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JCB 3CX, 4CX, 214e, 214, 215, 217 & VARIANTS Backhoe Loader. Service Manual - page 4

Section B

Body & Framework

Section B

20 - 1

Service Procedures

20 - 1

Air Conditioning

Checking Refrigerant Charge Level

The pressure in the system, i.e. the refrigerant charge level

Leak Testing

can be determined by checking the state of refrigerant at the

receiver drier sight glass.

Note: The refrigerant is heavier than air and will leak

downwards from the defective component. Check in still

If the level of charge is correct the sight glass will be clear. If

conditions but in a well ventilated area.

the charge is low bubbles will be seen. Bubbles may also be

an indication of inadequate cooling, due to a restriction of air

Hose or pipe connections are likely leakage points of any

flow around the condenser coil. Recharging of the system

refrigerant circuit.

should be carried out by an air conditioning engineer. Check

refrigerant charge level as follows:

To test for leaks in the high pressure side of the system i.e.

from the compressor output to the expansion valve, run the

1

Park the machine on firm, level ground. Lower the

air conditioning for a few minutes then switch off the engine

backhoe and loader to the ground.

and test for leakage using an electronic leak detector.

2

Remove the starter key.

To test for leakage in the low pressure side of the system,

switch off the air conditioning and leave for a few minutes

3

Remove the front grille.

before testing.

! WARNING

! WARNING

Leak testing in Air Conditioning systems should be

When the engine is turning, there are parts rotating in

carried out only in a well ventilated area.

the engine compartment.

BF 1-2

Before starting this job make sure that you have no

loose clothing (cuffs, ties etc) which could get caught in

rotating parts.

Tightening Leaking Hoses

When the engine is turning, keep clear of rotating parts.

2-3-3-10

! WARNING

4

Start the engine and run at idle. Switch air conditioning

The air conditioning system is a closed loop system and

ON to circulate refrigerant.

contains pressurised refrigerant. No part of the system

5

Check refrigerant charge level at sight glass A.

must be disconnected except by a qualified refrigeration

engineer.

4-3-4-1

The refrigerant hoses have crimped ferrule end fittings. The

hose connectors have an 'O' ring seal which compresses

A

when the connection is tight, creating an air tight seal.

Hoses are used to connect the inlets and outlets of the

compressor, condenser, receiver drier and expansion valve

(the evaporator coil is connected to the expansion valve

within the air conditioning unit using rigid pipes).

If leakage is detected from a hose connector, either by

means of an electronic leak detector or soapy water, tighten

the connector up and repeat the leakage test. If leakage is

still evident, it will be necessary to de-gas the system and

renew the connector 'O' ring seal.

The 'O' rings used on an R-134a refrigerant system are of an

HNBR compound and are colour coded green. These 'O'

rings must be used as some 'O' ring materials can become

porous to R-134a systems, resulting in leakage.

S190460

9803/3280

Issue 1

Section B

Body & Framework

Section B

20 - 2

Service Procedures

20 - 2

Air Conditioning

- Refrigerant Charging and Discharging

Note: The procedures for refrigerant charging and

discharging must only be carried out by qualified service

personel who have received specialist training on the air

conditioning system.

! WARNING

The air conditioning system is a closed loop system and

contains pressurised refrigerant. No part of the system

should be disconnected until the system has been

discharged by a refrigeration engineer or a suitable

trained person. You can be severely frostbitten or injured

by escaping refrigerant.

4-3-4-1/2

Refrigerant Recovery

The recovery process clears the system refrigerant proir to

servicing or for refrigerant renewal.

Lo

Hi

1

Ensure that the engine is OFF and the starter key

removed.

2

Connect the manifold to the system as shown, with the

To system Low

To system High

blue hose connected to the system low pressure port.

Pressure port.

Pressure port.

DO NOT connect the red hose. Make sure that both

Valve OPEN

Valve CLOSED

valves are closed.

3

Connect the yellow hose to the ‘Javac’ unit filter.

Filter

4

Connect the filter to the ‘Javac’ unit.

5

Connect the ‘Javac’ unit to an empty receiver bottle.

Weigh the bottle before and after filling to assess

system capacity.

IN

DIS

6

Switch on ‘Javac’ unit and open the low pressure

Refrigerant

manifold valve.

Cylinder

'Javac' Unit

7

The ‘Javac’ unit will automatically switch off when a

pressure balance exists between the system and the

receiver bottle. Switch off ‘Javac’at main switch, but

Scales

leave the system connected. Switch on after

10

minutes, the ‘Javac’ will restart if residual pressure

A396820

remains.

8

Close valves and remove equipment.

Notes:

DO NOT fill the receiver bottle to more than 80% by weight.

DO NOT re-use refrigerant unless you are aware of its purity.

If the high pressure warning light on the ‘Javac’ unit comes

on, throttle back the manifold low pressure valve to provide

a restriction.

The JCB recommended ‘Javac’ unit only recovers refrigerant

as a gas. Other units can recover refrigerant as a liquid

and/or gas. ALWAYS check manufacturers instructions

before using.

9803/3280

Issue 1

Section B

Body & Framework

Section B

20 - 3

Service Procedures

20 - 3

Air Conditioning

- Refrigerant Charging and Discharging

Note: The procedures for refrigerant charging and

discharging must only be carried out by qualified service

personel who have received specialist training on the air

conditioning system.

! WARNING

The air conditioning system is a closed loop system and

contains pressurised refrigerant. No part of the system

should be disconnected until the system has been

discharged by a refrigeration engineer or a suitable

trained person. You can be severely frostbitten or injured

by escaping refrigerant.

4-3-4-1/2

Evacuating (Vacuuming)

This procedure follows on from the ‘Recovery’ process and

is necessary to ensure proper refilling of the system with

refrigerant.

Lo

Hi

To avoid leakage in the vacuum system itself, DO NOT use

extensions to the yellow hose (use standard 2 metre length).

To system Low

To system High

1

Recover all refrigerant from the system as described in

Pressure port.

Pressure port.

Refrigerant Recovery.

Valve OPEN

Valve OPEN

2

Close all valves and connect the manifold as shown.

CPSVG100

Connect the blue hose to the system low pressure port

Vacuum guage

and the red hose to the high pressure port.

(If used)

3

Connect the yellow hose to the vacuum pump.

4

Open manifold valves.

Vacuum Pump

5

Switch on the vacuum pump until 740mm (29 in)

A396780

mercury vacuum reads on both gauges.

6

Maintain suction for approximately 30 minutes.

7

Close valves and remove equipment.

Notes:

If the vacuum falls rapidly the system is leaking. Check all

connections and reseal. If the point of leakage is not

obvious, recharge the system and test again. Refer to

Service Procedures, Air Conditioning - Leak Testing.

Achievable vacuum will vary with altitude. Maximum gauge

reading will be 25mm (1 in) less for every 305 metres ( 1000

feet) above sea level.

9803/3280

Issue 1

Section B

Body & Framework

Section B

20 - 4

Service Procedures

20 - 4

A396790

Electronic Vacuum Gauge

The CPS VG100 vacuum gauge is an electronic type using

LED’s to indicate various states of vacuum. It is used in

place of or to supplement the gauge on the vacuum pump.

Before connecting into the system switch on to check that

the first LED lights to show that the battery is in good

condition.

Note: The indicator lights show pressure in inches of

mercury (Hg) and vacuum in microns (0.001mm Hg).

ATM/BAT

Normal atmospheric pressure reading.

Battery condition.

15’’/510mbar

381mm (15 in)Hg. Partial vacuum -

Vacuum system is operating.

29’’/980mbar

736mm (29 in)Hg. No vacuum drawn -

Possible system leakage.

8000µ

8.0mm (0.31 in)Hg. Partial vacuum -

If the reading does not progress the

system may have a slow leak.

1000µ

1.0mm (0.039 in)Hg. Deeper vacuum.

600µ

0.6mm (0.023 in)Hg. Deep vacuum.

400µ

0.4mm (0.015 in)Hg. Deep vacuum.

200µ

0.2mm (0.0078 in)Hg. Deep vacuum.

25µ

0.025mm (0.00098 in)Hg. Pump Test.

Maximum sustainable vacuum.

9803/3280

Issue 1

Section B

Body & Framework

Section B

20 - 5

Service Procedures

20 - 5

Air Conditioning

- Refrigerant Charging and Discharging

Note: The procedures for refrigerant charging and

discharging must only be carried out by qualified service

personel who have received specialist training on the air

conditioning system.

! WARNING

The air conditioning system is a closed loop system and

contains pressurised refrigerant. No part of the system

should be disconnected until the system has been

discharged by a refrigeration engineer or a suitable

trained person. You can be severely frostbitten or injured

by escaping refrigerant.

4-3-4-1/2

Relubricating

Pre-lubrication is essential after recovering system

refrigerant, vacuuming and component flushing.

The system should be evacuated to a vacuum of 740mm (29

Lo

Hi

in) of mercury before re-lubricating.

1

Ensure that the engine is OFF and the starter key is

removed.

To system Low

To system High

Pressure port.

Pressure port.

2

Close all valves and connect the manifold as shown,

Valve OPEN

Valve OPEN

with the blue hose connected to the oil injector and the

red hose to the system high pressure port.

3

Connect the yellow hose to the vacuum pump.

Oil Injector

4

Connect the other end of the oil injector to the system

Vacuum Pump

low pressure point.

5

Switch on the vacuum pump and open the high

To system Low

pressure side valve.

Oil injector valve -

Pressure port.

Open when full

6

Unscrew the oil injector cap and add the specified

vacuum is obtained.

quantity of refrigerant oil.

A396800

7

When 740mm (29 in) mercury shows on the vacuum

gauge, open the oil injector valve to allow the oil into

the system.

8

If more oil is needed repeat the above procedure. The

quantity of oil should be the same as that taken out

during the ‘Recovery’ procedure.

Notes:

Use only PAG oil in R-134a systems.

9803/3280

Issue 1

Section B

Body & Framework

Section B

20 - 6

Service Procedures

20 - 6

Air Conditioning

- Refrigerant Charging and Discharging

Note: The procedures for refrigerant charging and

discharging must only be carried out by qualified service

personel who have received specialist training on the air

conditioning system.

! WARNING

The air conditioning system is a closed loop system and

contains pressurised refrigerant. No part of the system

should be disconnected until the system has been

discharged by a refrigeration engineer or a suitable

trained person. You can be severely frostbitten or injured

by escaping refrigerant.

4-3-4-1/2

Charging

This procedure is industry recommended practice for

refilling air conditioning systems with refrigerant.

Evacuate the system beforehand to 740mm (29 in) of

Lo

Hi

mercury.

1

Close all valves and connect the manifold as shown.

To system Low

To system High

Connect the blue hose to system low pressure and the

Pressure port.

Pressure port.

red hose to system high pressure. Connect the yellow

Valve CLOSED

Valve OPEN

hose to the refrigerant cylinder.

2

Invert single valve cylinder on the scales and zero the

Refrigerant

scale reading (see Notes: for twin valve cylinders).

Cylinder

Thermal Blanket

3

Slowly open the high pressure valve and allow the

vacuum to draw-in refrigerant to the specified weight

for the system. Refer to Technical Data.

Scales

4

Close all valves and remove the equipment.

A396810

Notes:

Add refrigerant as a LIQUID, not as a gas. Some refrigerant

cylinders have separate valves for gas and liquid. Be sure to

connect to the liquid port when following the above

procedure.

Refrigerant can be used either in gas or liquid form. If

recharging with gas follow the manufacturers instructions

and recharge only via the low pressure port. DO NOT use

liquid refrigerant at the low pressure port.

Add refrigerant until the scales indicate the specified weight

for the system or the weight obtained when the system

refrigerant was previously recovered.

To speed up the process a thermostatically controlled

thermal blanket can be used around the replenishing

cylinder.

9803/3280

Issue 1

Section B

Body & Framework

Section B

20 - 8

Service Procedures

20 - 8

Air Conditioning

Condenser Matrix

2

Remove the starter key.

It is likely that over a period of time, because of the

3

Remove the front grille.

machine's working environment, the airflow around the

condenser matrix will become restricted due to a build up of

4

Remove both side panels.

airborne particles.

5

Support the condenser 1.

If the build up of particles is severe, heat dissipation from

the refrigerant to the air will be significantly reduced,

6

Undo the nuts and bolts 2 at the three mounting

resulting in poor air conditioning performance.

brackets 3.

In extreme cases, over pressurisation of the system occurs,

7

Remove the screws 4 fixing the condenser to the

causing the high pressure cut out switch to operate and

mounting brackets. Remove the brackets 3 to enable

switch off the system.

the condenser to be moved away from the radiator.

This can be done without removing the hoses i.e. with

High pressure cut out can also be caused by an internal

the system fully charged.

blockage of the condenser matrix.

8

With the condenser fully supported, use compressed

Condenser Matrix Cleaning

air or low pressure water to backflow through the

matrix fins. Take care not to damage the fins.

Take care not to damage the condenser fins or tubes.

Damaged fins must be straightened out to ensure a good

9

Refit the condenser matrix by reversing the removal

airflow through the matrix.

procedure. Refit both side panels and bonnet.

1

Park the machine on firm level ground. Raise and block

10

Run the air conditioning and check cooling

the loader arms. Lower the backhoe to the ground and

performance.

stop the engine.

4

4

1

2

3

A401500

9803/3280

Issue 1

Section B

Body & Framework

Section B

20 - 9

Service Procedures

20 - 9

Air Conditioning

Filters - Changing and Cleaning

Air Intake Filter

1

Stop the engine and remove the starter key.

2

Remove Screws D, air intake cover E and filter F.

Clean filter element using compressed air. Refit filter

into the cover and refit.

E

F

D

S190470

9803/3280

Issue 1

Section B

Body & Framework

Section B

20 - 10

Service Procedures

20 - 10

Air Conditioning

Compressor Drive Belt - Adjusting

1

Park the machine on firm level ground. Raise and block

the loader arms. Lower the backhoe to the ground and

stop the engine.

X

2

Remove the starter key.

C

B

! WARNING

Make sure the engine cannot be started. Disconnect the

battery before doing this job.

2-3-3-5

3

Raise the Bonnet

4

Remove both Side Panels

5

Loosen pivot fastening bolt A. Loosen adjustment link

A

fastening bolts B and C.

6

Position the compressor so that there is approximately

S209393

10 mm (3/8 in) slack at point X midway along the belt.

7

Tighten bolts A, B and C. Make sure that bolt A is the

last to be tightened.

Note: If a new belt is fitted, check the belt tension after the

first 20 hours of operation.

9803/3280

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

parking brake. Stop the engine. Put protective covers

over the cab seat and control pedestals.

2

a Laminated glass - leave installed until the old

sealant has been cut away, after which it will be

possible to lift the broken screen away from its

A

frame housing in one piece.

b Toughened glass

- remove as much of the

shattered glass as possible prior to cutting out the

old sealant.

3

Cut out the old sealant, leaving approximately 1 to 2

mm on the cab frame. There are several tools and

S186380

techniques for doing this:

a Pneumatic Knife A provides one of the easiest

methods of removing the sealant around laminated

glass. The tool, powered by compressed air,

B D

should be sourced locally.

Note: This tool must not be used on toughened glass (see

E

WARNING on previous page).

C

D

(i)

Press the handle to start the knife blade oscillating.

(ii)

Insert the knife blade into the sealant.

E

(ii)

Slowly move the knife along the sealant with the

blade positioned as close to the glass as possible.

Do not allow the knife blade to overheat or the

D

sealant will melt.

b Braided Cutting Wire and Handles B. This method

uses a 3-core wire, a wire starter tube and two

S189870

handles (see Service Tools).

(i)

Insert the steel tube C into the old sealant on the

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.

C

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

the sealant to the outer side of the glass.

(iv) Secure each end of the braided cutting wire in the

special handles E.

S189880

(v) Move the cutting wire backwards and forwards in a

sawing motion and at the same time gently push or

pull the wire to cut through the old sealant.

9803/3280

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)

F

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

left handed or right handed tool. For the knife and its

replaceable blades, refer to Service Tools.

(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.

d 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, for details of

H

this and any other tools.

4

a Laminated glass - lift out the broken pane using

glass lifters (see Service Tools).

b Toughened glass - remove the cut off sealant and all

remaining particles of shattered glass.

S186370

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.

6

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

J

a Paintwork was damaged or scratched during the

glass/sealant removal procedures.

b The old sealant was inadvertently cut back to the

cab frame during the glass/sealant removal

procedures.

Preparing the Cab Frame Aperture

1

If damp or wet, dry the aperture area using a hot air gun

(sourced locally).

2

Use 'Active Wipe 205' to thoroughly clean and 'prime'

the trimmed sealant. Use a lint free cloth to apply the

S189900

'Active Wipe 205', allow 5 minutes flash off (drying)

time.

Note: Do not use any other type of cleaning fluids, otherwise

they may be absorbed into the old sealant and ultimately

prevent the new glass from bonding.

9803/3280

Issue 2*

Section B

Body & Framework

Section B

21 - 4

Service Procedures

21 - 4

Direct Glazing (cont'd)

K

Preparing the New Glass

! CAUTION

M

The laminated front screen must be handled with extra

care to prevent breakage. Wherever possible, store and

handle it in a vertical attitude. When placing or lifting the

screen in a horizontal attitude it must be supported over

its whole area, not just at the edges.

BF 1-8

1

Make sure that the new glass correctly fits the frame

aperture K.

a Put two spacer blocks L onto the bottom part of the

frame aperture.

L

b Install the new glass on the spacer blocks - ALWAYS

S189910

USE GLASS LIFTERS M (see Service Tools). 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

N

two common gap widths. If necessary they can be trimmed

to a smaller size to give an equal sized gap around the glass.

IMPORTANT: The glass edges MUST NOT touch the frame,

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

it on a purpose made glass stand N (see Service

Tools).

S186280

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

P

easier and safer to handle small panes of glass. The board

should be covered with felt or carpet to give an anti-scratch

surface. Resting the glass on four spacer blocks will ensure

clearance of the cartridge nozzle tip during application of the

polyurethane sealant.

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.

S186291

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)

R

time.

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

'Active Wipe 205'.

b If the glass does not have a black ceramic ink band,

paint a band on the glass using 'Black Primer 206J'.

The band should be approximately 25mm (1in) wide,

and the edge should be a neat straight line as shown

at R.

S189920

9803/3280

Issue 1

Section B

Body & Framework

Section B

21 - 5

Service Procedures

21 - 5

Direct Glazing (cont'd)

S

Preparing the New Glass (cont'd)

5

Install the Ultra Fast Adhesive cartridge (see Sealing

and Retaining Compounds 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'.

T

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

T

cartridges must be pre-heated in a special oven (see

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

S186440

Typical m/c installation

sealant protruding from the nozzle. This will prevent any

adhesive left in the cartridge from 'curing'.

Installing the New Glass

1

Make sure the two spacer blocks are in position (see

X

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

press too hard or too much adhesive will squeeze

out.

S189910

9803/3280

Issue 1

Section B

Body & Framework

Section B

22 - 1

Service Procedures

22 - 1

Cab ROPS/FOPS Structure - Checks

! WARNING

The machine is fitted with a Roll Over Protection

Structure (ROPS) and a Falling Objects Protection

Structure (FOPS). You could be killed or seriously injured

if you operate the machine with a damaged or missing

ROPS/FOPS. If the ROPS/FOPS has been in an accident,

do not use the machine until the structure has been

renewed. Modifications and repairs that are not

approved by the manufacturer may be dangerous and

will invalidate the ROPS/FOPS certification.

INT-2-1-9/3

Failure to take these precautions could result in death or

injury to the operator.

Check the structure for damage. Check that the mounting

bolts are installed and undamaged. Check the bolt torques.

Tighten them to the correct torque if necessary.

Torque Settings

Bolts A 205 Nm (150 lbf ft)

Bolts B 476 Nm (352 lbf ft)

A

B

S260180

9803/3280

Issue 1

Section B

Body and Framework

Section B

25 - 1

Service Procedures

25 - 1

Extending Dipper

- Wear Pad Adjustment

The Extradig dipper wear pads are bolt-on replaceable

Inspecting the Top Wear Pads

items. They support and guide the inner dipper section

during extension and retraction. The following procedures

1

Park the machine on level ground. Engage the parking

explain how to inspect, and where applicable, adjust the

brake and put the transmission in neutral.

pads.

2

Position the boom and dipper as shown at C. Retract

There is a front and rear set of pads, each set comprises top

the Extradig dipper D. Make sure that the bucket is

wear pads A and bottom wear pads B.

clear of the ground and the dipper is supported.

The top wear pads A are not adjustable and must be

3

Stop the engine and remove the starter key.

replaced with new pads once they have worn to their limit.

See Inspecting the Top Wear Pads.

Renew the pads when, or before they are worn down to the

depth of the recess/chamfer as shown at E. If the pads are

The bottom wear pads B are adjustable and take up the

worn near to their limit then inspect them more frequently

wear on both the top and bottom pads. They must also be

than recommended in the Service Schedules. To avoid

replaced with new pads once they have worn to their limit.

damage to the dipper or wear pad make sure the pads are

See Adjusting the Bottom Wear Pads.

fitted the correct way round as shown at J.

New wear pads A and B must be replaced as a set and

Torque Settings

fitted by a qualified service engineer.

Item

Nm

kgf m

lbf ft

F

56

5.7

4

F

A

A

E

B

B

D

J

C

S312991

9803/3280

Issue 1

Section B

Body and Framework

Section B

25 - 2

Service Procedures

25 - 2

Extending Dipper

If the gap is greater than ¹/16 in (1.5 mm) then adjust as

follows:

- Wear Pad Adjustment (Cont’d)

a Remove one adjusting bolt H and discard one

Adjusting the Bottom Wear Pads

washer J.

1

Park the machine on level ground. Engage the parking

b Refit and tighten bolt H.

brake and put the transmission in neutral.

c Repeat the procedure for the remaining 3 adjusting

2

Support the boom and dipper as shown at C.

bolts H on the same side of the dipper.

3

Stop the engine.

d Visually re-check the gap is no greater than 1.5 mm

(1/16 in) as shown at G, if necessary repeat steps a

4

Clean the sliding faces of the inner dipper with a

to c for the other 4 bolts H on the opposite side of

suitable solvent.

the dipper.

5

Start the engine. Retract the Extradig dipper D. Make

e Make sure that the inner dipper seats central to the

sure that the bucket is clear of the ground and the

sides of the outer dipper.

dipper is supported.

Note: Remember to alternate sides each time an adjustment

6

Stop the engine.

is made.

7

With grease, mud etc. removed from the sliding faces

Note: When all the adjusting washers J have been removed

visually check the gap between inner dipper and top

and the clearance is greater than 1.5 mm (¹/16 in), then wear

wear pad A, as shown at G. The gap should be no

pads A and B must be replaced as a set and fitted by a

greater than 1.5 mm (¹/16 in).

qualified service engineer.

When the adjustments have been completed, apply Waxoyl

to the runners of the inner dipper.

A

A

G

G

J

D

H

C

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Issue 1

Section B

Body & Framework

Section B

26 - 1

Service Procedures

26 - 1

Sideshift

- Hydraclamp Clearance Setting

If the kingpost clearance D is not set correctly leaks may

occur or the seal could become dislodged, use the

procedure below to set the clearance.

1

Park the machine on firm level ground, engage the

parking brake and set the transmission to neutral.

Lower the loader arms to the ground.

2

Select the carriage clamps to lock.

3

Measure all four clamps clearance, all measurements

should be taken on the centre line A to allow for

twisting of the clamp pot as shown at B and C:

Manual

3 - 5 mm (0.11 - 0.19 in)

Power Sideshift

3 - 5 mm (0.11 - 0.19 in)

4

Release the clamps and tighten/loosen nut 1 as

required, recheck measurement. When correct bend

tab to lock nut.

D

A

D

D

B

C

338630

9803/3280

Issue 1

Section B

Body & Framework

Section B

26 - 2

Service Procedures

26 - 2

Power Sideshift - Wear Pad Renewal

Inspection (1000 hours)

Assembly

When the wear pads are worn to 6 mm (0.23 in) or below

9

Fit wear pad H, plate J and bolt D.

they should be replaced.

10

Fit new lock tab B and fit nut C.

It is permissible to rotate the top wear pads 180° to prolong

service life, provided the contact surface is more than 6 mm

11

Set the hydraclamp clearance as described in Sideshift

(0.23 in) thick.

- Hydraclamp Clearance Setting.

Note: If rotating the wear pad the grease nipples will have to

12

Repeat procedure steps 5 to 11 for the bottom clamp.

be swopped over.

The only difference on the bottom clamps is the wear

pad is on the opposite side of the rail from the top

Dismantling

clamp so bolt K need not be completely removed.

1

Park the machine on firm level ground, engage the

Note: If the wear pad is trapped between the rail and

parking brake and set the transmission to neutral.

carriage, lower the bucket to relieve the load on the wear

Lower the loader arms to the ground.

pad.

2

Set the carriage fully to end of travel A, shown in centre

13

Lift the bucket and set the carriage to the opposite end

position for clarity.

of the travel, repeat the procedure for opposite side.

3

Lower the bucket to take the weight off the kingpost.

14

When all clamps have been assembled recheck the

hydraclamp clearance of all clamps.

4

Switch OFF the engine and remove the starter key,

operate the control levers to vent residual hydraulic

pressure.

5

Unlock top lock tab B and unscrew nut C.

6

Remove bolt D through the slot in the rail E.

7

Hydraulic clamp F and washer G should remain in

position.

8

Remove plate J and wear pad H.

D

J

H

E

G

F

B

K

C

A

A326840

9803/3280

Issue 1

Section B

Body & Framework

Section B

26 - 3

Service Procedures

26 - 3

Power Sideshift - Chain Adjustment

The chain tension should be checked at the initial 100 hours

Removal

service and every 500 hours.

1

Park the machine on firm level ground, engage the

Check and Adjust

parking brake and set the transmission to neutral.

Lower the loader arms to the ground.

1

Park the machine on firm level ground, engage the

parking brake and set the transmission to neutral.

2

Position the carriage centrally and rest the bucket on

Lower the loader arms to the ground.

the ground, remove the starter key.

2

Position the carriage centrally and rest the bucket on

3

Undo and remove nuts B.

the ground, remove the starter key.

4

Remove split pins D and pin E.

3

Check the chain tension which should be 5 to 10mm

(0.19 to 0.39in) deflection A at the mid point. The

5

Withdraw chains from the machine.

tension should be equal for all chains.

Assembly

4

If adjustment is required, slacken locknuts C and adjust

on nuts B as required, tighten locknuts C on

1

Thread the chains around the pulley and secure to the

completion.

carriage with pin E, fit new split pins D.

5

Repeat steps 3 and 4 for the opposite pair of chains.

2

Connect chain adjusters, tension chains as required,

see Check and Adjust.

Note: When there is no thread left for adjustment fit new

chains.

6

Operate the carriage side to side several times and

recheck the deflection.

D

E

D

B C

C

B

A

A326830

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Issue 1

Section B

Body & Framework

Section B

30 - 1

Air Conditioning

30 - 1

R

T

S

W

V

X

A401280

Component Key:

R A/C Controls

S Expansion Valve

T Re-circ Air Inlet

V Water Valve

W HVAC Unit

X Bulkhead Plate

9803/3280

Issue 1

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