Section E

Hydraulics
Service Manual - 8014, 8016, 8018, 8020
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section D - Controls
Section E - Hydraulics
Section F - Gearboxes
Section J - Track and Running Gear
Section K - Engine

717260

Publication No.
9803/9350-4

World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
 Section E - Hydraulics

Notes:

E-0 9803/9350-4 E-0

 Section E - Hydraulics

Contents Page No.

Service Tools
Numerical List ........................................................................................... E-1

Technical Data
All Machines ............................................................................................. E-3

Basic System Operation

Introduction to Hydraulic Schematic Symbols .......................................... E-6
General (Basic and Functional Symbols) ............................................. E-6
Control Valves .................................................................................... E-10
Example of Schematic Circuit .............................................................E-11
Hydraulic Circuit ..................................................................................... E-12
Neutral Pressure Circuit ..................................................................... E-12
Servo Circuit ....................................................................................... E-12

Schematic Circuits
8014, 8016 ............................................................................................. E-14
Component Key .................................................................................. E-14
Hose Colour Data ............................................................................... E-16
8018 ....................................................................................................... E-18
Component Key .................................................................................. E-18
Hose Colour Data ............................................................................... E-20
8020 ....................................................................................................... E-22
Component Key .................................................................................. E-22
Hose Colour Data ............................................................................... E-24

Fault Finding
Hydraulic System .................................................................................... E-26
General Fault Diagnosis ..................................................................... E-26
Slew Motor and Gearbox ........................................................................ E-28

Service Procedures
Hydraulic Contamination ........................................................................ E-29
Hydraulic Fluid Quality ....................................................................... E-29
Effects of Contamination .................................................................... E-29
Cleaning Operation ............................................................................ E-29
Contaminant Standards ...................................................................... E-30
Filters .................................................................................................. E-30
Pressure Testing ..................................................................................... E-31
Main Relief Valves .............................................................................. E-31
Auxiliary Relief Valves ........................................................................ E-33
Servo Pressure ................................................................................... E-34
Cross Line Relief Valves .................................................................... E-35

Control Valve
Description .............................................................................................. E-36
Component Locations ........................................................................ E-36
Control Valve Sections ....................................................................... E-38
Removal and Replacement .................................................................... E-47
Removal ............................................................................................. E-47
Replacement ...................................................................................... E-47
Dismantling and Assembly ..................................................................... E-48
Dismantling ......................................................................................... E-48
Inspection ........................................................................................... E-49
Assembly ............................................................................................ E-49

E-i E-i
 Section E - Hydraulics
Contents

Contents Page No.

Hydraulic Pump (8014, 8016, 8020)
General Description ................................................................................ E-50
Dismantling, Inspection and Assembly ................................................... E-52
Dismantling ......................................................................................... E-52
Inspection ........................................................................................... E-52
Assembly ............................................................................................ E-52
Pump Flow Testing ................................................................................. E-54

Hydraulic Pump (8020)

General Description ................................................................................ E-55
Removal and Replacement .................................................................... E-57
Removal ............................................................................................. E-57
Replacement ...................................................................................... E-58
Pump Flow Testing ................................................................................. E-59
Troubleshooting ...................................................................................... E-61

Main Relief Valve

Removal and Replacement .................................................................... E-62
Removal ............................................................................................. E-62
Replacement ...................................................................................... E-62

Auxiliary Relief Valves

Removal, Dismantling, Inspection and Assembly ................................... E-63
Removal ............................................................................................. E-63
Dismantling ......................................................................................... E-64
Inspection ........................................................................................... E-64
Assembly ............................................................................................ E-64

Pressure Maintenance Valve

and Dual Solenoid Valve
Removal and Replacement .................................................................... E-65
Removal ............................................................................................. E-65
Replacement ...................................................................................... E-65

Track Motor
General Description ................................................................................ E-66
Normal Operation ............................................................................... E-68
Braking ............................................................................................... E-68
Counterbalance Operation ................................................................. E-68
Motor Low Speed, High Traction Selected (where applicable) ........... E-68
Motor High Speed, Low Traction Selected (where applicable) ........... E-70
Auto Kick Down Function (where applicable) ..................................... E-72
Track Motor Dismantling and Assembly ................................................. E-73
Dismantling ......................................................................................... E-73
Assembly ............................................................................................ E-73
Brake Valve Dismantling and Assembly ................................................. E-75
Dismantling ......................................................................................... E-75
Assembly ............................................................................................ E-75

Slew Motor
General Description ................................................................................ E-76
Hydraulic Motor Section ..................................................................... E-78
Cross Line Relief Valve Section ......................................................... E-79
Anti Cavitation Valve Section .............................................................. E-80

E-ii E-ii
 Section E - Hydraulics
Contents

Contents Page No.

Removal and Replacement .................................................................... E-81
Removal ............................................................................................. E-81
Replacement ...................................................................................... E-82
Dismantling and Assembly ..................................................................... E-83
Dismantling ......................................................................................... E-84
Assembly ............................................................................................ E-84

Rotary Coupling
8014, 8016 Single Speed Machines ....................................................... E-85
Removal ............................................................................................. E-85
Replacement ...................................................................................... E-85
Dismantling ......................................................................................... E-87
Inspection ........................................................................................... E-87
Assembly ............................................................................................ E-87
8016, 8018 Two Speed Machines .......................................................... E-88
Removal ............................................................................................. E-88
Replacement ...................................................................................... E-88
Dismantling ......................................................................................... E-90
Inspection ........................................................................................... E-90
Assembly ............................................................................................ E-90
8018, 8020 Two Speed and Extending
Undercarriage Machines ........................................................................ E-91
Removal ............................................................................................. E-91
Replacement ...................................................................................... E-91
Dismantling ......................................................................................... E-93
Inspection ........................................................................................... E-93
Assembly ............................................................................................ E-93

Hydraulic Rams
Precautions During Use .......................................................................... E-94
Installation .......................................................................................... E-94
Caution During Use ............................................................................ E-94
Maintenance, Inspection Points ......................................................... E-94
Removal and Replacement .................................................................... E-96
Boom, Dipper and Bucket Rams ........................................................ E-97
Dozer Ram ......................................................................................... E-98
Swing Ram ......................................................................................... E-99
Dismantling and Assembly ................................................................... E-100
All Rams ........................................................................................... E-100

E-iii E-iii
 Section E - Hydraulics

Page left intentionally blank

E-iv E-iv
 Section E - Hydraulics

Service Tools
Numerical List

The tools listed in the table are special tools required for details of all tools, including the content of kits and sets,
carrying out the procedures described in this manual. refer to Tool Detail Reference, Section 1.
These tools are available from JCB Service.
Note: Tools other than those listed will be required. It is
Some tools are available as kits or sets, the part numbers expected that such general tools will be available in any
for parts within such kits or sets are not listed here. For full well equipped workshop or be available locally from any
good tool supplier.

Part Description
Number
- Bonded Washers - see Tool Detail Reference (Section 1) for content
- Female Cone Blanking Plugs - see Tool Detail Reference (Section 1) for content
- Female Connectors - see Tool Detail Reference (Section 1) for content
- Hydraulic Flow Test Equipment - see Tool Detail Reference (Section 1) for content
- Hydraulic Hand Pump Equipment - see Tool Detail Reference (Section 1) for content
- Male Adapters - BSP x BSP - see Tool Detail Reference (Section 1) for content
- Male Adapters - BSP x NPT (USA only) - see Tool Detail Reference (Section 1) for content
- Male Cone Blanking Caps - see Tool Detail Reference (Section 1) for content
- Pressure Test Points - Adaptors - see Tool Detail Reference (Section 1) for content
- Pressure Test Points - 'T' Adaptors - see Tool Detail Reference (Section 1) for content
331/22966 Pump Drive Alignment Tool
331/31069 Test Block for A.R.V.
892/00039 Spool Clamp
892/00137 Micro-Bore Hose
892/00223 Hand Pump
892/00253 Hydraulic Circuit Pressure Test Kit - see Tool Detail Reference (Section 1) for content
892/00254 Hose
892/00271 Adapter
892/00272 Adapter
892/00273 Adapter
892/00274 Adapter
892/00275 Adapter
892/00276 Adapter
892/00277 Adapter
892/00279 Gauge
892/00280 Gauge

E-1 9803/9350-4 E-1

 Section E - Hydraulics
Service Tools
Numerical List

Part Description
Number
892/00334 Ram Seal Fitting Tool
892/00346 Gauge
892/00347 Connector
892/00706 Test Probe
892/01016 Ram Protection Sleeve for 25 mm Rod Diameter
892/01017 Ram Protection Sleeve for 30 mm Rod Diameter
892/01018 Ram Protection Sleeve for 40 mm Rod Diameter
892/01019 Ram Protection Sleeve for 50 mm Rod Diameter
892/01020 Ram Protection Sleeve for 50 mm Rod Diameter (slew ram)
892/01021 Ram Protection Sleeve for 60 mm Rod Diameter
892/01022 Ram Protection Sleeve for 60 mm Rod Diameter (slew ram)
892/01023 Ram Protection Sleeve for 65 mm Rod Diameter
892/01024 Ram Protection Sleeve for 70 mm Rod Diameter
892/01025 Ram Protection Sleeve for 75 mm Rod Diameter
892/01026 Ram Protection Sleeve for 80 mm Rod Diameter
892/01027 Piston Seal Assembly Tool
992/02800 ARV Extractor
992/09300 Hexagon Spanner 55mm A/F
992/09400 Hexagon Spanner 65mm A/F
992/09500 Hexagon Spanner 75mm A/F
992/09600 Hexagon Spanner 85mm A/F
992/09700 Hexagon Spanner 95mm A/F
992/09900 Hexagon Spanner 115mm A/F
992/10000 Hexagon Spanner 125mm A/F
992/10100 Spool Clamp

E-2 9803/9350-4 E-2

 Section E - Hydraulics

Technical Data
All Machines

8014/8016 8018/8020
Pump
Type Three section gear pump driven directly from the engine crankshaft.
Flow Rates at neutral circuit
pressure
Pumps P1 and P2 13.5 l/min. (3.0 UK gall/min.) @ 2450 rev/min 15.7 l/min. (3.5 UK gal/min.) @
2450 rev/min
Pump P3 12.2 l/min. (2.7 UK gall/min.) @ 2450 rev/min

8014 8016 8018/8020

Relief Valve Operating Pressures(1) bar lbf/in2 bar lbf/in2 bar lbf/in2
Main Relief Valves (M.R.V.)
Swing/Dozer/Slew 160 2320 160 2320 160 2320
Tracks/Dipper/Aux 230 3335 230 3335 220 3190
Tracks/Boom/Bucket 230 3335 230 3335 220 3190
Servo Pressure
Maintenance Valve - Single Speed 30 435 30 435 30 435
Maintenance Valve - Two Speed 30 435 30 435 30 435
Auxiliary Relief Valves (A.R.V.)
Boom rod side 275 3988 275 3988 275 3988
Dipper rod and head side 275 3988 275 3988 275 3988
Dozer head side 220 3190 220 3190 220 3190
Slew Crossline Relief Valves 160 2320 160 2320 160 2320

(1) At hydraulic oil temperature of 50 °C (122 °F)

E-3 9803/9350-4 E-3

 Section E - Hydraulics
Technical Data
All Machines

Bore Rod Dia Stroke

Rams mm in mm in mm in
Boom 55 2.16 30 1.18 369 14.5
Dipper (8014, 8016) 50 1.97 30 1.18 410 16.14
Dipper (8018, 8020) 55 2.16 30 1.18 410 16.14
Bucket (8014, 8016) 50 1.97 30 1.18 292 11.5
Bucket (8018, 8020) 55 2.16 30 1.18 292 11.5
Swing (8014, 8016) 50 1.97 30 1.18 311.5 12.26
Swing (8018, 8020) 55 2.16 30 1.18 311.5 12.26
Dozer (8014, 8016) 70 2.76 35 1.38 85 3.35
Dozer (8018 70 2.76 35 1.38 85 3.35
Undercarriage Extension 55 2.16 30 1.18 360 14.17

Ram Speed at max. Engine Revs. 8014/8016 8018/8020

Boom Up 3.0 Sec 2.3 Sec
Boom Down 2.1 Sec 1.8 Sec
Dipper In 3.7 Sec 3.8 Sec
Dipper Out 2.5 Sec 3.0 Sec
Bucket Dump 1.8 Sec 2.2 Sec
Bucket Crowd 2.7 Sec 2.9 Sec
Dozer Up 1.5 Sec 1.5 Sec
Dozer Down 1.9 Sec 1.9 Sec
Slew (5 rev) Left 30.7 Sec 30.7 Sec
Slew (5 rev) Right 30.7 Sec 30.7 Sec
Tracking (25 m) 40.2 Sec 40.2 Sec
Swing Left 3.3 Sec 3.3 Sec
Swing Right 2.7 Sec 2.7 Sec

Track Motors Single Speed Two Speed

Type PHK-120-37-5-8431A PHV-120-37-5T-8424A
Displacement 3
8.9 cm /rev 9.5 cm3/rev
Max Operating Pressure 23 MPa 22 MPa
Max Flow 12.94 l/min 15 l/min
Reduction ratio 36.96:1 36.96:1
Weight 14.5 kg (32.0 lb) 18 kg (39.7 lb)

E-4 9803/9350-4 E-4

 Section E - Hydraulics
Technical Data
All Machines

Slew Motor 8014/8016/8018 8020

Type Piston - PCR-50-10-1S28295A Piston - PCR-1B-05A-8747A
Displacement 18.1 cm3/rev 18.1 cm3/rev
Max. Flow 12 l/min 12 l/min
Gear Ratio 10 : 1 10 : 1
Weight 22 kg (48.5 lb) 22 kg (48.5 lb)

Filtration
Main Bypass pressure 2.5 bar (36 lbf/in2)

Hydraulic System Capacities

Hydraulic System 28 litres (6.2 UK Gal)

E-5 9803/9350-4 E-5

 Section E - Hydraulics

Basic System Operation

Introduction to Hydraulic Schematic Symbols
TE-001

General (Basic and Functional Symbols) Table 2. Rams

Complex hydraulic components and circuits can be Single acting

described to the engineer by using graphical symbols. The
following pages illustrate and give a brief description for
some of the more common symbols used.
Double acting
There are many symbols in use and it would be impossible
to include them all here. However it should be noted that
most are only variations or refinements on the basic
principles explained here. If more detailed information is Double ended
required you are recommended to obtain a copy of
BS2917 or IS01219.
Double acting with damping
Once familiar with the symbols, the engineer can use at rod area end
hydraulic circuit diagrams as an aid to fault finding. It will
be possible to see the complete hydraulic circuit and
decipher the relationship between hydraulic components. Table 3. Pumps and Motors
Table 1. General
Variable capacity pump two
Spring directions of flow

Flow restriction affected by

viscosity Fixed capacity motor one
direction of flow
Direction of flow

Fixed capacity motor two

directions of flow
Indication of rotation

Variable capacity motor one

Indication of direction and direction of flow
paths of flow

Variable capacity motor two

Variable control directions of flow

E-6 9803/9350-4 E-6

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

Used to enclose several Throttling orifice - normally

valves indicating they are closed
supplied as one unit

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

centered pilot operated valve open

3-position, 6-port spring

centered pilot operated valve

Relief valve
3-Position, 4-port spring
centered solenoid & pilot
pressure operated valve

3-Position, 4-port spring

centered detent hand Variable restrictor
operated valve

Non-return valve

Non-return valve with back

pressure spring

Pilot operated non-return

valve

One way restrictor

High pressure selector

(shuttle valve)

E-7 9803/9350-4 E-7

 Section E - Hydraulics
Basic System Operation
Introduction to Hydraulic Schematic Symbols
Table 5. Energy Transmissions and Conditioning
Working line, return or feed Reservoir - return line below
fluid level
Pilot control

Drain lines

Header tank
Flexible pipe

Pressure sealed tank

Line junction

Accumulator

Crossing lines Filter or strainer

Water trap

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

Line plugged with take off line Cooler - indicating direction

of coolant flow

Quick release couplings -

connected
Heater
Quick release couplings -
disconnected

Reservoir - return line above

fluid level

E-8 9803/9350-4 E-8

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

Rotating shaft - two directions Solenoid two windings

Detent Electric motor operated

M

Locking device Internal pressure pilot

operated

Over centre device

External pressure pilot
operated

Simple linkage
Pressure operated spring
release

General control
Pilot operated by solenoid
pilot valve

Push button operated

Pilot operated by a solenoid
or seperate pilot valve

Lever operated

Pressure guage

Pedal operated

Pressure switch
Stem operated

Spring operated

Roller operated

Roller trip operated (one

directional)

E-9 9803/9350-4 E-9

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

Control Valves
Control valves are usually represented by one or more
square boxes.

K Fig 1. ( T E-10) shows a control valve represented by

three boxes. The number of boxes indicates the number of
possible valve operating positions, (3 boxes - 3 positions
etc).

Fig 4.

It must be noted that not all spools are of the same type.
Fig 1.
Their operating designs can be seen by following the path
the flow arrows take in their respective operating squares.
K Fig 2. ( T E-10) - In circuit diagrams the pipework is
usually shown connected to the box which represents the
Three typical JCB style spools are known as 'D' spools, 'F'
unoperated condition. (Hydraulic circuit diagrams are
spools and 'N' spools.
usually shown in the unoperated condition).
The 'D' spools generally control rams because when in the
neutral position the outlet ports are blocked, preventing
ram movement. K Fig 4. ( T E-10) shows a 'D' type spool.

K Fig 5. ( T E-10) - 'F' spools are often shown as four

position spools with the three normal positions for neutral
and service control; and the forth position, which has a
Fig 2. detent, connects both sides of the ram together to allow the
service to 'float'.
K Fig 4. ( T E-10) shows a valve described as a 3-
position, 4-port control valve. Port describes the openings
to and from the valve by which the hydraulic fluid enters or
leaves. In the fig shown, Position 2 indicates that in an
unoperated condition all 4 ports are blocked.

Fig 5.

K Fig 6. ( T E-10) - 'N' spools are sometimes used to

control hydraulic motors, and it can be seen from the flow
arrows, that in neutral position both service ports are
connected to the exhaust oil port
Fig 3.

If the valve spool was moved to Position 1, movement of

the spool would connect Port P1 to Port P2, and Port P3 to
Port P4. K Fig 4. ( T E-10).

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

the spool would connect Port P1 to Port P4, and Port P3 to Fig 6.
Port P2. K Fig 4. ( T E-10).

E-10 9803/9350-4 E-10

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

Example of Schematic Circuit

A
B

C G
D E

Fig 7. Simple Schematic Circuit

Some of the symbols described on the preceding pages Example Circuit Key
have been arranged into a simple schematic circuit.
K Fig 7. ( T E-11).
7-A Hydraulic Tank
Hydraulic tank 7-A is a pressurised tank with an internally 7-B Strainer
mounted strainer 7-B on the suction line to the fixed 7-C Fixed Displacement Pump
displacement pump 7-C. System pressure is limited to the
setting of relief valve 7-D. 7-D Relief Valve
7-E Spool
Valve spool 7-E is an open-centre spool that is in neutral 7-F One Way Valve
position; flow from the pump passes through the spool and
returns to the hydraulic tank. 7-G Double Acting Hydraulic Ram

If the lever operated spool is moved away from neutral

position hydraulic fluid is directed to either head side or rod
side of hydraulic ram 7-G. Notice that the fluid must first
open one way valve 7-F before flowing to the ram.

E-11 9803/9350-4 E-11

 Section E - Hydraulics
Basic System Operation
Hydraulic Circuit

Hydraulic Circuit

Note: Circuit and description are for ISO Machines. (rod side only) from damage that might be generated
through over-pressure conditions during operation.
Note: The annotations relate to the Hydraulic Schematic. .
When the A.R.V.'s are open, over pressure fluid is routed
The hydraulic circuit is fed from a hydraulic oil tank 11, to the control valve exhaust chamber and back to tank 11.
located behind operator's cab.
The service lines to the dozer ram, the track motors and
The system is powered by a three section pump 9, the pilot line from the high speed selector to the track
connected directly to the engine crankshaft. motors are routed through a rotary coupling 3. This device
allows the machine upper structure to turn without
Sections P1, P2 and P3 are fixed displacement gear damaging hoses connected to services mounted on the
pumps. undercarriage.

When the engine is running, the pump draws fluid from the The remaining service lines connect directly to their
tank and routes it through the main control valve block 4. relevant devices. Return fluid from services or from the
neutral pressure circuit is routed back to tank through an
Pump section P1 supplies the control valve sections for: exhaust line and return filter 10.

4a Track Right Neutral Pressure Circuit

4b Boom Ram
With the engine running, but no service selected, the pump
4c Bucket Ram flows are routed from pump sections P1, P2 and P3 to their
respective sections of the control valve.
Pump section P2 supplies the control valve sections for:
The valve spools are spring loaded to the neutral position,
allowing fluid to pass through the valve's neutral circuit and
4f Track Left
returned to tank through the return line.
4e Dipper Ram
4d Aux Excess pressure in the selected circuit opens the M.R.V.
associated with the valve section supplied and vents
excess pressure back to tank 11.
Pump section P3 supplies the control valve sections for:

Servo Circuit
4h Dozer Ram
4g Swing Ram With the isolator solenoid 8a energised, neutral circuit
4j Slew pressure from the pumps connects to the hand controllers
5 and 6. As the hand controllers are operated, the neutral
circuit pressure is directed to and begins to select the
Supply from all three pumps is also directed to the
desired excavator spool.
pressure maintenance valve 8, fitted with a servo Isolation
solenoid valve 8a and two speed tracking solenoid 8b
(8016, 8018, 8020 only).

Main relief valves (M.R.V.) 4K, 4L and 4M are fitted in the

main control valve blocks to vent hydraulic pressure,
venting excess flow to tank 11.

Auxiliary relief valves (A.R.V.) 4N are fitted to protect the

dipper (rod and head side), boom (rod side only) and dozer

E-12 9803/9350-4 E-12

 Section E - Hydraulics
Basic System Operation
Hydraulic Circuit

Page left intentionally blank

E-13 9803/9350-4 E-13

 Schematic Circuits
E-14

8014, 8016

Component Key 13 Boom Swing Ram

14 Arm Ram
K Fig 9. ( T E-19).
15 Bucket Ram

1 Left Hand Track Motor 16 Boom Ram

2 Right Hand Track Motor 17 Dozer Ram

3 Rotary Joint
4 Main Control Valve
4a Travel
4b Boom
4c Bucket
9803/9350-4

4d Auxiliary
4e Arm
4f Travel
4g Boom Swing
4h Dozer
4j Slew
4k ARV
4m MRV

Section E - Hydraulics
5 Left Hand Controller
6 Right Hand Controller

Schematic Circuits
7 Manifold Block
8 Pressure Maintaining Valve
8a Servo Isolation Solenoid Valve
9 Main Pump

8014, 8016
10 Return Filter
11 Tank
E-14

12 Slew Motor
 Section E - Hydraulics
Schematic Circuits
8014, 8016
8a

Fig 8. 236/60023 issue 12

4m
4g

4h
4c

4e
4d
4b
4a

4f

4j
4m
4k

4k

4k
4m
4
E-15 9803/9350-4 E-15
 Section E - Hydraulics
Schematic Circuits
8014, 8016

Hose Colour Data

From To Colour Comment

PUMP VALVE BLOCK RED
VALVE B3 SWING RAM DUMP D ORANGE
VALVE A3 SWING RAM ROD S ORANGE
VALVE B1 LH PORT SLEW S LIGHT GREEN
VALVE A1 RH PORT SLEW D LIGHT GREEN
P1 PMV P1 RED
P2 PMV P2 RED
P3 PMV P3 RED
PMV P PRESSURE BLOCK RED
PMV T TANK BLOCK BLUE
RHJ1 (RIGHT HAND JOYSTICK) BOOM TOP S WHITE
RHJ3 BOOM BOTTOM D WHITE
RHJ4 BUCKET TOP S GREY
RHJ2 BUCKET BOTTOM D GREY
RHJT TANK BLOCK BLUE
RHJP PRESSURE BLOCK RED
LHJ3 (LEFT HAND JOYSTICK) DIPPER TOP S PURPLE
LHJ1 DIPPER BOTTOM D PURPLE
LHJ2 SLEW BOTTOM D LIGHT GREEN
LHJ4 SLEW TOP S LIGHT GREEN
LHJP PRESSURE BLOCK RED
LHJT TANK BLOCK BLUE
BOTTOM OIL COOLER FILTER BLUE
VALVE RETURN TOP OIL COOLER BLUE
VALVE B8 BOOM ROD S WHITE
VALVE A8 BOOM DUMP D WHITE
VALVE B5 DIPPER ROD S PURPLE
VALVE A5 DIPPER DUMP D PURPLE
RJ1 (ROTARY JOINT) LH TRACK D PINK
RJ2 LH TRACK S PINK
RJ3 RH TRACK S LILAC
RJ4 RH TRACK D LILAC
RJ7 RH TRACK DRAIN BLUE
RJ7 LH TRACK DRAIN BLUE
RJ5 DOZER DUMP D YELLOW
RJ6 DOZER ROD S YELLOW

E-16 9803/9350-4 E-16

 Section E - Hydraulics
Schematic Circuits
8014, 8016

From To Colour Comment

VALVE B2 RJ5 D YELLOW
VALVE A2 RJ6 S YELLOW
VALVE A9 RJ1 D PINK
VALVE B9 RJ2 S PINK
VALVE B4 RJ3 S LILAC
VALVE A4 RJ4 D LILAC
VALVE LOCKOUT PRESSURE BLOCK RED
VALVE LOCKOUT VALVE LOCKOUT RED
RJ TANK TANK BLUE
SLEW DRAIN ROTARY JOINT BLUE
TANK BLOCK TANK BLUE
SLEW MOTOR LH SIDE TANK DRAIN BLUE
SINGLE ACTING AUX KIT S BROWN
SINGLE ACTING AUX KIT D BROWN
VALVE B7 BUCKET ROD S GREY LONG DIPPER
VALVE A7 BUCKET DUMP D GREY LONG DIPPER
VALVE B7 BUCKET ROD S GREY XL DIPPER
VALVE A7 BUCKET DUMP D GREY XL DIPPER
VALVE B7 BUCKET ROD S GREY GRAVEMASTER
VALVE A7 BUCKET DUMP D GREY GRAVEMASTER
BUCKET BUCKET S GREY
BUCKET BUCKET D GREY
BOOM PILOT BOOM PILOT D WHITE
BUCKET PILOT BUCKET PILOT D GREY
DIPPER PILOT DIPPER PILOT D PURPLE

E-17 9803/9350-4 E-17

 8018
E-18

Component Key 14 Arm Ram

15 Bucket Ram
K Fig 9. ( T E-19).
16 Boom Ram

1 Left Hand Track Motor 17 Dozer Ram

2 Right Hand Track Motor 18 Change Valve

3 Rotary Joint 19 Extender Ram

4 Main Control Valve

4a Travel
4b Boom
4c Bucket
4d Auxiliary
4e Arm
9803/9350-4

4f Travel
4g Boom Swing
4h Dozer
4j Slew
4k ARV
4m MRV
5 Left Hand Controller
6 Right Hand Controller

Section E - Hydraulics
7 Manifold Block
8 Pressure Maintaining Valve
8a Servo Isolation Solenoid Valve

Schematic Circuits
8b Two Speed Tracking Solenoid
9 Main Pump
10 Return Filter
11 Tank
12 Slew Motor
E-18

8018
13 Boom Swing Ram
 Section E - Hydraulics
Schematic Circuits
8018
8a 8b

Fig 9. 236/60025 issue 13

4m
4g

4h
4c

4d
4b
4a

4k 4e

4f

4j
4k

4k
4m
4m
4
E-19 9803/9350-4 E-19
 Section E - Hydraulics
Schematic Circuits
8018

Hose Colour Data

From To Colour Comment

PUMP VALVE BLOCK RED
VALVE B9 RJ 1 S PINK
VALVE A9 RJ5 D PINK
VALVE B4 RJ 2 S LILAC
VALVE A4 RJ 6 D LILAC
VALVE B3 SWING RAM DUMP D ORANGE
VALVE A3 SWING RAM ROD S ORANGE
VALVE B1 LH PORT SLEW S LIGHT GREEN
VALVE A1 RH PORT SLEW D LIGHT GREEN
VALVE B2 CHANGE VALVE TOP D YELLOW
VALVE A2 CHANGE VALVE BOT S YELLOW
PMV 2 SPEED RJ9 RED
CHANGE VALVE D RJ7 D YELLOW
CHANGE VALVE D1 RJ8 S YELLOW
CHANGE VALVE P RJ3 D DARK GREEN
CHANGE VALVE P1 RJ4 S DARK GREEN
P1 PMV P1 RED
P2 PMV P2 RED
P3 PMV P3 RED
TANK RJ BLUE
PMV P PRESSURE BLOCK RED
PMV T TANK BLOCK BLUE
RHJ1 (RIGHT HAND JOYSTICK) BOOM TOP S WHITE
RHJ3 BOOM BOTTOM D WHITE
RHJ4 BUCKET TOP S GREY
RHJ2 BUCKET BOTTOM D GREY
RHJT TANK BLOCK BLUE
RHJP PRESSURE BLOCK RED
LHJ3 (LEFT HAND JOYSTICK) DIPPER TOP S PURPLE
LHJ1 DIPPER BOTTOM D PURPLE
LHJ2 SLEW BOTTOM D LIGHT GREEN
LHJ4 SLEW TOP S LIGHT GREEN
LHJP PRESSURE BLOCK RED
LHJT TANK BLOCK BLUE
BOTTOM OIL COOLER FILTER BLUE
VALVE RETURN TOP OIL COOLER BLUE

E-20 9803/9350-4 E-20

 Section E - Hydraulics
Schematic Circuits
8018

From To Colour Comment

VALVE B8 BOOM ROD S WHITE
VALVE A8 BOOM DUMP D WHITE
VALVE B5 DIPPER ROD S PURPLE
VALVE A5 DIPPER DUMP D PURPLE
RJ5 (ROTARY JOINT) LH TRACK D PINK
RJ1 LH TRACK S PINK
RJ2 RH TRACK S LILAC
RJ6 RH TRACK D LILAC
RJ8 DOZER ROD S YELLOW
VALVE LOCKOUT PRESSURE BLOCK RED
VALVE LOCKOUT VALVE LOCKOUT RED
SLEW DRAIN ROTARY JOINT BLUE
TANK BLOCK TANK BLUE
RJ3 EXT RAM DUMP D DARK GREEN
RJ4 EXT RAM ROD S DARK GREEN
RJ TEE t MOTOR DRAIN BLUE
RJ TEE T MOTOR 2 SPEED RED
RJ7 DOZER DUMP D YELLOW
SLEW MOTOR LH SIDE BLUE
SINGLE ACTING AUX KIT S BROWN
SINGLE ACTING AUX KIT D BROWN
VALVE B7 BUCKET ROD S GREY LONG DIPPER
VALVE A7 BUCKET DUMP D GREY LONG DIPPER
VALVE B7 BUCKET ROD S GREY XL DIPPER
VALVE A7 BUCKET DUMP D GREY XL DIPPER
VALVE B7 BUCKET ROD S GREY GRAVEMASTER
VALVE A7 BUCKET DUMP D GREY GRAVEMASTER
BUCKET BUCKET S GREY
BUCKET BUCKET D GREY
BOOM PILOT BOOM PILOT D WHITE
BUCKET PILOT BUCKET PILOT D GREY

E-21 9803/9350-4 E-21

 8020
E-22

Component Key 14 Arm Ram

15 Bucket Ram
K Fig 9. ( T E-19).
16 Boom Ram

1 Left Hand Track Motor 17 Dozer Ram

2 Right Hand Track Motor 18 Change Valve

3 Rotary Joint 19 Extender Ram

4 Main Control Valve

4a Travel
4b Boom
4c Bucket
4d Auxiliary
4e Arm
9803/9350-4

4f Travel
4g Boom Swing
4h Dozer
4j Slew
4k ARV
4m MRV
5 Left Hand Controller
6 Right Hand Controller

Section E - Hydraulics
7 Manifold Block
8 Pressure Maintaining Valve
8a Servo Isolation Solenoid Valve

Schematic Circuits
8b Two Speed Tracking Solenoid
9 Main Pump
10 Return Filter
11 Tank
12 Slew Motor
E-22

8020
13 Boom Swing Ram
E-23

19 3 ROTARY
JOINT

EXTENDER

1 DR 5
LH TRACK
!
P1 230 bar
Pp1
LH CONTROLLER 6 RH CONTROLLER

RED
P T P T
MOTOR B
4a
PP
A9

B9
TRAVEL
4m
4k
DOZER
Pb8 Pa8

BOOM

2 DR A8
1

RH TRACK
! B8
275 bar
4b 1 2 3 4 2 3 4
RED

MOTOR B 1.2 mm

Pb7 Pa7
BUCKET
A7

BOOM
PP B7 4c
16 7 MANIFOLD
A6
AUX. T2
4d BLOCK

15 BUCKET
B6

4k
275 bar

14 Pb5
A5

B5 ARM
275 bar
Pa5
4e PR A
DIPPER 30 bar
9803/9350-4

A4

B4 TRAVEL

13 4m
BOOM SWING
P2
230 bar
Pp2
4f 8a 8b
PI
8
DR PMV
A
A3

B3 4g
T
BOOM SWING
4k
230 bar P3 P2 P1 T PV PT
A2
RED.

B
B2
DOZER
4h
A1
B1 SLEW
4j 10 bar
Pb1 Pa1
SLEW
MOTOR 4m

Section E - Hydraulics
T1

12 P3
160 bar
P3 P2 P1

V (VALVE) V1

Schematic Circuits
2200
E RPM

PUMP
M

18
10 0 S1

9
RETURN
D E D1 E1
FILTER

11 10 ABSOLUTE
2.5 BAR BYPASS

TANK 125 STRAINER

E-23

8020
Fig 10. 332-T6601 issue 1
 Section E - Hydraulics
Schematic Circuits
8020

Hose Colour Data

From To Colour Comment

PUMP VALVE BLOCK RED
VALVE B9 RJ 1 S PINK
VALVE A9 RJ5 D PINK
VALVE B4 RJ 2 S LILAC
VALVE A4 RJ 6 D LILAC
VALVE B3 SWING RAM DUMP D ORANGE
VALVE A3 SWING RAM ROD S ORANGE
VALVE B1 LH PORT SLEW S LIGHT GREEN
VALVE A1 RH PORT SLEW D LIGHT GREEN
VALVE B2 CHANGE VALVE TOP D YELLOW
VALVE A2 CHANGE VALVE BOT S YELLOW
PMV 2 SPEED RJ9 RED
CHANGE VALVE D RJ7 D YELLOW
CHANGE VALVE D1 RJ8 S YELLOW
CHANGE VALVE P RJ3 D DARK GREEN
CHANGE VALVE P1 RJ4 S DARK GREEN
P1 PMV P1 RED
P2 PMV P2 RED
P3 PMV P3 RED
TANK RJ BLUE
PMV P PRESSURE BLOCK RED
PMV T TANK BLOCK BLUE
RHJ1 (RIGHT HAND JOYSTICK) BOOM TOP S WHITE
RHJ3 BOOM BOTTOM D WHITE
RHJ4 BUCKET TOP S GREY
RHJ2 BUCKET BOTTOM D GREY
RHJT TANK BLOCK BLUE
RHJP PRESSURE BLOCK RED
LHJ3 (LEFT HAND JOYSTICK) DIPPER TOP S PURPLE
LHJ1 DIPPER BOTTOM D PURPLE
LHJ2 SLEW BOTTOM D LIGHT GREEN
LHJ4 SLEW TOP S LIGHT GREEN
LHJP PRESSURE BLOCK RED
LHJT TANK BLOCK BLUE
BOTTOM OIL COOLER FILTER BLUE
VALVE RETURN TOP OIL COOLER BLUE

E-24 9803/9350-4 E-24

 Section E - Hydraulics
Schematic Circuits
8020

From To Colour Comment

VALVE B8 BOOM ROD S WHITE
VALVE A8 BOOM DUMP D WHITE
VALVE B5 DIPPER ROD S PURPLE
VALVE A5 DIPPER DUMP D PURPLE
RJ5 (ROTARY JOINT) LH TRACK D PINK
RJ1 LH TRACK S PINK
RJ2 RH TRACK S LILAC
RJ6 RH TRACK D LILAC
RJ8 DOZER ROD S YELLOW
VALVE LOCKOUT PRESSURE BLOCK RED
VALVE LOCKOUT VALVE LOCKOUT RED
SLEW DRAIN ROTARY JOINT BLUE
TANK BLOCK TANK BLUE
RJ3 EXT RAM DUMP D DARK GREEN
RJ4 EXT RAM ROD S DARK GREEN
RJ TEE t MOTOR DRAIN BLUE
RJ TEE T MOTOR 2 SPEED RED
RJ7 DOZER DUMP D YELLOW
SLEW MOTOR LH SIDE BLUE
SINGLE ACTING AUX KIT S BROWN
SINGLE ACTING AUX KIT D BROWN
VALVE B7 BUCKET ROD S GREY LONG DIPPER
VALVE A7 BUCKET DUMP D GREY LONG DIPPER
VALVE B7 BUCKET ROD S GREY XL DIPPER
VALVE A7 BUCKET DUMP D GREY XL DIPPER
VALVE B7 BUCKET ROD S GREY GRAVEMASTER
VALVE A7 BUCKET DUMP D GREY GRAVEMASTER
BUCKET BUCKET S GREY
BUCKET BUCKET D GREY
BOOM PILOT BOOM PILOT D WHITE
BUCKET PILOT BUCKET PILOT D GREY

E-25 9803/9350-4 E-25

 Section E - Hydraulics

Fault Finding
Hydraulic System

Before carrying out the following checks, ensure that General Fault Diagnosis
where applicable:
1 Is the fault in all services or one only?
1 The correct hydraulic fluid is used and the system is
filled to the correct level. ALL:Check 2.

2 The hydraulic fluid, filter and suction strainer are ONE:Check 6.

clean.
2 Are the hydraulics inoperative or lacking in power?
3 There are no visible leaks in the system.
INOPERATIVE:Check 4.
4 Engine maximum speed and condition is as
specification. POOR PERFORMANCE: Check 3.

5 Hydraulic pressures for each service are correct to 3 Is the servo pressure to specification?
specification.
YES:Check 4.
If possible the machine should be operated to identify the
fault and to bring the systems to their normal working NO:Adjust.
temperature.
4 Is the pump operating correctly?
After completing these initial checks, proceed as follows:
YES:Check M.R.V's.
1 If all the hydraulic services are at fault start at check 1.
NO:Check 5.
2 If servo controllers only are at fault start at check 13.
5 Is the pump noisy in operation?
3 If tracking services only are at fault start at check 16.
YES:Purge air from pump casing.
4 If slew service only is at fault start at check 21.
NO:Check 6.

6 Is the pump drive broken?

YES:Renew

NO:Check 7.

7 Is one service only down on pressure?

YES:Check 8.

NO:Check 9.

E-26 9803/9350-4 E-26

 Section E - Hydraulics
Fault Finding
Hydraulic System
8 Is the cable adjustment correct? (Tracks, dozer & 17 Is the tracking fault in one track in one or both
auxiliary services only) directions?

YES:Check 9. ONE:Swap hoses between pumps P2 & P3, If the

fault changes to other track, service pump. If fault
NO:Adjust cable. stays check 18. Check for sticking motor
counterbalance spool.
9 Is the control valve spool sticking?
BOTH:Check 18.
YES:Overhaul valve block section.
18 Is the fault in one track only and in both directions?
NO:Check 10.
YES:With track stalled measure lubrication return to
10 Is the service A.R.V. operating correctly? tank flow (1) at top of rotary joint and (2) out of track
motor.
YES:Check 11.
If (1) high and (2) normal service rotary joint. If (1)
NO:Reset or renew. high and (2) high check track motor.

11 Is the valve block section cracked? 19 Is high speed engaging?

YES:Renew section and check valve block mounting YES:Check 20.

12 Are the rams faulty? NO:Check operation of high speed solenoid valve,
rotary joint seals or motor high speed selector spool.
YES:Overhaul or renew.
20 Is the track motor high speed selector servo hose
13 Is the fault in all servo operated services or only one? crossed with motor lubrication drain hose?

ALL:Check servo isolator microcircuit, check servo YES:Correct connections

solenoid valve, check 14.
21 Is the slew motor performance/braking poor?
ONE: Check 15.
YES:Check for correct pressure settings of cross line
14 Is the servo system operating correctly? relief valves. Check slew motor anti-cavitation check
valves are closing.
YES: Check 15.
22 Does the slew motor performance improve if bucket
NO:Check servo pressure maintenance valve. service stalled?

15 Is the hand controller plunger leaking/sticking? YES:Check servo pressure maintenance valve non
return valves are closing.
YES: Service hand controller, K Inspection ( T D-5).

16 Is the tracking fault in both tracks and in one or both

directions?

ONE:Check control linkage, check 17.

BOTH:Check 4.

E-27 9803/9350-4 E-27

 Section E - Hydraulics
Fault Finding
Slew Motor and Gearbox

Slew Motor and Gearbox

Table 7.
Fault Possible Cause Action
Motor does not turn (The supplied Relief valve pressure too low or faulty Renew the relief valve
pressure is correct) Motor has too much internal leakage Renew the motor assembly
Motor has burned inner parts Renew the motor assembly
Reduction gears damaged Renew the gears
Overload Remove the overload
Insufficient torque Relief valve pressure too low or faulty Renew the relief valve
Motor has too much internal leakage Renew the motor assembly
Motor has burned inner parts Renew the motor assembly
Reduction gears damaged Renew the gears
Bearings damaged Renew the bearings
Abnormal noise Cavitation noise due to insufficient flow Check oil level and pipework
Motor has damaged sliding parts Renew the motor assembly
Reduction gears damaged Renew the gears
Bearings damaged Renew the bearings
Pinion gear damaged Renew pinion
Oil leakage at housing joint face Damaged `O' rings Renew `O' rings
Loose bolts Retighten
Oil leakage at pinion gear Damaged oil seal Renew oil seal
Delay in starting Relief valve pressure too low or faulty Renew the relief valve
Check valve internal leakage Renew check valve
Excessive heat generation Motor has burned or damaged sliding Renew the motor assembly
parts
Reduction gears damaged Renew the gears
Bearings damaged Renew the bearings

E-28 9803/9350-4 E-28

 Section E - Hydraulics

Service Procedures
Hydraulic Contamination
TE-002_2

Hydraulic Fluid Quality cleaning unit. K Fig 11. ( T E-29). General Bulletin 011
also refers.
Construction machinery uses a large volume of fluid in the
hydraulic system for power transmission, equipment Procedure
lubrication, rust prevention and sealing. According to a
survey conducted by a pump manufacturer, seventy per Connect the cleaning unit in place of the hydraulic filter.
cent of the causes of problems in hydraulic equipment K Fig 11. ( T E-29). Run the system for sufficient time to
were attributable to inadequate maintenance of the quality pump all the hydraulic fluid through the unit. Disconnect
of the hydraulic fluid. Therefore, it is obvious that control of the cleaning unit and reconnect the filter. Top up the
the quality of the hydraulic fluid helps prevent hydraulic system with clean hydraulic fluid as required.
equipment problems and greatly improves safety and
reliability. Furthermore from an economic angle it extends
the life of the hydraulic fluid if quality is maintained.

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

1 Solid Particles - sand, fibres, metallic particles,

welding scale, sealing materials and wear particles
etc.
Fig 11. Cleaning Unit
2 Liquid - usually water and incompatible oils and
greases.

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

corrosive compounds if dissolved in the fluid.

These contaminants can appear during manufacture,

assembly and operation.

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

E-29 9803/9350-4 E-29

 Section E - Hydraulics
Service Procedures
Hydraulic Contamination

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

1 micron = 0.001 mm (0.0000394 in).

Listed below are a few typical comparisons:

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

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

Smallest particle visible to the naked eye is 40 microns

(0.00157) approximately.

Standards will often be quoted to ISO (International

Standards Organisation) for which literature can be
obtained.

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

To ensure optimum performance and reliability it is

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

E-30 9803/9350-4 E-30

 Section E - Hydraulics
Service Procedures
Pressure Testing

Pressure Testing

Main Relief Valves Table 8.

A Pump 3 Section
1 Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure Dozer, Swing, Slew.
gauge to the port on the single or double solenoid
B Track Left Section
pressure maintenance valve as below.
Track left, Dipper, Auxilliary.
C Track Right Section
Track right, Boom, Bucket.

B C

P3
P2
P1 A
PR
PV
T
PT

Fig 12.
Fig 13.
2 With the engine running at maximum speed and
hydraulic fluid at normal working temperature, 3 Check the gauge reading is as detailed in Technical
operate to full travel one of the rams in the circuit Data. If incorrect, use a spanner to prevent body F
served by the valve under test K Table 8. ( T E-31) from turning and remove cap nut D. With the ram held
K Fig 13. ( T E-31) at full travel and body F still prevented from turning,
use a screwdriver to adjust the M.R.V. by means of
the screw E until the gauge reads the correct
pressure.

4 Fit cap nut D and tighten to 25 Nm (18 lbf ft). Do not

overtighten. Check gauge reading is correct. Repeat
procedure as necessary. If body F is disturbed,
tighten to 50 Nm (37 lbf ft).

Note: Torque setting of the MRV is very critical to ensure

correct MRV pressure and prevent oil leakage. The
adjuster cap nut D can removed and refitted once only

E-31 9803/9350-4 E-31

 Section E - Hydraulics
Service Procedures
Pressure Testing
using the existing washer and then tightened to 25 Nm (18
lbf ft). If the cap is removed and refitted again, a new
washer must be fitted and the cap tightened to 22 Nm (16
lbf ft).

5 Switch off engine. Remove pressure gauge and refit

blanking cap.

E
D

Fig 14.

E-32 9803/9350-4 E-32

 Section E - Hydraulics
Service Procedures
Pressure Testing

Auxiliary Relief Valves

1 Remove the auxiliary relief valve from the control
valve and plug the valve port.

2 Install the auxiliary relief valve into the test block B

part number 331/31069.

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

and hand pump, part number 892/00223, to test
block.

4 Operate pump and adjust pressure setting plug C

until valve opens at correct pressure, K Technical
Data ( T E-3).

5 Lock the pressure setting plug with the locknut D and

retest. Remove auxiliary relief valve from test block
and refit to control valve.

Fig 15.

E-33 9803/9350-4 E-33

 Section E - Hydraulics
Service Procedures
Pressure Testing

Servo Pressure
1 Remove the blanking cap and connect a 0 - 40 bar (0
- 600 lbf/in2) pressure gauge to the test point PR on
the pressure maintenance valve (PMV).

2 With the engine running at maximum speed and

hydraulic fluid at normal working temperature,
operate the dipper service and check the gauge
reading.

3 If the servo pressure is incorrect K Technical

Data ( T E-3), adjust as follows: Slacken lock nut A
and turn adjusting screw B clockwise to increase the
pressure or anti-clockwise to decrease. Tighten lock
nut to 25 Nm (18 lbf ft). Recheck the pressure as
described in step 2.

4 Switch off engine. Remove pressure gauge and refit

blanking cap.

P3
P2
P1 A
PR
PV
T
PT

B A
Fig 16.

E-34 9803/9350-4 E-34

 Section E - Hydraulics
Service Procedures
Pressure Testing

Cross Line Relief Valves

There is a single relief valve A and B for each direction of
slew. These valves are located in the head of the slew
motor. The pressures should be checked to the values
quoted using the method described below K Technical
Data ( T E-3) .

Ensure the hydraulic system is at correct operating

temperature.

A
P3
P2
P1 A
PR
PV
T
PT

B Fig 18.

3 Engage slew lock. With the engine running at

maximum speed and the hydraulic fluid at working
temperature K Technical Data ( T E-3), fully select
slew left and hold whilst checking the pressure gauge
reading.

Fig 17. 4 Check that the pressure gauge reading equals the
cross line relief setting K Technical Data ( T E-3).
Cross Line Relief Valves A and B The relief valve cartridges are not pressure
adjustable, if the recorded pressure is low, remove
1 Gain access to the slew motor. the valve from the motor and check for debris or failed
seals. Clean valve components and renew seals if
2 Connect a 0 - 400 bar (0 - 6000lbf/in2) pressure gauge necessary, refit to motor and retest. if the correct
at test point on the pressure maintenance valve, as pressure is still not obtainable the relief valve should
shown. be changed for a new one.

5 Repeat the test fully selecting slew right.

6 Stop the engine, remove the pressure gauge and fit

blanking cap.

E-35 9803/9350-4 E-35

 Section E - Hydraulics

Control Valve
Description

Component Locations

8 9
7

5 6 19
15
4
3
1 2 12 18 14
11
17 B8 B9
10 B7
B6
B5 P1
B3 B4
B2 A8 A9
B1 A7
A6
T1 P2 A5
A3
A4
A2
P3 A1 16
13

Fig 19.

E-36 9803/9350-4 E-36

 Section E - Hydraulics
Control Valve
Description
Spools Auxiliary Relief and Anti-Cavitation Valves

1 K Slew ( T E-44) Dozer Port

2 K Dozer ( T E-43) 10 ARV, Rod side A2
3 K Swing ( T E-42)
4 K Track Left ( T E-38) Swing Port

5 K Dipper ( T E-46) 11 Anti-cavitation valve, Rod side A3

6 K Auxiliary ( T E-45) 12 Anti-cavitation valve, Head side B3

7 K Bucket ( T E-41)
Dipper Port
8 K Boom ( T E-40)
13 ARV, Rod side B5
9 K Track Right ( T E-39)
14 ARV, Head side A5
Pump Ports
Boom Port

P1 Pump Section 1 15 ARV, Rod side B8

P2 Pump Section 2 16 Anti-cavitation valve, Head side A8

P3 Pump Section 3
Main Relief Valve
Service Ports
17 MRV, LH Track, Boom, Bucket

A1 to A9 18 MRV, Dozer, Swing, Slew, Dipper boost

B1 to B9 19 MRV, Dipper, Boom Boost

Tank Ports

T1 Tank Line

E-37 9803/9350-4 E-37

 Section E - Hydraulics
Control Valve
Description

Control Valve Sections

1
Track Left
1A
Note: These sections are not interchangable
2 3

Fig 20. 5
Torque Settings and Key

Table 9.
A Head side port
B Rod side port
1 MRV Adjuster Cap See Note See Note
2 MRV 50 Nm 37 lbf ft
3 Capscrew 4.5 Nm 40 lbf in
4 Capscrew 2.5 Nm 22 lbf in
5 Spring Adjuster 4.5 Nm 40 lbf in
2
Note: Torque setting of the MRV is very critical to ensure
correct MRV pressure and prevent oil leakage. The
adjuster cap 1 can removed and refitted once only using
the existing washer 1A and then tightened to 25 Nm (18 lbf
ft). If the cap is removed and refitted again, a new washer
must be fitted and the cap tightened to 22 Nm (16 lbf ft). Fig 21.

E-38 9803/9350-4 E-38

 Section E - Hydraulics
Control Valve
Description
Track Right

Note: These sections are not interchangeable.

1
1A
2 3

Fig 22. 4
Torque Settings and Key
5
Table 10.
A Head side port
B Rod side port
1 MRV Adjuster Cap See Note See Note
2 MRV 50 Nm 37 lbf ft
3 Capscrew 4.5 Nm 40 lbf in
4 Capscrew 2.5 Nm 22 lbf in
5 Spring Adjuster 4.5 Nm 40 lbf in

Note: Torque setting of the MRV is very critical to ensure

correct MRV pressure and prevent oil leakage. The
adjuster cap 1 can removed and refitted once only using 2
the existing washer 1A and then tightened to 25 Nm (18 lbf
ft). If the cap is removed and refitted again, a new washer
must be fitted and the cap tightened to 22 Nm (16 lbf ft).

Fig 23.

E-39 9803/9350-4 E-39

 Section E - Hydraulics
Control Valve
Description
Boom

Fig 24.
7
Torque Settings and Key

A Head side port 6 1

B Rod side port
1 Capscrew 4.5 Nm 40 lbf in 2
2 Spring Adjuster 4.5 Nm 40 lbf in
3 Cap 22 Nm 16 lbf ft
4 ARV 50 Nm 37 lbf ft
5 Check Valve Plug 20 Nm 15 lbf ft
6 Cap 22 Nm 16 lbf ft
7 ARV/Anti-cavitation 30 Nm 22 lbf ft
Valve

4
7

Fig 25.

E-40 9803/9350-4 E-40

 Section E - Hydraulics
Control Valve
Description
Bucket

1
4

Fig 26.

Torque Settings and Key A

A Head side port

3
B Rod side port
1 Capscrew 4.5 Nm 40 lbf in
2 Spring Adjuster 4.5 Nm 40 lbf in
3 Check Valve Plug 20 Nm 15 lbf ft B
4 Blanking Plug 30 Nm 22 lbf ft

Fig 27.

E-41 9803/9350-4 E-41

 Section E - Hydraulics
Control Valve
Description
Swing

4 1

6
Fig 28.

Torque Settings and Key

7
A Head side port 2
B Rod side port 8
1 Capscrew 4.5 Nm 40 lbf ft
2 Spring Adjuster 4.5 Nm 40 lbf ft
3 Cap 22 Nm 16 lbf in
4 Anti-cavitation 30 Nm 22 lbf in
Valve
5 Check Valve Plug 20 Nm 15 lbf ft
6 Anti-cavitation 30 Nm 22 lbf ft
Valve
7 Cap 22 Nm 16 lbf ft
8 Capscrew 2.5 Nm 22 lbf ft

4 6
Fig 29.

E-42 9803/9350-4 E-42

 Section E - Hydraulics
Control Valve
Description
Dozer

7
1

Fig 30.
5
Torque Settings and Key

A Head side port 4

2
B Rod side port 3
1 Capscrew 4.5 Nm 40 lbf in
2 Spring Adjuster 4.5 Nm 40 lbf in
3 Capscrew 2.5 Nm 22 lbf in
4 Cap 22 Nm 16 lbf ft
5 ARV 50 Nm 37 lbf ft
6 Check Valve Plug 20 Nm 15 lbf ft
7 Blanking Plug 30 Nm 15 lbf ft

7
5
Fig 31.

E-43 9803/9350-4 E-43

 Section E - Hydraulics
Control Valve
Description
Slew

Fig 32.

Torque Settings and Key

A Head side port

1
B Rod side port
1 Capscrew 4.5 Nm 40 lbf in
2 Spring Adjuster 4.5 Nm 40 lbf in 2
3 Check Valve Plug 20 Nm 15 lbf ft

Fig 33.

E-44 9803/9350-4 E-44

 Section E - Hydraulics
Control Valve
Description
Auxiliary

4 1

Fig 34. 4

Torque Settings and Key

2
A Head side port
B Rod side port
1 Capscrew 4.5 Nm 40 lbf in
2 Capscrew 2.5 Nm 22 lbf in
3 Plug 20 Nm 15 lbf ft
4 Blanking Plug 30 Nm 22 lbf ft

Fig 35.

E-45 9803/9350-4 E-45

 Section E - Hydraulics
Control Valve
Description
Dipper

Fig 36.
4
Torque Settings and Key
2
1 Spring Adjuster 4.5 Nm 40 lbf in 3
2 Capscrew 2.5 Nm 22 lbf in
3 Cap 22 Nm 16 lbf ft
1
4 ARV/Anti- 50 Nm 37 lbf ft
Cavitation Valve
5 Check Valve Plug 20 Nm 15 lbf in
6 ARV 50 Nm 37 lbf ft
7 Cap 22 Nm 16 lbf ft

4
6

Fig 37.

E-46 9803/9350-4 E-46

 Section E - Hydraulics
Control Valve
Removal and Replacement

Removal and Replacement

Removal
A
!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your A
skin, get medical help immediately.
INT-3-1-10_2

1 Position the machine on firm level ground. Stop the

engine and vent the hydraulics.

2 Raise the cab, see Section B, Cab Tilting.

3 Remove the controls assembly, see Section D,

Control Bar.
A
4 Undo and plug the feed and return hoses to the Fig 38.
hydraulic tank.
Replacement
5 Disconnect the hydraulic hoses from the valve block,
plug both the hoses and the valve block to prevent the
Replacement is a reversal of the removal procedure. On
ingress of dirt. Identify the hoses as they are
completion, check the linkage for freedom of operation, top
removed, ready for replacement.
up the hydraulic system and test the circuits for circuit
operation, leakage etc.
6 Remove the linkages to the valve spools.

7 Remove the three screws and washers A securing

the valve block to the frame. Remove the valve block
from the machine to a clean working area.

E-47 9803/9350-4 E-47

 Section E - Hydraulics
Control Valve
Dismantling and Assembly

Dismantling and Assembly

Dismantling
Important: Absolute cleanliness is essential when
stripping and assembling hydraulic components.

Note: It is not necessary to separate valve sections to

remove valve spools, connections, relief valves etc. from
the valve block. If spools are removed, label them to make
sure they are assembled in their original positions and
facing the correct direction as each one is machined to
match its bore.

1 Remove the nuts A from one end of the valve tie rods.

2 Stand the valve vertically on the other end of the tie

rods.

3 Withdraw the sections one by one, discarding the

intersection `O' rings as you proceed. Note the
position and orientation of the sections before
removing them.
A

Fig 39.

E-48 9803/9350-4 E-48

 Section E - Hydraulics
Control Valve
Dismantling and Assembly

Inspection
1 Check the mating faces of the valve sections for
scratching, pitting, burrs and/or corrosion. Renew
valve sections as necessary.

2 Check the `O' ring seatings, check valve locations

and check valves for scratching, pitting, burrs and/or
corrosion. Renew control valve sections or check
valves as necessary.

Assembly
Note: Use new seals and `O' rings, smeared with hydraulic
fluid on assembly.

Note: If a load check valve has been dismantled then

when assembling check the valve poppet and seat for
scratches, damage and cleanliness. Begin assembly with
the poppet, followed by the spring and finally the plug.
Screw the unit in by hand to feel for any misalignment or
cross threading.

Note: If a spool is removed, when assembling ensure that

the `O' ring and wiper seal (if fitted) are correctly seated
and not damaged. Pay particular attention to cleanliness
and the smooth finish of the spool. Ensure that the spools
are fitted in their correct positions.

1 Ensure all sections are returned to their original

location. Assembly must be carried out on a clean,
smooth surface.

2 Screw the nuts to one end of each tie rod (to the end
with the shortest length of thread).

3 Insert the tie rods into the first section of the valve.
Place the section on the bench with the free length of
the tie rod uppermost.

4 Lubricate the necessary `O' rings and place on the

required seats. Add the elements to the tie rods
ensuring that mating surfaces are thoroughly clean.

5 After all elements are installed screw the nuts into the
tie rods and tighten to 50% of the required torque.

6 Tighten the tie rods to a torque of 25 Nm (18.5 lbf ft)

using a torque wrench.

E-49 9803/9350-4 E-49

 Section E - Hydraulics

Hydraulic Pump (8014, 8016, 8020)

General Description

The three section gear pump A is driven directly from the

engine crankshaft. All three gear pump drive shafts P1, P2
and P3 are linked together via a splined coupling B.

Each pump consists of two equal sized gears C running in

mesh, one gear is part of the pump driven shaft and the
second gear is part of an idler shaft.

The basic principle of a gear pump depends on the

meshing of these two equal size spur gears C. On the inlet
side of the pump, oil is picked up and trapped in the space
between the teeth on both gear wheels and the pump
body. As the gears rotate the oil is carried around the pump
until the spaces are filled by the meshing teeth of the
second gear. This forces the oil out of the space, through
the pump outlet and into the machine's hydraulic circuit.

The three section pumps have a single inlet port D to the

centre pump section, the two end pumps are fed via an
internal gallery E.

E-50 9803/9350-4 E-50

 Section E - Hydraulics
Hydraulic Pump (8014, 8016, 8020)
General Description

E
D
E

B
B

717310

Fig 40.

E-51 9803/9350-4 E-51

 Section E - Hydraulics
Hydraulic Pump (8014, 8016, 8020)
Dismantling, Inspection and Assembly

Dismantling, Inspection and Assembly

Dismantling the bushes should not show any prominent signs of

wear.
For assembly the sequence should be reversed.
5 Gear side faces, teeth and journals must be free from
The numerical sequence shown on the illustration is scoring, wear steps, bruising or pitting.
intended as a guide to dismantling.
Assembly
Note: Before starting, lightly mark the pump sections,
flange and end cover to ensure correct alignment on re- 1 Renew all seals and 'O' rings.
assembly.
2 If refitting used components, ensure that they are
1 Use a soft-faced hammer to separate the pump fitted in their original positions.
sections but do not hammer the coupling off the shaft
as this will result in internal damage. Do not use 3 Fit seal 55 with its spring inwards.
levers of any kind to separate pump components.
4 Tighten screw 4 to the torque settings given below.
2 Bushes 12 - 15, 29 - 32 and 46 - 49 must be marked
to denote their location within the body. Do not
Item Nm Kgf m lbf ft
dismantle sub-assemblies A, B or C until this has
been done. 4 47 - 55 4.8 - 5.6 34.6 - 40.5

Note: The bushes are split into two halves, e.g. items 12 5 After assembly, pour a small amount of hydraulic oil
and 13. Each half must be individually marked to ensure into each outlet port and check that the shaft can be
correct re-assembly. rotated without undue force, using a smooth jawed
hand wrench hooked around the shaft or a suitable
3 Remove bushes, gears and seals, keeping half coupling locked against the key.
components of each section of the pump together in
their relative positions. Note: After fitting to the vehicle, check and top up
hydraulic fluid level before starting. see Section 3,
Note: Note: Replacement pump sections are available. Routine Maintenance.

Inspection
1 Bodies 18, 35 and 52 can only be re-used if the 'cut-
in'(where the gears wipe into the body) is bright and
polished in appearance and the depth does not
exceed 0.076 mm (0.003 in.)

2 Ensure that the end cover, spacer plates and flange

are free from damage which could result in oil leakage
in the region of the seal contact faces.

3 If the shaft seal bore is worn, JCB Threadlocker and

Sealant should be applied to the outside diameter of
the seal.

4 The bushes must be perfectly flat on the faces which

contact the gear side faces. The bearing bores must
be free from scoring or other damage. The outside of

E-52 9803/9350-4 E-52

 Section E - Hydraulics
Hydraulic Pump (8014, 8016, 8020)
Dismantling, Inspection and Assembly

4
5
6
7
A 8
18
14
16
12
11
10
9
19
56
21
15
20
17
22
13 23
24
B 25
35
31
33
29
28 56
27
26
36
56
38 32
37 34
30 39
40
41
C 42
52
48
50
3
46
45
44 56
43
53 56
55 49
54 51
47

2
1
Fig 41.

E-53 9803/9350-4 E-53

 Section E - Hydraulics
Hydraulic Pump (8014, 8016, 8020)
Pump Flow Testing

Pump Flow Testing

Note: To achieve accurate flow figures it is recommended 10 Move flow meter to pumps P1 and P2 in turn. To
that the following procedure is adopted. measure pump P1 the bucket service should be
operated to maximum ram travel and held at
Note: When gear pump testing, the two main pumps P1 & maximum M.R.V. pressure. Similarly, to measure
P2 are equal capacity, it may therefore only be necessary pump P2 output the dipper service should be
to compare the flows one to another. operated and stalled to M.R.V. pressure, ensuring
engine speed is readjusted.
!MWARNING
Accurate pump performance can only be measured
with the hydraulic system at normal operating
temperature. Consequently various hose connections
may be required with HOT hoses, pipes and fittings.
Care must be taken to avoid touching metallic fittings
with bare hands and prevent hot oil dripping onto the
skin.
8-3-5-9

1 With the hydraulic system at the correct working

temperature, park the machine with the excavator
end resting on the ground.

2 Stop the engine, leave the isolator lever in the 'down'

position and ignition switch 'on', operate all excavator
services to vent residual pressure.

3 Remove ignition key for safety.

4 Raise the cab, see Section B, Cab Tilting.

5 Disconnect pump P3 pressure hose from the

pressure testing steel pipe.

6 Insert flow meter into pump P3 pressure line ensuring

there is a least 1 metre (36 in) of straight hose with
straight fittings from pump to flow meter, this will
prevent oil turbulence interfering with the recorded
flow on the flow meter.

7 Start the engine and run at rated speed. K Technical

Data ( T E-3)

8 Operate the dozer service to maximum M.R.V.

pressure and check engine speed, readjust if
necessary.

9 Note maximum flow recorded on meter. K Technical

Data ( T E-3) for correct flow limit, if pump output falls
below service limit, renew pump.

E-54 9803/9350-4 E-54

 Section E - Hydraulics

Hydraulic Pump (8020)

General Description

K Fig 43. ( T E-56). swash plate draws the pistons out of the barrel, filling the
vacated space on top of the piston with oil, once past top
The hydraulic pump is a small lightweight compact unit dead centre the swash plate pushes the pistons back into
containing single piston pump A components, which is the barrel displacing the oil out into the hydraulic circuits of
able to supply two equal flows to the hydraulic system. the machine.
Mounted on the back of the pump body is a gear pump B
supplying oil to the aux, dipper boost, dozer, slew and When the machine starts to dig the pressures in the circuits
swing circuits. begin to rise, this is sensed back to the pump and registers
against the crown of the pistons G as the barrel rotates.
The piston pump rotating group of components seal The force of the pressure felt on the piston crowns is
against a fixed valve plate C in the pump casing. The valve transmitted onto the swash plate and once the spring force
plate has a single groove S machined for suction, but two of the summator is exceeded, the swash plate angle
concentric pressure grooves P1 & P2 both bridging the progressively decreases. This in turn decreases the piston
piston bores in the rotating barrel D, the outer groove stroke reducing the volume of oil pumped into the hydraulic
supplies one hydraulic circuit whilst the inner groove circuits.
supplies the second, both circuits receive equal flows.
The gear pump is a fixed displacement pump, and should
this come under pressure whilst the machine is digging,
P1 the horsepower demands on the engine will increase.
However, there is a pilot gallery H sensing gear pump
S P2 pressure, running through the main pump housing to a
plunger J behind the swash plate. This increases the load
against the summator springs E decreasing the angle of
swash plate further and so reducing the piston pump flows
thus maintaining a constant horsepower demand on the
engine.

A395070

Fig 42.

The piston pump has a constant horsepower control E

which responds to hydraulic system pressure demands, as
pressure in the circuits rise so the volume of oil being
pumped into the circuits decreases, maintaining the
horsepower demands within the power output of the
engine and preventing an engine stall situation.

The constant horsepower control, or summator, is a simple

design incorporating a trunnion mounted 'swash plate' F
which governs the stroke of the pistons in the pump barrel.
This swash plate is spring loaded to an angle matching the
maximum piston stroke hence maximum flow position. As
the pistons G and barrel D rotate, driven by the engine, the

E-55 9803/9350-4 E-55

 Section E - Hydraulics
Hydraulic Pump (8020)
General Description

Fig 43.

E-56 9803/9350-4 E-56

 Section E - Hydraulics
Hydraulic Pump (8020)
Removal and Replacement

Removal and Replacement

Removal

Fig 44.

!MWARNING 5 Remove the left hand counterweight. (Weight

approximately 180 kg.)
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the Note: The lifting eye on the counterweight is at the point of
skin. Keep face and hands well clear of fluid under balance.
pressure and wear protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect 6 Drain the hydraulic tank into a clean container of
the cardboard for signs of fluid. If fluid penetrates your suitable capacity, for reuse.
skin, get medical help immediately.
INT-3-1-10_2 7 Disconnect hydraulic hoses and pipes 1, 2, 3 and 4
from the pump, cap open ports to prevent dirt ingress.
1 Gain access to the engine compartment.
8 Remove the screws and washers 5 securing the
2 Select the starter switch to the ON position. pump to the engine flywheel housing.

3 Relieve pressure from the hydraulic system.

4 Select the starter switch to the OFF position and

remove the key. Disconnect the battery.

E-57 9803/9350-4 E-57

 Section E - Hydraulics
Hydraulic Pump (8020)
Removal and Replacement

Replacement
K Fig 44. ( T E-57).

1 Renew filtered adaptor B fitted to gear pump.

2 Fill pump body with clean hydraulic fluid through

suction port adaptor A. Cap adaptor to prevent oil
draining whilst pump is refitted to flywheel housing.

3 Engage the pump driveshaft into coupling K, ensuring

the shaft gear teeth mesh correctly with the splines in
the coupling. Torque set bolts 5 to 98 Nm (72 lbf ft).

4 Replace pump connections 1, 2, 3 and 4. When fitting

the adapters 2, 3 and 4, slacken the lock nuts
completely and screw in the adapters as far as
possible. With the adapters correctly phased, tighten
the lock nuts to 108 Nm (80 lbf ft).

Note: There should not be any thread showing between

lock nuts and adapters.

5 Refit suction hose 1 to adaptor A as quickly as

possible to prevent oil loss, tighten worm drive clips.

6 Refit the left hand counterweight.

7 Refill hydraulic tank with oil to the correct level.

8 Ensure maximum no load engine speed does not

exceed the figure specified K Technical Data ( T K-1).

Running-In

A new pump is correctly bedded in by the manufacturer

and will require no further running in after fitting.

E-58 9803/9350-4 E-58

 Section E - Hydraulics
Hydraulic Pump (8020)
Pump Flow Testing

Pump Flow Testing

The following procedure can be used to establish hydraulic

pump performance. The hydraulic pump is factory set and Y
should not be adjusted. If the performance of the pump is
poor it should be returned to JCB Service for inspection.

Note: When variable displacement pump flow testing the B

results are critical to assessing the pumps performance Z X
and therefore the flow meters and pressure gauges must
be checked for accuracy. A

!MWARNING D

Accurate pump performance can only be measured

with the hydraulic system at normal operating
C
temperature. Consequently various hose connections
may be required with HOT hoses, pipes and fittings.
Care must be taken to avoid touching metallic fittings
with bare hands and prevent hot oil dripping onto the
skin. P3
8-3-5-9 P1+P2
Note: Before the following flow testing is attempted all Fig 45.
hydraulic pressures should be checked for accuracy. It
may be an incorrectly set relief valve causing engine over 4 Open the engine cover and disconnect pumps P1 and
load or poor machine performance. P2 pressure hoses from the pressure testing steel
pipes.
1 With the hydraulic system at the correct working
temperature, park the machine with the excavator 5 Connect suitable lengths of hose to both steel pipes
end resting on the ground. and join together with a Tee piece.

2 Stop the engine, leave the isolator lever in the 'down' 6 Run a 1 metre (36 in) length of hose (to prevent oil
position and ignition switch 'on'. Operate all excavator turbulence interfering with the flow meter) to a
services to vent residual pressure. suitably accurate reading flow meter and pressure
gauge A and manual pressure loading restrictor valve
3 Remove ignition key for safety. B.

7 Run a length of hose from the meter to a second Tee

piece then divide the flows along the correct neutral
circuit paths X & Y of pumps P1 and P2.

8 Disconnect the hose from pump P3. Run a 1 metre

(36 in) length of hose (to prevent oil turbulence
interfering with the pressure gauge). to a suitably
accurate reading pressure gauge C and manual
pressure loading restrictor valve D.

9 Connect the resulting flow along the correct neutral

circuit path Z for pump P3.

E-59 9803/9350-4 E-59

 Section E - Hydraulics
Hydraulic Pump (8020)
Pump Flow Testing
Important: Both the load valves B and D must be fully
open, otherwise major pump damage will occur. 40

10 Ensure the load valves B and D are fully open so that 35

Flow P1 + P2 (litres/min)
no hydraulic pressure is imposed on engine start.
30
11 Start the engine and set the throttle to the rated speed
P3 = 190 bar
as detailed in Technical Data. 25
12 Slowly and progressively screw load valve D in to 20
increase the load on pump P3 to 190 bar (8025Z and
8030Z) or 206 bar (8035Z) as recorded on the 15
pressure gauge C.
10
13 Note the flow and pressure figures on the pressure
gauge and flow meter A.
5
14 Slowly and progressively screw the load valve B in to
increase the load on pumps P1 and P2 by 50 bar as 0
recorded on the pressure gauge A. 0 100 200 300 400

15 Note the flow and pressure figures on the pressure

Pressure P1 + P2 (bar)
gauge and flow meter A. Fig 47. 8030Z Theoretical Pump Performance

16 Continue to increase the load on pumps P1 and P2 in

50 bar intervals up to a maximum load of 300 bar.

17 Compare the results against the data shown to

determine pump performance.

40

35
Flow P1 + P2 (litres/min)

30
P3 = 190 bar

25

20

15

10

0 Fig 48. 8035Z Theoretical Pump Performance

0 100 200 300 400
Pressure P1 + P2 (bar)
Fig 46. 8025Z Theoretical Pump Performance

E-60 9803/9350-4 E-60

 Section E - Hydraulics
Hydraulic Pump (8020)
Troubleshooting

Troubleshooting

Fault Possible cause Action

Overload to Engine Speed is higher than standard Re-adjust it as standard
Setting pressure is higher than specifications Re-adjust it to specifications
Damage of internal parts of pump Repair or renew
Low Pump flow or low pressure Speed down of Engine Re-adjust Engine speed
Wrong Coupling Repair or renew
Damage of internal parts of pump Repair or renew
Abnormal noise or abnormal Air in the Oil Check piping. Bleed the air in the
vibration (Cavitations) hydraulic circuit
Water in the Oil Renew Oil
Clogged up Suction filter Clean or Renew
High Suction pressure Correct the pressure
Damage of Piston shoe Renew Piston shoe
Installation condition is no good Correct installation condition
Wrong Coupling Renew Coupling
Oil Leakage Damage of O ring or packing Renew O ring
Loosened Plug Tighten Plug
Leaking from Oil seal Renew Oil Seal

E-61 9803/9350-4 E-61

 Section E - Hydraulics

Main Relief Valve

Removal and Replacement

Removal 1 Obtain access to the control valve, see Section E,

Control Valve.
The M.R.V.'s are located in the two track sections and the
swing section of the control valve: 2 Relieve hydraulic pressure, if necessary disconnect
and blank hydraulic hoses from the valve block.

A Pump 3 Section - Dozer, Swing and Slew 3 Unscrew the M.R.V.(s) from the valve block, covering
B Pump 2 Section - Track Left, Dipper, Aux the port(s) to prevent the ingress of dirt. Remove to a
clean working area.
C Pump 1 Section - Track Right, Boom, Bucket

Replacement
B
C Note: Seals are made from special material, ensure
correct replacements are used.

Note: Torque setting of the M.R.V. is very critical to ensure

correct M.R.V. pressure and prevent oil leakage. The
A adjuster cap can removed and refitted once only using the
existing washer and then tightened to 25 Nm (18 lbf ft). If
the cap is removed and refitted again, a new washer must
be fitted and the cap tightened to 22 Nm (16 lbf ft).

1 Screw the M.R.V. assembly into the valve block and

tighten to 50 Nm (37 lbf ft).

2 Reconnect hydraulics and set the valve.

3 Refit the components removed to gain access to the

valve(s).

Fig 49.

!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
INT-3-1-10_2

E-62 9803/9350-4 E-62

 Section E - Hydraulics

Auxiliary Relief Valves

Removal, Dismantling, Inspection and Assembly

Removal 1 Obtain access to the control valve, see Section E,

Control Valve.
ARV's are located in the following sections of the main
control valve: 2 Relieve hydraulic pressure, disconnect and blank any
hoses or pipes which may interfere with the removal
of the relief valve(s).
A Dozer
B Dipper 3 Unscrew the auxiliary relief valve(s) from the control
valve and remove to a clean working area.
C Boom

B
C

Fig 50.

!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
INT-3-1-10_2

E-63 9803/9350-4 E-63

 Section E - Hydraulics
Auxiliary Relief Valves
Removal, Dismantling, Inspection and Assembly

Dismantling Inspection
1 Prise off plastic locking cap. Check valve components for scratching, pitting, distortion
and/or corrosion.
2 Release adjuster lock nut 1 and remove adjuster
screw 2. Note: If any part other than O-rings and washer are
damaged the entire valve must be renewed.
3 Remove spring 3 and relief valve poppet 4.
If the valve has been dismantled it should be pressure
4 Unscrew upper valve body 5 and remove poppet 6 tested before refitting.
and springs 7.
Assembly
1 Clean the valve body and components in an
1 appropriate solvent.
2
2 Assemble in the reverse order of dismantling.
3
4 3 If the valve has been dismantled it should be pressure
tested before refitting.

Fig 51.

E-64 9803/9350-4 E-64

 Section E - Hydraulics

Pressure Maintenance Valve

and Dual Solenoid Valve
Removal and Replacement

Removal Replacement

!MWARNING 1 Replacement
procedure.
is the reverse of the removal

Fluid Under Pressure

Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
INT-3-1-10_2

1 Stop the machine on level ground with the bucket

resting on the ground. Stop the engine and vent
residual pressure from the servo accumulator by
turning the ignition on and lowering the L.H. arm rest
to the excavator operate position. Operate both
excavator control levers in all directions until stored
servo pressure in the accumulator has been
exhausted.

2 Remove the key. Remove the left and right side skirts
to gain access to the pressure maintenance valve
and dual solenoid valve.

Note: It is possible to remove a valve cartridge for cleaning

or resealing without removing the complete valve from the
machine.

3 To remove the valve, mark hoses for correct

replacement and remove. plug hoses to prevent the
ingress of dirt. On the dual solenoid valve, disconnect
the cables.

4 Remove the bolts holding the valve to the slew frame.

Important: If there is evidence of damage to the valve or

its seat caused by debris then the cartridges will require
renewing. If a cartridge or valve complete is renewed it is
recommended that the filtered adapters in the feed ports of
the valve are also renewed.

E-65 9803/9350-4 E-65

 Section E - Hydraulics

Track Motor
General Description

The track motor consists of a fixed section, made up of a

hydraulic motor and valve unit, and a rotary section which
is a simple double-step planetary speed reduction.

When both tracks are selected to operate, the pump

section P1 feeds the valve block section for the RH travel
motor, P2 feeds the valve block section for the LH travel
motor. Track feeds from the selected spools flow through
the rotary coupling to the respective track motors.

The motor valve plate A has two sets of ports B and C.

B and C are connected to the motor inlet and outlet lines

via the counterbalance valve. When pressurised fluid is
introduced through A, pistons E, on the B side are forced
against the swash plate D.

Reaction force from the swash plate generates radial force

causing rotation of the cylinder block F. Torque generated
at the cylinder block is transmitted to the output shaft G,
through splines on the cylinder block.

The end of the output shaft G has a spline connected gear

which drives two sets of planetary gears H. These reduce
output speed in two steps and transmit rotation to the
rotary section of the motor via an integral ring gear J.

Exhaust fluid is discharged from C. When the control

valve, on the main valve block, is selected to opposite
position, C becomes inlet port, B becomes outlet and
rotation is reversed.

For low speed operation (if two speed option is fitted), the
2-speed control valve supplies fluid to all ports on the port
B side (or port C side), producing maximum torque.

E-66 9803/9350-4 E-66

 Section E - Hydraulics
Track Motor
General Description

Fig 52.

Note: The track motor shown is typical only. The motors

fitted to this machine differs in detail.

E-67 9803/9350-4 E-67

 Section E - Hydraulics
Track Motor
General Description

Normal Operation Counterbalance Operation

K Fig 53. ( T E-68). K Fig 53. ( T E-68).

When travel is selected, pressure is fed from the main When the machine is on an incline it will tend to travel
pump to one of the motor control valve ports, either X or Y under gravity. Under such conditions the motor
depending on the direction of travel. Each port provides a overspeeds, acting as a pump, increasing outlet pressure
restricted feed to either end of plunger Z via a small drilling and lowering inlet pressure.
from the port into the plunger bore. Pressure from the inlet
port causes the plunger to move across, allowing flow to Differential pressure causes the counterbalance plunger Z
enter the motor via the control valve to port C. Oil is to shift and allow more flow from the counterbalance valve.
returned through the other port back to the tank. Increased flow from counterbalance valve to motor causes
motor inlet pressure to rise and balance outlet pressure
compensating for gravitational action.

Motor Low Speed, High Traction

Selected (where applicable)
K Fig 54. ( T E-69).

With the high speed button deselected, the return spring A

above two speed selector spool B returns the spool to the
low speed position.

Service ports C and D are connected via the rotary

coupling to the track spool in the valve block. Depending
on whether track forward or track reverse is selected either
port C or D may be pressurised, the other port then returns
exhaust oil back to tank via the rotary coupling and the
track spool.

The illustration shows the upper service port C

pressurised. Because the two speed tracking selector is
Fig 53. not selected, the return spring A holds the selector spool B
down allowing this pressurised oil to cross the spring cavity
Braking and on to two inlet ports in the valve plate E as well as
across the top waisted section of the spool into the centre
K Fig 53. ( T E-68). port of the valve plate. This means that at least four of the
motor pistons receive high pressure oil, driving the motor
When the control valve is reset to neutral, ports X and Y at maximum torque (tractive effort) although at the lower
are connected to the tank return line. Pressure on both speed.
ends of the plunger is reduced to exhaust value and the
plunger is re-centred. The metering notches on the plunger The opposite four pistons of the track motor are connected
gradually limit the flow of return fluid from the motor and to tank via the lower waisted section of the two speed
machine speed is smoothly reduced. selector spool.

E-68 9803/9350-4 E-68

 Section E - Hydraulics
Track Motor
General Description

Fig 54.

K Motor Low Speed, High Traction Selected (where

applicable) ( T E-68).

E-69 9803/9350-4 E-69

 Section E - Hydraulics
Track Motor
General Description

Motor High Speed, Low Traction

Selected (where applicable)
K Fig 55. ( T E-71).

With the high speed button selected, servo pressure from

the servo pressure maintenance valve via the rotary
coupling fills the cavity under the two speed selector spool
B and lifts it against the return spring A.

Service ports C and D are connected via the rotary

coupling to the track spool in the valve block. Depending
on whether track forward or track reverse is selected either
port C or D may be pressurised, the other port then returns
exhaust oil back to tank via the rotary coupling and the
track spool.

The illustration shows the upper service port C

pressurised. Because servo pressure has lifted spool B,
pressurised oil crosses the top waisted section only of the
spool into the centre port of the valve plate E, supplying a
maximum of two of the motor pistons, driving the motor at
maximum speed (minimum torque/tractive effort).

The opposite two pistons of the track motor displace the oil
to tank via the lower waisted section of the two speed
selector spool.

E-70 9803/9350-4 E-70

 Section E - Hydraulics
Track Motor
General Description

Fig 55.

K Motor High Speed, Low Traction Selected (where

applicable) ( T E-70).

E-71 9803/9350-4 E-71

 Section E - Hydraulics
Track Motor
General Description

Auto Kick Down Function (where

applicable)
When the pilot switch for high speed is turned on, the pilot
pressure for high speed is lead into chamber #1 of the auto
kick down valve A, and force F1 is applied. Force F1
overcomes spring force F4, and shifts the auto kick down
valve to the right, then the motor is switched to high speed
mode.

On the other hand, drive pressure of the hydraulic motor is

lead into chambers #2 and #3, generating forces F2 and
F3. At this point, force F3 is larger than force F2 due to the
larger cross-sectional area. The difference between F2
and F3 becomes larger when higher pressure is applied.

When the motor drive pressure exceeds the specified

value to change the speed from high to low mode, the total
force of F3 and F4 becomes larger than the total of F1 and
F2, and the auto kick down spool shifts to the left, then the
motor is switched to low speed mode.

Fig 56.

E-72 9803/9350-4 E-72

 Section E - Hydraulics
Track Motor
Track Motor Dismantling and Assembly

Track Motor Dismantling and Assembly

Dismantling Assembly
K Fig 57. ( T E-74). K Fig 57. ( T E-74).

The numerical sequence shown on the illustration is For assembly the sequence should be reversed.
intended as a guide to dismantling.
1 Renew all O-rings and oil seals.
Note: K Brake Valve Dismantling and
Assembly ( T E-75) for components of item 2. 2 Before fitting the oil seal 24, fill the inside of the lip
with grease.
When dismantling, remove pistons 11 for inspection. If
pistons or cylinder bores are worn, renew the complete 3 Install the oil seal 24 and the bearing 22 with a
cylinder block and pistons assembly 9. compression force of approximately 500 kgf (1100
lbf).

4 Before fitting the body 2 to body 26, pour hydraulic

fluid into body 26.

Table 11. Torque Settings

Item Nm Kgf m lbf ft
1 28 - 30 2.8 -3.0 20 - 22

E-73 9803/9350-4 E-73

 Section E - Hydraulics
Track Motor
Track Motor Dismantling and Assembly

20
23

22

24 26
19

1
25

6
5
4

14
16
18
8
2 7
12
10
3
15
17

13 11

T020470
T020470
Fig 57.

E-74 9803/9350-4 E-74

 Section E - Hydraulics
Track Motor
Brake Valve Dismantling and Assembly

Brake Valve Dismantling and Assembly

7
1
2
11
10
9
8
6
5
4
3

17
18
19
20
21

16
15
14 12
13
Fig 58.

Dismantling Assembly
The numerical sequence shown on the illustration is For assembly the sequence should be reversed.
intended as a guide to dismantling.
Renew all the `O' rings supplied in the seal kit.
1 Cover all open orifices to prevent dirt entering the
hydraulic system.

2 When removing the valve spools, note their

orientation; they must be refitted correctly or the valve
will not operate properly.

E-75 9803/9350-4 E-75

 Section E - Hydraulics

Slew Motor
General Description

The slew motor consists of a reduction gearbox G,

hydraulic motor M and hydraulic cross-line relief valve
assembly C.

The hydraulic motor is an axial piston type and converts

G
hydraulic energy supplied from the hydraulic pump into a
rotary motion.
M
The hydraulic valve consists of cross-line relief valves D,
which in conjunction with a double acting spool fitted to the
valve block ensures that the inertia produced when
stopping the machine is absorbed through the cross-line

)(
D
relief valves . This in turn produces a smooth machine stop
also preventing the hydraulic motor becoming overloaded.
C

The gearbox is a single step planetary type, the gearing )(

)(
converts high speed rotary motion from the hydraulic motor
D
into low-speed high torque, transmitted to the pinion shaft.

G Reduction Gearbox )(
M Hydraulic Motor
C Cross Line Relief Valve Assembly
D Cross Line Relief Valves
E Anti-Cavitation Valve E E
DR Drain Port
A A Port
B B Port
DR A T B 760260
T T Port
Fig 59.

E-76 9803/9350-4 E-76

 Section E - Hydraulics
Slew Motor
General Description

D
C

B
A

D DR

G
M

760240

Fig 60.

E-77 9803/9350-4 E-77

 Section E - Hydraulics
Slew Motor
General Description

Hydraulic Motor Section

2
5
3
1

B
Fig 61.

The hydraulic motor is an axial piston type, and changes

the hydraulic energy supplied from the pump to the rotary
motion required to drive the gearbox.

Through a hydraulic valve, the pressurized oil is supplied

to the valve plate 1. When the pressurized oil is supplied to
the A port, this pressurized oil pushes the piston 2 in the
cylinder barrel 3. This pushing force is changed to the
rotational power by the swash plate 4 and transmitted to
the shaft 5 which is connected to the gear section. The
return flow from the cylinder port is going out through the
B port of the valve plate 1. To reverse rotation, pressurized
oil is supplied to the B port and returning oil exits through
the A port.

E-78 9803/9350-4 E-78

 Section E - Hydraulics
Slew Motor
General Description

Cross Line Relief Valve Section First Stage

The shockless relief valve consists of the direct relief valve When the P1 pressure is going up, the poppet 1 opens due
(poppet) 1 and the piston 2 for changing the spring force in to the pressure of the spring force F1.
two stages. K Fig 62. ( T E-79)
Second Stage
When hydraulic pressure is removed from port A or port B
of the hydraulic motor, the motor carries on running due to When P1 pressure enters the second chamber through the
inertia. The motor works as a pump, and the pressure orifices A and B, the piston moves to its stroke-end C. With
(brake pressure) is felt on the output port side. The this action, the spring is compressed, the spring force
shockless relief valve releases this brake pressure with becomes stronger, and the P1 pressure is increased to the
two stages of operation. This makes the shock smooth, setting pressure Ps.
and prevents the motor being damaged. It also makes the
start of the motor smooth.

Fig 62.

E-79 9803/9350-4 E-79

 Section E - Hydraulics
Slew Motor
General Description

Anti Cavitation Valve Section

T020230-2
Fig 63.

When the swing motor is decelerated by operating the

control valve, it continues to be moved by the inertia of the
machine. Then, it works as pump, and the pressure of
chamber C tends to become negative. However, when B
port pressure is below cracking pressure of the relief valve,
all flow in A port goes out from B port through the motor.
Therefore, if chamber C can get flow only from the control
valve, the flow will not be enough to prevent the negative
pressure; as a result, cavitation could occur. The anti-
cavitation valve 12 works to supply the flow from T port to
chamber C, and thus prevents cavitation.

E-80 9803/9350-4 E-80

 Section E - Hydraulics
Slew Motor
Removal and Replacement

Removal and Replacement

M
Y

X F

G
Fig 64.

Removal 1 Vent residual pressure from within the hydraulic tank

by releasing the tank filler cap. Gain access to the

!MWARNING slew motor by raising the cab. See Section B, Cab

Tilting Procedure.
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the 2 Label, then disconnect the hydraulic hoses from the
skin. Keep face and hands well clear of fluid under motor head, plug hoses and blank open ports to
pressure and wear protective glasses. Hold a piece of prevent the ingress of dirt.
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your 3 Mark gearbox casing X and motor casing Y to aid re-
skin, get medical help immediately. assembly.
INT-3-1-10_2
4 Remove ring of capscrews F locating motor casing to
It is not necessary to remove the motor/gearbox complete gearbox casing.
to service either the motor M or the cross-line relief valves
D. 5 Lift motor clear of gearbox and remove to a clean
area for dismantling, if required.
Important: Lubrication drain hose is a direct connection to
hydraulic tank, consequently it must be plugged 6 Protect open gearbox from ingress of dirt.
immediately to prevent excessive oil loss.

E-81 9803/9350-4 E-81

 Section E - Hydraulics
Slew Motor
Removal and Replacement
7 If it is necessary to remove the gearbox, omit step 4
above and remove capscrews G. Remove the
complete assembly to a clean area, then remove
capscrews F.

Replacement

!MCAUTION
If gearbox mounting dowels have been left in slew
frame, make sure the holes in the gearbox flange
accurately align with the dowels on reassembly.
Incorrectly aligned dowels may be pushed through the
slew frame and abut against the slew ring as the
gearbox retaining bolts are tightened. If this occurs
the slew frame may need separating from the
undercarriage to retrieve the dowels.
8-3-1-6

1 Remove protective cover from gearbox, position slew

motor over gearbox, ensuring correct engagement of
drive shaft splines.

2 Align marks made prior to dismantling, fit capscrews

F and tighten to 26 - 32 Nm (19 - 23 lbf ft).

3 If fitting a new motor or one that has been drained of

oil, fill the motor casing with hydraulic oil via port T
before starting the engine.

4 Check relief valve settings. K Pressure

Testing ( T E-31)

5 When fitting gearbox to mainframe, tighten

capscrews G to 215 - 275 Nm (160 - 200 lbf ft).

E-82 9803/9350-4 E-82

 Section E - Hydraulics
Slew Motor
Dismantling and Assembly

Dismantling and Assembly

9
8

7
4

5
2
6
1
12

11
10
13

14 15
Fig 65.

E-83 9803/9350-4 E-83

 Section E - Hydraulics
Slew Motor
Dismantling and Assembly

Dismantling
The numerical sequence shown on the illustration is
intended as a guide to dismantling.

For assembly the sequence should be reversed.

Remove pistons for inspection. If pistons or cylinder bores

are worn, renew the complete cylinder block and pistons
assembly 8.

Assembly
Renew all O-rings and oil seals.

Before fitting the valve plate 9, ensure copper face is

uppermost and smear with oil.

Table 12. Torque Settings

Item Nm Kgf m lbf ft
Cross Line Relief 127-166 13.0-17.0 93-122
Valve
Check Valve 56-61 5.7-6.2 41-44

E-84 9803/9350-4 E-84

 Section E - Hydraulics

Rotary Coupling
8014, 8016 Single Speed Machines

Removal
Note: Before removing a suspected leaking coupling,
ensure that the leak is from the coupling core and not a
hose adaptor. Ensure all adaptors are tight.

!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
INT-3-1-10_2

1 Raise cab to gain access to rotary coupling, see Cab

tilting procedure Section B.

!MWARNING
Postion the machine on a firm, level surface before
tilting the cab. The tilting gas struts must be fully
raised and locked in position before attempting any
service procedure.
8-5-1-4

2 Identify and remove the hydraulic hoses from the

adaptors A and B. Blank both the hoses and the
adaptors.

3 Remove the four bolts, nuts and washers C securing

the rotary coupling to the undercarriage and lift clear
of the mainframe.

Replacement
1 Replace in reverse order of removal.

2 Reconnect hydraulic hoses using new lightly

lubricated 'O' rings.

3 Test the assembly for leaks.

E-85 9803/9350-4 E-85

 Section E - Hydraulics
Rotary Coupling
8014, 8016 Single Speed Machines

A A

K H
L
J

B B

D
Fig 66.

E-86 9803/9350-4 E-86

 Section E - Hydraulics
Rotary Coupling
8014, 8016 Single Speed Machines

Dismantling
1 Note the positions and remove the adaptors A and B
from the coupling. Discard the O-rings.

2 Remove the external circlip D and the ring E from the

base of the coupling.

3 From the top of the coupling, carefully withdraw the

core F from the shell G.

4 Remove the `V' seal H and the ring J.

5 Remove and discard the 'O' rings K and seals from

the shell L.

Inspection
1 All 'O' rings and seals must be replaced with new.

2 If the core or shell show signs of wear, replace the

complete rotary coupling.

Assembly
1 Assemble in reverse order of dismantling, fitting new
O-rings and back-up rings, lightly lubricate with
hydraulic fluid.

2 Fit lip seal M in the position and attitude shown.

E-87 9803/9350-4 E-87

 Section E - Hydraulics
Rotary Coupling
8016, 8018 Two Speed Machines

8016, 8018 Two Speed Machines

Removal
Note: Before removing a suspected leaking coupling,
ensure that the leak is from the coupling core and not a
hose adaptor. Ensure all adaptors are tight.

!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
INT-3-1-10_2

1 Raise cab to gain access to rotary coupling, see Cab

tilting procedure Section B.

!MWARNING
Postion the machine on a firm, level surface before
tilting the cab. The tilting gas struts must be fully
raised and locked in position before attempting any
service procedure.
8-5-1-4

2 Identify and remove the hydraulic hoses from the

adaptors A and B. Blank both the hoses and the
adaptors.

3 Remove the four bolts, nuts and washers C securing

the rotary coupling to the undercarriage and lift clear
of the mainframe.

Replacement
1 Replace in reverse order of removal.

2 Reconnect hydraulic hoses using new lightly

lubricated 'O' rings.

3 Test the assembly for leaks.

E-88 9803/9350-4 E-88

 Section E - Hydraulics
Rotary Coupling
8016, 8018 Two Speed Machines

M
N
A A

L
H

B
B

E
D B

F
G

Fig 67.

E-89 9803/9350-4 E-89

 Section E - Hydraulics
Rotary Coupling
8016, 8018 Two Speed Machines

Dismantling
1 Note the positions and remove the adaptors A and B
from the coupling. Discard the O-rings.

2 Remove the four capscrews F retaining cover plate G.

3 Remove the external circlip D and spacer ring E from

the base of the coupling.

4 From the top of the coupling carefully withdraw the

coupling core H from the shell J.

5 Remove the `V' seal K and the ring L.

6 Remove and discard back-up rings N and O-rings M

from the core.

Inspection
1 All rotary coupling core O-rings and back-up rings
must be replaced with new and are only available as
a set.

2 If the core H or shell J show signs of wear replace the

complete rotary coupling.

Assembly
1 Assemble in reverse order of dismantling, fitting new
O-rings and back-up rings, lightly lubricate with
hydraulic fluid.

2 Fit lip seal P in the position and attitude shown.

E-90 9803/9350-4 E-90

 Section E - Hydraulics
Rotary Coupling
8018, 8020 Two Speed and Extending Undercarriage Machines

8018, 8020 Two Speed and Extending

Undercarriage Machines

Removal
Note: Before removing a suspected leaking coupling,
ensure that the leak is from the coupling core and not a
hose adaptor. Ensure all adaptors are tight.

!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
INT-3-1-10_2

1 Raise cab to gain access to rotary coupling, see Cab

tilting procedure Section B.

!MWARNING
Postion the machine on a firm, level surface before
tilting the cab. The tilting gas struts must be fully
raised and locked in position before attempting any
service procedure.
8-5-1-4

2 Identify and remove the hydraulic hoses from the

adaptors A and B. Blank both the hoses and the
adaptors.

3 Remove the four bolts, nuts and washers C securing

the rotary coupling to the undercarriage and lift clear
of the mainframe.

Replacement
1 Replace in reverse order of removal.

2 Reconnect hydraulic hoses using new lightly

lubricated 'O' rings.

3 Test the assembly for leaks.

E-91 9803/9350-4 E-91

 Section E - Hydraulics
Rotary Coupling
8018, 8020 Two Speed and Extending Undercarriage Machines

Fig 68.

E-92 9803/9350-4 E-92

 Section E - Hydraulics
Rotary Coupling
8018, 8020 Two Speed and Extending Undercarriage Machines

Dismantling
1 Note the positions and remove the adaptors A and B
from the coupling. Discard the O-rings.

2 Remove the external circlip F and ring G from the top

of the coupling.

3 From the top of the coupling carefully lift the coupling

shell H from the core J.

4 Remove and discard back-up rings and O-rings from

the core.

Inspection
1 All rotary coupling core O-rings and back-up rings
must be replaced with new and are only available as
a set.

2 If the core or shell show signs of wear replace the

complete rotary coupling.

Assembly
1 Assemble in reverse order of dismantling, fitting new
O-rings and back-up rings, lightly lubricate with
hydraulic fluid.

E-93 9803/9350-4 E-93

 Section E - Hydraulics

Hydraulic Rams
Precautions During Use
TE-006

Installation Special seal materials are necessary so check to

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

Caution During Use Maintenance, Inspection Points

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

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

E-94 9803/9350-4 E-94

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

2 Use genuine JCB parts when replacing parts.

a If parts other than genuine JCB parts are used,

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

3 Caution during dismantling and reassembly.

a Dismantling the ram while it is still installed on the

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

b If reassembled with dirty hands, foreign matter

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

c Follow the instructions in the diagrams regarding

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

E-95 9803/9350-4 E-95

 Section E - Hydraulics
Hydraulic Rams
Removal and Replacement

Removal and Replacement

!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
INT-3-1-10_2

!MWARNING
A raised and badly supported machine can fall on you.
Position the machine on a firm, level surface before
raising one end. Ensure the other end is securely
chocked. Do not rely solely on the machine hydraulics
or jacks to support the machine when working under
it.

Disconnect the battery, to prevent the engine being

started while you are beneath the machine.
GEN-1-1

!MWARNING
If air or hydraulic pressure is used to force out the
piston assembly, ensure that the end cap is securely
fitted. Severe injury can be caused by a suddenly
released piston rod.
HYD-1-2

E-96 9803/9350-4 E-96

 Section E - Hydraulics
Hydraulic Rams
Removal and Replacement

Boom, Dipper and Bucket Rams 5 Run the engine at idle and with the servo isolator lock
in the operate position, move the control lever rapidly
Removal in both directions to vent any trapped pressure. Stop
the engine.
1 With the engine idling, set the machine with the
bucket on the ground. !MWARNING
2 Support the excavator under the angle between the It is not possible to vent all residual pressure. Loosen
dipper and boom to ensure it will not move when the the connection one full turn and allow the pressure to
ram is removed. dissipate. Keep face and hands well clear of
pressurised hydraulic oil and wear protective glasses.
3 On boom and bucket rams, remove the protection HYD-4-3
plate. Support the ram under the gland bearing and
remove locknut A and bolt B from the pivot at the eye 6 Support the ram and remove the locknut A and the
end of the ram. Drive out the pivot pin C. bolt B from the pivot at the base of the piston. Drive
out the pivot pin C. Disconnect the hoses. Remove
the ram from the machine.

Replacement

1 Locate the pivot point on the ram into the location on

the machine structure. Fit the pivot pin C and secure
using the bolt B and new locknut A.

2 Support the ram under the gland end of the cylinder,

reconnect the hoses. With the engine idling, slowly
extend the ram until the eye end locates correctly in
the machine structure. Fit pin C. Secure using the bolt
B and new locknut A.

3 Apply grease to the pivot points through the grease

nipples. For grease specification see, Section 1,
Fluids Lubricants and Capacities.

4 Connect the hoses to the cylinder, torque tighten.

5 On the bucket and boom rams, fit the protection plate

and secure using the bolts.

Fig 69.

4 With the engine idling, gently retract the ram rod into
the cylinder by operating the relevant service.

E-97 9803/9350-4 E-97

 Section E - Hydraulics
Hydraulic Rams
Removal and Replacement

Dozer Ram

B G

G
C
E
A
F

Fig 70.

Removal Replacement

1 Set the machine in the posture shown with the dozer 1 Locate the pivot point on the cylinder end of the ram
grounded onto suitable supports. into the dozer frame.

2 With the starter switch turned OFF, relieve residual 2 Fit pivot pin F and secure with bolt E and new locknut
hydraulic pressure by operating the hydraulic D.
controls.
3 Fit the pivot point at the rod end of the ram to the
3 Disconnect the hydraulic hoses. Blank off the hoses machine.
and the open ports of the ram.
4 Fit the pivot pin C and secure using the bolt B and
4 Remove locknut A and the bolt B from the pivot at the new locknut A.
rod end of the ram. Support the ram and drive out the
pin C. Lower the ram end onto a suitable support. 5 Apply grease to the pivot points through the grease
nipples G.
5 Remove locknut D and bolt E. Support the ram and
drive out pin F. Carefully remove the ram from the 6 Connect the hoses to the cylinder.
machine.
Note: Refer to Standard Torque Settings ( Section 1)
and Retaining Compounds ( Section 1) for torque
settings and sealant information.

E-98 9803/9350-4 E-98

 Section E - Hydraulics
Hydraulic Rams
Removal and Replacement

Swing Ram Replacement

Removal 1 Connect hoses to new/serviced ram. Locate the ram

into the machine upper structure and align the
1 Position the machine with upper structure slewed at cylinder end pivot point with the mating location in the
90º right to the tracks. machine frame.

2 Swing the machine dig end fully to the right and lower 2 From underneath the upper structure fit the pivot pin
the excavator to the ground. and secure with bolt, washer and keep plate.

3 Remove keep plate A at the rod end of the ram. 3 Reconnect the hoses.

4 Support the cylinder and drive out the pivot pin B. 4 With the engine idling, slowly extend the ram until the
With the engine idling, slowly retract the ram until the rod end locates into the kingpost C, stop the engine.
eye end clears the king post C. Stop the engine.
5 Fit the pivot pin B. Refit and secure keep plate A.
5 Operate the swing pedal in both directions to vent any
residual pressure. Note: Refer to Standard Torque Settings ( Section 1)
and Retaining Compounds ( Section 1) for torque
6 Remove floor mat and floorplates. Disconnect the settings and sealant information.
ram feed hoses at the valve block, Plug the hoses and
cap the open ports of the valve.

7 Locate the ram from underneath the upper structure.

Remove the bolts and the spring washers securing
the keep plate at the base end of the cylinder.

8 Remove the pivot pin.

9 Withdraw ram with hoses attached.

Fig 71.

E-99 9803/9350-4 E-99

 Section E - Hydraulics
Hydraulic Rams
Dismantling and Assembly

Dismantling and Assembly

All Rams 5 Remove end cap 1 from piston rod and remove the
remaining `O' rings and seals. Check the end cap

!MWARNING bush for damage, scores or nicks. If damaged, the

bush must be replaced as part of the end cap
If air or hydraulic pressure is used to force out the assembly.
piston assembly, ensure that the end cap is securely
fitted. Severe injury can be caused by a suddenly 6 Ensure that metal components are free from scoring,
released piston rod. nicks and burrs. A damaged rod will impair the life of
the seals.
HYD-1-2

Dismantling 7 Check the bore of the ram cylinder for damage.

8 Discard all seals and `O' rings.

The numerical sequence shown on the illustrations are
intended as a guide to dismantling only.
Inspection
For assembly the sequence should be reversed.
Piston Rod Warp

K Bucket Ram ( T E-101) 1 Support the piston rod on a pair of 'V' blocks.
K Dozer Ram ( T E-102)
2 Set a dial test indicator (D.T.I.) at the approximate
K Swing Ram ( T E-102)
centre of the rod. Set the D.T.I. to zero.
K Boom Ram ( T E-103)
K Dipper Ram ( T E-103) 3 Rotate the piston rod in its blocks, noting any variation
in D.T.I. reading.
K Extending Undercarriage Ram ( T E-104)
4 If warp (half the difference between maximum and
1 Support ram assembly as shown. minimum readings) exceeds 0.5 mm (0.02 in) the
piston rod must be replaced.

Pivot Bush Clearances

1 Using an internal micrometer measure the internal

diameter (I.D.) of the pivot pin bushes in the piston
rod and cylinder ends.

2 Compare the readings with the permitted tolerances

shown. Remove and replace pin bushes as
H07890-B1
Fig 72. necessary.

2 Slacken end cap 1 using Hook spanner / spanner and Piston Rod/Rod Bush Clearances
remove the piston rod assembly 2 from the cylinder.
1 Using internal and external micrometers, measure
3 Position piston rod assembly on bench in place of ram the piston rod outside diameter (O.D.) and the rod
cylinder. Remove seals 3 and wear rings from piston bush inside diameter (I.D.).
head.
2 Compare the readings taken with the permitted
4 Undo nut/locking pin and remove / unscrew piston clearances. If necessary, renew the piston rod and/or
head from rod. the rod bush.

E-100 9803/9350-4 E-100

 Section E - Hydraulics
Hydraulic Rams
Dismantling and Assembly
Pin Bush Clearances Bucket Ram

1 Using internal and micrometers, measure the inside

diameter (I.D.) of the pin bushes in the piston rod and
cylinder ends.

2 Compare the readings taken with the permitted

clearances. Remove and replace pin bushes as 2
necessary.
9
Assembly 1
8
1 Completely remove oil, grease, dirt and hardened
locking compound from all threads. Remove all traces 11
of rust using a wire brush.
10
4
2 Apply JCB Activator to threads of piston rod and 6
cylinder. Apply JCB Threadlocker and Sealer to 7 3
threads of end cap 1. Wait 15 minutes before 5
assembly, using correct torque figures. K Torque
Settings ( T E-101)

Table 13. Torque Settings

End Cap (1) Lock Nut (5)
Nm (lbf ft) Nm (lbf ft)
8014/8016 Bucket Ram, 490 (361) 274 (202)
Swing Ram, Dipper Ram
8018/8020 Bucket Ram 637 (470) 343 (253)
8018/8020 Swing Ram, 637 (470) 274 (202) Fig 73.
Dipper Ram
Boom Ram 637 (470) 274 (202)
Dozer Ram 588 (433) 490 (361)
Extending Undercarriage 637 (470) 343 (253)
Ram

3 Use new seals and `O' rings, lubricated with hydraulic

fluid before assembly.

4 Take care not to damage seals during assembly.

5 Apply JCB High Strength Threadlocker & Sealer to

thread of lock nut / locking pin.

6 Allow one hour at 20°C before filling the ram with oil.

E-101 9803/9350-4 E-101

 Section E - Hydraulics
Hydraulic Rams
Dismantling and Assembly
Dozer Ram Swing Ram

2
2
9
9 1
1
8
11
8 10
4 11 4
6 10 6
7 3 7 3
5 5

Fig 75.
Fig 74.

E-102 9803/9350-4 E-102

 Section E - Hydraulics
Hydraulic Rams
Dismantling and Assembly
Boom Ram Dipper Ram

2 2
9 9
1 1
8 8
12 11
11 10
10
4 4
6 6
7 7
3 3
5
5

Fig 76.
Fig 77.

E-103 9803/9350-4 E-103

 Section E - Hydraulics
Hydraulic Rams
Dismantling and Assembly
Extending Undercarriage Ram

2
9
1
8
11
10
4
6
7
3
5

Fig 78.

E-104 9803/9350-4 E-104