BACKHOE LOADER SERVICE UPDATE SPRING 2010

The new Backhoe Loader

Train the Trainer event by

Tim Coulson & Andrew Haynes

BACKHOE LOADER SERVICE UPDATE SPRING 2010

AGENDA :Design Brief & Marketing Background ECO Modes Options Break Machine Walk Around

Technical Information
Brake Testing Questions??

Animation

Design Brief
The design platform aims to:
Meet our key customer values;
o cost of ownership o quality and reliability o ease of use

o operator environment
o performance o residual value.

Major improvements in machine efficiencies to lower owning and operating costs.

Styling Influence
Over the past 10 years all automotive manufactures have moved to a

much more aggressive look for their cars.

Sharp lines and contours.

Branding
Increase brand recognition at a

distance
Increased distinction between current and new.

The JCB logo does remain the

same and has not changed.

Front End
Lines follow down from bonnet, through the grill and into the counterweight, creating a more aggressive feel

Bonnet and counterweight

Back mounting position Single piece design Deeper profile More aggressive look Improved opening Better fit
Counterweight
fixings

Bonnet
New under bonnet geometry aids opening

Bonnet
Tool holder under bonnet more space inside toolbox New design to latch mechanism More positive engagement

Roof
Slender roof Fastrac and Midi CX corporate. Improved run off channels Improved mounting Improved production technique Slender, more sleek design

Work Lights
Independent adjustable lighting Same number of filaments but double the number of lights Provides the same illumination as P21 Allows work lights to be positioned at the ground for loading and at the level of a truck for unloading Follows the new corporate direction for cab lights

Interior Influences
The trend has swayed towards a black interior reducing metal components

Changes to cab interior

Interior colour change
more automotive
Black internal plastics Reduced silver

Light grey B posts

Seat colour change

Black More comfortable softer material

Current interior

Better wearing

Our new interior .....................

Cab Interior contd

Side console Updated in line with cab interior updates

New switch panel with new switches

Maintains good positioning within the cab

Laser Cut Switches

New laser cut switches are influenced by the automotive industry Provide a better impression of quality

Better feel for the operator

Softer profile New bright red / crisp white illumination

Loader Profile
Deeper throat on the arms Slight change in profile shown opposite

Excavator Profile
Sharper edges, Cleaner design Squared off corners at the top of the dipper

16% FUEL SAVING

 Lower engine RPM 3rd hydraulic pump

Lower emissions
15% fuel efficiency Quieter

Economical digging - reduced fuel consumption

Up to 15% reduced fuel consumption when excavating Longer working between refuelling increases productivity Reduced noise levels as the engine is working at lower rpm Reduced wear and tear as the engine is working at lower rpm Reduces the emissions impact to the environment

ecoDIG
Industry exclusive innovation three pump design Available on Manual and Easycontrol machines as standard Fuel benefits are gained by using the engine at a more fuel efficient part of its torque curve. Adding a third gear pump increasing the total hydraulic flow and allows the engine speed to be reduced. The overall fuel saving for the using the ecoDig system is 15%. Class leading noise levels are reduce even further Less engine wear Improved extradig speed

New - Emissions
Due to a 400 rpm reduction the engine produces less emissions
On an excavating only cycle current BHL produces 247g/kWh (at 2200rpm) producing 20.10 kg of CO2 per hour. Doing exactly the same cycle with new BHL produces 224g/kWh 18.42 kg of CO2 per hour. This is an 8% saving from current.

Current Vs New ecoDIG

Pump Flow Comparison current against ecodig
160

140

Hydraulic Flow l/min

120

100

400 rpm
80

Eco Dig Flow Current Flow

60

40 600 800 1000 1200

Engine Speed r.p.m. 1400 1600

1800

2000

2200

2400

ecoDIG Operation eco mode

Select Eco mode and 3 pumps will be used. Only when the operator is within the rpm band of 650 to 1,700rpm. This acts to reduce fuel consumption.

RPM range <650 Tickover (900)-1,700 1,700 1,900 >1,900

Pump 1

Pump 2

Pump 3 (engine) X

Transition Period (time delay)

Pump control demo

ecoDIG Operation eco mode Summary

Select Eco mode and 3 pumps will be used. Pump 3 used only when the operator is within the rpm band of 650 to 1,700rpm. Pump 3 is off when below 650rpm to prevent stalling at idle. Eg stab legs lower. If engine revs rise above 650rpm Pump 3 is switched on after only a one second transition period. If engine revs rise to between 1700rpm 1900rpm then 10 second transition period commences. (Time Delay). After this period Pump 3 is switched off. If engine revs fall below 1700rpm within the 10 second transition period then Pump 3 stays on. If the revs rise again then another 10 sec transition period commences. If revs rise above 1900rpm then Pump 3 is instantly switched off with no transition period.

If revs then drop below 1700rpm Pump 3 is switched on after only a one

ecoDIG Operation lo mode

Select Lo mode and only pumps 2 & 3 will be in use while excavating. Only pump 2 will be used for loading which is computer controlled. This is based on the position of the Forward/Reverse lever. If 4th gear is selected thenPump only1one pump (P2) will be operating. Operation Pump 2 Pump 3 (engine)
Excavating

Loading (FNR selected)

 Hydraulic Speed Control switch (Lo)

High torque at low engine speed Class leading productivity

 Patented Torque Lock system 20% more working area 25% fuel saving 10% greater average speed Reduced carbon footprint

Power Brakes

Power Brakes Customer Benefits

Recessed pedals (closer to bulkhead)
Increased foot room Easier entry and exit

Reduced service checks Reduced pedal travel improved comfort and ergonomics Proportional braking effort Improved feel with more car like position Maintain road speeds for longer No brake drag - more efficient while roading up to 1%

Side Console

Side Console Options Menu

TIME-SRV Hours to next service LANGUAGE Allows appropriate language to be set. (Three options) S/W VERSION Displays software version entered (Currently Version 8) H/W VERSION - Displays hardware version entered (Currently Version 1) GRD HTR For machines with a Grid Heater option (Default is on) BST PUMP Boost pump 3 on Manual/Easy Control machines. (Default is on) BUZ MUTE Allows panel buzzer to be temporarily turned off.

Side Console Options Menu

TIME-SRV Hours to next service LANGUAGE Allows appropriate language to be set. (Three options) S/W VERSION Displays software version entered (Currently Version 8) H/W VERSION - Displays hardware version entered (Currently Version 1) GRD HTR For machines with a Grid Heater option (Default is on) BST PUMP Boost pump 3 on Manual/Easy Control machines. (Default is on) BUZ MUTE Allows panel buzzer to be temporarily turned off.

Side Console Options Menu

TIME-SRV Hours to next service LANGUAGE Allows appropriate language to be set. (Three options) S/W VERSION Displays software version entered (Currently Version 8) H/W VERSION - Displays hardware version entered (Currently Version 1) GRD HTR For machines with a Grid Heater option (Default is on) BST PUMP Boost pump 3 on Manual/Easy Control machines. (Default is on) BUZ MUTE Allows panel buzzer to be temporarily turned off.

Side Console Software Access

To make any software changes to the side console a link harness and switch are required. (None currently necessary) Harness part number 332/F6268 Switch part number 701/60000

The harness plugs into rear of the side console panel.

Options

Hydraulics Auxiliary Pipework

Combined Hammer / BiDirectional pipework

Increased versatility Independent circuit Compatible with full range of 3CX & 4CX machines Low flow / high flow function as standard Wide range of attachments Independent hammer circuit

Hammer / Bi-directional Operation

Auxiliary Mode Switch 3 positions Position 1 Hammer Mode is selected Position 2 Off Position 3 Bi-Directional Mode is selected

Flow Switch 2 positions Position 1 High Flow selected uses pumps 1 & 2 Position 2 Low Flow selected uses pump 2 (for bi-directional)
ECO

uses pump 2 (for hammer >1,700rpm) uses pumps 2 & 3 (for hammer <1,700rpm) Note that Low and High flow generate the same pressure of 207 bar

Cab Controls
Bi-Directional Flow
Scroll on left hand joystick gives fully proportional control when Bi-directional mode is engaged

Hammer Flow
Foot button gives full flow when Hammer mode is engaged

In-Cab Controls Manual Machine

Bi-Directional Flow
Scroll on left hand control knob gives fully proportional control when Bi-directional mode is engaged

Hammer Flow
As before, foot button gives full flow when Hammer mode is engaged

Hose Reel
Now offered as a factory fitted option on 2CX, 3CX & 4CX Increases the working radius of hand held attachments Reduces potential damage during use Offers additional protection for the hose during storage

Beverage Machine
Available as an option on 3CX & 4CX Produces tea or coffee Uses existing 12V circuit

Designed to fit with existing cab layout

Marketing Material

Micro Site- www.jcbinnovations.com

Break

Machine Walk Around

Technical Information

BACKHOE LOADER SERVICE UPDATE SPRING 2010

SERVICE MANUAL INFORMATION.

9813/0250 NEW GENERATION 3CX/4CX. 9803/3290 OLD GENERATION 3CX/4CX/3C. SERIAL NUMBER RANGE.
2000000 ONWARDS - NEW GENERATION.

Current Backhoe Loader Manual Control Machine Main Schematic

Suction

Pump 1

Pump 2

CURRENT 3CX / 4CX MAIN SCHEMATIC

New Generation Manual Control Machine Main Schematic

Suction

Pump 1

Pump 2

Pump 3

NEW GENERATION 3CX / 4CX MANUAL CONTROL MAIN SCHEMATIC

Pump 3 input

Suction

Pump 1

Pump 2

Pump 3

NEW GENERATION 3CX / 4CX MANUAL CONTROL MAIN SCHEMATIC

Circuit Image
Loader valve block Pump 2
= Pump 1 = Pump 2 P3 pump boost valve Excavator valve block

Pump 3

= Pump 3

Pump 1

Auxiliary valve

Steer priority & Charge valve

Pump 3 location

New Generation Manual Machine Component layout P2 & P3 Intersection

Pump 3 boost valve feed

Pump 3 boost valve

Steer priority/ Brake charge valve

Pump 3 boost valve tank line

Eco
BI-Directional

Hammer

Lo

Manual and Easycontrol Control Machine Power Brake Circuit

BACKHOE LOADER INTRODUCTION

POWER BRAKE CIRCUIT - STANDBY

POWER BRAKE CIRCUIT - STANDBY

Steering selected

BACKHOE LOADER INTRODUCTION

POWER BRAKE CIRCUIT STEERING SELECTED

Brakes pedals pressed

BACKHOE LOADER INTRODUCTION

POWER BRAKE CIRCUIT BRAKES PRESSED

Power Brakes Manual/Easy Control machines

New pedal arrangement Steer priority valve

More deck space Brake system stored energy accumulator Brake valve (Safim) Steer orbitrol valve Steer L S

Left & right brake supply lines

Steer feed
Brake supply lines Low pressure warning switch Tank return lines Full back-off brake pistons

Advanced Easycontrol Machine Master Priority Valve - Standby

BACKHOE LOADER INTRODUCTION

LVB STEERING FEED STEERING LS BRAKE VALVE

LVB LS

PUMP PRESSURE TEST

LS PRESSURE TEST

EVB LS

ADVANCED EASYCONTROL PRIORITY / BRAKE VALVE - Standby

Advanced Easycontrol Machine Master Priority valve Steering Selected

BACKHOE LOADER INTRODUCTION

LVB STEERING FEED STEERING LS BRAKE VALVE

LVB LS

PUMP PRESSURE TEST

LS PRESSURE TEST

EVB LS

ADVANCED EASYCONTROL MASTER PRIORITY VALVE Steering Selected

Advanced Easycontrol Machine Master Priority valve Brakes Selected

BACKHOE LOADER INTRODUCTION

LVB STEERING FEED STEERING LS BRAKE VALVE

LVB LS

PUMP PRESSURE TEST

LS PRESSURE TEST

EVB LS

ADVANCED EASYCONTROL MASTER PRIORITY VALVE Brakes Selected

Brake valve operation

BACKHOE LOADER INTRODUCTION

To Right-Hand Brake Piston

To Left-Hand Brake Piston

POWER BRAKE CIRCUIT Single Pedals Operation

To Right-Hand Brake Piston

To Left-Hand Brake Piston

POWER BRAKE CIRCUIT Brake pedals Locked

To Right-Hand Brake Piston

To Left-Hand Brake Piston

POWER BRAKE CIRCUIT Brake Imbalance

To Right-Hand Brake Piston

To Left-Hand Brake Piston

POWER BRAKE CIRCUIT Brake Back-Off

BACKHOE LOADER SERVICE UPDATE SPRING 2010

RUPTURE PLUG

BACKHOE LOADER SERVICE UPDATE SPRING 2010

Test point location

BACKHOE LOADER SERVICE UPDATE SPRING 2010

New Generation Advanced Easy Control

Current Advanced Easy Control

BACKHOE LOADER SERVICE UPDATE SPRING 2010

REAR AXLE BRAKES, BACK OFF.

OLD GENERATION CONTROL BACKOFF NEW GENERATION POSITIVE BACK OFF.

With power brake system the take up has been increased from 0.8mm per brake set to 1mm minimum. (1mm to 2.5mm allowable). This reduces drag.

BACKHOE LOADER SERVICE UPDATE SPRING 2010

Hammer circuit, using bi- directional circuit gear pump.

Hammer Feed Hammer Return Hammer return to filter

Bi-Directional / Hammer Mode Solenoid

Hammer return to tank

When Auxiliary Mode switched from Bi-Directional Mode to Hammer Mode, valve opens and flow returns direct to tank through blue hose and filter

BACKHOE LOADER SERVICE UPDATE SPRING 2010

Bi-directional circuit gear pump.

Bi-Directional Feed / Return Bi-Directional Feed / Return Bi-directional return to tank

Bi-Directional / Hammer Mode Solenoid

Hammer return to tank

When Auxiliary Mode switched from Hammer Mode to Bi-directional Mode, valve closes and flow returns to tank through light blue hose via valve block

Easy Control Bi- Directional circuit

Green Feed and return hoses from bi-dir valve to excavator. Red Hammer return circuit, this is only used in hammer mode and opens the return line direct to tank through the accumulator and filter. Yellow Pilot circuit used to control the system, pwm controlled pilot valve. Purple Bi-dir valve tank return line. Pink Bi-dir valve feed line from EVB hpco port, uses Magnom filter.

BACKHOE LOADER SERVICE UPDATE SPRING 2010

Brake System Testing

BACKHOE LOADER INTRODUCTION

Advanced Easycontrol Pressure Test points Brake pressure test point

Advanced Easycontrol Pressure Test points

Pump pressure test point LS Pressure test point

Advanced Easycontrol Pressure Test points

Brake Pressure test point

LS Pressure test point

Pump Pressure test point

BACKHOE LOADER SERVICE UPDATE SPRING 2010

BRAKE TESTING FULLY EXHAUST RESIDUAL HYDRAULIC BRAKE PRESSURE

- Engine off, both pedals linked. Pump the pedal until no resistance is felt. - This may take several pumps, depending on the length of time since the engine was last run. Important, this operation MUST be carried out before any attempt is made to disconnect any hydraulic connections, including the brake pressure switch.

BACKHOE LOADER SERVICE UPDATE SPRING 2010

BRAKE TESTING CHECKING LOW PRESSURE SWITCH OPERATION - Having previously vented brake pressure. -Connect a pressure gauge to the steering priority/brake charge valve (refer to priority/braking valve slide for pressure test point location). -Start the engine and build accumulator charge pressure, note the charge pressure warning light A will go off. - Switch the engine off, then switch ignition on. - Observing the pressure gauge and the warning light, gently pump the brake pedals. - The warning light A will come on at approximately 90 bar, continue to vent pressure. - Restart the engine and check light switches off at 90 bar.
A

BACKHOE LOADER SERVICE UPDATE SPRING 2010

BRAKE TESTING CHECKING ACCUMULATOR CUT IN / CUT OUT.

- With the pressure gauge still connected. Restart the engine. -Observe the pressure gauge, pressure will build until 133bar (+/-7) is reached. BRAKE CHARGE CUT OUT
- Gently press the brake pedals. Note the pressure on the gauge at which the charge pressure is topped up by the brake valve. This is approximately 110bar. BRAKE CHARGE CUT IN.

BACKHOE LOADER SERVICE UPDATE SPRING 2010

BRAKE TESTING CHECKING ACCUMULATOR GAS PRESSURE.

- With the pressure gauge still connected. Restart the engine. -Observe the pressure gauge, pressure will build until 133bar (+/-7) is reached.
- Switch the engine off and press the brake pedals repeatedly. When the pressure reaches 40 bar you should notice the pressure reading instantly fall to zero. This is the accumulator gas pressure setting.

BACKHOE LOADER SERVICE UPDATE SPRING 2010

Questions ???