil seal 8, withthe seal lip facing inwards, against the installer. Feed axleshaft 5 into the casing.

Assemble the inner race of bearing 6 onto axle shaft 5 andslide sprocket 4 onto the splines of the axle shaft.

Note: The front sprocket should be assembled with its bosstowards the casing, as at X. The rear sprocket should beassembled with its boss away from the casing, as at Y.

Screw threaded stud C of assembly tool B (825/10002) fullyinto the end of the axle shaft as shown then continue turningthe stud to pull the axle shaft into the casing so that the oilseal is fully installed. Release the assembly tool and removethe oil seal installer. Note that it may be necessary to gentlytap the end of the shaft to release the installer.

Reassemble tool B and continue pulling the axle shaft intoposition by tightening stud C to preload the bearings. Rotatethe shaft during this process to seat the bearings.

Fit a torque meter to the head of stud C and check thetorque required to rotate the axle shaft. The correct rollingtorque should be 80 Nm (59 lbf ft, 8.2 kgf m). Continuetightening stud C until the correct rolling torque is achieved.

Rotate the axle shaft 1 full revolution to ensure that thebearings are fully seated then recheck the rolling torque and,if necessary, tighten further to 80 Nm (59 lbf ft, 8.2 kgf m).

Position a dial gauge against the flat face of the sprocket asshown at D and zero the gauge. Reposition the dial gaugeonto the end of the axle shaft as shown at E and note thereading. Remove the gauge and assembly tool.

continued


9803/8530

Section F

3 - 3

Issue 1

Wheel Hubs CONTENTS

333181

A

A

B

D

E333191

C

3 - 4

Wheel Hub Assembly

Assembly (continued)

Preload washer 3 is available in various thicknesses to allowfor the correct preload of bearings 6 and 7 as follows:

Part No. Thickness242/00096 0.025 - 0.045 mm823/10303 0.05 - 0.11 mm823/10304 0.115 - 0.175 mm823/10254 0.18 - 0.24 mm823/10255 0.245 - 0.305 mm823/10256 0.31 - 0.37 mm823/10257 0.375 - 0.435 mm823/10258 0.44 - 0.50 mm823/10259 0.505 - 0.565 mm823/10317 0.57 - 0.63 mm

Select the preload washer which gives the closest match tothe dial gauge reading.

Assemble the preload washer 3 onto the axle shaft with thestepped face towards the shaft (part numbered face awayfrom the shaft). Fit washer 2 and bolt 1. Tighten bolt 1 to thecorrect torque whilst rotating the shaft to seat the bearings.

Fit a torque meter to the head of bolt 1 and check the rollingtorque is still 80 Nm (59 lbf ft, 8.2 kgf m).

Torque Settings

Item Nm lbf ft kgf m1 220 162 22.49 28 21 3


9803/8530

Section F

3 - 4

Issue 1

Wheel Hubs CONTENTS

4 - 1

Removal and Replacement

Removal

It is assumed that roadwheels are removed and the machineis correctly supported.

Drain the oil from the chain case (see Drive ChainLubrication, Section 3).

Remove the chain case access cover X (right hand sideshown).

Remove the hub assemblies D and E (see Wheel Hubs, thissection).

Lift the chains B and C from the sprockets on the drivemotor A and withdraw the chains from the chaincase.

Replacement

Replacement is the reverse of the removal sequence.

The chains should be positioned as shown. The upperillustration shows the right hand side of the machine, thelower illustration shows the left hand side.

Refit the wheel hub assembly (see Wheel Hubs, thissection).

Adjust the chains (see Drive Chain Adjustment, thissection).

Refit the chaincase access cover X using a new gasket.Refil l the chaincase with the correct oil (see Fluids,Capacities and Lubricants, section 3).


9803/8530

Section F

4 - 1

Issue 1

Drive Chains CONTENTS

A C

D

B

E

385750

B

E

C

A

D

385740X

385730

4 - 2

Adjustment

Note: The drive chains are pre-tensioned duringmanufacture and do not require routine adjustment inservice. The following procedure should be carried outwhenever the chains are disturbed or renewed.

Chain Adjustment

Adjust as follows:

1 Drain the oil from the chaincase.

2 Remove the chaincase access cover A.

3 Loosen the eight hub mounting bolts B.

4 Slacken locknut D and screw adjustment bolt E out topush the hub away from the centre of the machine andso tighten the chain. The hub will pivot about dowel C.

5 Rotate the sprocket so that one side of the chain is taut.Position the hub to give 25 mm (1 in) of slack on theopposite side of the chain at the midway point.

6 When the correct tension is achieved, tighten thesecond locknut to the adjustment bolt E.

7 Torque tighten bolts B to 220 Nm (162 lbf ft, 22.4 kgf m).

8 Refit the chaincase access cover A using a new gasket.Refill the chaincase with the correct oil.


9803/8530

Section F

4 - 2

Issue 1

Drive Chains CONTENTS

C

B

D

E

A

385480

8 - 1

Hydraulic System

!!WARNINGFine jets of hydraulic fluid at high pressure can penetratethe skin. Do not use your fingers to check for hydraulicfluid leaks. Do not put your face close to suspectedleaks. Hold a piece of cardboard close to suspectedleaks and then inspect the cardboard for signs ofhydraulic fluid. If hydraulic fluid penetrates your skin, getmedical help immediately.INT-3-1-10/1

Checking the Fluid Level - for interval see Service Schedule

The oil level should be checked when the oil is cool or cold.

1 Lower the l ift arm and fully crowd the shovel/attachment as shown at X. Stop the engine.

2 Look at the fluid level in the sight glass A. The levelshould be at the mark on the sight glass.

If the fluid in the sight glass appears cloudy, then wateror air has entered the system. The hydraulic pump couldbe severely damaged if the machine is operated.

3 If more fluid is needed, open the hydraulic tank filler capB and top up with engine oil.

Changing the Filter - for interval see Service Schedule

1 Stop the engine and wait until the system has cooled.

2 Open the engine top cover.

3 Loosen the hydraulic tank filler cap B and allow allpressure to dissipate. Remove the filler cap.

4 Unscrew the old filter canister C, using a chain wrench ifnecessary, and discard.

5 Lubricate seal D on the new filter canister with cleanengine oil.

6 Screw on the new filter canister hand tight only.

7 Refit cap B, run the engine for a few minutes, then re-check the fluid level.

Note: Old filters should be disposed of in accordance withlocal Health and Safety regulations.

Section 3 Routine Maintenance

9803/8530

Section 3

8 - 1

Issue 2*

CONTENTS

378180

378170

A

B

C

X

D

*

*

8 - 2

Hydraulic System (contd)

Changing the High-flow Filter - for interval see ServiceSchedule


2 Open the engine compartment top cover.

3 Loosen the hydraulic tank filler cap B and allow allpressure to dissipate. Remove the filler cap.

4 Remove the seat base and floor plate.

4 Unscrew the old filter canister E, using a chain wrench ifnecessary, and discard.

5 Lubricate seal F on the new filter canister with cleanengine oil.

6 Screw on the new filter canister hand tight only.

7 Add engine oil through filler point B. (See Fluids,Capacities and Lubricants).

8 Refit cap B, run the engine for a few minutes, then re-check the oil level.

9 Replace the floorplate and seat base.

Note: Old filters should be disposed of in accordance withlocal Health and Safety regulations.

Changing the Hydraulic Tank Breather - for interval seeService Schedule


2 Open the engine top cover.

3 Loosen the hydraulic tank filler cap B and allow allpressure to dissipate.

4 Clean the area around the tank breather G.

5 Unscrew the old breather and discard.

6 Screw on the new breather and tighten securely.

7 Refit filler cap B.


9803/8530

Section 3

8 - 2

Issue 1

CONTENTS

B

382380

G

378190

E

F

9 - 2

Transmission (cont'd)

Tyres and Wheels

Inflating the Tyres

!!WARNINGOver-inflated or overheated tyres can explode. Do notcut or weld the rims. Get a tyre/wheel specialist to doany repair work.5-3-2-4

These instructions are for adding air to a tyre which isalready inflated. If the tyre has lost all its air pressure, call ina qualified tyre mechanic. The tyre mechanic should use atyre inflation cage and the correct equipment to do the job.

1 Prepare the Wheel

Before you add air to the tyre, make sure it is correctlyfitted on the machine or installed in a tyre inflation cage.

2 Prepare the Equipment

Use only an air supply system which includes a pressureregulator. Set the regulator no higher than 1.38 bar (20lbf/in2, 1.4 kgf/cm2) above the recommended tyrepressure. See Table below.

Use an air hose fitted with a self-locking air chuck andremote shut-off valve.

3 Add the Air

Make sure that the air hose is correctly connected to thetyre valve. Clear other people from the area. Standbehind the tread of the tyre while adding the air.

Inflate the tyre to the recommended pressure. Do notover-inflate.

Tyre Pressure Table

Replacing Segments of Optional Non-Inflatable Tyres

Non-inflatable tyres are available as an option for use inenvironments where a puncture could have seriousconsequences. These tyres consist of a number of individualsegments bolted to the wheel rim.

Damaged segments can be renewed individually. Loosenand remove the four nuts and washers A (two each side ofthe wheel). Lift the segment clear by extracting its fixingstuds from the holes in the wheel rim.

Fit a new segment in reverse order to removal, then tightenthe retaining nuts to a torque of 28 Nm (21 lbf ft, 3 kgf m).

Checking the Wheel Nut Torques

On new machines, and whenever a wheel has beenremoved, check the wheel nut torques every two hours untilthey stay correct.

Every day, before starting work, check that the wheel nutsare tight.

The correct torque is shown in the table below.

!!WARNINGIf, for whatever reason, a wheel stud is renewed, all thestuds for that wheel must be changed as a set, since theremaining studs may have been damaged.2-3-2-8


9803/8530

Section 3

9 - 2

Issue 1

CONTENTS

A

Make Size Pressure bar (lbf/in2)

Omega HD 12 x 16.5 x 10 Ply 3.5 (50)

Omega HD WT 12 x 16.5 x 10 Ply 3.5 (50)

Galaxy 12 x 16.5 x 10 Ply 3.5 (50)

Galaxy WT 12 x 16.5 x 10 Ply 3.5 (50)

Galaxy 33/1550 x 16.5 x 12 Ply 4.0 (60)

Front and Rear

Nm lbf ft kgf m244 180 25

R: iuytilu:

190-1110 probsolv

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