Section E

Hydraulics
Service Manual - 3DX / 4DX Backhoe Loader
Section 1 - General Information
Section 2 - Operator’s Manual
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section D - Controls
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering
Section K - Engine

Publication No.
9813/2050-5

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 9813/2050-5 E-0

 Section E - Hydraulics

Contents Page No.

Technical Data
Machine Hydraulics .................................................................................. E-1
Hydraulic Pump Flow and System Pressure ............................................ E-2
Gear Pump ............................................................................................... E-3
Loader Valve Block ................................................................................... E-4
Main Relief Valve .................................................................................. E-4
Excavator Valve Block ............................................................................. E-5
Backhoe ............................................................................................... E-5
Gear Pump ............................................................................................... E-6
Loader Valve Block ................................................................................... E-7
Main Relief Valve .................................................................................. E-7
Excavator Valve Block ............................................................................. E-8
Backhoe ............................................................................................... E-8
Attachments ......................................................................................... E-9

Basic System Operation

Introduction to Hydraulic Schematic Symbols ........................................ E-10
General (Basic and Functional Symbols) ........................................... E-10
Control Valves .................................................................................... E-14
Example of Schematic Circuit ............................................................ E-15
Component Location and Neutral Circuit Descriptions ........................... E-16
Gear Pump - Double Pump ................................................................ E-16

Hydraulic Schematics
3DX BSIII with JCB Ecomax Engine ...................................................... E-18
From Serial Number ........................................................................... E-18
From Serial Number ........................................................................... E-19
3DX Xtra, 3DX Super and 4DX .............................................................. E-21
From Serial Number ........................................................................... E-21

Hydraulic Pump
Gear Pump - Operation .......................................................................... E-31
Single Pump - Operation .................................................................... E-31
Double Pump ...................................................................................... E-31
Machines from Serial no. 964125 (High Pressure) ............................ E-32
Unloader Valve ................................................................................... E-34
Main Relief Valve (MRV) - Operation ................................................. E-35
Main Relief Valve (MRV) .................................................................... E-37
Loader Valve - Neutral Circuits ............................................................... E-38
Neutral Circuit ..................................................................................... E-38
Unloader Operation (If fitted) .............................................................. E-39
Hydraulic Speed Control (HSC) .......................................................... E-41
Load Hold Check Valves .................................................................... E-43
Arms Lower Operation ....................................................................... E-45
Float ................................................................................................... E-45
Auxiliary Relief Valve .......................................................................... E-47
Main Relief Valve (MRV) Operation .................................................... E-49

E-i E-i
 Section E - Hydraulics
Contents

Contents Page No.

Excavator Valve ...................................................................................... E-52
Neutral Circuit ..................................................................................... E-52
Excavator Valve .................................................................................. E-54
One Way Restrictor ............................................................................ E-54
Excavator Valve - Slew Operation ...................................................... E-55
Slew Ram End Damping .................................................................... E-57
Slew A.R.V. and Anti-Cavitation Operation ........................................ E-58
Excavator Valve - A.R.V. Operation .................................................... E-59
Auxiliary Relief Valve Operation ......................................................... E-60
Auxiliary Relief Valve - Anti-Cavitation ............................................... E-61
Excavator Valve - Dipper Make-Up Check Valve and Anti-Cavitation Oper-
ation .................................................................................................... E-62
Hydraclamp (Sideshift Machines) ....................................................... E-63

Service Procedures
Hydraulic Contamination ........................................................................ E-65
Hydraulic Fluid Quality ....................................................................... E-65
Effects of Contamination .................................................................... E-65
Cleaning Operation ............................................................................ E-65
Contaminant Standards ...................................................................... E-66
Filters .................................................................................................. E-66
Connecting/Disconnecting Hydraulic Hoses ........................................... E-67
Introduction ......................................................................................... E-67
Connecting the Hydraulic Hoses ........................................................ E-67
Disconnecting the Hydraulic Hoses .................................................... E-68
Quick Release Couplings ................................................................... E-69
Hydraulic Pump ...................................................................................... E-71
Flow and Pressure Testing ................................................................. E-71
Loader Valve (Unloader valve) ........................................................... E-73
Shovel Ram Rod Side A.R.V. Pressure Testing ................................. E-74
Removal and Replacement ................................................................ E-75
Dismantling, Inspection and Assemble .............................................. E-76
Loader Valve - Pressure Testing ............................................................. E-79
Main Relief Valve (M.R.V.) .................................................................. E-79
Unloader Valve ................................................................................... E-80
Hydraulic Speed Control (HSC) .......................................................... E-81
Auxiliary Relief Valves - Using Hand Pump ........................................ E-82
Excavator Valve - Pressure Testing ........................................................ E-87
Auxiliary Relief Valves - Using Hand Pump ........................................ E-87
Ram Creep Tests - All Services .............................................................. E-88
Valve Block Spool Seals ......................................................................... E-94
Seal Fitting - 3DX ............................................................................... E-94
Seal Fitting - 3DX ECO ...................................................................... E-97
Hydraclamp Valve - Dismantling and Assembly ............................... E-101
Hydraulic Adaptors (Positional Type) ................................................... E-103
Fitting Procedure .............................................................................. E-103

Loader Valve
Removal and Replacement .................................................................. E-104
Removal ........................................................................................... E-104
Replacement .................................................................................... E-104

E-ii E-ii
 Section E - Hydraulics
Contents

Contents Page No.

Dismantle and Assemble ...................................................................... E-106
Main Relief Valve (MRV) .................................................................. E-106
Auxiliary Relief Valves (ARV) and Load Hold Check Valves (LHCV) E-108
Unloader Valve ..................................................................................E-110
Standard Spool ..................................................................................E-112
Float Spool ........................................................................................E-114
Electric Detent Spool .........................................................................E-116

Loader Valve
Component Identification ....................................................................... E-118
3DX Xtra and 4DX .............................................................................E-118
3DX Super .........................................................................................E-119
Removal and Installation ...................................................................... E-122
Removal ........................................................................................... E-122
Installation ........................................................................................ E-122
Dismantle and Assemble ...................................................................... E-123
Main Relief Valve (MRV) .................................................................. E-123
Unloader Valve ................................................................................. E-123
Open End Kit .................................................................................... E-123

Excavator Valve
Removal and Replacement .................................................................. E-125
Dismantle and Assemble ...................................................................... E-127
Valve Block ....................................................................................... E-127
Auxiliary Relief Valves (ARV's) ......................................................... E-130
Hydraclamp Valve (Sideshift Machines) ........................................... E-132
Hoses and Pipes (Sideshift Valve) ................................................... E-134
Hoses and Pipes (Centremount Valve) ............................................ E-135

Excavator Valve
Description ............................................................................................ E-137
For 3DX Xtra, 3DX Super (Base and AC) ........................................ E-137
For 3DX Xtra and 3DX Super (Servo) .............................................. E-139
4DX .................................................................................................. E-141
Removal and Replacement .................................................................. E-143
Sideshift Machine ............................................................................. E-143
Dismantle and Assemble ...................................................................... E-144
Valve Block ....................................................................................... E-144

Servo Joysticks
Description and Operation .................................................................... E-149
Description ....................................................................................... E-149
Operation .......................................................................................... E-149
Removal and Replacement .................................................................. E-150
Removal ........................................................................................... E-150
Replacement .................................................................................... E-150

Hydraulic Rams
Precautions During Use ........................................................................ E-153
Installation ........................................................................................ E-153
Caution During Use .......................................................................... E-153
Maintenance, Inspection Points ....................................................... E-153

E-iii E-iii
 Section E - Hydraulics
Contents

Contents Page No.

Removal and Replacement .................................................................. E-155
Loader Shovel Ram .......................................................................... E-155
Loader Lift Ram ................................................................................ E-157
Bucket Crowd Ram .......................................................................... E-160
Dipper Ram ...................................................................................... E-162
Boom Ram ....................................................................................... E-164
Slew Ram ......................................................................................... E-166
Stabiliser Ram (Sideshift) ................................................................. E-169
Priority Valve .................................................................................... E-170
JCB Ram Sealing Procedure ........................................................... E-172
Assembly and Disassembly .................................................................. E-174
Typical Ram ...................................................................................... E-174
Slew Ram ......................................................................................... E-181

Fault Finding
Introduction ........................................................................................... E-191

E-iv E-iv
 Section E - Hydraulics
Technical Data
Machine Hydraulics

Technical Data
Machine Hydraulics

Table 1. 3DX BSIII and 3DX Xtra

Machine 3DX BSIII 3DX Xtra
(1888500 (1494400 to
to 1502999)
1899999)
Recommended Hydraulic Fluid JCB Standard 4002/1000 or 4002/08000
Recommended Oil Charge Interval 2000 Hour - Tank oil and 4000 hrs Complete system oil
Recommended charge interval for filter Element 500 hours Maximum
ISO Cleanliness Standard on brand New System 16/13
Total System Capacity 120 litres (Tank - 70 litres)
Maximum allowable Water content 0.1%
By pass valve setting of return Line filter 1.5 Bar
Breather assembly - Outer valve Intlet 0.34 to 0.35 bar
Inlet valve 0.02 to 0.04 bar
Working temperature of Hydraulic Fluid Intermittent 1600 C Maximum
Continuous (in Excavation) 800 C Maximum
Recommended Engine RPM for Low Idle (+/- 50RPM) 900 RPM 900 RPM
Recommended Engine RPM for Hand Throttle (+/- 50RPM) 1550 1550 RPM
RPM
Micron Rating of filter Element 10 microns

E-1 9813/2050-5 E-1

 Section E - Hydraulics
Technical Data
Hydraulic Pump Flow and System Pressure

Hydraulic Pump Flow and System Pressure

Table 2. 3DX BSIII and 3DX Xtra

Machine 3DX BSIII (1888500 to 1899999) 3DX Xtra (1494400 to 1502999)
Model Double pump Double pump
Steering pump Seperate Steering pump Seperate Steering pump
Main pump flow (P1:P2) CC 33:21 CC 29:29 CC
Pressure (P1/P2) Bar 227/207 250/227
Steering pump flow (CC) (i = 1.625) 14 CC 14 CC
Steering pressure (Bar) 125 125

E-2 9813/2050-5 E-2

 Section E - Hydraulics
Technical Data
Gear Pump

Gear Pump

Table 3.
Hydraulic Pumps (Parker) 3DX BSII
Model/ Reference Double Pump (9-81377-3DX)
Rotation Anti-clockwise
Mounting Chassis (driveshaft driven)
Flow at 2200 rev/mm and system pressure at 500 C 23:23 cc - 101 litres
Maximum Working Pressure see- Relief valve Operating
Pressures

Table 4.
Hydraulic Pumps (Parker) 3DX After 3DX BSIII 3DX Xtra 3DX Super 3DX 4DX
1855501 To 1855500 India Super
Export
Model/ Reference Double Double Double Double Double Double
Pump Pump Pump Pump Pump Pump
(onwards) (onwards) (onwards) (onwards) (onwards) (onwards)
Rotation Anti- Anti- Anti- Anti- Anti- Anti-
clockwise clockwise clockwise clockwise clockwise clockwise
Mounting Gearbox Gearbox Gearbox Gearbox Gearbox Gearbox
Flow at 2200 rev/mm and system 33:21cc - 29:21cc - 33:23 cc - 23:23 cc - 33:23 cc - 37:33 cc -
pressure at 500C 118.8 litres 110 litres 123 litres 101 litres 123 litres 154 litres
Maximum Working Pressure see- Relief valve Operating Pressures

E-3 9813/2050-5 E-3

 Section E - Hydraulics
Technical Data
Loader Valve Block

Loader Valve Block

Main Relief Valve

Table 5.
Operating Pressures @1500 RPM Bar kg/cm2 lb/in2
3DX (upto9-815777) 207 211 3000
3DX (9-815777onwards) 228 233 3300
3DX Xtra 245 251 3600
4DX 228 233 3300

Table 6.
Unloader Valve Bar kg/cm2 lb/in2
3DX BSII 207 211 3000
3DX BSIII 207 211 3000
3DX Xtra 221 226 3200
3DX Super 207 211 3000
4DX 207 211 3000

E-4 9813/2050-5 E-4

 Section E - Hydraulics
Technical Data
Excavator Valve Block

Excavator Valve Block

Backhoe
Table 7.
Auxiliary Relief Valve (A.R.V.) bar kg/cm2 Ib/in2
Boom Ram Head Side 241-255 246-260 3500-3700
Boom Ram Rod Side 303-317 309-323 4400-4600
Bucket Ram Head Side 303-317 309-323 4400-4600
Bucket Ram Rod Side 241-255 246-260 3500-3700

Dipper Ram Head Side 241-255 246-260 3500-3700

Dipper Ram Rod Side 241-255 246-260 3500-3700
Slew Left and Right 255-269 260-274 3700-3900

Attachments

Table 8.
Extradig Ram Head Side *207-220 211-225 3000-3200
Jaw Bucket Ram Head Side 138-145 141-148 2000-2100
Jaw Bucket Ram Rod Side 207-214 211-218 3000-3100
Knuckle Ram Head Side 138-145 141-148 2000-2100
Knuckle Ram Rod Side 207-214 211-218 3000-3100
Hammermaster 207-214 211-218 3000-3100
Roadbreaker *138-150 141-153 2000-2200
Sequence valve 21 21 300

Return Line Filter

Table 9.
By-Pass pressure - 3DX 1.4 1.4 20

E-5 9813/2050-5 E-5

 Section E - Hydraulics
Technical Data
Gear Pump

Gear Pump

Table 10.
Hydraulic Pumps (Parker) 3DX 3DX Xtra 3DX Super 4DX
(1855501 to 189999) (Base + Servo + (Base + Servo + (Base + Servo +
AC) AC) AC)
(1491201 to (1491201 to (1415101 to
1502999) 1502999) 1416999)
Standard and Servo
Model / Reference Duble Pump
Rotation Anticlock wise
Mounting Gear box
Flow at 2200 rev/mm 33:21 cc 29:29 cc 33 :21 cc 37:33 cc
118.8 Litres 127.6 Litres 116.6 Litres 154 Litres

E-6 9813/2050-5 E-6

 Section E - Hydraulics
Technical Data
Loader Valve Block

Loader Valve Block

Main Relief Valve

Table 11.
Relief Valve Pressure Machine Serial Number bar kg/cm2 lb/in2
Range
3DX (1855501 to 189999) 227 231 3292
3DX Xtra ( Base + Servo + AC ) (1491201 to 1502999) 250 255 3626
3DX Super ( Base + Servo + AC ) (1491201 to 1502999) 227 231 3292
4DX ( Base + Servo + AC ) (1415101 to 1416999) 227 231 3292

Table 12.
Unloader Valve Machine Serial Number bar kg/cm2 lb/in2
Range
3DX (1855501 to 189999) 207 211 3002
3DX Xtra ( Base + Servo + AC ) (1491201 to 1502999) 225 229 3263
3DX Super ( Base + Servo + AC ) (1491201 to 1502999) 207 211 3002
4DX ( Base + Servo + AC ) (1415101 to 1416999) 207 211 3002

Table 13.
Auxiliary Relief Valve (A.R.V.) 3DX Xtra 3DX Super 4DX
– Shovel Ram Head Side 174 bar (2524 lb/in ) 170 bar (2466 lb/in ) 172 bar (2495 lb/in2)
2 2

– Shovel Ram Rod Side 310 bar (4496 lb/in2) 310 bar (4496 lb/in2) 310 bar (4496 lb/in2)

E-7 9813/2050-5 E-7

 Section E - Hydraulics
Technical Data
Excavator Valve Block

Excavator Valve Block

Backhoe
Table 14. 3DX Xtra (Base + Servo + AC)
Auxiliary Relief Valve (A.R.V.) bar kg/cm2 Ib/in2
Boom Ram Head Side 260 265 3771
Boom Ram Rod Side 350 357 5076
Bucket Ram Head Side 260 265 3771
Bucket Ram Rod Side 260 265 3771
Dipper Ram Head Side 260 265 3771
Dipper Ram Rod Side 260 265 3771
Slew Left and Right 260 265 3771

Table 15. 3DX Super (Base + Servo + AC)

Auxiliary Relief Valve (A.R.V.) bar kg/cm2 Ib/in2
Boom Ram Head Side 250 255 3626
Boom Ram Rod Side 310 316 4496
Bucket Ram Head Side 250 255 3626
Bucket Ram Rod Side 250 255 3626
Dipper Ram Head Side 250 255 3626
Dipper Ram Rod Side 250 255 3626
Slew Left and Right 260 265 3771

Table 16. 4DX (Base + Servo + AC)

Auxiliary Relief Valve (A.R.V.) bar kg/cm2 Ib/in2
Boom Ram Head Side 250 255 3626
Boom Ram Rod Side 350 357 5076
Bucket Ram Head Side 250 255 3626
Bucket Ram Rod Side 310 316 4496
Dipper Ram Head Side 250 255 3626
Dipper Ram Rod Side 250 255 3626
Slew Left and Right 260 265 3771

E-8 9813/2050-5 E-8

 Section E - Hydraulics
Technical Data
Excavator Valve Block

Attachments
Table 17.
Extradig Ram Head Side *207-220 211-225 3000-3200
Jaw Bucket Ram Head Side 138-145 141-148 2000-2100
Jaw Bucket Ram Rod Side 207-214 211-218 3000-3100
Knuckle Ram Head Side 138-145 141-148 2000-2100
Knuckle Ram Rod Side 207-214 211-218 3000-3100
Hammermaster 207-214 211-218 3000-3100
Roadbreaker *138-150 141-153 2000-2200
Sequence valve 21 21 300

E-9 9813/2050-5 E-9

 Section E - Hydraulics

Basic System Operation

Introduction to Hydraulic Schematic Symbols
TE-001

General (Basic and Functional Symbols) Table 19. 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 20. Pumps and Motors
Table 18. 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-10 9813/2050-5 E-10

 Section E - Hydraulics
Basic System Operation
Introduction to Hydraulic Schematic Symbols
Table 21. 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-11 9813/2050-5 E-11

 Section E - Hydraulics
Basic System Operation
Introduction to Hydraulic Schematic Symbols
Table 22. 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-12 9813/2050-5 E-12

 Section E - Hydraulics
Basic System Operation
Introduction to Hydraulic Schematic Symbols
Table 23. 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-13 9813/2050-5 E-13

 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-14) 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-14) - 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-14) shows a 'D' type spool.

K Fig 5. ( T E-14) - '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-14) 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-14) - '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-14).

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-14).

E-14 9813/2050-5 E-14

 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-15).
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-15 9813/2050-5 E-15

 Section E - Hydraulics
Basic System Operation
Component Location and Neutral Circuit Descriptions

Component Location and Neutral Circuit Descriptions

Gear Pump - Double Pump

Oil is drawn from the hydraulic tank T by the hydraulic
pump. The pump has two sections, P1 and P2
K Fig 8. ( T E-17).

The hydraulic pump is mounted on the rear of the gearbox

and is driven by the engine via a drive shaft.

Oil from the larger section P1 flows direct to the loader

valve 3. Oil from pump section P2, flows to steering priority
valve 7, and in neutral circuit flows through the priority
valve to the auxiliary valve 5 and then to join the flow from
P1 at the loader valve.

From the loader valve neutral gallery, oil flows via a high
pressure carry-over line 1B to the excavator valve 4.

Some of the exhaust oil flows directly back to the tank

through an in-tank filter 6, and some of the exhaust oil
returns to tank via the hydraulic oil cooler 26.

To help prevent excavator dipper ram and loader lift ram

cavitation, there is a check valve 13 fitted to the return line.
The check valve raises approximately 5 bar (75 lbf/in2) of
pressure in the line, which improves the operation of the
respective anti-cavitation valves.

On side shift machines only, hydra clamp exhaust hose 62

is fitted. The hose connects the hydra clamp spool directly
into the exhaust circuit. This prevents the clamps from
`locking-up' when the side shifting operation is required.

Table 24.
Component Key:
T Hydraulic Tank
P1 Hydraulic Pump (main section)
P2 Hydraulic Pump (secondary section)
1B High Pressure Carry-over
3 Loader Valve Block
4 Excavator Valve
6 Return Line Filter (inside hydraulic tank)
7 Steer Circuit Priority Valve
13 Return Line Check Valve
26 Hydraulic Oil Cooler
62 Hydra clamp exhaust hose

E-16 9813/2050-5 E-16

 Section E - Hydraulics
Basic System Operation
Component Location and Neutral Circuit Descriptions

Fig 8.

E-17 9813/2050-5 E-17

 Hydraulic Schematics
E-18

3DX BSIII with JCB Ecomax Engine

From Serial Number

– 1888500 - 1899999

HYDRA CLAMP

CP

CT

SLEW RAM

SHOWEL RAM 262 bar

LOADER RAM 3.8 mm
SLE
W
1B

1A
262 bar 3.8 mm

1A 1B 2A 2B
SLEW RAM

4.5 mm
207 bar
Steer Cylinder 310 bar BOOM
2A
9813/2050-5

2B
248 bar
BOOM RAM
LIFT

Unloader BUCK
ET

P2

STABILIZER 3A

3B
HPCO
P1 STABILIZER RAM

STABILIZER
4A
310 bar
172 bar
4B
125bar STABILIZER RAM
227 bar

Steer Valve 200 cc

DIPPE
R
248 bar 5A

14 cc 33 cc 21 cc 5B

248 bar DIPPE

R RAM

3DX BSIII with JCB Ecomax Engine

i = 1.625 i= 1

Section E - Hydraulics
BUCKE
T
6A
248 bar

6B

BUCKET RAM

Hydraulic Schematics
248 bar

HYDRAULIC OIL COOLER

TANKCAP
(BREATHER)
OUTLET

RETURNLINE FILTER 10
microns

SUCTION STRAINER
125 micron

HYDRAULIC TANK

P041950-951
E-18

Fig 9. Hydraulic Schematic

 Section E - Hydraulics
Hydraulic Schematics
3DX BSIII with JCB Ecomax Engine
Fig 10.
From Serial Number
– 1828001 to 1899999
E-19 9813/2050-5 E-19
 Section E - Hydraulics
Hydraulic Schematics
3DX BSIII with JCB Ecomax Engine
Fig 11.
E-20 9813/2050-5 E-20
 Section E - Hydraulics
Hydraulic Schematics
3DX Xtra, 3DX Super and 4DX

3DX Xtra, 3DX Super and 4DX

From Serial Number

– 3DX Xtra from 1486501 to 1491201
– 3DX Super from 1486501 to 1491201
– 4DX from 1414001 to 1415101

10
9

30
29 11

28
6
7 8
12
27
1
21 22 23

16 26
4

26
5

25

14 14 cc 33 cc 21 cc
13 2

24
3
15
17
18 19 20

D070890-01
Fig 12. 3DX Super (Base)

E-21 9813/2050-5 E-21

 Section E - Hydraulics
Hydraulic Schematics
3DX Xtra, 3DX Super and 4DX

Item Description
1 Boom Ram
2 Dipper Ram
3 Bucket Ram
4 Stabiliser Ram Left Hand
5 Stabiliser Ram Right Hand
6 Slew Ram
7 Lift Ram
8 Showel Ram
9 Hydra Clamp
10 Hydra Clamp
11 Main Control Valve
12 Loader Control Valve
13 Main Gear Pump
14 Steering Pump
15 Hydraulic Oil Cooler
16 Steering Unit
17 Hydraulic Tank
18 Stainer
19 Pressurized Breather
20 Return Line Filter
21 Loader Valve Lift Spool
22 Loader Valve Bucket Spool
23 Loader Valve Auxiliary Spool
24 Bucket Spool
25 Dipper Spool
26 Stabilizer Spool
27 Boom Spool
28 Slew Spool
29 Neutral Passage
30 High Pressure Passage

E-22 9813/2050-5 E-22

 Section E - Hydraulics
Hydraulic Schematics
3DX Xtra, 3DX Super and 4DX

10
9

20 11
7 8

12

30
31 32

37
6
22

36
16
1
26 19 27 21

35
4

35
14 cc 33 cc 21 cc

13 28 18 29 5
14
34
2
15
17 33
23 24 25 3

D070890-02
Fig 13. 3DX Super (Servo)

E-23 9813/2050-5 E-23

 Section E - Hydraulics
Hydraulic Schematics
3DX Xtra, 3DX Super and 4DX

Item Description
1 Boom Ram
2 Dipper Ram
3 Bucket Ram
4 Stabiliser Ram Left Hand
5 Stabiliser Ram Right Hand
6 Slew Ram
7 Lift Ram
8 Showel Ram
9 Hydra Clamp
10 Hydra Clamp
11 Excavator Valve Block
12 Loader Valve Block
13 Main Gear Pump
14 Steering Pump
15 Hydraulic Oil Cooler
16 Steering Unit
17 Hydraulic Tank
18 Hydrocontrol Joystick Right Hand
19 Hydrocontrol Joystick Left Hand
20 Accumulator
21 Stabiliser Lever Servo
22 Steer Cylinder
23 Stainer
24 Pressurized Breather
25 Return Line Filter
26 Boom Joystick
27 Slew Joystick
28 Bucket Joystick
29 Dipper Joystick
30 Loader Valve Lift Spool
31 Loader Valve Shovel Spool
32 Loader Valve Auxiliary Spool
33 Bucket Spool
34 Dipper Spool
35 Stabilizer Spool
36 Boom Spool
37 Slew Spool

E-24 9813/2050-5 E-24

 Section E - Hydraulics
Hydraulic Schematics
3DX Xtra, 3DX Super and 4DX

10
9

11

28
7 8 6
12
27
22 1
23

16 26
4

26
18 5

25
2
13
14 cc 29 cc 29 cc

14
24
15 3

17
19 20 21

D070890-03
Fig 14. 3DX Extra (Base)

E-25 9813/2050-5 E-25

 Section E - Hydraulics
Hydraulic Schematics
3DX Xtra, 3DX Super and 4DX

Item Description
1 Boom Ram
2 Dipper Ram
3 Bucket Ram
4 Stabiliser Ram Left Hand
5 Stabiliser Ram Right Hand
6 Slew Ram
7 Lift Ram
8 Showel Ram
9 Hydra Clamp
10 Hydra Clamp
11 Excavator Control Valve
12 Loader Control Valve
13 Main Gear Pump
14 Steering Pump
15 Hydraulic Oil Cooler
16 Steering Unit
17 Hydraulic Tank
18 Pressure Sensor
19 Stainer
20 Pressurized Breather
21 Return Line Filter
22 Loader Valve Lift Spool
23 Loader Valve Bucket Spool
24 Bucket Spool
25 Dipper Spool
26 Stabilizer spool
27 Boom spool
28 Slew Spool

E-26 9813/2050-5 E-26

 Section E - Hydraulics
Hydraulic Schematics
3DX Xtra, 3DX Super and 4DX

10
9

7 8 20
11
12

30
31

36

6
35
16
26 27 21
1
19
22 34

4
i = 1.625
i=1
34
14 cc 29 cc 29 cc

13 28 29
14
18 5
33

15 2
17 32
23 24
3
25

D070890-04
Fig 15. 3DX Extra (Servo)

E-27 9813/2050-5 E-27

 Section E - Hydraulics
Hydraulic Schematics
3DX Xtra, 3DX Super and 4DX

Item Description
1 Boom Ram
2 Dipper Ram
3 Bucket Ram
4 Stabiliser Ram Left Hand
5 Stabiliser Ram Right Hand
6 Slew Ram
7 Lift Ram
8 Showel Ram
9 Hydra Clamp
10 Hydra Clamp
11 Main Control Valve
12 Loader Control Valve
13 Main Gear Pump
14 Steering Pump
15 Hydraulic Oil Cooler
16 Steering Unit
17 Hydraulic Tank
18 Hydrocontrol Joystick Right Hand
19 Hydrocontrol Joystick Left Hand
20 Accumulator
21 Stabiliser Lever Servo
22 Pressure Sensor
23 Stainer
24 Pressurized Breather
25 Return Line Filter
26 Boom Joystick
27 Slew Joystick
28 Bucket Joystick
29 Dipper Joystick
30 Loader Valve Lift Spool
31 Loader Valve Shovel Spool
32 Bucket Spool
33 Dipper Spool
34 Stabilizer Spool
35 Boom Spool
36 Slew Spool

E-28 9813/2050-5 E-28

E-29

6 7 17
8
9

26
27

32
5

31
13 22 23 1
18

16
9813/2050-5

30
4

i = 1.625 30
i=1

10 24 25
11
14 cc 37 cc 33 cc

4
15
29
2
12

Section E - Hydraulics
14 28

3DX Xtra, 3DX Super and 4DX

20 3

Hydraulic Schematics
19
21

D070890-05
Fig 16. 4DX (Servo)
E-29
 Section E - Hydraulics
Hydraulic Schematics
3DX Xtra, 3DX Super and 4DX

item Description
1 Boom Ram
2 Dipper Ram
3 Bucket Ram
4 Stabiliser Ram Left Hand
5 Slew Ram
6 Lift Ram
7 Showel Ram
8 Main Control Valve
9 Loader Control Valve
10 Main Gear Pump
11 Steering Pump
12 Hydraulic Oil Cooler
13 Steering Unit
14 Hydraulic Tank
15 Hydrocontrol Joystick Right Hand
16 Hydrocontrol Joystick Left Hand
17 Accumulator
18 Stabiliser Lever Servo
19 Stainer
20 Pressurized Breather
21 Return Line Filter
22 Boom Joystick
23 Slew Joystick
24 Bucket Joystick
25 Dipper Joystick
26 Loader Valve Lift Spool
27 Loader Valve Shovel Spool
28 Bucket Spool
29 Dipper Spool
30 Stabilizer Spool
31 Boom Spool
32 Slew Spool

E-30 9813/2050-5 E-30

 Section E - Hydraulics
Hydraulic Pump
Gear Pump - Operation

Hydraulic Pump
Gear Pump - Operation

Double Pump
K Fig 19. ( T E-33). Both sections P1 and P2 operate as
described below:

The basic principle of the gear pump depends on the

meshing of two spur gears A, one of which is engine driven
while the other is an idler.

Oil is picked up by the gear teeth on the inlet side of the

pump and carried around between the teeth and the pump
body. As the gears come into mesh, the space carrying the
oil is filled by a gear tooth on the mating gear, forcing the
Fig 17. oil out of the space and the through the pump outlet.

Single Pump - Operation The wear plates B are loaded towards the gears by
pressurised oil which is fed to the backs of the wear plates
K Fig 18. ( T E-31). The hydraulic pump is a gear type. via channels C. This ensures that the clearance between
The basic principle of the pump depends on the meshing the wear plates and gears is prevented from becoming
of the two spur gears A and B, one of which is engine- excessive as outlet pressure rises.
driven whilst the other is an idler. Oil is picked up on the
inlet side of the pump by the gears and carried round The side of each wear plate that faces the gears has two
between the gear teeth and the pump body. As the gears recesses D. The recess on the inlet side of the pump
come into mesh the oil is forced through the pump outlet. assists the flow of oil into the gear spaces, thus raising the
cavitation threshold of the pump. The recess on the outlet
Lubrication is provided by the hydraulic oil which is side vents oil trapped between meshing gear teeth to
directed around the unit, via special oil ways, by the motion prevent compression loads on the bearings.
of the meshing gears.
Table 25. Key to Oil Flow and Pressure
Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Fig 18. Lock Up

E-31 9813/2050-5 E-31

 Section E - Hydraulics
Hydraulic Pump
Gear Pump - Operation
Table 26. D Recess.
Component Key:
P1 Main Section.
A Spur Gears.
P2 Secondary Section.
B Wear Plates.
C Channel.

Machines from Serial no. 964125 (High Pressure)

Relief Valve Pressures: K Fig 19. ( T E-33) bar kgf/cm2 lbf/in2

Main Relief Valve (M.R.V.) 248 - 252 253 - 256 3600 - 3650
Unloader Valve 224 - 231 228 - 235 3250 - 3350
Auxiliary Relief Valves (A.R.V.)
Shovel Ram Head Side 172 - 179 176 - 183 2500 - 2600
Shovel Ram Rod Side 310 - 317 316 - 323 4500 - 4600

Important: Relief valves fitted to machines prior to serial

no. 964125 cannot be adjusted to the high pressure.

Note: Instructions for pressure testing and adjustment are

described in Service Procedures, Loader Valve -
Pressure Testing.

E-32 9813/2050-5 E-32

 Section E - Hydraulics
Hydraulic Pump
Gear Pump - Operation

1 2
3
7
9

12 12 12 8

5 6 13
10 11

4 12 12 12

Fig 19.
Component Key:
1 Arms lift service 8 Unloader solenoid
2 Shovel service 9 Auxiliary relief valve
3 Auxiliary (optional) 10 Tank port
4 Pump section 1 - inlet 11 High pressure carry-over (HPCO) port
5 Pump section 2 - inlet 12 Service ports
6 Pressure test port 13 Load hold check valve assemblies
7 Unloader assembly

E-33 9813/2050-5 E-33

 Section E - Hydraulics
Hydraulic Pump
Gear Pump - Operation

Unloader Valve
Make sure that the hydraulic oil is at working temperature,
i.e. 50°C (122°F).

Lower the backhoe bucket and loader shovel to rest on the

ground; stop the engine; operate the control levers to vent
residual hydraulic pressure.

Make sure that the `hydraulic speed control' and `smooth

ride system' facilities are NOT switched on, otherwise the
correct unloader valve pressure cannot be obtained.

If the machine has a front-mounted roadbreaker, ensure

that the roadbreaker control valve lever is in the 'off'
position (lever down), otherwise the roadbreaker relief
valve will operate and prevent unloader valve pressure
from being reached. Fig 20.

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

gauge to pressure test connector A.

2 With the engine running at 1500 revs/min, slowly

operate arms raise or lower.

Note: The arms raise or lower service is specified because

it has no auxiliary relief valve (A.R.V.). Selecting this
service ensures that the pressure vents through the M.R.V.
and not an A.R.V.

3 When the service reaches full travel, return the lever

to the neutral position. Select the service again, very
slowly, the pressure gauge will rise until a step or kick
is seen in the rate of change in the pressure increase.
This is the start of unloader operation. Keep selecting
the service until a sudden sharp increase in pressure
is observed with a change of engine sound, this point
is the unloader setting and should be as specified in
Technical Data.

4 If the pressure is incorrect, slacken locknut E and

adjust cap F. Turn it clockwise to increase pressure
and anti-clockwise to decrease the pressure. When
the pressure is correct, tighten the locknut and check
the pressure again. Adjust as required. If the correct
pressure cannot be achieved, add or subtract shims
as required, refer to Loader Valve - Fixed Flow,
Dismantling and Assembly - Unloader Valve.

E-34 9813/2050-5 E-34

 Section E - Hydraulics
Hydraulic Pump
Gear Pump - Operation

Main Relief Valve (MRV) - Operation

K Fig 21. ( T E-36).

The main relief valve (M.R.V.) 3B, situated in the loader

valve block, provides control of both loader and excavator
pressures.

1 Valve at Rest

The illustration 1 shows a loader service selected by spool

3D causing pressure to rise in the service line and back
through the loader valve to the pump via line 1A. The
service is operating under light load and the pressure is not
sufficient to cause any response in the M.R.V.

The main plunger A is held on its seat B by the combined

effect of spring C and the pump pressure which enters
chamber D through the small drilling E. Pump pressure
outside the chamber is not high enough to lift the plunger
off its seat.

2 Pilot Valve Opens

If, as shown in view 2, pump pressure rises high enough to

force the pilot valve F from its seat (against spring G), the
pressure in chamber D is vented into the exhaust gallery H.

Unless the pressure continues to rise, plunger A will

remain on its seat.

3 Valve Moves off its seat

In view 3, pump pressure at 1A has risen to the setting of

the main relief valve but pressure in chamber D has not
risen because the seat orifice of pilot valve F is larger than
small drilling E and oil is unable to fill the chamber as
quickly as it is being exhausted.

Pressure acting on the upper faces of main plunger A is

therefore greater than the combined force of spring C and
the pressure in chamber D. The plunger then moves off its
seat, allowing pressure to be released to the exhaust
gallery.

As the pump pressure decreases, the pilot valve is able to

reseat and pressure in chamber D assists spring C to force
the main plunger A back onto its seat.

E-35 9813/2050-5 E-35

 Section E - Hydraulics
Hydraulic Pump
Gear Pump - Operation

Fig 21.

See also K Table 25. Key to Oil Flow and Pressure

( T E-31).

E-36 9813/2050-5 E-36

 Section E - Hydraulics
Hydraulic Pump
Gear Pump - Operation

Main Relief Valve (MRV)

Make sure that the hydraulic oil is at working temperature,
i.e. 50°C (122°F).

Lower the backhoe bucket and loader shovel to rest on the

ground; stop the engine; operate the control levers to vent
residual hydraulic pressure.

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

gauge to pressure test connector A on the loader
valve, (refer to Service Tools).

2 With the engine running at 1500 revs/min, check

M.R.V. pressure by raising or lowering the loader
arms until the rams are fully open or closed and
noting the maximum gauge reading. CAUTION: Do Fig 22.
not select 'float'. The maximum pressure should be as
stated in Technical Data.

Note: The rams must be 'held' open or closed when

reading gauge.

3 If the pressure is incorrect, loosen locknut D and

adjust screw C. Turn it clockwise to increase pressure
and anti-clockwise to decrease the pressure. When
the pressure is correct, tighten the locknut and check
the pressure again. Adjust as required.

E-37 9813/2050-5 E-37

 Section E - Hydraulics
Hydraulic Pump
Loader Valve - Neutral Circuits

Loader Valve - Neutral Circuits

Neutral Circuit
K Fig 23. ( T E-40).

The loader valve is mounted on the chassis frame, right

hand side (when viewed from the rear).

It includes the lift ram spool 3C, shovel ram spool 3D and
auxiliary spool 3E. Linkage rods connect the spool ends to
the control levers.

In neutral circuit hydraulic oil from the pump section P2

enters the loader valve at 1C via the steering priority valve.
On entering the valve block, oil flows around the waisted
section of the unloader valve 3L, past check valve 3N and
joins the flow from pump section P1.

Oil from pump section P1 enters the loader valve at 1A.

Combined oil flow from P1 and P2 passes the main relief

valve (MRV) 3B and fills the parallel gallery B. From the
parallel gallery the oil flows around the waisted central
portions of spools 3C, 3D and 3E (all in neutral position)
and flows on to feed the excavator valve via high pressure
carry over line 1B K Table 27. ( T E-38).

Table 27. Key to Oil Flow and Pressure

Full Pressure.

Pressure.

Servo.

Neutral.

Exhaust.

Cavitation.

Lock Up.

E-38 9813/2050-5 E-38

 Section E - Hydraulics
Hydraulic Pump
Loader Valve - Neutral Circuits

Unloader Operation (If fitted)

K Fig 24. ( T E-40).

Unloader spool operation protects the engine from being

overloaded if a service is being worked particularly hard,
for example when using the excavator to tear out. It does
this by dumping the oil from the pump section P2 to tank,
allowing engine power to be applied fully to the main pump
section P1.

If the pressure in the inlet gallery C rises to the setting of

the pilot valve 3M, this valve will open, allowing oil in spring
cavity 3P to escape more quickly than it can be replaced
by oil entering through the small drilling D.

This creates a pressure differential between the spring

cavity 3P and gallery C. Higher pressure in gallery C acts
on the face of spool 3L causing the spool to be moved off
its seat.

Oil entering the valve block from pump section P2 now

flows directly to tank T.

High pressure in gallery C also holds check valve 3N firmly

closed, preventing oil from pump section P1 from also
being dumped.

When pressure in inlet gallery C falls, for example if the

excavator has stopped tearing out, pilot valve 3M will
close. This means oil in spring cavity 3P will be at the same
pressure as oil in gallery C, spring pressure will move
spool 3L back onto its seat, closing pump section P2
connection to tank.

Also refer K Table 27. ( T E-38).

E-39 9813/2050-5 E-39

 Section E - Hydraulics
Hydraulic Pump
Loader Valve - Neutral Circuits

3C 3D
3E
3M
3L
B
1B T
1C(P2)
C

3Q
3B

1A(P1) 3N 3J
A401150

A401150

Fig 23.

3M
3P
3L T

P2

3N P1
A401160

A401160
Fig 24.

E-40 9813/2050-5 E-40

 Section E - Hydraulics
Hydraulic Pump
Loader Valve - Neutral Circuits

Hydraulic Speed Control (HSC)

Solenoid valve 3Q allows the operator to control the
unloader spool movement (to dump flow from the hydraulic
pump section P2) using a switch in the cab. There are two
main applications for this operation:

1 More tractive force can be applied to the loader end

when entering a stock pile. This is because more
power is available from the engine as flow from pump
section P2 is being dumped directly to tank.

2 More power can be made available from the engine

whilst the machine is travelling on the highway. Again,
this is because flow from pump section P2 is being
dumped directly to tank.

When the solenoid valve 3Q is de-energised its spool is

moved by spring pressure. This spool movement makes a
connection from the unloader spool chamber 3P to tank.

Because the unloader chamber is now connected to tank,

and so at exhaust pressure, pressure in gallery C (neutral
shown) acts on the face of unloader spool 3L causing the
spool to be moved off its seat. Oil entering the valve block
from pump section P2 now flows directly to tank.

When solenoid valve 3Q is energised its spool closes the

connection from the unloader valve spool chamber to tank.
Spool 3L is once again controlled by system pressure.

E-41 9813/2050-5 E-41

 Section E - Hydraulics
Hydraulic Pump
Loader Valve - Neutral Circuits

Fig 25.

See also K Table 27. Key to Oil Flow and Pressure

( T E-38).

E-42 9813/2050-5 E-42

 Section E - Hydraulics
Hydraulic Pump
Loader Valve - Neutral Circuits

Load Hold Check Valves

Operation 1

K Fig 26. ( T E-43)

The illustration shows 'arms raise' being selected by the lift

ram spool 3C.

The weight of the loaded shovel, as indicated by the

arrows, produces a higher pressure in service line D than
in the parallel gallery B.

This pressure differential causes load hold check valve 3J

to close, thus preventing the load from dropping.

For colour identification see the table.

Fig 26.

E-43 9813/2050-5 E-43

 Section E - Hydraulics
Hydraulic Pump
Loader Valve - Neutral Circuits
Operation 2

K Fig 27. ( T E-44)

As the neutral circuit has been blocked by the central land

of the selected spool 3C, the pressure in parallel gallery B
increases until it is greater than that in service line D.

At this point, load hold check valve 3J opens, allowing oil

to flow from the parallel gallery into the service line and
operate the lift rams 33 and 34.

Fig 27.

E-44 9813/2050-5 E-44

 Section E - Hydraulics
Hydraulic Pump
Loader Valve - Neutral Circuits

Arms Lower Operation

When a spool is selected as shown at 3C, the central land
of the spool C blocks the neutral circuit. Oil from the pump,
entering at 1A, is diverted into the parallel gallery B, opens
the load hold check valve 3J, and flows around the waisted
section of the spool D and out to the rod side of lift rams 33
and 34.

The lower land of the selected spool E blocks the flow from
the parallel gallery to the head side port and oil returning
from the rams is diverted into the exhaust gallery
K Fig 28. ( T E-46).

For the colour Identification see the table

K Table 27. ( T E-38).

Float
The float facility is provided to allow the arms to move up
and down so that the shovel can follow the surface
contours as the machine is driven over uneven ground.

This is achieved by moving the lift spool 3C down beyond

'arms lower' into the 'float' detent, when the feed from the
parallel gallery to the service ports is blocked and the
neutral circuit is re-opened. Both service ports are
connected to exhaust via the spool waists A.

Oil can then be displaced from either end of the lift rams 33
and 34 into the exhaust gallery, allowing the rams to open
and close as required K Fig 29. ( T E-46).

E-45 9813/2050-5 E-45

 Section E - Hydraulics
Hydraulic Pump
Loader Valve - Neutral Circuits

3C

D B
3J

1A
C

E
33
34

A396390

A396390
Fig 28.

3C

33
34

A396400

A396400
Fig 29.

E-46 9813/2050-5 E-46

 Section E - Hydraulics
Hydraulic Pump
Loader Valve - Neutral Circuits

Auxiliary Relief Valve

K Fig 30. ( T E-48).

Under normal operating conditions, with the shovel in the

'carry' position, the mechanical linkage keeps the shovel
level as the arms are raised, to prevent spillage of the load.

If, as illustrated, the shovel is fully tipped when the arms

are being raised, the shovel is unable to tip further,
producing back pressure in the head side of the shovel
rams 31 and 32 and cavitation in the rod side.

As the arms continue to rise, the back pressure increases

until it reaches the setting of A.R.V. 3F. This A.R.V. then
opens, allowing the excess back pressure to be dumped to
exhaust and prevent the rams and linkage from being
damaged.

The rod side A.R.V. 3G senses a higher pressure in the

exhaust gallery than in the service port and therefore
opens to allow exhaust oil to overcome the cavitation.

For the colour Identification see the table

K Table 27. ( T E-38).

E-47 9813/2050-5 E-47

 Section E - Hydraulics
Hydraulic Pump
Loader Valve - Neutral Circuits

3C

3G

1A

32
31

3F

A396370

Fig 30.

E-48 9813/2050-5 E-48

 Section E - Hydraulics
Hydraulic Pump
Loader Valve - Neutral Circuits

Main Relief Valve (MRV) Operation

K Fig 31. ( T E-50). The main relief valve (MRV) 3B,
housed in the loader valve block, sets the maximum
operating pressure for both the loader and excavator
hydraulic services.

1 Valve at Rest:

The view 1 shows a loader service selected by spool 3D,

causing pressure to rise in the service line and back
through the loader valve to the pump via line 1A. The
service is operating under light load, therefore the
pressure is not sufficient to cause any response in the
MRV.

The main plunger A is held on its seat B by the combined

effect of spring C and the pump pressure which enters
chamber D through the small drilling E. Pump pressure
outside the chamber is not high enough to lift the plunger
off its seat.

2 Pilot Valve Poppet Opens:

In view 2, pump pressure rises high enough to force the

pilot valve F from its seat (against spring G), the pressure
in chamber D is vented into the exhaust gallery H.

Unless the pressure continues to rise, plunger A will

remain on its seat.

3 Main Valve Opens:

In view 3, pump pressure at 1A has risen to the setting of

the main relief valve but pressure in chamber D has not
risen because the seat orifice of pilot valve F is larger than
small drilling E and oil is unable to fill the chamber as
quickly as it is being exhausted.

Pressure acting on the upper faces of main plunger A is

therefore greater than the combined force of spring C and
the pressure in chamber D. The plunger then moves off its
seat, allowing pressure to be released to the exhaust
gallery.

As the pump pressure decreases, the pilot valve is able to

reseat and pressure in chamber D assists spring C to force
the main plunger A back onto its seat.

E-49 9813/2050-5 E-49

 Section E - Hydraulics
Hydraulic Pump
Loader Valve - Neutral Circuits

3D

A
B
D E
H 1A A
F D
G 2 C

3B
D
E 1A
A
C 1A 1
F A401180

3
Fig 31.

See also K Table 27. Key to Oil Flow and Pressure

( T E-38).

For a further detailed description of a typical pilot operated

relief valve operation, see K Pilot Operated Main Relief
Valve Operation ( T E-51).

E-50 9813/2050-5 E-50

 Section E - Hydraulics
Hydraulic Pump
Loader Valve - Neutral Circuits
Pilot Operated Main Relief Valve Operation

E
G G
F F
D F
C C

H H H

B
A A A

1 2 3
D070840-34
Fig 32.

1 Valve at Rest: the main poppet B, causing it to lift and vent oil
pressure from gallery A directly into the exhaust
Oil pressure in gallery A will be acting on the bottom gallery H.
face of the main poppet B, and will also be felt inside
the valve through the drilling in the piston C.

Oil pressure on the top face of the main poppet B,

combined with the force of the springs D and E, keep
the main poppet and the pilot poppet F tightly seated.

2 Pilot Valve Poppet Opens:

When the pressure in gallery A reaches the pilot

setting of the valve, pilot poppet F lifts, allowing oil to
escape through cavity G into the exhaust gallery H.

3 Main Poppet Opens:

As the pressure in gallery A continues to rise and oil

escapes through cavity G, the pressure differential
between the top and bottom surfaces of piston C,
causes the piston to lift and seat against the end of
the pilot poppet F. The oil flow through cavity G is
then closed off. This produces a pressure drop above

E-51 9813/2050-5 E-51

 Section E - Hydraulics
Hydraulic Pump
Excavator Valve

Excavator Valve

Neutral Circuit

Fig 33.

Oil from the loader valve enters the excavator valve at A Component Key:
and flows through the neutral gallery and around the waists
of the solid spools. It also fills the parallel gallery B but is 4F Bucket Spool
not at a high enough pressure to open the load hold check
valves C K Fig 33. ( T E-52).

Table 28.
Component Key:
A Inlet
B Parallel Galley
C Load Hold Check Valve
4A Slew Spool
4B Boom Spool
4C Stabiliser Spool
4D Stabiliser Spool
4E Dipper Spool

E-52 9813/2050-5 E-52

 Section E - Hydraulics
Hydraulic Pump
Excavator Valve

Fig 34.

Fig 35.

E-53 9813/2050-5 E-53

 Section E - Hydraulics
Hydraulic Pump
Excavator Valve

Excavator Valve
Operation 1

Flow to the service via a typical solid spool 4B is controlled

by the load hold check valve 4S which is a spring-loaded
non-return valve operating across the pressure feed from
the parallel gallery B. The valve prevents reverse flow from
the rams into the pressure feed line, so maintaining ram
pressure until exceeded by system pressure. The
illustration shows a service selected but back pressure D
exceeds system pressure which closes the load hold
check valve K Fig 34. ( T E-53).

Operation 2

When pressure in the feed line exceeds the back pressure,

the load check valve 4S opens and oil operates the ram.
The remaining load hold check valves are also opened by
system pressure but the galleries are dead-ended
because the spools are in neutral K Fig 35. ( T E-53).

Table 29.
Component Key:
B Parallel Gallery
D Service Line
4B Spool
4S Load Hold Check Valve

One Way Restrictor

Because of its weight, the excavator end could take over
control when boom lower was selected. The falling boom
would tend to push oil out of the ram faster than the head
side was being filled. Consequently, when the excavator
had reached the ground, there would be a time lapse while
the ram filled with oil before the service would operate
again K Fig 36. ( T E-55).

To prevent this from happening, the boom service is fitted

with a one way restrictor. When the boom is being raised,
the poppet in restrictor E is held off its seat by pressurised
oil flow, therefore oil delivery to the boom ram rod side is
unrestricted.

When the boom is being lowered, the oil flow through the
one way restrictor E re-seats the poppet, therefore the flow
of oil is restricted through the small drilling in the base of
the poppet. This slows the boom down to a controllable
speed.

E-54 9813/2050-5 E-54

 Section E - Hydraulics
Hydraulic Pump
Excavator Valve

Fig 36.

Excavator Valve - Slew Operation

The illustration shows R.H. slew selected. The lower port
C has been pressurised by the spool. Oil flows from the
parallel gallery B, out past A.R.V. 4H to both the head side
of the L.H. slew ram and the rod side of the R.H. slew ram.
The boom therefore slews to the right hand side of the
machine. Displaced oil from the rod side of the L.H. slew
ram and from the head side of the R.H. slew ram flows
back through the upper service port D and back to tank
K Fig 37. ( T E-56).

E-55 9813/2050-5 E-55

 Section E - Hydraulics
Hydraulic Pump
Excavator Valve

Fig 37.

E-56 9813/2050-5 E-56

 Section E - Hydraulics
Hydraulic Pump
Excavator Valve

Slew Ram End Damping

As ram A nears the closed position, damping rod B seats
in cone C, where it is held by spring D. Tapered flutes on
the end of the rod produce a restricting orifice, thus
restricting the speed of the oil being exhausted from the
ram. This provides a cushioning effect between the piston
and the dump end of the ram, effectively damping out the
shock loads which would otherwise occur when the boom
reaches the end of its slewing are K Fig 38. ( T E-57).

Fig 38.

Table 30.
A Ram
B Damping Rod
C Cone Seat
D Spring

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 Section E - Hydraulics
Hydraulic Pump
Excavator Valve

Slew A.R.V. and Anti-Cavitation slew cylinder. This opens A.R.V. 4J and dumps oil to
exhaust. At this point the cylinders cavitate and exhaust oil
Operation
pressure causes A.R.V. 4H to open, allowing oil from the
exhaust gallery to fill the L.H. cylinder. Top picture of
The spool 4A is in neutral but the momentum of the
K Fig 39. ( T E-58).
slowing excavator end creates back pressure in the head
side of the R.H. slew cylinder and in the rod side of the L.H.

Fig 39.

E-58 9813/2050-5 E-58

 Section E - Hydraulics
Hydraulic Pump
Excavator Valve

Excavator Valve - A.R.V. Operation For a further detailed description, refer also Auxiliary Relief
Valve Operation.
The illustration shows the bucket spool 4F selected to
operate the service against an immovable object. This Table 31.
forces the dipper away from the obstruction and Component Key:
pressurises the head side of the dipper ram. Bottom 4A Slew Spool
picture of K Fig 40. ( T E-59).
4E Dipper Spool
When this pressure reaches the setting of A.R.V. 4M, this 4F Bucket Spool
valve opens, relieving the pressure into the exhaust 4H ARV
gallery.
4J ARV
Cavitation occurs in the rod side of the dipper service until 4M ARV
A.R.V 4N opens, allowing the higher pressure in the 4N ARV
exhaust gallery to supplement that in the service line.
4P ARV
4Q ARV

Fig 40.

E-59 9813/2050-5 E-59

 Section E - Hydraulics
Hydraulic Pump
Excavator Valve

Auxiliary Relief Valve Operation The ARV pressure setting is adjustable by means of spring
D and adjusting screw E. Turning the screw clockwise
A.R.V's are positioned in the excavator valve block in order compresses the spring and therefore, increases the
to relieve excessive pressure in the services as shown in pressure setting and conversely, turning the screw anti-
the figure. clockwise releases the spring which decreases the
pressure.
Valve at Rest
Pilot Valve opens
Illustration 1 of shows the service is in neutral and there
are no excessive forces acting on the equipment. Illustration 2 of K Fig 41. ( T E-60) shows the Pressure
in the service gallery A has reached the setting of the ARV.
The force of spring D acting through Collar C keeps the
poppet B firmly held on its seat. The pressure on the service side of the poppet is high
enough to overcome the force of spring D so poppet B lifts
Chamber J is connected to the exhaust gallery via small off its seat. Oil in the chamber J is displaced through small
drilled holes H, this means the pressure in the chamber will drilled holes H.
always be at Exhaustive pressure.
Service pressure at A is now released into exhaust gallery
K.

Fig 41.

E-60 9813/2050-5 E-60

 Section E - Hydraulics
Hydraulic Pump
Excavator Valve

Auxiliary Relief Valve - Anti-Cavitation Illustration 2 of K Fig 42. ( T E-61) shows the service
gallery cavitating.
When the service gallery is cavitating, the ARV anti-
cavitation operation allows oil from the exhaust gallery to The pressure in exhaust gallery K is sufficient to overcome
supplement the cavitating service line. the force of spring F. The cone and its assembly move
down allowing oil in the exhaust gallery to enter the service
Illustration 1 of K Fig 42. ( T E-61) shows the ARV gallery and limit the effects of cavitation.
subjected to normal operating pressure in Service gallery
A. When the service gallery is no longer cavitating,
compressed spring F will return to its relaxed position and
The force of spring F and the pressure in the service thus bring the anti-cavitation cone back onto its seat.
gallery acting on the bottom face of anti-cavitation cone G
keep the cone firmly on its seat.

Fig 42.

E-61 9813/2050-5 E-61

 Section E - Hydraulics
Hydraulic Pump
Excavator Valve

Excavator Valve - Dipper Make-Up Check Additional flow from the exhaust gallery is therefore
provided by means of the make-up check valve 4X which
Valve and Anti-Cavitation Operation
opens due to the pressure differential.
The illustration shows the dipper spool 4E fully selected to
The combined flow past A.R.V. and make-up check will
lower the loader bucket K Fig 43. ( T E-62).
ensure that sufficient oil is fed to the head side of the ram
to maintain smooth operation of the service as the dipper
As the engine is running slowly, and the ram is opening
goes past the vertical.
quickly, the pressure in the parallel gallery B falls to a lower
level than that in the exhaust gallery. This causes A.R.V.
The make-up check valve will open in the same way to
4M to open but the flow past the A.R.V. is insufficient to
prevent cavitation when other services are operated.
keep the head side of dipper ram 55 filled with oil.

Fig 43.

E-62 9813/2050-5 E-62

 Section E - Hydraulics
Hydraulic Pump
Excavator Valve

Hydraclamp (Sideshift Machines)

Fig 44.

E-63 9813/2050-5 E-63

 Section E - Hydraulics
Hydraulic Pump
Excavator Valve
Hydraclamp Operation (Sideshift Machines)

K Fig 44. ( T E-63) The hydra clamp control valve 4G is

positioned in the inlet end of the excavator valve block and
is connected directly to the parallel gallery B. Sleeve C is
connected to the clamp control lever by linkage D.

1 - Clamps Pressurised

When the control lever is pulled upwards and an excavator

service is operated, oil from the parallel gallery B is
allowed to pressurise the clamps 62 as follows.

Oil enters the hollow poppet E via grooves in plug L and

exits via the small orifice F. Pressure acts on both ends of
the poppet which is therefore `floating' in its bore. Pressure
also acts on poppet G lifting it of its seat against spring
pressure to allow oil to feed the clamps.

2 - Clamps Released

When the control lever is lowered, the valve sleeve C is

rotated so that radial holes H align with the metering
cavities J in the valve bore. These cavities are connected
to an external drain port X.

3 - Clamps Locked Up

If no service is being operated, pressure in the parallel

gallery falls to that of the neutral circuit (blue in the inset)
and spring force assists poppet G to re-seat. Pressure is
therefore trapped (yellow) in the line to the clamps,
maintaining the excavator end in a securely clamped
condition.

E-64 9813/2050-5 E-64

 Section E - Hydraulics

Service Procedures
Hydraulic Contamination
TE-002_3

Hydraulic Fluid Quality cleaning unit. K Fig 45. ( T E-65). General Bulletin 011
also refers.
This machine uses a large volume of fluid in the hydraulic
system for power transmission, equipment lubrication, rust Procedure
prevention and sealing. According to a survey conducted
by a pump manufacturer, seventy per cent of the causes of Connect the cleaning unit in place of the hydraulic filter.
problems in hydraulic equipment were attributable to K Fig 45. ( T E-65). Run the system for sufficient time to
inadequate maintenance of the quality of the hydraulic pump all the hydraulic fluid through the unit. Disconnect
fluid. Therefore, it is obvious that control of the quality of the cleaning unit and reconnect the filter. Top up the
the hydraulic fluid helps prevent hydraulic equipment system with clean hydraulic fluid as required.
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. S168050-1
Fig 45. 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-65 9813/2050-5 E-65

 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-66 9813/2050-5 E-66

 Section E - Hydraulics
Service Procedures
Connecting/Disconnecting Hydraulic Hoses

Connecting/Disconnecting Hydraulic Hoses

T4-004_2

Introduction Connecting the Hydraulic Hoses

!MWARNING 1 Make the machine safe. Refer to Routine

Maintenance, Prepare the Machine for
Fluid Under Pressure Maintenance.
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under 2 Vent the hydraulic system. Refer to Routine
pressure and wear protective glasses and gloves. Maintenance, Releasing the Hydraulic Pressure.
Hold a piece of cardboard close to suspected leaks
and then inspect the cardboard for signs of fluid. If 3 If necessary, remove the blanking caps.
fluid penetrates your skin, get medical help
immediately. 4 Check the hoses and adaptors for damage. Refer to
INT-3-1-10_3 Routine Maintenance, Checking for Damage.

!MWARNING 5 Connect the hoses.

Hydraulic Pressure If the hoses have quick releases couplings, refer to

Hydraulic fluid at system pressure can injure you. Quick Release Couplings.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service a Make sure that the hose is not twisted. Pressure
hose line must be vented. Make sure the hose service applied to a twisted hose can cause the hose to
line has been vented before connecting or removing fail or the connections to loosen.
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2

Some attachments are hydraulically powered. The

following procedures show how to connect and disconnect
the hydraulic hoses safely.

T037400
Fig 46.

b Make sure that the hose does not touch hot parts.
High ambient temperatures can cause the hose to
fail.

c Make sure that the hose does not touch parts

which can rub or cause abrasion.

d Use the hose clamps (where possible) to support

long hose runs and keep the hoses away from
moving parts, etc.

E-67 9813/2050-5 E-67

 Section E - Hydraulics
Service Procedures
Connecting/Disconnecting Hydraulic Hoses

Disconnecting the Hydraulic Hoses

1 Make the machine safe. Refer to Routine
Maintenance, Prepare the Machine for
Maintenance.

2 Vent the hydraulic system. Refer to Routine

Maintenance, Releasing the Hydraulic Pressure.
T037420
Fig 47. 3 Disconnect the hoses.

To allow for length changes when the hose is If the hoses have quick releases couplings, then refer
pressurised, do not clamp at the bend. The curve to Quick Release Couplings.
absorbs the change.
4 Check the hoses and adaptors for damage. Refer to
Routine Maintenance, Checking for Damage.

5 If necessary, install the blanking caps

6 Check for leaks.

a Start the engine.

b Operate the related control to increase the

pressure in the hydraulic system.

c Stop the engine then remove the starter key.

d Check for indications of leakage at the hose

T037410
Fig 48. connections. Correct, as necessary.

6 Check for leaks.

a Start the engine.

b Operate the related control to increase the

pressure in the hydraulic system.

c Stop the engine then remove the starter key.

d Check for indications of leakage at the hose

connections. Correct, as necessary.

E-68 9813/2050-5 E-68

 Section E - Hydraulics
Service Procedures
Connecting/Disconnecting Hydraulic Hoses

Quick Release Couplings by dirt in the coupling or physical damage due to

abuse.

!MWARNING – Connect and disconnect new couplings two or three

times to work the PTFE seals. Sometimes a new
The external surfaces of the couplings must be clean coupling will stick if the seal has not been worked.
before connecting or disconnecting. Ingress of dirt – When fitting couplings, only apply the spanner or
will cause fluid leaks and difficulty in connecting or grips to the hexagon and nowhere else.
disconnecting. You could be killed or seriously injured
– Avoid damage to the coupling faces. Burrs and
by faulty Quick Release Couplings.
scratches cause damage to the seals and cause
2-4-1-15
leaks. They can also impede connection and
disconnection of the couplings.
Flat face quick release couplings allow the operator to
remove and install attachments swiftly and efficiently. – Periodically lubricate the internal locking balls on the
Generally, your machine pipework will be fitted with a female half of the coupling with silicone grease.
female coupling A and a male coupling B. The optional
attachment hoses will also be fitted with a female coupling Essential Don'ts
A and a male coupling B. K Fig 49. ( T E-70).
– Never attempt to reconnect using a damaged half
The quick release couplings should be trouble free and coupling as this will destroy the seals in the mating
relatively easy to connect and disconnect, provided they half and necessitate replacement of both halves.
are kept clean and used correctly. The recommendations – Do not leave the coupling where it may be run over by
listed below should always apply when using flat face a vehicle or otherwise crushed - this will distort the
quick release couplings. sleeve and prevent connection and disconnection.
– Never try to turn the sleeve when the coupling is
Finally, please read the correct fitting and releasing disconnected since this will cause the locking ball to
procedures before you install or remove any optional jam under the locking sleeve and damage the
attachment fitted with quick release couplings. coupling.

Essential Do's – Never try to strip the coupling down, there are no user
serviceable parts. If the coupling is damaged it should
be replaced with a new one. See coupling guides for
– Before connecting or removing any hydraulic hose,
a reference.
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service – Never hit the centre poppet of the coupling to try and
line has been vented before connecting or removing release locked in pressure. This can cause
hoses. irreparable damage to the coupling and serious injury.
– Always wipe the two mating faces clean before – When fitting couplings, never clamp on the sleeve of
connecting. the female or nose of the male - this will cause
distortion and/or damage.
– Use caps and plugs when the couplings are
disconnected. – Never subject the couplings to external forces,
especially side load. This can reduce the life of the
– Always align the external locking ball (if used) with the
coupling or cause failure.
notch in the locking sleeve and then pull the locking
sleeve back fully to disconnect. – Never allow the torsional forces transmitted from
hoses to unscrew/screw together couplings.
– If a coupling sticks, first check that pressure has been
released. Ensure the locking ball and notch in the – Never use a coupling as a plug.
locking sleeve are aligned, pull back the sleeve and – Do not connect and disconnect with pressure in the
twist the couplings apart. Sticking is normally caused line unless the coupling type is specifically designed
to do so.

E-69 9813/2050-5 E-69

 Section E - Hydraulics
Service Procedures
Connecting/Disconnecting Hydraulic Hoses
Connecting Quick Release Couplings

1 Remove any residual hydraulic pressure trapped in

the service line hose.

2 Wipe the two faces of the male and female couplings

and make sure they are clean.

3 Make sure that ball C in the female coupling is located

in one of its slots.

4 Fit the male coupling into the female coupling.

5 Where applicable, rotate sleeve E half a turn and

make sure that the locking ball C does not align with
the slot D.

Disconnecting Quick Release Couplings

1 Remove any residual hydraulic pressure trapped in

the service line hose.

2 Where applicable, align the slot D with ball C.

3 Pull back sleeve E to release the coupling.

C007100-1
Fig 49.

E-70 9813/2050-5 E-70

 Section E - Hydraulics
Service Procedures
Hydraulic Pump

Hydraulic Pump

Flow and Pressure Testing 2 Pump section 2 - disconnect hose D from the pump.
Fit the flow meter and load valve (see Note 2)
Before removing the pump it is necessary to determine the between hose D and the pump.
source of any problem by measuring the output flow at
system pressure from both of the pump outlet ports. Note: 2) Make sure the load valve is in the open position,
i.e. with the adjusting knob screwed fully out, before
To check flow it is necessary to fit flow meter A into the carrying out the Checking Flow procedure.
output line of each pump section in turn. If available, load
valve B (service tool 892/00270) should also be installed Removing
(see Note 1). Make sure the flow meter is installed with its
arrow pointing away from the pump and, if applicable, Removing is the reverse of fitting.
located between the pump and the load valve.
Checking the Pump Flow
Note: 1) If no load valve is available, ignore the references
to the load valve in Fitting and Removing a Flow Meter and 1 Check the setting of the Main Relief Valve (MRV) as
Load Valve below. An alternative method of determining described in Loader Valve, Pressure Testing.
flow is included in the Checking Flow procedures following. Adjust if necessary.

Fitting and Removing a Flow Meter and Load 2

Valve
a Using a load valve - fit a flow meter and load
Before fitting or removing a flow meter and load valve, valve, as described in Fitting, to each pump outlet
switch off the machine and operate the loader and in turn. Fit a 0-400 bar (0-6000 lbf/in2) pressure
excavator controls a few times to vent system pressure. gauge to the load valve pressure test connector.

!MWARNING
b If no load valve is available - fit a flow meter, as
described in Fitting, to each pump output in turn.
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. 3 Start the engine and bring the hydraulics up to
working temperature 50ºC (122ºF). Set the engine
Before connecting or removing any hydraulic hose,
speed to 2200 rpm.
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
4
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open. a Using a load valve - adjust the load valve so that
the pressure gauge reading is just below the MRV
INT-3-1-11_2
setting.

!MWARNING b If no load valve is available - raise or lower the

loader arms until the rams are fully open or
Take care when disconnecting hydraulic hoses and
closed. Continue to operate the raise or lower
fittings as the oil will be HOT.
control so that system pressure builds up. Watch
TRANS-1-2
the flow meter and note its reading at the moment
the MRV operates.
Fitting
5 The flow reading should be as listed in Technical
1 Pump section 1 - disconnect hose C from the pump.
Data.
Fit the flow meter and load valve (see Note 2)
between hose C and the pump.

E-71 9813/2050-5 E-71

 Section E - Hydraulics
Service Procedures
Hydraulic Pump

Fig 50.

Fig 51.

E-72 9813/2050-5 E-72

 Section E - Hydraulics
Service Procedures
Hydraulic Pump

Loader Valve (Unloader valve) 4 If the pressure is incorrect, slacken locknut E and
adjust cap F. Turn it clockwise to increase pressure
Make sure that the hydraulic oil is at working temperature and anti-clockwise to decrease the pressure. When
i.e. 50°C (122°F). the pressure is correct, tighten the locknut and check
the pressure again. Adjust as required
Lower the backhoe bucket and loader shovel to rest on the K Fig 53. ( T E-73).
ground; stop the engine; operate the control levers to vent
residual hydraulic pressure If the correct pressure cannot be achieved, add or
subtract shims as required.
Make sure that the smooth ride system facility is NOT
switched on, if fitted, otherwise the correct unloader valve
pressure cannot be obtained.

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

gauge to pressure test connector A
K Fig 52. ( T E-73).

2 With the engine running at 1500 revs/min., slowly

operate arms raise or lower.

Fig 53.

Fig 52.

Note: The arms raise or lower service is specified because

it has no auxiliary relief valve (A.R.V.). Selecting this
service ensures that the pressure vents through the M.R.V.
and not an A.R.V.

3 When the service reaches full travel, return the lever

to the neutral position. Select the service again, very
slowly, the pressure gauge will rise until a step/kick is
seen in the rate of change in the pressure increase.
This is the start of unloader operation. Keep selecting
the service until a sudden sharp increase in pressure
is observed with a change of engine sound, this n
Technical Data

E-73 9813/2050-5 E-73

 Section E - Hydraulics
Service Procedures
Hydraulic Pump

Shovel Ram Rod Side A.R.V. Pressure

Testing
Testing of A.R.V's on the machine should be avoided (use
hand pump method). However, the procedure described
below is a secondary checking method which can be used
if no hand pump is available.

The shovel ram rod side A.R.V. is set at a higher pressure

than the M.R.V. (maximum system pressure). To raise the
pressure in the shovel ram rod side service line above
system pressure, it is necessary to disconnect/connect
hoses (as shown in the following procedures) so that oil
displaced from the LIFT ram (rod side) is fed through the
A.R.V.

Make sure that the hydraulic oil is at working temperature,

i.e. 500C (1220F).
Fig 54.
Rest the shovel on the ground, stop the engine and vent all
services.

Disconnect hoses B and C from metal pipes B1 and C1

respectively, shown at K Fig 54. ( T E-74).

Screw a tee piece fitted with a 0400 bar (0-6000 Ibf/in2)

pressure gauge to metal pipe B1, shown at
K Fig 55. ( T E-74).

Pull the hose C down from behind the loader arm and fit to
the other side of the tee piece as shown at V.

Fit a cap to metal pipe C and fit a plug to hose B.

Note: For reference, C1 is the service hose for the shovel

ram, rod side. B is the service hose for the lift ram, rod side.

With the engine running at 1000 revs/mm, select and

operate slowly the loader arms lift service until the ram
Fig 55.
creeps, keep raising the arms slowly until a reading on the
pressure gauge is obtained.

The highest pressure value shown on the gauge will be the

setting of the shovel ram rod side A.R.V. (see Technical
Data). If necessary, adjust as detailed below.

If the pressure is incorrect, the A.R.V. must be adjusted.

E-74 9813/2050-5 E-74

 Section E - Hydraulics
Service Procedures
Hydraulic Pump

Removal and Replacement 3 Reconnect the pump outlet hoses C and D to the
elbow fittings.
The following Procedure describes removal and
replacement of a double section pump. Note: All hydraulic adaptors that are installed together with
a bonded sealing washer must also have sealant JCB
Removal Threadseal applied to the threads of the adaptor.

4 Reconnect the pump inlet hose flange to the pump

!MWARNING body with bolts B (4 off).
Working Under the Machine
5 Fit the propshaft, refer to Section F, Transmission
Make the machine safe before getting beneath it.
Propshafts - Removal and Replacement.
Ensure that any fitments on the machine are secure;
engage the park brake, remove the starter key,
6 Fill the system to the correct level with recommended
disconnect the battery.
hydraulic fluid, see Section 3, Maintenance -
INT-3-3-8_2
Lubricants and Capacities.
1 Remove the propshaft, refer to Section F,
Note: Replace the suction strainer and return line filter
Transmission, Propshaft- Removal and
after fitting a new or serviced pump.
Replacement.
7 After fitting a new or serviced pump and before
2 Drain the hydraulic fluid from the hydraulic tank.
starting the engine screw the main relief valve out.
Run the engine and check for leaks, also check the
3 Remove flange bolts B (4 off) and disconnect the
main relief valve (MRV) operating pressure. Refer to
pump inlet hose flange from the pump body. Blank off
service procedures, pressure testing - M.R.V
all exposed connections to prevent ingress of dirt.

4 Disconnect the pump outlet hoses C and D from the

elbow fittings. Blank off all exposed connections to
prevent ingress of dirt.
C
!MWARNING
This component is heavy. It must only be removed or E
handled using a suitable lifting method and device. D
BF-4-1_1

5 Secure the pump using a sling around the pump body,

remove the pump mounting bolts E and carefully
withdraw the pump clear of the gearbox.

Replacement

Replacement is the reverse of the removal procedure. B

Fig 56.
1 Clean off all traces of gasket compound from the
pump and gearbox mounting faces. Apply a thin bead
of JCB Muligasket to the gearbox mounting face.

2 Locate the splined shaft of the pump into the gearbox.

Apply JCB Thread locker and Sealer to bolts E and
secure the pump flange to the gearbox mounting
face.

E-75 9813/2050-5 E-75

 Section E - Hydraulics
Service Procedures
Hydraulic Pump

Dismantling, Inspection and Assemble pump should be removed and dismantled for re-sealing
only.
Before removing and dismantling the pump, check flow
and pressure. If either of these are low, the pump must be Before removing and dismantling the pump, make sure the
changed. Renewal of components such as gears, bearings exterior of the pump and working area is thoroughly
and housing will not affect a permanent cure. If the pump cleaned and free of possible sources of contamination.
output is satisfactory but there is external leakage, the

Fig 57.

E-76 9813/2050-5 E-76

 Section E - Hydraulics
Service Procedures
Hydraulic Pump
Dismantle mounting flange and all sealing faces must be free of
burrs and scores which could result in seal damage
K Fig 57. ( T E-76) and hence hydraulic oil leakage.

1 Remove the four bolts 3 and serrated washers 4 2 Renew the pump if any of the following symptoms
which clamp the units together. exist:

2 Use a soft faced hammer to separate front body 5 and a The PTFE coated bearings in the pump bodies,
rear body 6 after first marking them to ensure correct the mounting flange and the end cover are worn
re-assembly. through to reveal the bronze backing.

3 Remove spindle coupling 7 and O-rings 8. Discard b The gear side faces are scored. Often
the O-rings. contaminated fluid results in a distinct wear step
coincident with the gear root diameter. This can
4 Use a soft faced hammer to separate end cover 9 normally be felt by drawing a sharp point across
from rear body 6, after first marking them to ensure the gear side face from the journal towards the tip
correct re-assembly. of the gear.

5 Remove drive gear 10 from its bore. Pushing it out of c There is a noticeable wear groove on driveshaft
the rear body will also remove balance plate 11 23 where seals 22 run.
complete with seal 12 and seal energiser 13. Discard
the seal and seal energiser. Note the position of the d The balance plate faces are scored, particularly in
drive shaft and the balance plate to ensure correct re- the area adjacent to the gear root diameter.
assembly.
e The shaft splines are worn or severely fretted.
6 Remove driven gear 14, followed by balance plate 15
complete with seal 16 and seal energiser 17. Discard f The gear `cut-in' area in the low pressure side of
the seal and seal energiser. the pump body is deeper than 0.15 mm (0.006 in)
or has a torn or pitted appearance.
7 Discard O-ring 18.
Assemble
8 Use a soft hammer to separate mounting flange 19
from front body 5, after first marking them to ensure K Fig 57. ( T E-76)
correct re-assembly.
When carrying out the following procedure, renew all seals
9 Remove circled 21 and shaft seals 22. Note which and O-rings. Lubricate using JCB Special Hydraulic Fluid.
way round the seal lips are fitted to ensure correct
fitting of new seals on re-assembly. 1 Fit shaft seals 22 into mounting flange 19, making
sure the seal lips are the correct way round as noted
10 Remove drive shaft 23 from front body 5. Removal in dismantling. Fit circlip 21 into its groove in the
will also remove balance plate 28 complete with seal flange. Coat the seal lips with high melting point
29 and seal energiser 30. Discard the seal and seal grease.
energiser.
Note: If the seal recess is scored, it is permissible to seal
11 Remove driven gear 27 followed by balance plate 24, outside diameter with JCB Multigasket to prevent leakage.
seal 25 and seal energiser 26. Discard the seal and
seal energiser. 2 Stand front body 5 on its rear face. Fit seal 25 and
seal energiser 26 into balance plate 24.
12 Discard O-ring 31.
3 Ensuring that the seals do not fall out, carefully feed
13 Remove all sealant from the contact faces of the the balance plate into the bores of the front body 5
mounting flange, front body, end cover and rear body with the two small holes through the balance plate to
interfaces. the low pressure side of the body (i.e. side with the
large 4-bolt port pattern).
14 Wash all components and immediately apply a
coating of hydraulic oil to prevent corrosion. 4 Insert driveshaft 23 and driven gear 27 into the
original bores.
Inspection
5 Fit balance plate 28 over the driveshaft and gear stub.
1 Generally check all pump parts for damage and or Insert seal 29 and seal energiser 30 into the balance
wear. The O-ring grooves, the seal recess in the plate.

E-77 9813/2050-5 E-77

 Section E - Hydraulics
Service Procedures
Hydraulic Pump
6 Fit O-ring 31 into the groove on mounting flange 19. Table 32. Torque Settings
Item Nm kgf m lbf ft
7 Apply a small amount of JCB Multi gasket to the face
3 90 - 100 9.2 - 10.2 66 - 74
of front body 5 which seals with mounting flange 19
(i.e. the face containing the clamping bolt holes).

8 Carefully feed mounting flange 19 over driveshaft 23

in its original position, as marked earlier. Use a soft
faced hammer to tap the flange onto its location
spigot.

9 Support the front pump assembly on the mounting

flange (but not the driveshaft). Fit O-rings 8 into the
grooves on the rear face of the front body 5. Install
splined coupling 7.

10 Fit rear body 6 onto front body 5 in its original position,

as marked earlier, ensuring that it locates on the
dowels and that the clamping bolt holes line up.

11 Fit seal 16 and seal energiser 17 into balance plate

15. Ensuring that the seals do not fall out, carefully
feed the balance plate into rear body 6 with the two
small holes through the balance plate to the low
pressure side (i.e. side without a port).

12 Fit drive gear 10 so that it locates with splined

coupling 7. Fit driven gear 14.

13 Fit balance plate 11 in its original position (i.e. with the

two small holes to the low pressure side). Fit seal 12
and seal energiser 13 into the balance plate.

14 Fit O-ring 18 into end cover 9.

15 Apply a small amount of JCB Multigasket to the

exposed face of rear body 6 (i.e. the face containing
the clamping bolt holes).

16 Fit end cover 9 in its original position, as marked

earlier.

17 Install the four bolts 3, each with a serrated washer 4,

and tighten evenly and progressively. Torque tighten
the bolts, K Table 32. Torque Settings ( T E-78).

18 Pour a small amount of clean JCB Special Hydraulic

Fluid into the ports. Check that driveshaft 23 rotates
without undue force. If excessive force is required it is
possible that one or more of the balance plate seals
are trapped, in which case it will be necessary to
dismantle and assemble the pump again.

E-78 9813/2050-5 E-78

 Section E - Hydraulics
Service Procedures
Loader Valve - Pressure Testing

Loader Valve - Pressure Testing

Main Relief Valve (M.R.V.)

Make sure that the hydraulic oil is at working temperature,
i.e. 50°C (122°F).

Lower the excavator bucket and loader shovel to rest on

the ground; stop the engine; operate the control levers to
vent residual hydraulic pressure.

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

gauge to pressure test connector A on the loader
valve, (refer to Service Tools).

2 With the engine running at 1500 revs/min., check

M.R.V. pressure by raising or lowering the loader
arms until the rams are fully open or closed and
noting the maximum gauge reading. CAUTION: Do
Fig 59. 3DX ECO
not select 'float'. The maximum pressure should be as
stated in Technical Data.

Note: The rams must be 'held' open or closed when

reading gauge.

3 If the pressure is incorrect, loosen locknut D and

adjust screw C. Turn it clockwise to increase pressure
and anti-clockwise to decrease the pressure. When
the pressure is correct, tighten the recount and check
the pressure again. Adjust as required.

Fig 58. 3DX

E-79 9813/2050-5 E-79

 Section E - Hydraulics
Service Procedures
Loader Valve - Pressure Testing

Unloader Valve
Make sure that the hydraulic oil is at working temperature,
i.e. 50°C (122°F).

Lower the backhoe bucket and loader shovel to rest on the

ground; stop the engine; operate the control levers to vent
residual hydraulic pressure.

Make sure that the `hydraulic speed control' and `smooth

ride system' facilities are NOT switched on, otherwise the
correct unloader valve pressure cannot be obtained.

If the machine has a front-mounted roadbreaker, ensure

that the roadbreaker control valve lever is in the 'off'
position (lever down), otherwise the roadbreaker relief
valve will operate and prevent unloader valve pressure
Fig 60.
from being reached.

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

gauge to pressure test connector A.

2 With the engine running at 1500 revs/min. slowly

operate arms raise or lower.

Note: The arms raise or lower service is specified because

it has no auxiliary relief valve (A.R.V.). Selecting this
service ensures that the pressure vents through the M.R.V.
and not an A.R.V.

3 When the service reaches full travel, return the lever

to the neutral position. Select the service again, very
slowly, the pressure gauge will rise until a step or kick
is seen in the rate of change in the pressure increase.
This is the start of unloader operation. Keep selecting
the service until a sudden sharp increase in pressure
is observed with a change of engine sound, this point
is the unloader setting and should be as specified in
Technical Data.

4 If the pressure is incorrect, slacken locknut E and

adjust cap F. Turn it clockwise to increase pressure
and anti-clockwise to decrease the pressure. When
the pressure is correct, tighten the locknut and check
the pressure again. Adjust as required. If the correct
pressure cannot be achieved, add or subtract shims
as required, refer to Loader Valve - Fixed Flow,
Dismantling and Assembly - Unloader Valve.

E-80 9813/2050-5 E-80

 Section E - Hydraulics
Service Procedures
Loader Valve - Pressure Testing

Hydraulic Speed Control (HSC)

The following procedure can be used to establish if the
hydraulic speed control facility is working correctly.

Make sure that the hydraulic oil is at working temperature,

i.e. 50°C (122°F).

Lower the backhoe bucket and loader shovel to rest on the

ground; stop the engine; operate the control levers to vent
residual hydraulic pressure.

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

gauge to the hydraulic test point A at the loader valve
as shown.

2 With the engine running at 1500 revs/min., slowly

operate arms raise, the pressure should be
approximately 138 bar (2000 lbf/in2).

3 Make sure that the HSC rocker switch (mounted on

the console) is in the OFF position. Raise the arms
slowly and select the rocker switch to ON, the arms
should raise slower.

4 Make sure that the HSC rocker switch (mounted on

the console) is in the OFF position. Raise the arms
slowly and press the button on the loader control
knob, the arms should raise slower.

5 If the loader arms fail to respond, then check the HSC

hydraulic and electrical circuits for any faults.

Fig 61.

E-81 9813/2050-5 E-81

 Section E - Hydraulics
Service Procedures
Loader Valve - Pressure Testing

Auxiliary Relief Valves - Using Hand Pump

To pressure test and re-set the auxiliary relief valves

(A.R.V.'s), service kit 892/00309 must be used.
The service kit comprises; a test block 1, a setting body
2 with adjusting pin 3, a special spanner 4, anti-cavitation
lock out bung 5. A.R.V. cartridge removal tool 892/00335
comprises; an extractor cap 6 and a 'C' washer 7.

Fig 62.

1 Remove the complete A.R.V. assembly from the

valve block. If the A.R.V. sub-assembly 7 remains in
the valve block, proceed as follows:
a Fit extractor cap 11 over the A.R.V. sub-
assembly 7, into the valve block E.
b Fit 'C' washer 12 on top of the extractor cap,
but under the anti-cavitation spring seat as
shown.
c Unscrew the extractor cap, - the A.R.V. sub-
assembly will withdraw with the extractor cap.

Fig 63.

E-82 9813/2050-5 E-82

 Section E - Hydraulics
Service Procedures
Loader Valve - Pressure Testing

2 Use special spanner 4 located in cross holes A and

separate the A.R.V. sub-assembly 7 from its cap 8.

Fig 64.

3 Install adjusting pin 3 into setting body 2.

Fig 65.

4 Install the A.R.V. sub-assembly into setting body 2.

Make sure that the adjusting pin 3 correctly locates
in adjusting screw 9.
Make sure that the lock nut 10 correctly locates in the
setting body socket - the anti-cavitation cone should
still be closed, as shown at B.

Fig 66.

5 Install the A.R.V. sub-assembly and setting body into

test block 1. Make sure that the assembly is installed
in the port marked 'RV' (relief valve).

Fig 67.

E-83 9813/2050-5 E-83

 Section E - Hydraulics
Service Procedures
Loader Valve - Pressure Testing

6 Connect a hydraulic hand pump to port 'P' (pump) of

the test block 1. Make sure that the hand pump is
filled with JCB Hydraulic fluid.
Connect a 0 to 400 bar (0 to 6000 lbf/in2) pressure
test gauge to port 'G' (gauge) of the test block 1.
Port 'T' (tank) can be left open when using a
hydraulic hand pump.

Fig 68.

7 Raise the pressure at the valve inlet using the

hydraulic hand pump, when the A.R.V. 'cracks' and
oil escapes from the port marked 'T' the pressure
gauge will indicate the A.R.V. setting.
If the A.R.V. setting is correct, move to step 12.
If the A.R.V. setting is not correct, move to step 8.

Fig 69.

8 Use the hand pump to raise approximately 172 bar

(2500 lbf/in2) pressure at the valve inlet.
Note: Raising the pressure at the valve inlet locks
the anti-cavitation cone C onto its seat, this allows
the A.R.V. adjusting screw lock nut 10 to be
loosened (step 10).
If the pressure is maintained move to step 10.
If the pressure falls off rapidly, or if no pressure can
be obtained it is possible that the anti-cavitation
cone is not seating effectively, in this instance move
to step 9.

Fig 70.

E-84 9813/2050-5 E-84

 Section E - Hydraulics
Service Procedures
Loader Valve - Pressure Testing

9 If no pressure can be raised (see step 8) at the valve

inlet, remove the A.R.V. assembly and install anti-
cavitation lock-out bung 6 in the port marked 'RV',
make sure that the bung O-ring face seal D is facing
out. Re-fit the A.R.V. assembly.
Note: The anti-cavitation lock-out bung seals and
locks the A.R.V. anti-cavitation function. The bung is
only suitable for the test block application and must
NEVER be fitted to the valve block.
The bung can be extracted using a
<FmNumerator>3/<FmDenominator>8 - 16 UNC
threaded bolt.

Fig 71.

10 Release the A.R.V. adjusting screw lock nut (see

note):
Engage the nut at the end of setting body 2 using
the slot in special spanner 4, turn the nut anti-
clockwise to release the A.R.V. adjusting screw lock
nut.
Note: Remember, it will not be possible to release
the lock nut if there is not approximately 172 bar
(2500 lbf/in2) pressure at the valve inlet.

Fig 72.

11 Insert an allen key into adjusting pin 3 (T-Bar type

shown). Push the adjusting pin down and make sure
it has engaged with the A.R.V. adjusting screw.
Rotate the T-bar clockwise to increase the pressure
setting and anti-clockwise to decrease the pressure
setting.
After adjustment, use the slot in spanner 4 to lock
the A.R.V. adjusting screw lock nut (see note).
Note: Remember, pressure must be maintained at
the valve inlet to ensure the lock nut is tightened.

Fig 73.

E-85 9813/2050-5 E-85

 Section E - Hydraulics
Service Procedures
Loader Valve - Pressure Testing

12 When the correct A.R.V. setting has been attained,

release the pressure in the test block. Remove the
A.R.V. sub-assembly and its setting body from the
test block.
Separate the A.R.V. sub-assembly from its setting
body.
Install the A.R.V. sub-assembly into its cap.

E-86 9813/2050-5 E-86

 Section E - Hydraulics
Service Procedures
Excavator Valve - Pressure Testing

Excavator Valve - Pressure Testing

Auxiliary Relief Valves - Using Hand

Pump

Fig 74.

The auxiliary relief valves found in the backhoe valve block

are identical in design to those found in the loader valve
block. For the correct pressure test procedures see
Loader Valve - Pressure Testing.

To pressure test and re-set the auxiliary relief valves

(A.R.V.'s), service kit 892/00309 must be used.

The service kit comprises; a test block 1, a setting body 2

with adjusting pin 3, a special spanner 4, anti-cavitation
lock out bung 5. A.R.V. cartridge removal tool 892/00335
comprises; an extractor cap 6 and a 'C' washer 7.

E-87 9813/2050-5 E-87

 Section E - Hydraulics
Service Procedures
Ram Creep Tests - All Services

Ram Creep Tests - All Services

If ram creep is suspected the following procedures must be

carried out to define if the leakage is within tolerance. Ram
creep can be caused by a number of reasons: cylinder or
piston leakage, spool leakage or ARV leakage.

The text and illustrations show a typical ram installation (in

this instance the boom ram), the principle applies to all
rams.

Note: The procedures are not applicable for rams fitted

with hose burst protection valves.

!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open. Fig 75.
INT-3-1-11_2
5 Measure the actual piston rod movement over 10
!MWARNING minutes. Measure the movement by checking the
pivot pin to pivot pin dimensions as at C. Alternatively
Take care when disconnecting hydraulic hoses and mark the rod with a felt tip pen 150mm (5.9 in) from
fittings as the oil will be HOT. the end cap and check the movement after 10
TRANS-1-2 minutes, this is not possible on the majority of boom
extending dipper rams.
A Test for Ram Creep
6 Using K Table 33. Creep Rates ( T E-90), check if
the piston rod movement is within the recommended
1 Operate the machine to bring the hydraulic oil to a tolerance. If so, the ram creep is acceptable.
normal working temperature of 50°C (122°F) which
can be measured using a hydraulic oil temperature Note: The table indicates the MAXIMUM permitted ram
probe (service tool 892/00285). movement.

2 Fit an appropriate pressure gauge A to a tee piece in 7 If the rate of movement is unacceptable, identify if the
the service hose which is pressurised when the ram fault is as a result of cylinder or piston leakage, or
in question is supported, see K Fig 75. ( T E-88). spool leakage at the control valve, see procedures B
and C.
3 Operate the rams to ensure they are full of hot oil.

4 Apply a load to the suspect ram for example the boom

ram by raising the dipper to the horizontal as at B.

E-88 9813/2050-5 E-88

 Section E - Hydraulics
Service Procedures
Ram Creep Tests - All Services
loader auxiliary, stabilisers or to the bucket rod side service
B Test Cylinder or Piston Leakage
except when a Rockbreaker is fitted.
1 Ensure that the oil temperature is at 50°C (122°F) by
using the hydraulic oil temperature probe detailed in A.R.V. Control Layout:
step A1. JCB ISO
Slew
2 Take the weight off the ram to be tested, in this
example, by positioning the backhoe with dipper - Right B1 B1
vertical and bucket on the ground. - Left A1 A1

3 Use a suitable pressure gauge A to blank off the Boom

supporting port of the ram K Fig 76. ( T E-89). - Rod B2 B5
- Head A2 A5
Dipper
- Rod A5 A2
- Head B5 B2
Bucket
- Rod A6 A6
- Head B6 B6

Note: Bucket ram rod side ARV only fitted to machines

equipped with Rockbreakers.

1 Render the A.R.V.'s inoperative in the suspect

service. This is achieved by removing the A.R.V. and
replacing with a blanking plug (part no. 25/609901)
and seal kit (25/610301).

2 Recheck the piston rod movement as described steps

A1 to A6.

Fig 76. 3 If the rod movement is now acceptable the A.R.V.

must be at fault. The A.R.V. may only require cleaning
4 Disconnect the hose from the opposite port D and and then resealing. If dirt is evident, the hydraulic tank
leave the port open to atmosphere. should be drained and cleaned. It is recommended
that when re-filling the hydraulic tank that new oil and
5 Apply a load to the suspect ram for example the boom filter be used to prevent further contamination. If the
ram by raising the dipper to the horizontal as at B. A.R.V. is worn it should be replaced.

6 After the initial movement measure the pin to pin

movement as at C and note the rod movement over
10 minutes.

7 If rod movement is evident the ram is defective.

C Test Spool Leakage

Note: The following procedure applies only to services

fitted with A.R.V.'s. Note A.R.V.'s are not fitted to loader lift,

E-89 9813/2050-5 E-89

 Section E - Hydraulics
Service Procedures
Ram Creep Tests - All Services

Fig 77.

Table 33. Creep Rates

Total Displacement - mm/10 minutes @
Ram Cylinder Dia. Rod Dia. 69 bar (1000 lb/in2) 138 bar (2000 lb/in2) 207 bar (3000 lb/in2)
(mm) (mm)
HEAD SIDE
Backhoe:
S/shift Jack Leg 70 40 13 44 91
Knuckle 100 60 6 16 32
Bucket 90 50 11 45 114
Bucket 100 60 10 40 99
Extending Dipper 70 40 13 32 65
Loader:
Clam 70 40 6 22 45
Lift 80 50 5 17 35
Lift 90 50 4 13 28

E-90 9813/2050-5 E-90

 Section E - Hydraulics
Service Procedures
Ram Creep Tests - All Services

Total Displacement - mm/10 minutes @

Ram Cylinder Dia. Rod Dia. 69 bar (1000 lb/in2) 138 bar (2000 lb/in2) 207 bar (3000 lb/in2)
(mm) (mm)
ROD SIDE
Backhoe:
Boom 110 60 8 26 52
Boom 120 65 6 22 44
Boom 130 70 5 19 37
Boom 140 75 5 16 32
Dipper 100 60 10 34 70
Dipper 110 65 8 28 57
Extending Dipper 70 40 19 66 96
Loader:
Shovel 70 40 10 33 68
Using the figures above, a graph can be plotted and the maximum amount of movement determined. See the next page
for a working example.

1 Using the figures given in the table, plot a graph for

the ram to be tested. Example: Boom Ram 110 x 60,
see K Fig 78. ( T E-92).

2 Check the pressure in the ram (induced by the

applied load). In this example the pressure on the
gauge reads 107 bar; 1500 lb/in2.

3 Draw a vertical line from the pressure reading to the

plotted graph line. Where the vertical line intercepts
the graph line, draw a horizontal line and read the
permitted ram displacement. In this example the
permitted maximum displacement is 18 mm.

E-91 9813/2050-5 E-91

 Section E - Hydraulics
Service Procedures
Ram Creep Tests - All Services

120

100
MAXIMUM RAM MOVEMENT PERMITTED (MM)

80

60
52mm

60
40
x
0
11
am
R
om
Bo

26mm

20
18mm

8mm

0 50 100 150 200 250

69bar 107bar 138bar 207bar

PRESSURE (BAR)
Fig 78.

Note: For a blank graph sheet to copy and use as

required, K Fig 79. ( T E-93).

E-92 9813/2050-5 E-92

 Section E - Hydraulics
Service Procedures
Ram Creep Tests - All Services

120

100
MAXIMUM RAM MOVEMENT PERMITTED (MM)

80

60

40

20

0 50 100 150 200 250

69bar 138bar 207bar

PRESSURE (BAR)
Fig 79. Blank Graph Sheet

E-93 9813/2050-5 E-93

 Section E - Hydraulics
Service Procedures
Valve Block Spool Seals

Valve Block Spool Seals

Seal Fitting - 3DX debris, use a pressure washer to clean the valve
block if available.
K Fig 80. ( T E-96)
8 Remove the boot 4, retaining plate and breather 2,
The following points MUST be avoided when dismantling CLEAN around the top of the spool.
and assembling the valve:
9 Undo cap screws 16 and remove end cap 15. Place a
– Contamination. container underneath to catch the oil when the spool
is removed, carefully remove the spool assembly.
– Damage to Spool.
– Damage to Seal Grooves. Note: If all spools on the valve block are being resealed,
the above operation must be done one at time.
All or any of the above points may result in possible
problems with the valve. 10 Remove the upper lip seal 5 and wiper seal 6 with a
non sharp object and thoroughly CLEAN the spool
Note: A Valve Spool Reseal Kit is available for the seal cavity area. Pay particular attention to the outer
following procedure: seal contact area 7. Check the spools for signs of
pitting or damage, i.e. scratches from previous
1 Park the machine on firm level ground, engage the damaged repairs. Replace as required.
parking brake and set the transmission to neutral.
11 Fit a new boot 4 to the seal retaining plate 2 and
2 Lower the loader arms and boom to the ground. grease the bottom of the seal plate with red lithium
Switch OFF the engine, remove the starter key and grease, included in the kit.
disconnect the battery.
12 Carefully fit the new lip seal 5 into the valve block.
3 Operate the controls to vent hydraulic pressure. Ensure squareness of the lip seal and that it is in the
correct orientation, seal lip inwards.
!MWARNING 13 Fit wiper seal 6 on top of lip seal 5, grease the top of
Hydraulic Pressure the valve seal plate contact area with red lithium
Hydraulic fluid at system pressure can injure you. grease.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service 14 Fit the new boot assembly with the breather groove 1
hose line must be vented. Make sure the hose service pointing to the rear of the valve block as illustrated,
line has been vented before connecting or removing only finger tighten bolts 3 at this stage.
hoses. Make sure the engine cannot be started while
the hoses are open. Note: If the lower wiper seal 9 requires changing, it is
INT-3-1-11_2 recommended the spring end mechanism 10 - 14 is
removed from the spool assembly using spool clamp tool
4 The control levers will need to be partially dismantled 992/10100. Insert the wiper seal onto the spool with the
to gain access to the loader or excavator valves (see bottom flat face of the wiper seal pointing along the length
Control Rods and Linkage, Dismantling and of the spool. Fit the seal retaining plate 10 and spring end
Assembly). mechanism 11 - 14, apply JCB Thread locker and sealer to
the thread of bolt 14 and torque tighten to 9.5 Nm (0.97 kgf
Note: Take care not to damage the rear horn or wiring. m, 7.0 lbf ft).

5 Inspect ALL the fittings, hoses and connecting joints 15 Fit the lower lipseal 8 into the valve block. Ensure
etc. to ensure and confirm the leakage is clearly squareness of the lipseal and that it is in the correct
coming from the valve spool seals. orientation, wider lip to cavity base. Apply red lithium
grease to bottom seal plate contact area.
Note: If a valve block is in a rusty or dirty condition, it is
recommended that the complete valve block is removed, 16 Using clean hydraulic oil as a lubricant, from the
(see Loader Valve or Excavator Valve Removal and bottom, insert spool through the valve block, do not
Replacement), and a complete spool valve kit is fitted. use excessive force when fitting, a turning motion
should ease the spool through the valve block.
6 Disconnect control linkages.
17 Check that the tang end of the spool passes through
7 Before removing the boot, clean the entire valve the boot without dislodging or damaging the boot.
block, make sure that all components are free of

E-94 9813/2050-5 E-94

 Section E - Hydraulics
Service Procedures
Valve Block Spool Seals
Ensure that the tang aligns with the control rod and
that the boot is not distorted and is located in the
spool land.

18 Fit end cap 15, torque tighten cap screws 16 to 9.5

Nm (0.97 kgf m, 7.0 lbf ft).

19 Torque tighten cap screws 3 to 9.5 Nm (0.97 kgf m,

7.0 lbf ft).

!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 and gloves.
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_3

20 Operate the machine and check for leaks.

E-95 9813/2050-5 E-95

 Section E - Hydraulics
Service Procedures
Valve Block Spool Seals

Fig 80.

E-96 9813/2050-5 E-96

 Section E - Hydraulics
Service Procedures
Valve Block Spool Seals

Seal Fitting - 3DX ECO 6 Disconnect control linkages.

The following points MUST be avoided when dismantling 7 Before removing the boot, clean the entire valve
and assembling the valve: block, make sure that all components are free of
debris, use a pressure washer to clean the valve
– Contamination block if available.
– Damage to Spool
8 Remove the boot 4, retaining plate and breather 2,
– Damage to Seal Grooves CLEAN around the top of the spool.

All or any of the above points may result in possible 9 Undo capscrews 16 and remove end cap 15. Place a
problems with the valve. container underneath to catch the oil when the spool
is removed, carefully remove the spool assembly.
Note: A Valve Spool Reseal Kit is available for the
following procedure: Note: If all spools on the valve block are being resealed,
the above operation must be done one at time.
1 Park the machine on firm level ground, engage the
parking brake and set the transmission to neutral 10 Remove the upper lip seal 5 and wiper seal 6 with a
K Fig 81. ( T E-100). non sharp object and thoroughly CLEAN the spool
seal cavity area. Pay particular attention to the outer
2 Lower the loader arms and boom to the ground. seal contact area 7. Check the spools for signs of
Switch OFF the engine, remove the starter key and pitting or damage, i.e. scratches from previous
disconnect the battery. damaged repairs. Replace as required.

3 Operate the controls to vent hydraulic pressure. 11 Fit a new boot 4 to the seal retaining plate 2 and
grease the bottom of the seal plate with red lithium
!MWARNING grease, included in the kit.

Hydraulic Pressure 12 Carefully fit the new lipseal 5 into the valve block.
Hydraulic fluid at system pressure can injure you. Ensure squareness of the lipseal and that it is in the
Before connecting or removing any hydraulic hose, correct orientation, seal lip inwards.
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service 13 Fit wiper seal 6 on top of lipseal 5, grease the top of
line has been vented before connecting or removing the valve seal plate contact area with red lithium
hoses. Make sure the engine cannot be started while grease.
the hoses are open.
INT-3-1-11_2 14 Fit the new boot assembly with the breather groove 1
pointing to the rear of the valve block as illustrated,
4 The control levers will need to be partially dismantled only finger tighten bolts 3 at this stage.
to gain access to the loader or excavator valves (see
Control Rods and Linkage, Dismantling and Note: If the lower wiper seal 9 requires changing, it is
Assembly). recommended the spring end mechanism 10 - 14 is
removed from the spool assembly using spool clamp tool
Note: Take care not to damage the rear horn or wiring. 992/10100. Insert the wiper seal onto the spool with the
bottom flat face of the wiper seal pointing along the length
5 Inspect ALL the fittings, hoses and connecting joints of the spool. Fit the seal retaining plate 10 and spring end
etc. to ensure and confirm the leakage is clearly mechanism 11 - 14, apply JCB Threadlocker and sealer to
coming from the valve spool seals. the thread of bolt 14 and torque tighten to 9.5 Nm (0.97 kgf
m, 7.0 lbf ft).
Note: If a valve block is in a rusty or dirty condition, it is
recommended that the complete valve block is removed, 15 Fit the lower lipseal 8 into the valve block. Ensure
(see Loader Valve or Excavator Valve Removal and squareness of the lipseal and that it is in the correct
Replacement), and a complete spool valve kit is fitted.

E-97 9813/2050-5 E-97

 Section E - Hydraulics
Service Procedures
Valve Block Spool Seals
orientation, wider lip to cavity base. Apply red lithium
grease to bottom seal plate contact area.

16 Using clean hydraulic oil as a lubricant, from the

bottom, insert spool through the valve block, do not
use excessive force when fitting, a turning motion
should ease the spool through the valve block.

17 Check that the tang end of the spool passes through

the boot without dislodging or damaging the boot.
Ensure that the tang aligns with the control rod and
that the boot is not distorted and is located in the
spool land.

18 Fit end cap 15, torque tighten cap screws 16 to 9.5

Nm (0.97 kgf m, 7.0 lbf ft).

19 Torque tighten cap screws 3 to 9.5 Nm (0.97 kgf m,

7.0 lbf ft).

!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 and gloves.
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_3

20 Operate the machine and check for leaks.

E-98 9813/2050-5 E-98

 Section E - Hydraulics
Service Procedures
Valve Block Spool Seals

E-99 9813/2050-5 E-99

 Section E - Hydraulics
Service Procedures
Valve Block Spool Seals
Fig 81.

E-100 9813/2050-5 E-100

 Section E - Hydraulics
Service Procedures
Valve Block Spool Seals

Hydraclamp Valve - Dismantling and

Assembly
The numerical sequence shown on the illustration is
intended as a guide to dismantling K Fig 82. ( T E-102).

For assembly the procedure should be reversed.

When Dismantling

Plug hoses 1 to prevent loss of oil entry of dirt.

When Assembling

Make sure that the orifice X is clear.

Lubricate new seal with JCB hydraulic Fluid.

Screw item 8 fully home into housing then back -off by no

more then 1800 until the flats align with capscrew centre
line as show at A K Fig 82. ( T E-102). Fit plate 6 in
position shown and connect clevis 2.

If necessary, adjust position of clevis 2 so that plate 6 can

be operated over full extent of its travel.

E-101 9813/2050-5 E-101

 Section E - Hydraulics
Service Procedures
Valve Block Spool Seals

Fig 82.

E-102 9813/2050-5 E-102

 Section E - Hydraulics
Service Procedures
Hydraulic Adaptors (Positional Type)

Hydraulic Adaptors (Positional Type)

Fitting Procedure
On a typical machine, some hydraulic components may
utilise `Positional Type' SAE Hydraulic Adaptors. When
fitting `Positional Type' Hydraulic Adaptors it is important to
adopt the following procedure. If this procedure is not
followed correctly, damage to the `O' ring seal A can occur
resulting in oil leaks.

1 Ensure the locknut B is screwed back onto the body

of the adaptor as far as possible as shown.

2 Check the `O' ring backing washer C is a tight fit on

the adaptor. Note that the washer should not move
freely, if the washer is slack do not use the adaptor.

3 Check the `O' ring A is fitted and that it is free from

damage or nicks. Before fitting the adaptor, smear the
`O' ring with clean hydraulic fluid.

Note: The dimensions and shore hardness of the `O' ring

is critical. Should it become necessary to replace the `O'
ring, ensure that only JCB Genuine Parts are used.

4 Screw the adaptor into the port of the hydraulic

component as far as possible, so that ALL the threads
engage and the `O' ring is correctly seated against
the sealing face.

5 Set the angular position of the adaptor as required,

then secure by tightening the locknut B.

Note: When fitted correctly no more than one thread

should be visible at Z as shown.

6 Torque tighten the locknut to 81 Nm (60 lbf ft).

Fig 83.

E-103 9813/2050-5 E-103

 Section E - Hydraulics

Loader Valve
Removal and Replacement

K Fig 84. ( T E-105). Replacement

!MWARNING Replacement is a reversal of the removal sequence.

Make the machine safe before working underneath it.

Park the machine on level ground, lower the !MWARNING
attachments to the ground. Apply the park brake, put Fluid Under Pressure
the transmission in neutral and stop the engine. Block Fine jets of fluid at high pressure can penetrate the
both sides of all four wheels. skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses and gloves.
Disconnect the battery, to prevent the engine being Hold a piece of cardboard close to suspected leaks
started while you are beneath the machine. and then inspect the cardboard for signs of fluid. If
GEN-4-1_1 fluid penetrates your skin, get medical help
immediately.
!MWARNING INT-3-1-10_3

Hydraulic Pressure After replacement check the main relief valve (M.R.V.) and
Hydraulic fluid at system pressure can injure you. auxiliary relief valve (A.R.V.) pressure settings.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service Note: All hydraulic adaptors that are installed together with
hose line must be vented. Make sure the hose service a bonded sealing washer must also have JCB Threadseal
line has been vented before connecting or removing applied to the threads of the adaptor.
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2

Removal
1 Operate the valve block levers back and forth to vent
residual pressure.

2 Remove clevis pins A and nuts B to disconnect the

control levers from the valve block spools.

3 Disconnect all hydraulic hoses from the valve block

and plug all orifices to prevent ingress of dirt. Label
each hose before disconnecting, this will ensure
correct position when refitting.

4 Uncouple the dump solenoid electrical connector G.

Uncouple the electric detent connector H (if fitted).

5 Loosen and remove the three fixing nuts J. Remove

the loader valve and spacing washers C.

E-104 9813/2050-5 E-104

 Section E - Hydraulics
Loader Valve
Removal and Replacement

Fig 84.

E-105 9813/2050-5 E-105

 Section E - Hydraulics
Loader Valve
Dismantle and Assemble

Dismantle and Assemble

Main Relief Valve (MRV)

Fig 85.

The numerical sequence shown on the illustration is Adjust pressure setting as required, refer to Service
intended as a guide to dismantling K Fig 86. ( T E-107). Procedures, Loader Valve - Pressure Testing.

For assembly the sequence should be reversed. Table 34. Torque Settings
Item Nm kgf m lbf ft
The following points MUST be avoided when dismantling
3 5.4 0.6 4
and assembling the valve:

– Contamination
– Damage to spool
– Damage to seal grooves

All or any of the above points may result in possible

problems with the valve.

Dismantle

When removing 'O' rings and seals, use an appropriately

rounded tool that WILL NOT cause any damage to the seal
grooves.

Discard ALL 'O' rings and back up rings. DO NOT use worn
or damaged items.

Inspect the valve components for scratches, nicks or any

other type of damage, replace with new if required.

Assemble

Renew all 'O' rings and back-up rings.

Lubricate parts with JCB Hydraulic Fluid before

assembling. Make sure that all the parts move freely.

Make sure that the 'O' rings and back-up rings are fitted the
correct way, items 10 and 11 K Fig 86. ( T E-107).

E-106 9813/2050-5 E-106

 Section E - Hydraulics
Loader Valve
Dismantle and Assemble

Fig 86. Main Relief Valve (MRV)

E-107 9813/2050-5 E-107

 Section E - Hydraulics
Loader Valve
Dismantle and Assemble

Auxiliary Relief Valves (ARV) and Load Table 35. Torque Settings
Hold Check Valves (LHCV) Item Nm kgf m lbf ft
1 65 6.6 48
The numerical sequence shown on the illustration is 3 24 2.5 18
intended as a guide to dismantling K Fig 87. ( T E-109).
15 81 8.3 60
For assembly the sequence should be reversed.

The following points MUST be avoided when dismantling

and assembling the valve:

– Contamination
– Damage to spool
– Damage to seal grooves

All or any of the above points may result in possible

problems with the valve.

The ARV's are identical in design but have different

pressure settings, refer to Technical Data.

The LHCV's are identical.

Dismantle

When removing 'O' rings and seals, use an appropriately

rounded tool that WILL NOT cause any damage to the seal
grooves.

Discard ALL 'O' rings and back up rings. DO NOT use worn
or damaged items.

Dismantle sub-assembly 14 from item 1 using a special

tool (see Service Tools). The special spanner locates in
cross holes B.

Make sure that small drilling A is not blocked.

Ensure good condition of seating faces on poppet 18 and

on the mating face of the valve block.

Inspect the valve components for scratches, nicks or any

other type of damage, replace with new if required.

Assemble

Renew all 'O' rings and back-up rings.

Lubricate parts with JCB Hydraulic Fluid before

assembling. Make sure that all the parts move freely.

Fit back-up ring 13 on the upper side of 'O' ring 12.

Fit flat face of sleeve 9 against shoulder of poppet 10.

Torque tighten item 14 using the special tool (see Service

Tools), until its shoulder seats firmly against item 1.

Pressure test the relief valves, refer to Service

Procedures, Loader Valve - Pressure Testing.

E-108 9813/2050-5 E-108

 Section E - Hydraulics
Loader Valve
Dismantle and Assemble

Fig 87. Auxiliary Relief Valve (ARV) and Load Hold Check Valve

E-109 9813/2050-5 E-109

 Section E - Hydraulics
Loader Valve
Dismantle and Assemble

Unloader Valve Table 36. Torque Settings

Item Nm kgf m lbf ft
The numerical sequence shown on the illustration is 1 6.7 0.7 5
intended as a guide to dismantling K Fig 88. ( T E-111).
5 27 2.8 20
For assembly the sequence should be reversed. 8 81 8.3 60
12 81 8.3 60
The following points MUST be avoided when dismantling
and assembling the valve: 16 45 4.6 33
19 34 3.5 25
– Contamination
– Damage to spool
– Damage to seal grooves

All or any of the above points may result in possible

problems with the valve.

Dismantle

When removing 'O' rings and seals, use an appropriately

rounded tool that WILL NOT cause any damage to the seal
grooves.

Discard ALL 'O' rings and back up rings. DO NOT use worn
or damaged items.

Use a nylon rod to push out spool assembly item 23, DO

NOT damage spool bore.

Inspect the valve components for scratches, nicks or any

other type of damage, replace with new if required.

Assemble

Renew all 'O' rings and back-up [Link] parts with

JCB Hydraulic Fluid before assembling.

Make sure that all the parts move freely. Ensure that the
small drilling through the centre of items 23, is clear.

Shims 21 are intended to limit the maximum pressure

setting, the specified pressure setting is achieved by
adjusting capnut 15.

If the specified pressure cannot be achieved under test, it

is permissible to add shims as required. There MUST be at
least one hardened shim next to the spring item 22.

Do not over-tighten the solenoid assembly, it may effect

the operation of the solenoid, use the spanner flats and
torque tighten to figure indicated in the table below (items
1 and 5).

Fit chamfered end of spring 22 against head of pilot poppet

item 23. Check pressure setting after refitting, refer to
Service Procedures, Loader Valve - Pressure Testing.

Check the operation of the hydraulic speed control, refer to

Service Procedures, Loader Valve - Pressure Testing.

E-110 9813/2050-5 E-110

 Section E - Hydraulics
Loader Valve
Dismantle and Assemble

Fig 88. Unloader Valve

E-111 9813/2050-5 E-111

 Section E - Hydraulics
Loader Valve
Dismantle and Assemble

Standard Spool 6 Torque tighten cap screws 1.

The numerical sequence shown on the illustration is 7 When fitting bolt 9, clean the threads thoroughly using
intended as a guide to dismantling. See JCB Cleaner and Degreaser, leave it for 10 minutes
K Fig 89. ( T E-113). then apply a small quantity of JCB Threadlocker and
Sealer to the threads of the spool.
For assembly the sequence should be reversed.
8 Make sure that all the parts move freely, check that
The following points MUST be avoided when dismantling item 10 does not interfere with item 13.
and assembling the valve:
9 Renew 'O' ring 15. Make sure the 'O' ring is not
– Contamination trapped or damaged.
– Damage to spool
10 Fit seal 15 and seal plate 14 to the valve block
– Damage to seal grooves section. Torque tighten capscrew 5 on completion.

All or any of the above points may result in possible Re-connect the lever mechanism to the tang (lever) end of
problems with the valve. the spool.

Dismantle Run the engine and inspect the valve for external leaks.

Remove the lever linkage from the tang (lever) end of the Table 37. Torque Settings
spool. Item Nm kgf m lbf ft
1 9.5 0.96 7
When removing 'O' rings and seals, use an appropriately
rounded tool that WILL NOT cause any damage to the 5 9.5 0.96 7
spool or seal grooves, for instance, item 3, which is a wiper 9 9.5 0.96 7
seal and is a press fit in the counterbore.

Care must be taken to ensure that the spool 8 is not

damaged when removing it from the valve block.

Hold the spool in clamp 992/10100, unscrew bolt 9 and

remove spring 12, spacer 10 and cups 11 and 13.

Check for surface contamination on the under side of the

seal plates 2 and 14. Clean if necessary. Check for the
flatness of the seal plate. If found to be bent - replace with
new (any work previously carried out on this valve may
have resulted in the bending of the seal plate).

Assemble

1 Fit the boot 1A to the seal plate 2.

2 Fit a new lipseal 4 into the valve block, ensure square.

Fit wiper 3 on top of lipseal.

3 Fit the seal plate and boot assembly to valve block

section but do not torque tighten capscrews 1 at this
stage. Ensure wiper locates into seal plate.

4 Use clean hydraulic oil as a lubricant. From the

bottom, insert spool through the valve block, do not
use excessive force when fitting, a turning motion
should ease the spool through the valve block.

5 Check that the tang end of the spool passes through

the boot without dislodging or damaging the boot.
Ensure that the tang aligns with the control rod and
that the boot is not distorted and is located in the
spool land.

E-112 9813/2050-5 E-112

 Section E - Hydraulics
Loader Valve
Dismantle and Assemble

Fig 89. Standard Spool

E-113 9813/2050-5 E-113

 Section E - Hydraulics
Loader Valve
Dismantle and Assemble

Float Spool that the boot is not distorted and is located in the
spool land.
The numerical sequence shown on the illustration is
intended as a guide to dismantling K Fig 90. ( T E-115). 6 Torque tighten cap screws 1.

For assembly the sequence should be reversed. 7 When fitting detent pin 20, clean the threads
thoroughly using JCB Cleaner and Degreaser, leave
The following points MUST be avoided when dismantling it for 10 minutes then apply a small quantity of JCB
and assembling the valve: Threadlocker and Sealer to the threads of the spool.

– Contamination 8 Apply grease liberally balls 10, this will help to hold
the balls in position whilst assembling.
– Damage to spool
– Damage to seal grooves 9 Renew 'O' ring 15. Make sure the 'O' ring is not
trapped or damaged.
All or any of the above points may result in possible
problems with the valve. 10 Fit seal 15 and seal plate 14 to the valve block
section. Torque tighten capscrew 6 on completion.
Dismantle
Re-connect the lever mechanism to the tang (lever) end of
Remove the lever linkage from the tang (lever) end of the spool.
spool.
Run the engine and inspect the valve for external leaks.
When removing 'O' rings and seals, use an appropriately
rounded tool that WILL NOT cause any damage to the Table 38. Torque Settings
spool or seal grooves, for instance, item 4, which is a wiper Item Nm kgf m lbf ft
seal and is a press fit in the counterbore.
1 9.5 0.96 7
Care must be taken to ensure that the spool 13 is not 6 9.5 0.96 7
damaged when removing it from the valve block. 20 9.5 0.96 7

Carefully remove collar 9 and collect detent balls 10.

Using tool 992/10100 to hold the spool, remove circlip 16,

plug 17, ball 18 and spring 19. Unscrew detent pin 20 and
remove spring 22 and cups 21 and 23.

Check for surface contamination on the under side of the

seal plates 3 and 14. Clean if necessary. Check for the
flatness of the seal plate. If found to be bent - replace with
new (any work previously carried out on this valve may
have resulted in the bending of the seal plate).

Assemble

1 Fit the boot 2 to the seal plate 3.

2 Fit a new lipseal 5 into the valve block, ensure square.

Fit wiper 4 on top of lipseal.

3 Fit the seal plate and boot assembly to valve block but
do not torque tighten capscrews 1 at this stage.
Ensure wiper locates into seal plate.

4 Use clean hydraulic oil as a lubricant. From the

bottom, insert spool through the valve block, do not
use excessive force when fitting, a turning motion
should ease the spool through the valve block.

5 Check that the tang end of the spool passes through

the boot without dislodging or damaging the boot.
Ensure that the tang aligns with the control rod and

E-114 9813/2050-5 E-114

 Section E - Hydraulics
Loader Valve
Dismantle and Assemble

Fig 90. Float Spool

E-115 9813/2050-5 E-115

 Section E - Hydraulics
Loader Valve
Dismantle and Assemble

Electric Detent Spool 7 When fitting spool end 15, clean the threads
thoroughly using JCB Cleaner and Degreaser, leave
The numerical sequence shown on the illustration is it for 10 minutes then apply a small quantity of JCB
intended as a guide to dismantling K Fig 91. ( T E-117). Threadlocker and Sealer to the threads of the spool.

For assembly the sequence should be reversed. 8 Make sure that the chamfer on item 14 faces away
from the solenoid, item 6.
The following points MUST be avoided when dismantling
and assembling the valve: 9 Renew lipseal 11. Make sure the lipseal is not trapped
or damaged.
– Contamination
10 Fit lipseal 11 and seal plate 10 to the valve block
– Damage to spool
section. Torque tighten capscrew 5 on completion.
– Damage to seal grooves
Check the operation of the solenoid 6 after assembly by
All or any of the above points may result in possible connecting a 12V supply. The spool should be held when
problems with the valve. it is pushed into the detent position and returned when the
supply is disconnected.
Dismantle
Run the engine and inspect the valve for external leaks.
When removing 'O' rings and seals, use an appropriately
rounded tool that WILL NOT cause any damage to the Table 39. Torque Settings
spool or seal grooves, for instance, item 3, which is a wiper Item Nm kgf m lbf ft
seal and is a press fit in the counterbore.
1 9.5 0.96 7
Care must be taken to ensure that the spool 12 is not 5 9.5 0.96 7
damaged when removing it from the valve block. 15 9.5 0.96 7

Use tool 992/10100 to hold the spool, remove circlip 13

and 'clapper' 14. Unscrew spool end 15 and remove spring
17 with cups 16 and 18.

Check for surface contamination on the under side of the

seal plates 2, 8 and 10. Clean if necessary. Check for the
flatness of the seal plate. If found to be bent - replace with
new (any work previously carried out on this valve may
have resulted in the bending of the seal plate).

Assemble

1 Fit the boot 1A to the seal plate 2.

2 Fit a new lipseal 4 into the valve block, ensure square.

Fit wiper 3 on top of lipseal.

3 Fit the seal plate and boot assembly to valve block but
do not torque tighten capscrews 1 at this stage.
Ensure wiper locates into seal plate.

4 Use clean hydraulic oil as a lubricant. From the

bottom, insert spool through the valve block, do not
use excessive force when fitting, a turning motion
should ease the spool through the valve block.

5 Check that the tang end of the spool passes through

the boot without dislodging or damaging the boot.
Ensure that the tang aligns with the control rod and
that the boot is not distorted and is located in the
spool land.

6 Torque tighten cap screws 1.

E-116 9813/2050-5 E-116

 Section E - Hydraulics
Loader Valve
Dismantle and Assemble

Fig 91. Electric Detent Spool

E-117 9813/2050-5 E-117

 Section E - Hydraulics

Loader Valve
Component Identification

3DX Xtra and 4DX

– From serial number 1486501 to 1502999 and
1414001 to 1416999

E-118 9813/2050-5 E-118

 Section E - Hydraulics
Loader Valve
Component Identification

C B

D1

D2

D1 D2

G
HPCO

A1 A2

T P1
P2
B1 B2
C

D070920-06
Fig 92. 3DX Xtra and 4DX
Item Description Port Description
A Main Relief Valve P2 Intelt
B Unloader Valve T Return to Tank
C Load Hold Check Valve HPCO High Pressure Carry Over
D1 Lift Spool A1 Lift Ram Head Side
D2 Bucket B1 Lift Ram Rod Side
G Gauge Port A2 Bucket Ram Head Side
B2 Bucket Ram Rod Side
Table 40.
Port Description 3DX Super
P1 Inlet
– From serial number 1415101 to 1416999

E-119 9813/2050-5 E-119

 Section E - Hydraulics
Loader Valve
Component Identification

E
D

D E F A
A A

T A1 A2 A3 G

P1
HPCO

B1 B2 B3 P2
B

D070920-09
Fig 93. 3DX Super

Table 41. Item Description

Item Description
D Lift Spool
A Main Relief Valve
E Bucket Spool
B Load hold Check Valve
F Aux. Spool
C Auxiliary Relief Valve

E-120 9813/2050-5 E-120

 Section E - Hydraulics
Loader Valve
Component Identification
Table 42.
Port Description
P1 Intelt
P2 Intelt
A1 Lift Ram Head Side
B1 Lift Ram Rod Side
A2 Bucket Ram Head Side
B2 Bucket Ram Rod Side
A3 Aux. Ram Head Side
B3 Aux. Ram Rod Side
T Return to Tank
G Gauge

E-121 9813/2050-5 E-121

 Section E - Hydraulics
Loader Valve
Removal and Installation

Removal and Installation

!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.

Disconnect the battery, to prevent the engine being

started while you are beneath the machine.
GEN-4-1_1

Before commencing work, ensure that the exterior of the

loader valve block and the working area are thoroughly
cleaned and free of possible sources of contamination.

Removal
1 Park the machine and make it safe. Obey the care
and safety procedures.
A B
2 Vent the hydraulic pressure.
D070920-13
Fig 94. Typical Valve
3 Disconnect the control rod linkages from the ends of
the spools.
Installation
4 Put a suitable receptacle beneath the valve block to
collect any hydraulic fluid spillage. Installation is a reversal of the removal procedure. During
the replacement procedure do this work also:
5 Working beneath the machine, label and disconnect
all the hydraulic hoses from the loader valve block. – Inspect the resilient mounts B for damage, cracking
etc. If the mounts are not in good condition, replace

!MWARNING them with new ones.

– Apply JCB Threadlocker and Sealer to the threads of
This component is heavy. It must only be removed or nuts A before fitting.
handled using a suitable lifting method and device. – Make sure that the hoses are correctly installed, and
BF-4-1_1 phased in the same position as removal to prevent
chafing.
6 Remove the three securing nuts A, then carefully lift
the valve block away from the resilient mounts B. – On completion, run the engine and check for leaks.

E-122 9813/2050-5 E-122

 Section E - Hydraulics
Loader Valve
Dismantle and Assemble

Dismantle and Assemble

Main Relief Valve (MRV) Open End Kit

Main relief valve is a complete kit with desire pressure Assemble
setting as per Machine model. Refer to Technical Data.
1 Put the quad ring 1 in between the casting and the
Put the relief valve A in the appropriate cavity and torque spool.
the relief valve to 80 Nm. K Fig 95. ( T E-123).

D071030-05
Fig 97.

2 Gently press the quad ring 1 to fit in the groove.

K Fig 97. ( T E-123).
D071030-10
Fig 95. 3 Install the spacer 2 with the wiper seal and gently
press the spacer 2.
Unloader Valve
Unloader valve is a complete kit with desire pressure
setting as per Machine model. Refer to Technical Data.

Put the unloader valve B in the appropriate cavity and

torque the relief valve to 60 Nm.

D071030-06
Fig 98.

4 Put the flange 3 over the each spacer 2.

D071030-11
Fig 96.

E-123 9813/2050-5 E-123

 Section E - Hydraulics
Loader Valve
Dismantle and Assemble

D071030-07
Fig 99.

5 Attach the flange 3 with the four screws 4 and torque

the screws to 10 Nm.

Fig 100.

6 Put the rubber boot 5 in the groove of the center ring

and the spool. K Fig 100. ( T E-124).

Dismantle

Dismantle is a reversal of the assemble sequence.

E-124 9813/2050-5 E-124

 Section E - Hydraulics
Excavator Valve
Removal and Replacement

Excavator Valve
Removal and Replacement

!MWARNING 4 Remove clevis pins B to disconnect the control levers

from the valve block spools.
Make the machine safe before working underneath it.
Park the machine on level ground, lower the 5 Disconnect all hydraulic hoses from the valve block
attachments to the ground. Apply the park brake, put and plug all orifices to prevent ingress of dirt. Label
the transmission in neutral and stop the engine. Block each hose and note the phasing before
both sides of all four wheels. disconnecting, this will ensure correct position when
refitting.
Disconnect the battery, to prevent the engine being
started while you are beneath the machine. 6 Uncouple the electrical connection to the hydraclamp
GEN-4-1_1 solenoid F (for side shift machine only).

!MWARNING 7 Uncouple the electrical connection to the rear horn G

( for side shift machine only).
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. 8 Loosen nuts H - do not completely remove the
Before connecting or removing any hydraulic hose, retaining nuts.
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
!MWARNING
hoses. Make sure the engine cannot be started while This component is heavy. It must only be removed or
the hoses are open. handled using a suitable lifting method and device.
INT-3-1-11_2 BF-4-1_1

Removal 9 Open the rear window. Wrap a suitable sling around

the valve, make sure that the weight of the valve is
1 Operate the valve block levers back and forth to vent supported by the sling.
residual pressure.
10 Remove nuts H. Remove the rear horn G. Lower the
2 Remove the rear valance. valve block to the ground.

3 In order to gain access for valve removal the Replacement

excavator control console A must be removed, see
Section D, Controls. Replacement is a reversal of the removal sequence.

Hoses and pipes (when applicable) must be re-connected

and phased in same position as removal. Refer to
Dismantling and Assembly, Hoses and Pipes.
A
Note: All hydraulic adaptors that are installed together with
a bonded sealing washer must also have JCB Threadseal
applied to the threads of the adaptor.

D070860-09
Fig 101.

E-125 9813/2050-5 E-125

 Section E - Hydraulics
Excavator Valve
Removal and Replacement

!MWARNING Adjust the control levers to the correct positions, see

Section D, Controls.
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the After replacement check the auxiliary relief valve (ARV)
skin. Keep face and hands well clear of fluid under pressure settings.
pressure and wear protective glasses and gloves.
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_3

S439000-C2
Fig 102.

Fig 103.

E-126 9813/2050-5 E-126

 Section E - Hydraulics
Excavator Valve
Dismantle and Assemble

Dismantle and Assemble

Valve Block Auxiliary relief valve dismantling and assembly procedures

are detailed separately, K Auxiliary Relief Valves
The numerical sequence shown on the illustration is (ARV's) ( T E-130).
intended as a guide to dismantling.
Note: All hydraulic adaptors that are installed together with
For assembly the sequence should be reversed. a bonded sealing washer must also have JCB Threadseal
applied to the threads of the adaptor.
Load Hold Check Valves
Assemble
Each of the identical load hold check valves 4R to 4W can
be removed as shown at 4W. Make-up check valve 4X is a 1 Fit the boot 10 to the seal plate 11.
smaller size but otherwise identical.
2 Fit a new lipseal 12A into the valve block, ensure
Ensure good condition of seating faces on poppets 4 and square. Fit wiper 12 on top of lipseal.
8 and on the mating faces in the valve block.
3 Fit the seal plate and boot assembly to valve block but
Service Spools do not torque tighten capscrews 9 at this stage.
Ensure wiper locates into seal plate.
Spools 4A, 4B, 4E and 4F are identical but must not be
interchanged as they are matched to their bores. Stabiliser 4 Use clean hydraulic oil as a lubricant. From the
spools 4C and 4D are identical to each other but different bottom, insert spool through the valve block, do not
from the excavator spools. use excessive force when fitting, a turning motion
should ease the spool through the valve block.
All spools have the same centring and sealing components
items 9 to 21. 5 Check that the tang end of the spool passes through
the boot without dislodging or damaging the boot.
To completely dismantle a spool, follow the sequence 9 to Ensure that the tang aligns with the control rod and
21. To prevent spool rotation when turning screw 15, hold that the boot is not distorted and is located in the
a rod through the eye end of the spool. spool land.

If only renewing the seals, dismantle as far as cap 14 then 6 Torque tighten cap screws 9, K Table 43. Torque
remove items 15 to 22 as an assembly. Settings ( T E-128).

Lubricate new seals with JCB Hydraulic Fluid and take 7 When fitting bolt 15, clean the threads thoroughly
care to prevent them from being damaged by the sharp using JCB Cleaner and Degreaser, leave it for 10
edges of the spool. minutes then apply a small quantity of JCB
Threadlocker and Sealer to the threads of the spool.
Apply JCB Threadlocker and Sealer to threads of screw
15. 8 Make sure that all the parts move freely, check that
item 16 does not interfere with item 18.
Auxiliary Relief Valves
9 Renew 'O' ring 21 and seal 20. Make sure the 'O' ring
and wiper seal are not trapped or damaged.
A.R.V's 4H to 4P appear identical but have various
pressure settings, refer to Technical Data. Ensure that
10 Fit seal 20 and seal plate 19 to the valve block
they are correctly adjusted and fitted in their specified
section. Torque tighten capscrew 13 on completion,
positions.
K Table 43. Torque Settings ( T E-128).

E-127 9813/2050-5 E-127

 Section E - Hydraulics
Excavator Valve
Dismantle and Assemble
Re-connect the lever mechanism to the tang (lever) end of
the spool. Run the engine and inspect the valve for
external leaks.

Table 43. Torque Settings

Item Nm kgf m lbf ft
1 122 12.4 90
5 80 8.3 60
9 9.5 0.96 7
13 7 0.7 5
15 11 1.1 8
23 95 10 70

E-128 9813/2050-5 E-128

 Section E - Hydraulics
Excavator Valve
Dismantle and Assemble

Fig 104.

E-129 9813/2050-5 E-129

 Section E - Hydraulics
Excavator Valve
Dismantle and Assemble

Auxiliary Relief Valves (ARV's) Dismantle

Eight A.R.V's are fitted at positions 4H to 4Q. These are K Fig 105. ( T E-131). The numerical sequence shown on
identical in design but have various pressure settings, refer the illustration is intended as a guide to dismantling.
to Technical Data.
For assembly the sequence should be reversed.
Note: The bucket rod side A.R.V. 4Q is only fitted to
machines equipped with a Rockbreaker. Dismantle sub-assembly 14 from item 1 using a special
tool (see Service Tools). The special spanner locates in
cross holes B.

Dismantle sub-assembly 14 into its component parts.

Make sure that small drilling A is not blocked.

Discard old and worn O-rings and back-up rings.

Assemble

Renew all O-rings and back-up rings. Lubricate O-rings

and back-up rings with JCB Hydraulic Fluid.

Fit back-up ring 13 on the upper side of 'O' ring 12 as

shown in the inset.

A.R.V. Position Key: Fit flat face of sleeve 9 against shoulder of poppet 10.

Control Layout Torque tighten item 14 using the special tool (see Service
JCB ISO Case Ford Tools), until its shoulder seats firmly against item 1.
Slew Right 4H 4H 4H 4H
Pressure test the relief valves, refer to Service
Slew Left 4J 4J 4J 4J Procedures, Excavator Valve - Pressure Testing.
Boom Rod 4K 4M 4M 4K
Table 44. Torque Settings
Boom Head 4L 4N 4N 4L
Item Nm kgf m lbf ft
Dipper Rod 4N 4L 4K 4N
1 65 6.6 48
Dipper Head 4M 4K 4L 4M
3 24 2.5 18
Bucket Rod 4Q 4Q 4Q 4P
Bucket Head 4P 4P 4P 4Q

E-130 9813/2050-5 E-130

 Section E - Hydraulics
Excavator Valve
Dismantle and Assemble

Fig 105. Auxiliary Relief Valve

E-131 9813/2050-5 E-131

 Section E - Hydraulics
Excavator Valve
Dismantle and Assemble

Hydraclamp Valve (Sideshift Machines) Do not over-tighten the solenoid assembly, it may affect
the operation of the solenoid, use the spanner flats and
The numerical sequence shown on the illustration is torque tighten to figure indicated in the table below (items
intended as a guide to dismantling. 11 and 13).

For assembly the sequence should be reversed. Check the operation of the electric hydraclamp, refer to
Circuit Descriptions, Excavator Valve - Manual Control
The following points MUST be avoided when dismantling - Hydraclamp Valve Operation.
and assembling the valve:
Table 45. Torque Settings
– Contamination Item Nm kgf m lbf ft
– Damage to poppet and seat 1 13.5 1.4 10
– Damage to seal grooves 3 24.5 2.5 18
5 13.5 1.4 10
All or any of the above points may result in possible
problems with the valve. 11 5.5 0.5 4
13 24.5 2.5 18
When removing 'O' rings and seals, use an appropriately
rounded tool that WILL NOT cause any damage to the seal
grooves. Discard ALL 'O' rings DO NOT use worn or
damaged items.

Note that the hydraclamp comprises two separate valve

assemblies; 1) the check valve assembly (items 1 to 8); 2)
the solenoid assembly (items 11 to 14).

Dismantle

Loosen nut 1 (turn anti-clockwise) and then remove the

check valve assembly from the valve block. If required, the
check valve assembly can be dismantled into its
component parts (items 1 to 8).

Inspect the valve components for scratches, nicks or any

other type of damage, particularly on the poppet and seat
faces. Replace with new if required.

Assemble

Renew all 'O' rings. The parts microfiche will identify the
correct seal kit part numbers for items 2, 2A, 4, 6, 10 and
14.

Fit seal 2A with the recess towards `O' ring 2, as shown at

A.

Lubricate parts with JCB Hydraulic Fluid before

assembling. Make sure that all the parts move freely.

Ensure that the small drilling through the centre of item 3,

is clear.

E-132 9813/2050-5 E-132

 Section E - Hydraulics
Excavator Valve
Dismantle and Assemble

Fig 106.

E-133 9813/2050-5 E-133

 Section E - Hydraulics
Excavator Valve
Dismantle and Assemble

Hoses and Pipes (Sideshift Valve)

Refer to K Removal and Replacement ( T E-125) for valve block removal and replacement procedure. Hoses and pipes
(when applicable) must be re-connected and phased in same position as removal.

Fig 107. ISO Excavator Valve

Fig 108. JCB Excavator Valve

E-134 9813/2050-5 E-134

 Section E - Hydraulics
Excavator Valve
Dismantle and Assemble

Hoses and Pipes (Centremount Valve)

Refer to K Removal and Replacement ( T E-125) for valve block removal and replacement procedure. Hoses and pipes
(when applicable) must be re-connected and phased in same position as removal.

Fig 109. ISO Excavator Valve

Fig 110. JCB Excavator Valve

E-135 9813/2050-5 E-135

 Section E - Hydraulics
Excavator Valve
Dismantle and Assemble

Page left intentionally blank

E-136 9813/2050-5 E-136

 Section E - Hydraulics
Excavator Valve
Description

Excavator Valve
Description

For 3DX Xtra, 3DX Super (Base and AC) The cleanliness of this component is critical and must
conform to JCB standard 9993/0003.
– From serial number 1486501 to 1491201
The valve block consists of six spools which controls the
slew, boom, stabilizer, dipper and the bucket.

K
J
H
G
F
E

A B

CT
T1 B1 B2 B3 B4 B5 B6

A1 A2 A3 A4 A5 A6 L

D070920-10
Fig 111. 3DX Xtra, 3DX Super (Base and AC)

Table 46. Item Description

Item Description
H Stabilizer Spool
A Main Relief Valve
J Dipper Spool
B Connector Pin
K Bucket Spool
C Load Hold Check Valve
D Auxiliary Relief Valve
E Swing Spool
F Boom Spool
G Stabilizer Spool

E-137 9813/2050-5 E-137

 Section E - Hydraulics
Excavator Valve
Description

Table 47.
Port Description
A1 Swing Ram Head Side
B1 Swing Ram Rod Side
A2 Boom Ram Head Side
B2 Boom Ram Rod Side
A3 Stabilizer Ram Head Side
B3 Stabilizer Ram Rod Side
A4 Stabilizer Ram Head Side
B4 Stabilizer Ram Rod Side
A5 Dipper Ram Head Side
B5 Dipper Ram Rod Side
A6 Bucket Ram Head Side
B6 Bucket Ram Rod Side
T1 Return to Tank
CT Clamp Tank
L HP Passage
M Neutral Passage

E-138 9813/2050-5 E-138

 Section E - Hydraulics
Excavator Valve
Description

For 3DX Xtra and 3DX Super (Servo)

– From serial number 1491201 to 1502999

B
PRA PR

D
CP
F E

G
C H

T1 B1 B2 B3 B4 B5 B6 J CT K

A1 A2 A3 A4 A5 A6

D070920-11
Fig 112. 3DX Xtra, 3DX Super (Servo)

Table 48. Port Description

Item Description
A2 Boom Ram Head Side
A Main Relief Valve
B2 Boom Ram Rod Side
B Load Hold Check Valve
A3 Stabilizer Ram Head Side
C Auxiliary Relief Valve
B3 Stabilizer Ram Rod Side
D Slew Control Servo
A4 Stabilizer Ram Head Side
E Boom Control Servo
B4 Stabilizer Ram Rod Side
F Stabilizer Spool
A5 Dipper Ram Head Side
G Dipper Control Servo
B5 Dipper Ram Rod Side
H Bucket Control Servo
A6 Bucket Ram Head Side
B6 Bucket Ram Rod Side
Table 49.
Port Description T1 Return to Tank

A1 Swing Ram Head Side CT Clamp Tank

B1 Swing Ram Rod Side CP Clamp Port

PR Pilot Port 1

E-139 9813/2050-5 E-139

 Section E - Hydraulics
Excavator Valve
Description

Port Description
PRA Pilot Port 2
J HP Passage
K Neutral Passage

E-140 9813/2050-5 E-140

 Section E - Hydraulics
Excavator Valve
Description

4DX
– 1415101 to 1416999

PR

PRA

H
G
C
E
D

K
B1 B2 B3 B4 B5 B6
T1 J
A1 A2 A3 A4 A5 A6

D070920-12
Fig 113. 4DX

Table 50. Table 51.

Item Description Port Description
A Main Relief Valve A1 Swing Ram Head Side
B Load Hold Check Valve B1 Swing Ram Rod Side
C Auxiliary Relief Valve A2 Boom Ram Head Side
D Slew Control Servo B2 Boom Ram Rod Side
E Boom Control Servo A3 Stabilizer Ram Head Side
F Stabilizer Spool B3 Stabilizer Ram Rod Side
G Dipper Control Servo A4 Stabilizer Ram Head Side
H Bucket Control Servo

E-141 9813/2050-5 E-141

 Section E - Hydraulics
Excavator Valve
Description

Port Description
B4 Stabilizer Ram Rod Side
A5 Dipper Ram Head Side
B5 Dipper Ram Rod Side
A6 Bucket Ram Head Side
B6 Bucket Ram Rod Side
T1 Return to Tank
PR Pilot Port 1
PRA Pilot Port 2
J Neutral Passage
K HP Passage

E-142 9813/2050-5 E-142

 Section E - Hydraulics
Excavator Valve
Removal and Replacement

Removal and Replacement

!MWARNING !MWARNING
Make the machine safe before working underneath it. This component is heavy. It must only be removed or
Park the machine on level ground, lower the handled using a suitable lifting method and device.
attachments to the ground. Apply the park brake, put BF-4-1_1
the transmission in neutral and stop the engine. Block
both sides of all four wheels. 7 Support the weight of the valve block with suitable
lifting equipment, then remove the securing nuts.
Disconnect the battery, to prevent the engine being Carefully lift the valve block away from the resilient
started while you are beneath the machine. mounts.
GEN-4-1_1

!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2

Sideshift Machine
To improve access to the valve block, sideshift the
excavator fully to the left, then lower to the ground.

Removal
Fig 114.
1 Park the machine and make it safe. Obey the care
and safety procedures. Installation

2 Vent the hydraulic pressure. Installation is a reversal of the removal procedure. During
the replacement procedure do this work also:
3 Put a suitable receptacle beneath the valve block to
collect any hydraulic fluid spillage. – Inspect the resilient mounts for damage, cracking etc.
If the mounts are not in good condition, replace them
4 Machines with Manual Spools: Disconnect the with new ones.
control rod linkages from the ends of the spools. – Apply JCB Threadlocker and Sealer to the threads of
nuts before fitting.
5 Machines with Servo Spools: Working beneath the
– Make sure that the hoses are correctly installed, and
machine, label and disconnect all the hydraulic hoses
phased in the same position as removal to prevent
from the excavator valve block. Note the phasing of
chafing.
the hoses.
– On completion, run the engine and check for leaks.
6 Cap the open hoses and ports to prevent
contamination.

E-143 9813/2050-5 E-143

 Section E - Hydraulics
Excavator Valve
Dismantle and Assemble

Dismantle and Assemble

Valve Block 5 Put the assembled control valve on a flat surface

table and check the alignment.
K Fig 115. ( T E-145). The numerical sequence shown on
the illustration is intended as a guide to dismantling. 6 Torque the tie rod nut 1 to 40 Nm (outlet side), at the
same time hold the inlet side tie rod nut 2 with a
For assembly the sequence should be reversed. spanner.

Service Spools 7 Do the same step for the inlet side tie rod nut 2.

Dismantle Note: Spool are NSP (non-serviceable parts) and non-

interchange. Spool are designed precise for the particular
1 Place the valve perpendicularly with respect to the section / functions.
surface.

2 Keep the inlet section at the bottom and the outlet

section must be at the top facing on surface table.

3 Loosen the tie rod nuts A on the outlet side, at the

same time hold the tie rod nuts B on the inlet side with
a spanner.

4 Remove the tie nut A and the split washer C.

5 Mark the valve block section for assembly aid.

6 Carefully remove each section one by one and

arrange in the same configuration of the control valve.

7 Replace the damage section with the new section.

Note: Each valve section comes with pre-assembled

spool and interface seals. Spools are NSP (non-
serviceable parts).

8 Make sure that the interface seal is properly fits in the

groove.

Assemble

1 Put the smaller thread length side of the tie rods in the
inlet side of the valve.

2 Tighten the four tie rod nuts 2 and four washers 4

(inlet side).

3 Install all the section one after another in the same

sequence as removed.

4 Install all the valve sections and tighten the tie rod
nuts 1 with split washers 3 (outlet side).

E-144 9813/2050-5 E-144

 Section E - Hydraulics
Excavator Valve
Dismantle and Assemble

7
8

10

11

12
D071030-01
Fig 115.

Load Hold Check Valve

Load check kit is a complete kit assembly as a spare.

1 Place the poppet along with spring and tighten the

plug A on the load check valve ports.

D071030-09
Fig 116.

2 Torque the plug A to 130 Nm.

E-145 9813/2050-5 E-145

 Section E - Hydraulics
Excavator Valve
Dismantle and Assemble
Auxiliary Relief Valves

Dismantle

ARV is a complete kit assembly and this is a drop-in

cartridge type.

A.R.V's appear identical but have various pressure

settings, refer to Technical Data. Make sure that they are
correctly adjusted and fitted in their specified positions.

1 Loosen the screw in the cap plug A and remove the

ARV B.
D071030-04
Fig 118.

3 Torque the plug to 40 Nm.

Open End Kit

Assemble
B
1 Put the quad ring 1 in between the casting and the
spool.

2 Replace the damage ARV with new ARV.

Assemble

1 Check the spring C, for the anti-cavitation function is

placed properly in lock nut of the ARV.

D071030-05
Fig 119.

2 Gently press the quad ring 1 to fit in the groove.

K Fig 119. ( T E-146).

3 Install the spacer 2 with the wiper seal and gently

press the spacer 2.

D071030-02
Fig 117.

2 Put the AVR cartridge B into the cavity and tighten the
screw in the cap plug with O-ring.

E-146 9813/2050-5 E-146

 Section E - Hydraulics
Excavator Valve
Dismantle and Assemble

Fig 122.
D071030-06
Fig 120.
6 Put the rubber boot 5 in the groove of the center ring
and the spool. K Fig 122. ( T E-147).
4 Put the flange 3 over the each spacer 2.
Dismantle

Dismantle is a reversal of the assemble sequence.

D071030-07
Fig 121.

5 Attach the flange 3 with the four screws 4 and torque

the screws to 10 Nm.

E-147 9813/2050-5 E-147

 Section E - Hydraulics
Excavator Valve
Dismantle and Assemble

Page left intentionally blank

E-148 9813/2050-5 E-148

 Section E - Hydraulics

Servo Joysticks
Description and Operation

Description
The joysticks basically comprise of a control lever 5, four
pressure adjustment valves and a housing 10.

Each pressure adjustment valve comprises of a control 5

spool 6, a control spring 7, a return spring 8 and a plunger
9.

Operation
12
When not actuated the control lever is held in zero position
by the four return springs 8. The control ports 1, 2, 3, 4 are
connected to the tank port T via the drilling 11.
9
With deflection of the control lever 5 the plunger 9 pushes
against the return spring 8and the control spring 7. The
control spring 7 firstly moves the control spool 6
8
downwards and closes the connection between the 7
appropriate port and tank port T. At the same time the
appropriate port is connected to the port P via the drilling 10
11. The control phase begins as soon as the control spool
6 has found its balance between the force of the control
spring 7 and the force which results from the hydraulic
pressure in the appropriate port ports 1, 2, 3 or 4.
11
Through the interaction of control spool 6 and control
spring 7 the pressure in the appropriate ports is 6
proportional to the stroke of the plunger 9 and thus the T057530

position of the control lever 5. Fig 123.

A rubber boot 12 protects the mechanical components of Table 52.

the housing from contamination. Port Description
P Supply
T Tank
1,2,3,4 Control

E-149 9813/2050-5 E-149

 Section E - Hydraulics
Servo Joysticks
Removal and Replacement

Removal and Replacement

Removal
Note: Only the left-hand (L.H.) joystick is shown in the
illustration K Fig 124. ( T E-151). The other joystick is
removed and replaced in the same way.

Ensure that the engine is stopped and all hydraulic

pressure is released from the system.

!MWARNING
It is not possible to vent all residual pressure. Loosen
the connection one full turn and allow the pressure to
dissipate. Keep face and hands well clear of
pressurised hydraulic oil and wear protective glasses.
HYD-4-3

1 Remove the covers from around the joystick body.

2 Mark the joystick flange and supporting flange to

ensure correct realignment on replacement.

3 Label then remove hydraulic hoses and plug exposed

connections to prevent ingress of dirt and water.

4 Disconnect the electrical connection if fitted.

5 Remove four screws 1 and washers 2, lift the joystick

unit clear.

Replacement
1 Replacement is a reversal of the removal procedure.

2 Torque tighten hydraulic connections to 30 Nm (22 lbf

ft).

3 Torque tighten screws 1 (4 off) to 10 Nm (7 lbf ft).

4 Reconnect the electrical connection if fitted. Replace

covers around the joystick body.

E-150 9813/2050-5 E-150

 Section E - Hydraulics
Servo Joysticks
Removal and Replacement

P 1
T
1
2
2
4

1 2 3 4

D070920-15
Fig 124.

E-151 9813/2050-5 E-151

 Section E - Hydraulics
Servo Joysticks
Removal and Replacement

Page left intentionally blank

E-152 9813/2050-5 E-152

 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

153 9813/2050-5 153

 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.

154 9813/2050-5 154

 Hydraulic Rams
Removal and Replacement

Removal and Replacement

Loader Shovel Ram 6 Remove kliprings B, shims C and spacers D.

Removal 7 Remove pivot pins E.

K Fig 125. ( T 156). Replacement

!MWARNING Replacement is a reversal of the removal sequence.

The loader arm interlevers are potentially dangerous,

when pivoting about their centre they form a 'scissor'
!MWARNING
point with the loader arm. Make sure the interlevers Fluid Under Pressure
are securely blocked when working in the loader arm Fine jets of fluid at high pressure can penetrate the
area. skin. Keep face and hands well clear of fluid under
BF-2-1
pressure and wear protective glasses and gloves.
Hold a piece of cardboard close to suspected leaks
1 Park the machine on firm level ground. Engage the and then inspect the cardboard for signs of fluid. If
parking brake and set the transmission to neutral. fluid penetrates your skin, get medical help
immediately.
2 Rest the shovel flat on the ground. INT-3-1-10_3

!MWARNING Coat pivot pins with anti-rust lubricant.

Hydraulic Pressure All klipring installations to have a maximum end float of

Hydraulic fluid at system pressure can injure you. 2mm (0.080 in).
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service Make sure that each klipring is installed with a shim.
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2

3 Switch off the engine and vent residual hydraulic

pressure from the loader end by operating the loader
controls back and forth several times.

4 Label and then remove the shovel ram hoses A. Plug

and cap all open orifices to prevent loss of fluid and
ingress of dirt.

!MWARNING
This component is heavy. It must only be removed or
handled using a suitable lifting method and device.
BF-4-1_1

5 Fasten lifting straps to the shovel ram, make sure that

the weight of the ram is supported by the sling.

155 9813/2050-5 155

 Hydraulic Rams
Removal and Replacement

D070860-19
Fig 125. Boom Ram

156 9813/2050-5 156

 Hydraulic Rams
Removal and Replacement

Loader Lift Ram

D070930-08
Fig 126. Loader Lift Ram

Removal

K Fig 126. ( T 157).

157 9813/2050-5 157

 Hydraulic Rams
Removal and Replacement

!MWARNING 7 Remove pivot pin retaining bolt D.

The loader arm interlevers are potentially dangerous, 8 Remove klipring E and shim F from both sides of ram,
when pivoting about their centre they form a 'scissor' use slide hammer kit (service tool 993/68100) to
point with the loader arm. Make sure the interlevers remove pivot pin G.
are securely blocked when working in the loader arm
area. 9 Remove the lift ram.
BF-2-1
Replacement
1 Park the machine on firm level ground. Engage the
parking brake and set the transmission to neutral. Replacement is a reversal of the removal sequence.

2 Raise the loader arms to give access to the lift ram

pivot pins C. The loader arms must be supported, use
!MWARNING
a tool as shown. Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
!MWARNING skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses and gloves.
Hydraulic Pressure Hold a piece of cardboard close to suspected leaks
Hydraulic fluid at system pressure can injure you. and then inspect the cardboard for signs of fluid. If
Before connecting or removing any hydraulic hose, fluid penetrates your skin, get medical help
residual hydraulic pressure trapped in the service immediately.
hose line must be vented. Make sure the hose service INT-3-1-10_3
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while Coat pivot pins with anti-rust lubricant. Make sure that the
the hoses are open. head of item D is on the engine side. Coat mainframe
INT-3-1-11_2 bores with grease. Assembly sequence for shim F and
klipring:
3 Switch off the engine and vent residual hydraulic
pressure from the loader end by operating the loader
1st shim
controls back and forth several times.
2nd ram
Note: If a hose burst protection valve is fitted on the ram, 3rd shim (as required)
the system will not vent. Extreme caution must be used
4th klipring
when releasing hydraulic connections - release the
connections one turn and allow the pressure to dissipate. Pivot pins with M24 pin extractor hole:
1st spacer
4 Label and then remove the lift ram hoses A. Plug and
cap all open orifices to prevent loss of fluid and 2nd ram
ingress of dirt. 3rd shim (as required)
4th klipring
!MWARNING
All klipring installations to have a maximum end float of
This component is heavy. It must only be removed or
2mm (0.080 in).
handled using a suitable lifting method and device.
BF-4-1_1

5 Fasten lifting straps to the lift ram, make sure that the
weight of the ram is supported by the sling.

6 Remove pivot pin retaining bolt B and then remove

the pivot pin C.

158 9813/2050-5 158

 Hydraulic Rams
Removal and Replacement

D070930-09
Fig 127. Loader Shovel Ram

159 9813/2050-5 159

 Hydraulic Rams
Removal and Replacement

Bucket Crowd Ram Replacement

Removal Replacement is a reversal of the removal sequence.

K Fig 128. ( T 161). !MWARNING

1 Park the machine on firm level ground, engage the Fluid Under Pressure
parking brake and set the transmission to neutral. Fine jets of fluid at high pressure can penetrate the
Lower the backhoe and loader end to the ground and skin. Keep face and hands well clear of fluid under
stop the engine. pressure and wear protective glasses and gloves.
Hold a piece of cardboard close to suspected leaks

!MWARNING and then inspect the cardboard for signs of fluid. If

fluid penetrates your skin, get medical help
Hydraulic Pressure immediately.
Hydraulic fluid at system pressure can injure you. INT-3-1-10_3
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2

2 Vent residual hydraulic pressure from the backhoe

hoses by operating the backhoe controls back and
forth several times.

Note: If a hose burst protection valve is fitted on the ram,

the system will not vent. Extreme caution must be used
when releasing hydraulic connections - release the
connections one turn and allow the pressure to dissipate.

3 Label and then remove the bucket crowd ram hoses

A. Plug and cap all open orifices to prevent loss of
fluid and ingress of dirt.

!MWARNING
This component is heavy. It must only be removed or
handled using a suitable lifting method and device.
BF-4-1_1

4 Fasten lifting straps to the bucket crowd ram, make

sure that the weight of the ram is supported by the
sling.

5 Remove the pivot pin retaining nut B and bolt C,

remove the pivot pin D.

6 Remove the bucket crowd ram.

160 9813/2050-5 160

 Hydraulic Rams
Removal and Replacement

D070860-20
Fig 128. Bucket Crowd Ram

161 9813/2050-5 161

 Hydraulic Rams
Removal and Replacement

Dipper Ram Replacement

Removal Replacement is a reversal of the removal sequence.

K Fig 129. ( T 163). !MWARNING

1 Park the machine on firm level ground, engage the Fluid Under Pressure
parking brake and set the transmission to neutral. Fine jets of fluid at high pressure can penetrate the
Lower the backhoe and loader end to the ground and skin. Keep face and hands well clear of fluid under
stop the engine. pressure and wear protective glasses and gloves.
Hold a piece of cardboard close to suspected leaks

!MWARNING and then inspect the cardboard for signs of fluid. If

fluid penetrates your skin, get medical help
Hydraulic Pressure immediately.
Hydraulic fluid at system pressure can injure you. INT-3-1-10_3
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2

2 Vent residual hydraulic pressure from the backhoe

hoses by operating the backhoe controls back and
forth several times.

Note: If a hose burst protection valve is fitted on the ram,

the system will not vent. Extreme caution must be used
when releasing hydraulic connections - release the
connections one turn and allow the pressure to dissipate.

3 Label and then remove the dipper ram hoses A. Plug

and cap all open orifices to prevent loss of fluid and
ingress of dirt.

!MWARNING
This component is heavy. It must only be removed or
handled using a suitable lifting method and device.
BF-4-1_1

4 Fasten lifting straps to the dipper ram, make sure that

the weight of the ram is supported by the sling.

5 Remove the pivot pin retaining nut B and bolt C,

remove the pivot pin D.

6 Remove dipper ram.

162 9813/2050-5 162

 Hydraulic Rams
Removal and Replacement

D070930-10
Fig 129. Dipper Ram

163 9813/2050-5 163

 Hydraulic Rams
Removal and Replacement

Boom Ram 8 Fasten lifting straps to the boom ram, make sure that
the weight of the ram is supported by the sling.
Removal
9 Remove the pivot pin retaining nut F and bolt G
K Fig 130. ( T 165). remove the kingpost pivot pin H.

1 Park the machine on firm level ground, engage the 10 Remove the boom ram.
parking brake and set the transmission to neutral.
Lower the backhoe and loader end to the ground and Replacement
stop the engine.
Replacement is a reversal of the removal sequence.
2 Remove pivot pin retaining nut A and bolt B. Remove
the pivot pin C. !MWARNING
3 Remove the grease nipple from the eye end of the Fluid Under Pressure
ram (through access hole D). Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
4 Use the machine hydraulics to SLOWLY retract the pressure and wear protective glasses and gloves.
ram. Hold a piece of cardboard close to suspected leaks
and then inspect the cardboard for signs of fluid. If
5 Remove the hose clamp. fluid penetrates your skin, get medical help
immediately.

!MWARNING INT-3-1-10_3

Hydraulic Pressure It will be necessary to extend the ram to align and engage
Hydraulic fluid at system pressure can injure you. the boom pivot pin C. As the ram extends, the ram will tend
Before connecting or removing any hydraulic hose, to turn.
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service For this reason it is recommended that a smaller diameter
line has been vented before connecting or removing steel bar is used to locate the boom ram at the kingpost
hoses. Make sure the engine cannot be started while casting. The steel bar can be more readily removed to
the hoses are open. allow for re-alignment of the boom pivot pin C.
INT-3-1-11_2
When the boom pivot pin has been correctly aligned and
6 Vent residual hydraulic pressure from the backhoe fitted, then fit the correct pivot pin H at the kingpost.
hoses by operating the backhoe controls back and
forth several times.

Note: If a hose burst protection valve is fitted on the ram,

the system will not vent. Extreme caution must be used
when releasing hydraulic connections - release the
connections one turn and allow the pressure to dissipate.

7 Label and then remove the boom ram hoses E. Plug

and cap all open orifices to prevent loss of fluid and
ingress of dirt.

!MWARNING
This component is heavy. It must only be removed or
handled using a suitable lifting method and device.
BF-4-1_1

164 9813/2050-5 164

 Hydraulic Rams
Removal and Replacement

D070860-19
Fig 130. Boom Ram

165 9813/2050-5 165

 Hydraulic Rams
Removal and Replacement

Slew Ram 11 Lift the slew ram assembly clear of the machine.

Removal Inspection

K Fig 131. ( T 168). Inspect the liner bearings 7 (located in the trunnion
retaining bracket 3) and liner bearing 8 for signs of
1 Slew the backhoe to the left to remove the right hand damage, wear, scores or nicks etc. Replace as required.
slew ram and visa versa.
To remove the liner bearing 8 use a jack located against
2 Lower the bucket to the ground and switch off the blanking plate 9. Shown in the inset at Y.
engine.
To remove the bearing liner 7 from the trunnion bracket use

!MWARNING flat faced bearing pullers.

Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2

3 Vent any residual hydraulic pressure by operating the

backhoe and slew control levers.

4 Disconnect the hydraulic hoses 1 to the slew rams -

before disconnecting the hoses make sure that they
are labelled (to assist with reassembly).

5 Plug and cap all open hydraulic connections to

prevent ingress of dirt and loss of hydraulic fluid.

6 Loosen and remove trunnion bracket retaining nuts 2

and hardened washers 2A (see note).

Note: On assembly, the correct grade of nut (grade 12)

and bolt (grade 10.9) must be used. Also, use hardened
washers 2A - NOT ordinary washers. Using incorrect
specification items could result in a reduction of clamping
efficiency.

7 Remove the trunnion bracket 3.

!MWARNING
This component is heavy. It must only be removed or
handled using a suitable lifting method and device.
BF-4-1_1

8 Attach suitable lifting straps to the slew ram assembly.

Note that the weight of the slew ram assembly is
approximately 44 kg (97 lbs).

9 Remove thin nuts 4 (2 off per pivot pin) and remove

the pivot pin retaining bolt 5. Use a 25 - 30 mm
diameter bar to knock the pin out vertically.

10 Remove the slew ram (eye end) pivot pin 6 and swing
the ram to clear the kingpost casting.

166 9813/2050-5 166

 Hydraulic Rams
Removal and Replacement
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 and gloves.
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_3

Replacement is generally a reversal of the removal

procedures, however note the following:

The liner bearings 7 and 8 have a `lead-in' diameter

(noticeable with a slight step), always install the smaller
diameter first into the pivot bore. The bearings must be
installed so that they sit flush.

The eye end pivot pins 6 should be secured first - i.e.

BEFORE the trunnion bracket retaining nuts 2, this will
help to maximise ram assembly alignment.

Make sure that the hydraulic hoses are correctly installed.

Make sure that any new or reused bearings are clean and
smeared with grease prior to reassembly of pins and
trunnion [Link] fully assembled, apply grease at
each grease nipple BEFORE operating the machine.

Table 53. Torque Settings (Un-plated Fasteners)

Item Nm lbf ft kgf m
2 565 417 57.5

Table 54. Torque Settings (Plated Fasteners)

Item Nm lbf ft kgf m
2 510 376 52

167 9813/2050-5 167

 Hydraulic Rams
Removal and Replacement

Fig 131. Slew Ram

168 9813/2050-5 168

 Hydraulic Rams
Removal and Replacement

Stabiliser Ram (Sideshift) 9 Loosen and remove the stabiliser hoses L, label the
hoses before removing (as an aid to assembly). Plug
Removal all open orifices to prevent loss of fluid and ingress of
dirt.
K Fig 132. ( T 170).
!MWARNING
1 Park the machine on firm level ground, engage the
parking brake and set the transmission to neutral. This component is heavy. It must only be removed or
Lower the backhoe and loader end to the ground. handled using a suitable lifting method and device.
BF-4-1_1
2 Lower the stabiliser legs until the pads are
approximately 4 in. (100 mm) off the ground and stop 10 Using suitable lifting equipment, lift the ram clear.
the engine.
Replacement
3 Remove the bottom locking nut A and bolt B. Drive
out the bottom pivot pin C and allow the stabiliser foot Replacement is a reversal of the removal sequence.
D to fall clear. Lift the inner leg and temporarily refit
the pivot pin C through inner leg and ram. !MWARNING
4 Place a block of wood underneath the stabiliser leg. Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
5 Remove circlips E and drive out top pivot pin F with skin. Keep face and hands well clear of fluid under
spacing collars G. pressure and wear protective glasses and gloves.
Hold a piece of cardboard close to suspected leaks
6 Start the engine and slowly extend the stabiliser ram and then inspect the cardboard for signs of fluid. If
so that the dump end of the ram protrudes from the fluid penetrates your skin, get medical help
top of the outer leg section. immediately.
INT-3-1-10_3
7 Attach suitable lifting gear to the ram as shown at H.
Make sure that the weight of the ram is supported by Use suitable lifting appliances to locate the stabiliser ram.
the sling and remove the bottom pivot pin C.
After replacing or fitting the ram, connect the hydraulic

!MWARNING pipes, make sure that the ram and leg operate freely and
do not foul.
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2

8 Make sure the engine is switched off, vent residual

hydraulic pressure by moving the backhoe and
stabiliser control levers back and forth.

Note: If a check valve is fitted on the ram, the system will

not vent. Extreme caution must be used when releasing
hydraulic connections - release the connections one turn
and allow the pressure to dissipate.

169 9813/2050-5 169

 Hydraulic Rams
Removal and Replacement

D070920-14
Fig 132. Stabiliser Ram (Sideshift)

Priority Valve member, behind the hydraulic tank. It is attached to the

chassis member by one bolt A, and is accessible from
Removal and Replacement below K Fig 133. ( T 171).

The priority valve is mounted on the left hand side chassis There are four connections to the valve as follows

170 9813/2050-5 170

 Hydraulic Rams
Removal and Replacement
For assembly the sequence should be reversed.
P - from hydraulic pump
CF to steering valve When Dismantling
EF to valve block
Press out the spool item 14 using a nylon pin. Take care
LS pilot connection from steering valve
not to damage the bores of the valve.
PP port is plugged
When Assembling
When replacing always renew sealing washers 2, 4, and
10. Make sure that spring seat of spool 14 faces toward LS
connection.

Clean all parts in clean paraffin. Lubricate all parts with

hydraulic fluid. Renew aluminium washers 8 and 12.

Note: All hydraulic adaptors that are installed together with

a bonded sealing washer must also have sealant (Loctite
577)applied to the threads of the adaptor.

Table 55. Torque Settings

Item Nm lbf ft
7 50 37
11 50 37

*To bleed the LS line, start the engine, loosen the

connection on the valve, turn and hold the steering wheel
fully in either direction. When bubble free oil flows from the
joint, tighten the connection.

Fig 133. priority valve

Dismantling and Assembly

The numerical sequence shown on the illustration is

intended as a guide to dismantling.

171 9813/2050-5 171

 Hydraulic Rams
Removal and Replacement

JCB Ram Sealing Procedure

TE-005_2

1 Fit new rod seals.

Use seal fitting tool 134-A to fit rod seals, the size
(diameter) and position of pins 134-B is determined
by the diameter and radial width of the rod seal being
fitted.

153212-1
Fig 136.

b Close the tool. K Fig 137. ( T 172). The seal

must form a reniform (kidney shape).

S216250-1
Fig 134. Seal Fitting Tool

The pins are screwed into threaded holes in the tool

body, the spacing of the holes is designed to suit
small or large diameter rod seals.

a Open the tool and insert the new rod seal 135-A. S161750 Y-1
The seal must be fitted behind the two front pins Fig 137.
but in front of the rear pin as shown.
c Before fitting the rod seals check the seal grooves
are free of contamination and sharp edges.

d Locate the seal in the end cap groove.

K Fig 138. ( T 172). When the seal is in position,
open the tool to release the seal. Make sure the
seal is correctly installed in its grooved and
remove the tool.

S161750 X-1
Fig 135.

Note: Later ram end caps and piston heads are metric
threads. The seals are also different, make sure the
correct seals are fitted. On metric threaded rams make
sure the seals are fitted the correct way round, as shown
at 136-A and 136-B.

S161750 Z-1
Fig 138.

e Fit rod wiper seal 136-A into seal groove. Make

sure the seal is correctly installed as shown.

172 9813/2050-5 172

 Hydraulic Rams
Removal and Replacement
Note: Some rod wipers, i.e. power track rod, may use a b Fit outer seal 140-C using the same procedure as
metal encased seal which is pressed into the housing. stated for seal 140-B. Check the external grooves
Care must be taken to ensure the seal is square before it are visible.
is pressed in.
c Ensure the O-ring is fitted into the internal seal
f Sleeve 139-A must be used to protect the rod groove on the piston head. Screw the piston head
seals from damage when fitting end cap onto the onto the thread of the piston rod, refer to the
piston rod. There are various sizes of sleeve, see relevant section for torque figure and completion
Service Tools, Section 1. Make sure the of ram assembly.
hexagon on the end cap is towards the eye end of
the rod. d Fit the piston head retaining dowel, refer to the
relevant section for torque figure and completion
of ram assembly.

e Fit wear rings 141-A and 141-B. Rotate the wear

rings so that the piston retention dowel is covered
by the wear ring, Not as shown at 141-C.

187361-1
Fig 139.

2 Fit new head piston seals.

a Use a blunt instrument 140-A (Part no. 892/

01027) to lever the inner seal 140-B into the
piston head seal groove. Do not let the seal twist.
There are identification marks on the outer
diameter of the seal, make sure the marks are
visible and the seal is free to rotate, if not remove
the seal and refit. 338490-1
Fig 141.

3 Fit the piston rod and head assembly into the cylinder.

a Insert the piston/rod assembly into the cylinder.

Align the rod and head assembly until parallel with
the cylinder then push the assembly into the
cylinder.

b Fit the end cap, refer to the relevant section for

torque figure and completion of ram assembly.

338480-1
Fig 140.

173 9813/2050-5 173

 Hydraulic Rams
Assembly and Disassembly

Assembly and Disassembly

Typical Ram
The procedures described below are applicable for the
following rams:

– Loader Shovel Ram

– Loader Lift Ram
– Bucket Crowd Ram
– Boom Ram
– Dipper Ram

Disassembly

The numerical sequence shown on the illustration is

intended as a guide to dismantling.
D070910-02
Fig 143.
For assembly the sequence should be reversed.
5 Rotate and pull the piston rod B from the tube.
!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

1 Clean the cylinder using good clean cloth. Ensure

that dirt does not go inside through ports.

D070910-03
2 Hold the cylinder on a Bench vise firmly with proper
Fig 144.
support by using rexin on the outer surface to prevent
any damage on the outer tube.
6 Place the piston rod on a V-block.
3 Remove seal from the head end cover.

D070910-04
Fig 145.

7 Insert a pipe in the rod end C. K Fig 145. ( T 174).

D070910-01
Fig 142.
8 Remove the snap ring D and the grub screw E.
4 Open the head end cover A. K Fig 146. ( T 175).

174 9813/2050-5 174

 Hydraulic Rams
Assembly and Disassembly

D070910-05
Fig 146. D070910-08
Fig 148.
9 Remove the piston bearing G.
11 Remove the piston nut J.

D070910-06
Fig 149.

12 Remove and disassemble the piston K.

D070910-07
Fig 147.

10 Open the grub screw H.

D070910-13
Fig 150.

175 9813/2050-5 175

 Hydraulic Rams
Assembly and Disassembly
13 Remove the head end cover. 16 Remove the piston seal P.

14 Use a bent screwdriver to remove the wiper seal L

and the secondary rod seal M.

D070910-11
Fig 153.

17 Remove the piston O-ring Q and the piston back up

ring R.

D070910-09
Fig 151.

15 Remove the piston bearing N.

D070910-12
Fig 154.

18 Examine all the components and seals for damage.

D070910-10
Fig 152.

176 9813/2050-5 176

 Hydraulic Rams
Assembly and Disassembly
Assembly

Clean all the components with Use JCB Cleaner and

Degreaser to ensure that all threads are free from grease,
hydraulic oil and sealant.

Make sure that lubricants used during assembly do not

come into contact with the JCB Threadlocker and Sealer
(High Strength).

For the correct method of fitting seals to the end cap and
piston head refer K JCB Ram Sealing
Procedure ( T 172).

1 Put the primary rod seal B in the head end cover A.

D070910-15
Fig 156.

3 Put the secondary rod seal D and the wiper seal E.

D070910-14
Fig 155.

2 Put the rod seal guide ring C in the head end cover.
K Fig 156. ( T 177).

D070910-16
Fig 157.

4 Put the piston O-rings F onto the piston.

177 9813/2050-5 177

 Hydraulic Rams
Assembly and Disassembly

D070910-19
Fig 160.

8 Clean the piston rod K.

D070910-17
Fig 158.

5 Put the piston seal G onto the piston.

D070910-20
Fig 161.

9 Install the retainer L.

D070910-21
Fig 162.

10 Put the head end cover on the piston rod A.

D070910-18 K Fig 163. ( T 179).
Fig 159.

6 Make sure screw driver does not have sharp edges.

7 Put the piston O-ring H and the back ring J inside the
piston head.

178 9813/2050-5 178

 Hydraulic Rams
Assembly and Disassembly

D070910-22
Fig 163.
D070910-25
Fig 166.
11 Lightly tap the head end cover with a rubber mallet to
install the cover. 15 Tighten the grub screw P and seal the joint.

12 Install the piston M.

D070910-23
Fig 164. D070910-26
Fig 167.
13 Tighten the nylon nut N to the correct torque value.
Refer to the torque table K Table 56. ( T 180). 16 Tighten the grub screw Q and assemble the snap ring
R.

D070910-24 D070910-27

Fig 165. Fig 168.

14 Tighten the piston M. 17 Install the piston bearing S and apply oil on the tube
assembly. K Fig 169. ( T 180).

179 9813/2050-5 179

 Hydraulic Rams
Assembly and Disassembly

D070910-28
Fig 169.

18 Install the piston rod assembly into the tube.

D070910-31
Fig 172.

Table 56. Torque Table

Ram Nm Kgfm
Loader Shovel 412-461 42-47
D070910-29 Ram
Fig 170.
Loader Lift Ram 539-588 55-60
19 Tighten the head end cover A. Bucket Crowd 1078-1176 110-120
Ram
Boom Ram 1765-1961 180-200
Dipper Ram 1667-1863 170-190

Performance Check

1 Pull the piston rod and push it back to check the

smoothness of assembly.

D070910-30
2 Mount the cylinder on the equipment and operate at
Fig 171. low speed, check for any leakage.

20 Seal the head end cover. 3 Ensure that air is not trapped in the cylinder by
operating the cylinder at low speed for 2 minutes.

180 9813/2050-5 180

 Hydraulic Rams
Assembly and Disassembly

Slew Ram
Disassembly

The numerical sequence shown on the illustration is

intended as a guide to dismantling.

1 Clean the cylinder with a clean cloth.

2 Position the cylinder in a bench vice. Use a soft jaws

to prevent any damage on the outer tube.

D070910-34
Fig 175.

5 Remove the port cap 23.

D070910-32
Fig 173.

3 Mark a straight line on trunnion and tube for assembly

aid.

D070910-35
Fig 176.

6 Remove the plunger 7 before removing the trunnion.

D070910-33
Fig 174.

4 Remove the hex socket set screw 10.

D070910-36
Fig 177.

181 9813/2050-5 181

 Hydraulic Rams
Assembly and Disassembly
7 Loosen the trunnion 4 in counterclockwise direction 10 Remove the grub screw 11.
with a rubber mallet or a nylon rod and hammer.

D070910-40
Fig 181.
D070910-37
Fig 178. 11 Mark a straight line on the piston and the piston rod
for assembly aid.
8 Remove the trunnion 4 along with the piston rod
assembly 3 from the tube.

D070910-38
Fig 179.
D070910-41
9 Put the piston rod assembly on clean bench and Fig 182.
remove the piston bearing strip 14.
12 Hold the rod eye and loosen the piston.

D070910-42
Fig 183.
D070910-39
Fig 180.
13 Remove the piston 2 from the piston rod 3.

182 9813/2050-5 182

 Hydraulic Rams
Assembly and Disassembly
16 Remove the trunnion O-ring 19 and back up ring 20
with a bend screw driver.

D070910-46
Fig 187.

D070910-43 17 Remove the metal gland wiper 22.

Fig 184.

14 Remove the piston rod 3 from the trunnion 4.

D070910-47
Fig 188.
D070910-44
Fig 185. 18 Remove the piston bearing strip 14.

15 Remove the snap ring 13 of metal gland wiper and

rod seal 21 with a bend screw driver.

D070910-45
Fig 186.

183 9813/2050-5 183

 Hydraulic Rams
Assembly and Disassembly
Assembly

1 Assemble the rod seal 21.

D070910-48
Fig 189.

19 Remove the piston seal 15. K Fig 190. ( T 184).

Fig 192.

2 Put the trunnion O-ring 19 and the back ring 20.

D070910-49
Fig 190. D070910-53
Fig 193.
20 Remove the piston O-ring 16.
3 Put the metal guard 22 and the snap ring 13.

D070910-54
Fig 194.

4 Make sure that the wiper and lips face against

pressure side.

D070910-50
Fig 191.

21 Examine all the components and seals for damage.

184 9813/2050-5 184

 Hydraulic Rams
Assembly and Disassembly

D070910-56
Fig 197.
D070910-51
Fig 195. 7 Apply petroleum jelly on the head end cover or the
trunnion O-ring and install the piston rod assembly 3
5 Install the O-ring 16 in the piston grove. into the trunnion 4.
K Fig 196. ( T 185).

D070910-55
Fig 196.

6 Install the piston seal 15 on the O-ring.

D070910-57
Fig 198.

8 Install the piston 2 on piston rod assembly 3.

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 Hydraulic Rams
Assembly and Disassembly

D070910-58
Fig 199.

9 Make sure that the cushion ring is in the centre.

K Fig 200. ( T 186). D070910-60
Fig 201.

11 Put the bearing strips 14 in grove of piston.

D070910-59
Fig 200.

10 Install the set screw 11 in the grove and seal the joint.
D070910-61
Fig 202.

12 The two piston bearing strips slot is in the opposite

direction.

186 9813/2050-5 186

 Hydraulic Rams
Assembly and Disassembly

D070910-62 D070910-64
Fig 203. Fig 205.

13 Apply hydraulic oil inside the tube 1 and install the 15 Tighten the head end cover or the trunnion and align
piston rod assembly 3 inside the tube. with the mark.

D070910-63 D070910-65
Fig 204. Fig 206.

14 Install the the head end cover or trunnion 4 on tube 1. 16 Install and seal the hex set screw 10.

187 9813/2050-5 187

 Hydraulic Rams
Assembly and Disassembly

D070910-66
Fig 207.

17 Install the port cap 23 and the plunger 7.

D070910-67
Fig 208.

188 9813/2050-5 188

189

8
7
23
4
10 22 13
21
19
20 12
14
15
14 16
11
2 18
5
9813/2050-5

17

Assembly and Disassembly

Hydraulic Rams
9
D070910-68
Fig 209.
189
 Hydraulic Rams
Assembly and Disassembly

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190 9813/2050-5 190

 Section E - Hydraulics

Fault Finding
Introduction

The purpose of this section is to help you trace hydraulic

faults to a faulty unit (valve, actuator, ram etc). Once you
have traced the faulty unit, refer to the appropriate
dismantling, inspecting and test instructions given
elsewhere in the hydraulics section.

To help identify circuits, valves, rams etc. mentioned in the

fault finding procedures, refer to the hydraulic schematic
diagrams (near the beginning of the Hydraulics Section).

1 Before you begin fault finding, read the Safety

information at the beginning of this manual.

2 Make simple checks before say, stripping a major

component.

3 Make sure that the hydraulic fluid is at correct working

temperature (50 0C, 122 0F).

4 What ever the fault, check the condition of the

hydraulic fluid. Drain and replace if necessary.

5 Make any relevant electrical checks before moving on

to the hydraulics.

6 Be sure to remove. ALL contamination and if possible

identify its origin. It may be part of a component from
elsewhere in the circuit Replace any seals such as '0'
rings before reassembling hydraulic components.

7 Replace any seals such as 'O' rings before

reassembling hydraulic components.

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 Section E - Hydraulics
Fault Finding
Introduction
Table 57.
Fault Probable Cause Action
Lack of power in all hydraulic functions. Insufficient hydraulic fluid. Check for leaks and top up as required.
Hydraulic leaks in system. Check hoses, replace as required.
Engine performance. Check engine performance, see
transmission section for stall speed
test procedures.
Main relief valve (MRV) setting Check and adjust as required.
incorrect.
Low pump flow. Check pump flow, if required service or
replace pump.
Hydraulic tank breather. Clean or replace the breather.
Tank filter by-pass valve. Check condition of hydraulic filter.
Unloader valve pressure setting too Check pressure setting of the unloader
high. valve.

Table 58.
Fault Probable Cause Action
All hydraulic rams slow to operate. Neutral circuit or low pressure lines Check pipe lines and replace as required.
leaking, damaged, trapped or kinked.
Low pump flow. Check pump flow, if required service or
replace pump.
Main Relief Valve (MRV) setting Check and adjust as required.
incorrect.
Unloader valve. Check if unloader valve is sticking, i.e.
dumping flow from pump section P2.
Tank filter by-pass valve. Check condition of hydraulic filter.
Hydraulic tank Breather. Clean or replace the breather.

Table 59.
Fault Probable Cause Action
One hydraulic service fails to operate Associated service pipe lines leaking, Check hoses, replace as required.
or is slow to operate. damaged, trapped or kinked.
Associated ram leaking. Complete ram leakage check, replace
seals as required.
Auxiliary relief valve (ARV) setting Check and adjust as required.
incorrect.
Associated valve block section leaking Check for leaks, rectify as required.
or not operating See also `Leaking Oil Seal (Control
Valves)'.
Check that the control lever and
associated linkage is operating the
spool, rectify as required. See also `A
Spool is Sticking'.

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 Section E - Hydraulics
Fault Finding
Introduction

Fault Probable Cause Action

Check valve malfunctioning (if fitted), Test check valve, rectify as required.
e.g. stabiliser circuit.
Hose burst protection valve Test HBPV, service as required.
malfunctioning (if fitted).
Piston rod is bent. Replace piston rod, check pressure
settings of MRV and ARV.
Check that associated pivot points are
adequately greased.

Table 60.
Fault Probable Cause Action
The engine tends to stall when M.R.V setting incorrect. Check and adjust as required.
hydraulics are under load.
Poor engine performance. Check engine performance, see
transmission section for stall speed
test procedure.
Unloader valve pressure setting too Check pressure setting of the unloader
high. valve.

Table 61.
Fault Probable Cause Action
A spool is sticking. Oil temperature abnormally high. Check for correct fluid, see lubricants
and capacities. Check oil cooler and
grille for blockage.
The hydraulic fluid is dirty. Clean the tank strainer. If strainer badly
clogged, drain and flush hydraulic
system. Fill with clean hydraulic fluid.
The service pipe connection is over Check tightening torque.
tightened.
The valve housing was twisted during Loosen retaining bolts and tighten to
installation. correct torque figures.
A control linkage is bent. Disconnect the linkage. Repair the
linkage if possible, or fit a new one.
A spool is bent. Dismantle the control valve. Renew
spool as necessary.
A return spring is broken. Renew as necessary.
A return spring or cap is out of Remove the cap, check that the spring
alignment. is in the correct position. Refit cap and
torque tighten bolts.
Temperature distribution within control Warm the entire system up before
valve not uniform. servicing.

E-193 9813/2050-5 E-193

 Section E - Hydraulics
Fault Finding
Introduction
Table 62.
Fault Probable Cause Action
Leaking Oil Seal (Control Valves) Paint or dirt on the seal face. Remove the seal and clean.
The back pressure in the valve circuit Check circuit pressures, adjust if
is excessively high. possible. Otherwise investigate
thoroughly.
Spool damaged. Dismantle. Inspect all parts. Renovate
or renew as necessary.
The seal is not secured. Clean the seal and tighten the retaining
bolts to the correct torque.
The seal is cut or damaged. Fit a new seal.

Table 63.
Fault Probable Cause Action
Ram creep Associated ram or pipe lines from ram Check and rectify as required.
leaking.
Check valve malfunctioning (if fitted), Test check valve, rectify as required.
e.g. stabiliser circuit.
Associated valve section spools Rectify, check for contamination.
leaking.
Associated ARV leaking. Rectify, check for contamination.

Table 64.
Fault Probable Cause Action
Hydraulic oil becomes too hot. Oil cooler obstructed. Remove debris from cooler fins.
Restriction in neutral circuit lines. Check hoses, replace as necessary.
Hydraulic filter clogged and by-pass Change hydraulic filter.
valve not working.

Table 65.
Fault Probable Cause Action
Steering fails to operate or stiff to Tyres not inflated to correct Pressure. Inflate tyres to correct Pressure.
operate.
Insufficient hydraulic fluid. Check for leaks and top up as required.
Low pump flow. Check pump flow, if required service or
replace pump.
Leak in the relevant hoses or Check hoses and for connection for
component connection. leaks.
Steer relief valve set incorrectly. Check pressure setting of steer unit
relief valve, adjust as required.

Table 66.
Fault Probable Cause Action
Steering fails to operate or stiff Priority valve not operating Check if the priority valve is sticking, rectify as
to operate (Cont.). correctly. required.

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 Section E - Hydraulics
Fault Finding
Introduction

Fault Probable Cause Action

Check the load sense line from the steer unit to
the priority valve for signs for leaking or poor
connection.
Steer mode valve not operating Check if the spool is sticking, rectify as required.
correctly.
Mechanical failure. Check for damaged axle components, such as
ram, track rods,linkages etc.
Check for damaged axle components, such as
ram, trackrods, linkages etc.
Check for damaged steer unit components.
Steering column and associated components
not set correctly.

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 Section E - Hydraulics
Fault Finding
Introduction

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E-196 9813/2050-5 E-196