Section E - Hydraulics

Operation
Excavator Valve

Slew A.R.V. and Anti-Cavitation Operation

C072200
Fig 14.

The spool 4A is in neutral but the momentum of the

slewing excavator end creates back pressure in the right
hand slew cylinder. This opens A.R.V. 4J and dumps oil to
exhaust. At this point the left hand slew cylinder cavitates
and exhaust oil pressure causes A.R.V. 4K to open,
allowing oil from the exhaust gallery to fill the left hand
cylinder.

E-25 9803/9960-1 E-25

E-26
9803/9960-1
C072210
Fig 15.

The illustration shows the bucket spool 4F selected to
operate the service against an immovable object.
Fig 15. ( E-26) This forces the dipper away from
the obstruction and pressurises the head side of the
dipper ram.
When this pressure reaches the setting of A.R.V. 4P,
this valve opens, relieving the pressure into the
exhaust gallery. Cavitation occurs in the rod side of
the dipper service. A.R.V. Pressure Relief
Operation ( E-27)

E-26
Operation
Section E - Hydraulics

Excavator Valve

A.R.V. Pressure Relief Operation
Fig 16.
1 Valve at Rest
A.R.V's are positioned in the excavator valve block in order
to relieve excessive pressure in the services. A.R.V.
Operation ( E-26)
When the service is in neutral and there are no excessive
forces acting on the equipment, service pressure at A will
be acting on the lower face of poppet B and will also be felt
inside the valve via hollow piston C.
The force of springs D and F, combined with the service
pressure acting on the upper faces of poppet B and piston
C, keeps poppets B and E tightly seated. The force of
spring F is adjustable to suit the relevant service by means
of adjuster screw and locknut G.
E-27 9803/9960-1
Section E - Hydraulics
Operation
Excavator Valve
C072220
2 Pilot Valve Opens
As service pressure reaches the pilot setting of the valve,
pilot poppet E lifts, allowing oil to escape into cavity H and
pass down the sides of sleeve J into the exhaust gallery K.
3 Main Poppet Opens
As service pressure continues to rise and oil escapes from
cavity L, the pressure differential between the upper and
lower surfaces of piston C causes this piston to rise and
seat on the point of pilot poppet E.
Oil continues to escape from cavity L but the incoming flow
to the cavity has been cut off. This produces a pressure
drop above poppet B, causing the poppet to lift and release
service pressure into exhaust gallery K.
E-27
 Section E - Hydraulics
Operation
Pressure Reducing Solenoid Valve

Pressure Reducing Solenoid Valve

A204763-B1
Fig 17.

From machine no. 751600 power via the loader joystick as before, but also
pressurising the brake circuit B (brakes OFF).
This valve supplies hydraulic oil at reduced pressure to
If the seat is rotated to face the rear of the machine, seat
operate the loader joystick and the automatic parking
switch 14 opens, de-energising relay 12. Both solenoids 9
brake. It is controlled by the seat position switch, the
and 10 de-energise, and the solenoid valve returns to
override switch and the park brake switch. It contains a
position X. In this condition, pressure from the auxiliary
reducing valve cartridge and a 3 position, 3 port cartridge
pump is dumped to tank (brakes ON and no hydraulic
solenoid valve. The relevant sections of the circuits are
pressure available at the loader joystick).
shown on the illustrations. Hydraulic Fig 17. ( E-28).
Electrical Fig 18. ( E-29)
When the override switch 11 is closed, the seat switch 14
is by-passed allowing the loader to be used with the seat
When first entering the machine, assuming the starter
facing rearwards.
switch is OFF, there is no hydraulic pressure as the
auxiliary pump is not running and the solenoid valve is in
position X as there is no electrical supply.

If the parking brake is ON (switch 7 in the position shown)

and the seat facing forward (seat switch 14 closed),
starting the engine energises the isolation relay 12 and
solenoid 9, moving the solenoid valve to position Y. In this
position the valve directs hydraulic power via the loader
joystick A to the loader valve and other circuits, but the
brake pressure is still dumped to tank T.

Operation of the parking brake switch 7 de-energises

solenoid 9 and energises solenoid 10. This causes the
solenoid valve to move to position Z, directing hydraulic

E-28 9803/9960-1 E-28

 Section E - Hydraulics
Operation
Pressure Reducing Solenoid Valve

Key to Electrical Schematic

7 Parking Brake switch
8 Parking Brake Solenoid
9 Operation Solenoid
10 Parking Brake Solenoid
11 Override Switch
12 Isolation Relay
14 Seat Switch

A204763-B2
Fig 18.

E-29 9803/9960-1 E-29

 Section E - Hydraulics
Operation
Drive Motor

Drive Motor

S167740
Fig 19.

Table 1. Component Key ( E-31)

E-30 9803/9960-1 E-30

 Section E - Hydraulics
Operation
Drive Motor
Table 1. Component Key When the motors are in reverse mode there is higher
A Output Shaft pressure in the B port and also through the orifice, so the
flow rate is higher in this mode.
B Brake Pack
C Cardan Shaft It is important, when checking the flushing circuit flow, to
D Gearwheel Set take the measurement in forward drive only.
E Valve Drive

Note: On the illustration the main parts of the motor are

shown slightly separated for purposes of explanation.
Fig 19. ( E-30)

Basically, this type of motor comprises a gearwheel set D

which is connected by a valve drive E to a disc valve F.

The gearwheel set consists of a toothed internal gear (the

rotating part) and a fixed external gear rim whose 'teeth'
are formed by rollers. The internal gear is free to rotate in
a circular orbit within the gear rim.

The disc valve is arranged to create a series of inlets and

outlets which, as the gear rotates, always align precisely
with the chambers formed between the internal gear teeth
and the gear rim rollers.
423040-B1

Oil under pressure passes through the disc valve inlets to Fig 20.
the inter-tooth chambers on one side of the gearwheel set.
These chambers are so shaped that the oil pressure within
them creates an imbalance of forces which causes the
internal gear to rotate. As the gear rotates the oil in the
chambers is progressively connected to the disc valve
outlets, from where it returns to tank.

A cardan shaft C connects the inner gear to the output

shaft A.

Brake pack B comprises a series of alternate friction plates

and brake pads. The brake is normally held 'on' by spring
force and released by hydraulic pressure.

From machine no. 751818, a different type motor is fitted

which has a flushing circuit. Fig 20. ( E-31) This is
used to cool the motors during operation.

To save efficiency losses the flushing is taken off through

an orifice on the low pressure side of the motor circuit.

Although the motors operate in both forward and reverse

they are expected to operate in the forward direction for
90% of the time so the flushing is taken off the return line
(port B when in forward). This is the normal flushing rate.

E-31 9803/9960-1 E-31

 Transmission in Neutral

E-32
9803/9960-1
A242320
Fig 21.
Key valve 4 and filter F1 to main pumps P1 and P2. A small
Key
amount of oil flows through the charge valve Pa,
C Cooler Pd Pressure Relief Valve enters the pump casing and is returned via line z to
F1 Filter Pe Pressure Relief Valve tank T.
P1 Main Pump M1 Left Hand Drive Motor
Oil is also fed from pump P3 to the transmission servo
P2 Main Pump M2 Right Hand Drive Motor joystick 8 but, because the joystick is not operated,
P3 Auxiliary Gear Pump S1 Suction Strainer the oil is blocked by the spools 8a, 8b, 8c and 8d and
therefore no servo pressure is applied to operate the
Pa Charge Valve swash plates of pumps P1 and P2.
Pb Pressure Relief Valve
With the engine running but no drive selected, oil from
Pc Pressure Relief Valve pump P3 is fed through the loader valve 2, excavator

E-32
Operation
Transmission in Neutral
Section E - Hydraulics
 Section E - Hydraulics
Operation
Transmission in Neutral
As the pump swash plates are spring loaded to the neutral
position there is no delivery from either pump and the
machine remains stationary.

The motor brakes x and y are released whenever the

engine is running by oil fed through the pressure reducing
valve 9. However the machine is prevented from moving
by oil locked up in the pump/motor circuit.

E-33 9803/9960-1 E-33

 Transmission in Forward Drive

E-34
9803/9960-1
Fig 22.
Key Key Key
C Cooler Pd Pressure Relief Valve 2Y Pressure Test Point
F1 Filter Pe Pressure Relief Valve 3 Check Valve (5 bar)
P1 Main Pump M1 Left Hand Drive Motor 4 Excavator Valve
P2 Main Pump M2 Right Hand Drive Motor 8 Drive Control Joystick
P3 Auxiliary Gear Pump S1 Suction Strainer 8a Joystick Control Spool
Pa Charge Valve 8b Joystick Control Spool
Pb Pressure Relief Valve 2 Loader Valve 8c Joystick Control Spool
Pc Pressure Relief Valve 2X Pressure Test Point 8d Joystick Control Spool

E-34
Transmission in Forward Drive
Operation
Section E - Hydraulics
 Section E - Hydraulics
Operation
Transmission in Forward Drive

Key
8e Shuttle Valves
9 Pressure Reducing Solenoid Valve
11 Filter By-pass Valve

When the joystick 8 is moved to select forward drive spool

8b is operated allowing oil from pump P3 to pass via
shuttle valves 8e to the swash plate servos on pumps P1
and P2. The swash plates are tilted causing flow to pass to
the motors M1 and M2 and the machine moves forward.

Return oil from the motors flows back into the main pumps.
Any excess oil from the pump casing is fed back to tank via
cooler C.

Shuttle valves 8e prevent servo pressure from being fed

into other servo circuits.

E-35 9803/9960-1 E-35

 Schematic Circuits

E-36
Standard Machines - Single Lever Drive Control

From Machine no. 751012 to 752462 2Z Pressure Test Point (Brake Pressure) & 8A Reverse Spool
Hand Pump Connector (Manual Brake 8B Left Turn Spool
Fig 23. ( E-37) Release)
8C Forward Spool
3 Check Valve (8 bar)
Table 2. Component Key 8D Right Turn Spool
C Cooler 4 Excavator Valve Block
9 Pressure Reducing Solenoid Valve
F1 Filter 4A Slew Spool
10 Check Valve (2 bar)
P1 Main Pump (Run in Tandem with P2) 4B Boom Spool
11 Filter By-pass Valve (3 bar)
P2 Main Pump (Run in Tandem with P1) 4C Stabiliser Spool
12 Auxiliary Feeds
P3 Auxiliary Gear Pump 4D Stabiliser Spool
30
M1 Left Hand Drive Motor 4E Dipper Spool
32 Stabiliser Ram
M2 Right Hand Drive Motor 4F Bucket Spool
33 Stabiliser Ram
S1 Suction Strainer 4G Auxiliary Spool
34 Slew Ram
T Tank 4H
35 Slew Ram

9803/9960-1
1 Loader Joystick 4J Slew ARV
36 Boom Ram
2 Loader Valve Block 4K Slew ARV
37 Dipper Ram
2A Crowd Spool 4L Boom Ram Head Side ARV
38 Bucket Ram
2B Lift Spool 4M Boom Ram Rod Side ARV
50 Bi-restrictor
2C Auxiliary Spool 4N Dipper Ram Rod Side ARV
51 Bi-restrictor
2D Main Relief Valve (MRV) 4P Dipper Ram Head Side ARV
52 One-way Restrictor
2E Crowd Ram Rod Side ARV 4Q Bucket Ram Rod Side ARV

2F Crowd Ram Head Side ARV 4R Bucket Ram Head Side ARV Note: Excavator services shown here are to the JCB
4S Auxiliary ARV 'X' control pattern. For ISO '+' control pattern,
2G Lift Ram Head Side ARV components 36 and 37 are swapped over.
2H Auxiliary ARV 4T Auxiliary ARV

2J Auxiliary ARV 5

2X Pressure Test Point (Main Relief Valve) 6 Manually Operated Dump Valve

2Y Pressure Test Point (Transmission 7 Lift Rams

Charge Pressure) 8 Drive Control Joystick
Standard Machines - Single Lever Drive Control

E-36
Schematic Circuits
Section E - Hydraulics
E-37
9803/9960-1
A243002A
Fig 23. Standard Machines - Single Lever Drive Control From Machine no. 751012 to 752462

Table 2. Component Key ( E-36)

Standard Machines - Single Lever Drive Control

E-37
Schematic Circuits
Section E - Hydraulics
 From Machine no. 752463 4B Boom Spool 34 Slew Ram

E-38
4C Stabiliser Spool 35 Slew Ram
Fig 24. ( E-39)
4D Stabiliser Spool 36 Boom Ram
Table 3. Component Key 4E Dipper Spool 37 Dipper Ram
C Cooler 4F Bucket Spool 38 Bucket Ram
F1 Filter 4G Auxiliary Spool 50 Bi-restrictor
P1 Main Pump (Run in Tandem with P2) 4H 51 Bi-restrictor
P2 Main Pump (Run in Tandem with P1) 4J Slew ARV 52 One-way Restrictor (1)
P3 Auxiliary Gear Pump 4K Slew ARV X Return line fitted from machine no.
M1 Left Hand Drive Motor 4L Boom Ram Head Side ARV 807226
M2 Right Hand Drive Motor 4M Boom Ram Rod Side ARV
S1 Suction Strainer (1) On machines fitted with a Husco Loader Valve,
4N Dipper Ram Rod Side ARV Oneway Restrictor 52 is deleted. On these
T Tank 4P Dipper Ram Head Side ARV machines a restrictor is incorporated in the
1 Loader Joystick Valve Block.
4Q Bucket Ram Rod Side ARV
2 Loader Valve Block 4R Bucket Ram Head Side ARV Note: Excavator services shown here are to the JCB
2A Crowd Spool 4S Auxiliary ARV 'X' control pattern. For ISO '+' control pattern,
2B Lift Spool components 36 and 37 are swapped over.
4T Auxiliary ARV

9803/9960-1
2C Auxiliary Spool 5
2D Main Relief Valve (MRV) 6 Manually Operated Dump Valve
2E Crowd Ram Rod Side ARV 7 Lift Rams
2F Crowd Ram Head Side ARV 8 Drive Control Joystick
2G Lift Ram Head Side ARV 8A Reverse Spool
2H Auxiliary ARV 8B Left Turn Spool
2J Auxiliary ARV 8C Forward Spool
2X Pressure Test Point (Main Relief Valve) 8D Right Turn Spool
2Y Pressure Test Point (Transmission 9 Brake Valve
Charge Pressure)
10 Check Valve (2 bar)
2Z Pressure Test Point (Brake Pressure) &
Hand Pump Connector (Manual Brake 11 Filter By-pass Valve (3 bar)
Release) 12 Auxiliary Feeds
3 Check Valve (8 bar) 30
4 Excavator Valve Block 32 Stabiliser Ram
4A Slew Spool 33 Stabiliser Ram
Standard Machines - Single Lever Drive Control

E-38
Schematic Circuits
Section E - Hydraulics
E-39
9803/9960-1
316741
Fig 24. Standard Machines - Single Lever Drive Control From Machine no. 752463

Table 3. Component Key ( E-38)

Standard Machines - Single Lever Drive Control

E-39
Schematic Circuits
Section E - Hydraulics
 Standard Machines - Dual Lever Drive Control

E-40
From Machine no. 751012 to 752462 3 Check Valve (8 bar) 32 Stabiliser Ram
4 Excavator Valve Block 33 Stabiliser Ram
Fig 25. ( E-41)
4A Slew Spool 34 Slew Ram
Table 4. Component Key 4B Boom Spool 35 Slew Ram
C Cooler 4C Stabiliser Spool 36 Boom Ram
F1 Filter 4D Stabiliser Spool 37 Dipper Ram
P1 Main Pump (Run in Tandem with P2) 4E Dipper Spool 38 Bucket Ram
P2 Main Pump (Run in Tandem with P1) 4F Bucket Spool 50 Bi-restrictor
P3 Auxiliary Gear Pump 4G Auxiliary Spool 51 Bi-restrictor
M1 Left Hand Drive Motor 4H 52 One-way Restrictor
M2 Right Hand Drive Motor 4J Slew ARV
S1 Suction Strainer Note: Excavator services shown here are to the JCB
4K Slew ARV 'X' control pattern. For ISO '+' control pattern,
T Tank 4L Boom Ram Head Side ARV components 36 and 37 are swapped over.
1 Left Hand Joystick 4M Boom Ram Rod Side ARV
2 Loader Valve Block 4N Dipper Ram Rod Side ARV

9803/9960-1
2A Crowd Spool 4P Dipper Ram Head Side ARV
2B Lift Spool 4Q Bucket Ram Rod Side ARV
2C Auxiliary Spool 4R Bucket Ram Head Side ARV
2D Main Relief Valve (MRV) 4S Auxiliary ARV
2E Crowd Ram Rod Side ARV 4T Auxiliary ARV
2F Crowd Ram Head Side ARV 5
2G Lift Ram Head Side ARV 6 Manually Operated Dump Valve
2H Auxiliary ARV 7 Lift Rams
2J Auxiliary ARV 8 Right Hand Joystick
2X Pressure Test Point (Main Relief Valve) 9 Pressure Reducing Solenoid Valve
2Y Pressure Test Point (Transmission 10 Check Valve (2 bar)
Charge Pressure)
11 Filter By-pass Valve (3 bar)
2Z Pressure Test Point (Brake Pressure) &
Hand Pump Connector (Manual Brake 12 Auxiliary Feeds
Release) 30
Standard Machines - Dual Lever Drive Control

E-40
Schematic Circuits
Section E - Hydraulics
E-41
9803/9960-1
A243003A
Fig 25. Standard Machines - Dual Lever Drive Control From Machine no. 751012 to 752462

Table 4. Component Key ( E-40)

Standard Machines - Dual Lever Drive Control

E-41
Schematic Circuits
Section E - Hydraulics
 From Machine no. 752463 4B Boom Spool 38 Bucket Ram

E-42
4C Stabiliser Spool 50 Bi-restrictor
Fig 26. ( E-43)
4D Stabiliser Spool 51 Bi-restrictor
Table 5. Component Key 4E Dipper Spool 52 One-way Restrictor (1)
C Cooler 4F Bucket Spool X Return line fitted from machine no.
F1 Filter 4G Auxiliary Spool 807226
P1 Main Pump (Run in Tandem with P2) 4H
P2 Main Pump (Run in Tandem with P1) (1) On machines fitted with a Husco Loader Valve,
4J Slew ARV Oneway Restrictor 52 is deleted. On these
P3 Auxiliary Gear Pump 4K Slew ARV machines a restrictor is incorporated in the
M1 Left Hand Drive Motor Valve Block.
4L Boom Ram Head Side ARV
M2 Right Hand Drive Motor 4M Boom Ram Rod Side ARV Note: Excavator services shown here are to the JCB
S1 Suction Strainer 4N Dipper Ram Rod Side ARV 'X' control pattern. For ISO '+' control pattern,
T Tank components 36 and 37 are swapped over.
4P Dipper Ram Head Side ARV
1 Left Hand Joystick 4Q Bucket Ram Rod Side ARV
2 Loader Valve Block 4R Bucket Ram Head Side ARV
2A Crowd Spool 4S Auxiliary ARV
2B Lift Spool 4T Auxiliary ARV

9803/9960-1
2C Auxiliary Spool 5
2D Main Relief Valve (MRV) 6 Manually Operated Dump Valve
2E Crowd Ram Rod Side ARV 7 Lift Rams
2F Crowd Ram Head Side ARV 8 Right Hand Joystick
2G Lift Ram Head Side ARV 9 Brake Valve
2H Auxiliary ARV 10 Check Valve (2 bar)
2J Auxiliary ARV 11 Filter By-pass Valve (3 bar)
2X Pressure Test Point (Main Relief Valve) 12 Auxiliary Feeds
2Y Pressure Test Point (Transmission 30
Charge Pressure)
32 Stabiliser Ram
2Z Pressure Test Point (Brake Pressure) &
Hand Pump Connector (Manual Brake 33 Stabiliser Ram
Release) 34 Slew Ram
3 Check Valve (8 bar) 35 Slew Ram
4 Excavator Valve Block 36 Boom Ram
4A Slew Spool 37 Dipper Ram
Standard Machines - Dual Lever Drive Control

E-42
Schematic Circuits
Section E - Hydraulics
E-43
9803/9960-1
316761
Fig 26. Standard Machines - Dual Lever Drive Control From Machine no. 752463

Table 5. Component Key ( E-42)

Standard Machines - Dual Lever Drive Control

E-43
Schematic Circuits
Section E - Hydraulics
 High Flow Machines - Single Lever Drive Control

E-44
From Machine no. 751012 to 752462 2Y Pressure Test Point (Transmission 8B Left Turn Spool
Charge Pressure) 8C Forward Spool
Fig 27. ( E-45) 2Z Pressure Test Point (Brake Pressure) & 8D Right Turn Spool
Hand Pump Connector (Manual Brake
Table 6. Component Key Release) 9 Valve
C Cooler 10 Check Valve (2 bar)
3 Check Valve (8 bar)
F1 Filter 11 Filter By-pass Valve (3 bar)
4 Excavator Valve Block
F2 High Flow Filter 12 Auxiliary Feeds
4A Slew Spool
P1 Main Pump (Run in Tandem with P2) 13 High Flow Pump
4B Boom Spool
P2 Main Pump (Run in Tandem with P1) 14 High-flow Valve
4C Stabiliser Spool
P3 Auxiliary Gear Pump 14A High-flow Pilot Valve
4D Stabiliser Spool
M1 Left Hand Drive Motor 14B High-flow Control Valve
4E Dipper Spool
M2 Right Hand Drive Motor 14C
4F Bucket Spool
S1 Suction Strainer 15
4G Auxiliary Spool
S2 High Flow Suction Strainer 30
4H
T Tank 32 Stabiliser Ram
4J Slew ARV

9803/9960-1
1 Loader Joystick 33 Stabiliser Ram
4K Slew ARV
2 Loader Valve Block 34 Slew Ram
4L Boom Ram Head Side ARV
2A Crowd Spool 35 Slew Ram
4M Boom Ram Rod Side ARV
2B Lift Spool 36 Boom Ram
4N Dipper Ram Rod Side ARV
2C Auxiliary Spool 37 Dipper Ram
4P Dipper Ram Head Side ARV
2D Main Relief Valve (MRV) 38 Bucket Ram
4Q Bucket Ram Rod Side ARV
2E Crowd Ram Rod Side ARV 50 Bi-restrictor
4R Bucket Ram Head Side ARV
2F Crowd Ram Head Side ARV 51 Bi-restrictor
4S Auxiliary ARV
2G Lift Ram Head Side ARV 52 One-way Restrictor
4T Auxiliary ARV
2H Auxiliary ARV
5
2J Auxiliary ARV Note: Excavator services shown here are to the JCB
6 Manually Operated Dump Valve 'X' control pattern. For ISO '+' control pattern,
2W Pressure Test Point (High-flow Relief components 36 and 37 are swapped over.
Valve) 7 Lift Rams

2X Pressure Test Point (Main Relief Valve) 8 Drive Control Joystick

8A Reverse Spool

E-44
High Flow Machines - Single Lever Drive Control
Schematic Circuits
Section E - Hydraulics