Section E

Hydraulics
Service Manual - 1CX
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section K - Engine

Publication No.
9803-9960-1

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

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

Notes:

E-0 9803-9960-1 E-0

 Section E - Hydraulics

Contents Page No.

Technical Data
Up to machine number 752462 ................................................................ E-1
From machine number 752463 ................................................................ E-4

General
Connecting/Disconnecting Hydraulic Hoses ............................................. E-7
Venting Hydraulic Pressure .................................................................. E-7
Connecting the Hoses .......................................................................... E-7
Disconnecting the Hoses ...................................................................... E-7
Hydraulic Contamination .......................................................................... E-9
Hydraulic Fluid Quality ......................................................................... E-9
Effects of Contamination ...................................................................... E-9
Cleaning Operation .............................................................................. E-9
Contaminant Standards ...................................................................... E-10
Filters .................................................................................................. E-10

Operation
General Description up to machine no. 752462 ...................................... E-11
Machine Neutral Circuit .......................................................................E-11
General Description from machine no. 752463 ...................................... E-13
Machine Neutral Circuit ...................................................................... E-13
Auxiliary Pump ........................................................................................ E-15
Loader Valve ........................................................................................... E-16
Neutral Circuit ..................................................................................... E-16
Lift Ram Operation 1 .......................................................................... E-17
Lift Ram Operation 2 .......................................................................... E-18
Crowd Ram Operation ........................................................................ E-19
Relief Valve Operation ........................................................................ E-20
Excavator Valve ...................................................................................... E-21
Neutral Circuit ..................................................................................... E-21
Operation ............................................................................................ E-22
Excavator Valve - Bi-Restrictor Operation .......................................... E-23
Slew Operation ................................................................................... E-24
Slew A.R.V. and Anti-Cavitation Operation ........................................ E-25
A.R.V. Operation ................................................................................. E-26
A.R.V. Pressure Relief Operation ....................................................... E-27
Pressure Reducing Solenoid Valve ........................................................ E-28
From machine no. 751600 ................................................................. E-28
Drive Motor ............................................................................................. E-30
Transmission in Neutral .......................................................................... E-32
Transmission in Forward Drive ............................................................... E-34

Schematic Circuits
Standard Machines - Single Lever Drive Control .................................... E-36
From Machine no. 751012 to 752462 ................................................ E-36
From Machine no. 752463 ................................................................. E-38
Standard Machines - Dual Lever Drive Control ...................................... E-40
From Machine no. 751012 to 752462 ................................................ E-40
From Machine no. 752463 ................................................................. E-42
High Flow Machines - Single Lever Drive Control .................................. E-44
From Machine no. 751012 to 752462 ................................................ E-44
From Machine no. 752463 ................................................................. E-46
High Flow Machines - Dual Lever Drive Control ..................................... E-48
From Machine no. 751012 to 752462 ................................................ E-48
From Machine no. 752463 ................................................................. E-50

E-i E-i
 Section E - Hydraulics
Contents

Contents Page No.

Optional Hand Tool Circuit ...................................................................... E-52
Description ......................................................................................... E-52

Fault Finding
Hydrostatic Transmission ....................................................................... E-53
Pumps from machine no. 751012 ...................................................... E-55
Checking for Faulty Pump or Motor .................................................... E-57
Checking Motor Leakage Rate ........................................................... E-58
Checking the Joystick Hydraulic Lines ............................................... E-60
Loader/Excavator Circuit ........................................................................ E-62

Pressure Testing
Main Relief Valve (M.R.V.) - In Situ ........................................................ E-65
Torque Settings .................................................................................. E-65
Auxiliary Relief Valve (A.R.V.'s) - Using Hand Pump .............................. E-67
Torque Settings .................................................................................. E-67
Check Valve ............................................................................................ E-68
Pressure Reducing Valve Cartridge ....................................................... E-69
Charge Pressure Checking and Adjustment .......................................... E-70

Pumps
Removal and Replacement .................................................................... E-72
Removal ............................................................................................. E-72
Replacement ...................................................................................... E-73
Pump/Engine Coupling ........................................................................... E-74
Start-up Procedure ................................................................................. E-75
Hydrostatic Pump from machine no. 751012 ......................................... E-77
Dismantling and Assembly ................................................................. E-77
Shaft Seal ........................................................................................... E-77
Charge Check and High Pressure Relief Valves ................................ E-78
Charge/Anti-stall Valve ....................................................................... E-79
Pump Neutral Adjustment .................................................................. E-80
Auxiliary Pump (Standard machines) ..................................................... E-82
Removal and Replacement ................................................................ E-82
Dismantling and Assembly ................................................................. E-82
Auxiliary Pump (High-flow machines) ..................................................... E-84
Dismantling and Assembly ................................................................. E-84

Valves
Loader Valve ........................................................................................... E-86
Removal ............................................................................................. E-86
Replacement ...................................................................................... E-87
Dismantling and Assembly ................................................................. E-88
Main Relief Valve and Auxiliary Relief Valves .................................... E-90
Excavator Valve ...................................................................................... E-91
Dismantling and Assembly ................................................................. E-92
Pressure Reducing Solenoid Valve (to serial no. 752462) ..................... E-95
Removal ............................................................................................. E-95
Replacament ...................................................................................... E-95
Dismantling ......................................................................................... E-95
Assembly ............................................................................................ E-96
Brake Valve from serial no. 752463 ........................................................ E-97
Dismantling ......................................................................................... E-97
Assembly ............................................................................................ E-97

E-ii E-ii
 Section E - Hydraulics
Contents

Contents Page No.

Drive Motors
Removal and Replacement .................................................................... E-98
Removal of the Drive Sprocket ........................................................... E-98
Removal of Motor ............................................................................... E-99
Replacement ...................................................................................... E-99
Dismantling and Assembly to machine no. 751011 .............................. E-101
Dismantling ....................................................................................... E-101
Assembly .......................................................................................... E-101
Dismantling and Assembly from machine no. 751012 to 807172 ........ E-104
Dismantling ....................................................................................... E-105
Assembly .......................................................................................... E-105
Later Type Motor with Twin Bearing Output Shaft. ........................... E-106
Dismantling and Assembly from machine number 807173 .................. E-108
Dismantling ....................................................................................... E-109
Assembly .......................................................................................... E-109

Servo Joysticks
All Joysticks ........................................................................................... E-111
Removal and Replacement ............................................................... E-111
Joystick up to machine number 807146 ................................................ E-112
Dismantling ........................................................................................E-114
Assembly ...........................................................................................E-114
Joystick from machine number 807147 ................................................. E-116
Dismantling ........................................................................................E-118
Assembly ...........................................................................................E-118

Rams
Typical Ram (with dowelled piston head) .............................................. E-119
Dismantling and Assembly ............................................................... E-120
Slew Cylinder ........................................................................................ E-124
Re-seal ............................................................................................. E-124
Filling Procedure .............................................................................. E-125

Filtration
Suction Strainer .................................................................................... E-126
Removal and Replacement .............................................................. E-126
Return Filter .......................................................................................... E-127
Removal and Replacement .............................................................. E-127

E-iii E-iii
 Section E - Hydraulics
Contents

Contents Page No.

E-iv E-iv
 Section E - Hydraulics

Technical Data
Up to machine number 752462

Note:
Hydraulic Contamination ( E-9)

Type Gear
Displacement 48 l/min (10.5 UK gal/min, 12.7 US gal/min) at 3000 rev/
min
Maximum Working Pressure 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2)
Maximum Speed 3200 rpm

Type Gear
Displacement - Front Section 90 l/min (19.8 UK gal/min, 23.8 US gal/min) at 3600 rev/
min
Displacement - Rear Section 57 l/min (12.5 UK gal/min, 15 US gal/min) at 3600 rev/
min
Maximum Working Pressure 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2)
Maximum Speed 3600 rpm

Type Tandem axial piston Series 42 M28

Displacement 28 cc/rev (1.71 in3/rev)
Control Servo non-feedback proportional, 15 bar (218 lbf/in2) to
give max pump displacement.
Maximum Working Pressure 350 bar (5076 lbf/in2)
Maximum Speed 3900 rpm
Charge Pressure (oil temperature at 50 C) 2 2

Servo Joysticks
Output Characteristics - Transmission control spools
Output Characteristics - Loader control spools
5 bar (72 lb/in2) at 15% stroke. 15 bar (217.5 lb/in2) at
95% stroke.
3.3 - 3.7 bar (48 - 53 lb/in2) at 15% stroke. 14.5 - 16.5 bar
(210 - 239 lb/in2) at 95% stroke.

E-1 9803/9960-1 E-1

 Section E - Hydraulics
Technical Data
Up to machine number 752462

Type MCR03
Displacement 328 cc/rev (20 in3/rev)
Maximum Working Pressure 414 bar (6000 lbf/in2) continuous
Maximum Speed 237 rpm continuous
Maximum Flow

2 2

Shovel Crowd
Shovel Dump 100-103 102-105 1450-1494

Slew Rams
Boom Raise
Boom Lower
Dipper In
Dipper Out
Bucket Crowd

Note: The return line auxiliary A.R.V. should be set to zero Information 1/011). The A.R.V. must be returned to the
when a Rockbreaker is fitted (Refer to Technical correct setting when the Rockbreaker is removed.

Maximum Inlet Pressure 207 Bar (3006 lbf/in2), 211 kgf/cm2)

Regulated Pressure 24 Bar (348 lbf/in2), 24.47 kgf/cm2)
Minimum Rated Flow 10 l/min (2.2 UK gal/min, 2.64 US gal/min)
Maximum Leakage 25 cc/min (1.52 in3/min) at 210 Bar (3045 lbf/in2) and 10
cSt
Oil Temperature Range - 40 C to +106 C
Solenoid Valve (including Diodes) 3 Position, 3 Port Cartridge Valve
Reducing Valve Cartridge Type

E-2 9803/9960-1 E-2

 Section E - Hydraulics
Technical Data
Up to machine number 752462

Filter
Type High Pressure Spin On - 5 micron
Suction Strainer

Rams Bore Rod Dia Stroke

Lift 30
Shovel 30
Boom 70 2.75 40 1.57 600 23.62
Dipper 70 2.75 40 1.57 500
Bucket 70 2.75 40 1.57 400 15.75
30

Ram Torque
Settings

Lift Rams
Shovel Rams (Crowd)
Boom Ram
Stabiliser Rams
Dipper Ram

Lift Rams
Shovel Rams (Crowd)
Boom Ram
Stabiliser Rams
Dipper Ram

E-3 9803/9960-1 E-3

 Section E - Hydraulics
Technical Data
From machine number 752463

From machine number 752463

Note:
Hydraulic Contamination ( E-9)

Type Gear
Displacement 48 l/min (10.5 UK gal/min, 12.7 US gal/min) at 3000 rev/
min
Maximum Working Pressure 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2)
Maximum Speed 3200 rpm

Type Gear
Displacement - Front Section 90 l/min (19.8 UK gal/min, 23.8 US gal/min) at 3600 rev/
min
Displacement - Rear Section 57 l/min (12.5 UK gal/min, 15 US gal/min) at 3600 rev/
min
Maximum Working Pressure 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2)
Maximum Speed 3600 rpm

Type Tandem axial piston Series 42 M28

Displacement 28 cc/rev (1.71 in3/rev)
Control Servo non-feedback proportional, 15 bar (218 lbf/in2) to
give max pump displacement.
Maximum Working Pressure 350 bar (5076 lbf/in2)
Maximum Speed 3900 rpm
Charge Pressure (oil temperature at 50 C) up to machine 2 2

number 807734

Note: Earlier machines may be adjusted to the higher pressure

if there is a requirement to raise the lift arms at engine idle.
Charge Pressure (oil temperature at 50 C) from machine 11.5 bar (167 lb/in2) at engine idle
number 807735 2

Servo Joysticks
Output Characteristics - Transmission control spools
Output Characteristics - Loader control spools
5 bar (72 lb/in2) at 15% stroke. 15 bar (217.5 lb/in2) at
95% stroke.
3.3 - 3.7 bar (48 - 53 lb/in2) at 15% stroke. 14.5 - 16.5 bar
(210 - 239 lb/in2) at 95% stroke.

E-4 9803/9960-1 E-4

 Section E - Hydraulics
Technical Data
From machine number 752463

Servo Joysticks
Output Characteristics
Transmission for/rev (spools 2 & 4)
Transmission left/right (spools 1 & 3)

Output Characteristics
Transmission control spools

Type MCR03
Displacement 328 cc/rev (20 in3/rev)
Maximum Working Pressure 414 bar (6000 lbf/in2) continuous
Maximum Speed 237 rpm continuous
Maximum Flow

2 2

Shovel Crowd
Shovel Dump 100-103 102-105 1450-1494

Slew Rams
Boom Raise
Boom Lower
Dipper In
Dipper Out
Bucket Crowd

Note: The return line auxiliary A.R.V. should be set to zero

when a Rockbreaker is fitted (Refer to Technical
Information 1/011). The A.R.V. must be returned to the
correct setting when the Rockbreaker is removed.

E-5 9803/9960-1 E-5

 Section E - Hydraulics
Technical Data
From machine number 752463

Type

Filter
Type High Pressure Spin On - 5 micron
Suction Strainer

Rams Bore Rod Dia Stroke

Lift 30
Shovel 30
Boom 70 2.75 40 1.57 600 23.62
Dipper 70 2.75 40 1.57 500
Bucket 70 2.75 40 1.57 400 15.75
30

Ram Torque
Settings

Lift Rams
Shovel Rams (Crowd)
6 in 1 Shovel
Boom Ram
Stabiliser Rams
Dipper Ram

Lift Rams
Shovel Rams (Crowd)
6 in 1 Shovel
Boom Ram
Stabiliser Rams
Dipper Ram

E-6 9803/9960-1 E-6


General
Connecting/Disconnecting Hydraulic Hoses
The following paragraphs describe how to connect and
disconnect the hydraulic hoses safely.
WARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before disconnecting or connecting hydraulic hoses
or couplings, vent the pressure trapped in the hoses in
accordance with the instructions given in this
publication.
HYD-1-5
WARNING
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
WARNING
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
Venting Hydraulic Pressure
1 Stop the engine. When the engine has stopped, vent
the hydraulic pressure as follows:
2 For the hoses at the excavator end, operate the
controls to release the trapped pressure.
E-7 9803/9960-1
Section E - Hydraulics
3 For hoses at the loader end, turn the starter key to
IGN:
Operate the auxiliary attachment control switch or the
auxiliary attachment detent switch for a short time to .
relieve residual pressure in the hydraulic circuit.
Turn the starter key to OFF and remove the key.
Connecting the Hoses
1 Connect the hoses
a Where the connection is of the quick release type,
see Quick Release Couplings in Section A.
b For all other hose connections, use correct tools
and ensure that connections are not cross-
threaded. Support the weight of the hose until the
connection is made. Do not exceed the
recommended torque loading.
2 Check for leaks.
a Start the engine.
b Either operate the Auxiliary Control Switch to build
up pressure in the loader end hoses or operate
the appropriate excavator control to pressurise an
excavator hose.
c Switch off the engine. Remove the starter key.
Check for signs of leakage at the hose
connections.
Disconnecting the Hoses
1 Vent the hydraulic pressure. Venting Hydraulic
Pressure ( E-7)
a Where the connection is of the quick release type,
see Quick Release Couplings in Section A.
b For all other hose connections, plug both sides of
the connection to prevent loss of fluid.
E-7
 Section E - Hydraulics
General
Connecting/Disconnecting Hydraulic Hoses
2 Check for leaks.

a Start the engine.

b Either operate the Auxiliary Control Switch to build

up pressure in the loader end hoses or operate
the appropriate excavator control to pressurise an
excavator hose.

c Switch off the engine. Remove the starter key.

Check for signs of leakage at the hose
connections.

E-8 9803/9960-1 E-8

 Section E - Hydraulics
General
Hydraulic Contamination

Hydraulic Contamination
TE-002_2

Hydraulic Fluid Quality Procedure

Construction machinery uses a large volume of fluid in the Connect the cleaning unit in place of the hydraulic filter.
hydraulic system for power transmission, equipment Fig 1. ( E-9). Run the system for sufficient time to
lubrication, rust prevention and sealing. According to a pump all the hydraulic fluid through the unit. Disconnect
survey conducted by a pump manufacturer, seventy per the cleaning unit and reconnect the filter. Top up the
cent of the causes of problems in hydraulic equipment system with clean hydraulic fluid as required.
were attributable to inadequate maintenance of the quality
of the hydraulic fluid. Therefore, it is obvious that control of
the quality of the hydraulic fluid helps prevent hydraulic
equipment problems and greatly improves safety and
reliability. Furthermore from an economic angle it extends
the life of the hydraulic fluid if quality is maintained.

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

1 Solid Particles - sand, fibres, metallic particles, Fig 1. Cleaning Unit

welding scale, sealing materials and wear particles
etc.

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
cleaning unit. Fig 1. ( E-9). General Bulletin 011 also
refers.

E-9 9803/9960-1 E-9

 Section E - Hydraulics
General
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-10 9803/9960-1 E-10

 Section E - Hydraulics

Operation
General Description up to machine no. 752462

The main components of the hydraulic circuit are the tank, If valve 9 is energised, oil is permitted to flow to the loader
pumps, drive motors, the servo operated loader and drive control valve 2. After passing through the loader valve, the
control circuits, the manually operated excavator valves, oil flows through the excavator valve 4 and then via the
filters, cooler, rams and pressure reducing solenoid valve. filter F1 to the main pumps P1 and P2. Oil from P1 and P2
is returned via the cooler C to the tank T. Valve 9 also
The pumps are driven by the engine and are mounted in allows the transmission brakes to be manually applied.
tandem. They deliver pressurised oil to the valves and
motors. The valves are operated by either a servo joystick
in the case of the loader or drive circuits, or a manual
control lever for the excavator circuit. When a valve is
operated, it delivers the oil to one end of the appropriate
ram or to the pump servo-controls depending on which
control is operated. The pressurised oil forces the ram's
piston along the bore of the ram or operates the pump
servo controls, which changes the flow direction to the
motors and hence the direction of rotation. A Pressure
Reducing Solenoid Valve maintains the required pressure
at various components and relief valves prevent system
pressure from rising too far.

The Pressure Reducing Solenoid Valve (together with its

associated electrical circuitry) is designed to both limit the
pressure in the circuit and act as a safety device. The
safety function ensures that the machine controls cannot
be operated without the operator being seated correctly in
his seat and the door properly closed and latched.

Machine Neutral Circuit

Fig 2. ( E-12)

This description should also be read in conjunction with the

the Schematic Circuits. Schematic Circuits ( E-36)

Oil is drawn from the tank T by the auxiliary pump P3 via a

suction strainer S1. The pump P3 delivers pressurised oil
to the pressure reducing solenoid valve 9 and, providing
that solenoid valve 9 is in the energised position, to the
loader control valve 2. In the de-energised position, valve
9 returns the oil to the hydraulic tank. This ensures that
there is insufficient pressure available to operate the 5 bar
check valve 3.

E-11 9803/9960-1 E-11

 Section E - Hydraulics
Operation
General Description up to machine no. 752462

204361-B1
Fig 2.

E-11)

E-12 9803/9960-1 E-12

 Section E - Hydraulics
Operation
General Description from machine no. 752463

General Description from machine no. 752463

The main components of the hydraulic circuit are the tank,

pumps, drive motors, the servo operated loader and drive
control circuits, the manually operated excavator valves,
filters, cooler, rams and solenoid brake valve.

The pumps are driven by the engine and are mounted in

tandem. They deliver pressurised oil to the valves and
motors. The valves are operated by either a servo joystick
in the case of the loader or drive circuits, or a manual
control lever for the excavator circuit. When a valve is
operated, it delivers the oil to one end of the appropriate
ram or to the pump servo-controls depending on which
control is operated. The pressurised oil forces the ram's
piston along the bore of the ram or operates the pump
servo controls, which changes the flow direction to the
motors and hence the direction of rotation. Relief valves
prevent system pressure from rising too far.

The Solenoid Brake Valve (together with its associated

electrical circuitry) acts as a safety device. The safety
function ensures that the machine loader and transmission
controls cannot be operated without the operator being
seated correctly and the door properly closed and latched.

Machine Neutral Circuit

Fig 3. ( E-14)

This description should also be read in conjunction with the

the Schematic Circuits. Schematic Circuits ( E-36)

Oil is drawn from the tank T by the auxiliary pump P3 via a

suction strainer S1. The pump P3 delivers pressurised oil
via non return valve 3 to the loader control valve 2. Oil
flows through the loader valve and onto the excavator
valve 4 then via the filter F1 to the main pumps P1 and P2.
Oil from P1 and P2 is returned via the cooler C to the tank
T. The oil feed for the servo controls is taken from the main
pump charge circuit via the solenoid brake valve 9.

The solenoid brake valve 9 acts as a safety device by

preventing the oil supply to the loader and transmission
servo controls until the operator is seated correctly and the
door properly closed and latched. The brake valve also
allows the transmission brakes to be manually applied.

E-13 9803/9960-1 E-13

 Section E - Hydraulics
Operation
General Description from machine no. 752463

316840-B1
Fig 3.

E-13)

E-14 9803/9960-1 E-14

 Auxiliary Pump
E-15
9803/9960-1

Section E - Hydraulics
C072110
Fig 4.

The auxiliary pump is a gear type pump. The working
principle of a gear pump depends on the meshing of
two spur gears A and B. Oil is picked up on the suction
side of the pump by the gears and carried round
between the gear teeth and the pump body. As the
slippage. Lubrication oil is drawn through the recess D
and around the counter bore. The oil then flows along
the scrolled grooves E in the bushes, induced by the
viscous drag of the rotating shaft.

Auxiliary Pump
gears come into mesh the oil is forced out through the

Operation
outlet port.

Some oil is allowed to circulate behind the bearings C

E-15

to hold them against the gears and minimise oil

 Loader Valve
E-16

Neutral Circuit
A Loader valve block 5 Auxiliary spool
Oil from the pump enters the valve at 1. When all the
spools are in the neutral position as shown, the oil 1 Inlet 6 Main relief valve
passes around the waisted central position of the 2 Outlet to excavator valve block 7 Auxiliary relief valves
spools and flows on to feed the excavator valve via
3 Crowd spool 8
outlet line 2. Oil trapped in the lines prevents
movement of the rams. Oil also fills the parallel gallery 4 Lift spool
X.
9803/9960-1

Section E - Hydraulics
Loader Valve
Operation
205110-B1

Fig 5.
E-16
 Lift Ram Operation 1
E-17
9803/9960-1

C072120
Fig 6.

The illustration shows Loader Arm Raise being pressure until exceeded by system pressure, thus

Section E - Hydraulics
selected by the lift ram spool 1. Fig 6. ( E-17) preventing the load from dropping.

Initially, the weight of the loaded shovel, as indicated

by the arrows, causes a higher pressure in the service
line than in the parallel gallery X. This pressure
differential causes the load hold check valve Y to
close.

Loader Valve
Operation
The load hold check valve Y is a spring-loaded non-
return valve operating across the pressure feed from
the parallel gallery X. It prevents reverse flow from the
E-17

rams into the pressure feed line, so maintaining ram

 Lift Ram Operation 2
E-18
9803/9960-1

C072130
Fig 7.

As the neutral circuit has been blocked by the central Should the pressure in the feed line rise above the set

Section E - Hydraulics
lands of the selected spool 1, the pressure in parallel pressure, the auxiliary relief valve will lift and dump
gallery X increases until it is greater than that in the pressure to tank.
service line.
Loader Arm Lower is a reverse of the above
At this point, the load hold check valve opens, procedure.
allowing oil to flow from the parallel gallery into the
service line and operate the lift ram 2 and so raise the
loader arms. As the arms rise, oil from the other side

Loader Valve
Operation
of the ram returns to the exhaust line via the control
valve and returns to tank.
E-18
 Crowd Ram Operation
E-19
9803/9960-1

Section E - Hydraulics
C072140
Fig 8.

Shovel Lift (Crowd)
The crowd spool operates, and is controlled by a load
hold check valve, in a similar manner to that described
for the lift spool. When the crowd spool 1 is selected
Both feed and return lines are protected from
overpressure by auxiliary relief valves.
Shovel Open

Loader Valve
Operation
for lift, pressure acts on the crowd ram piston 2 and This is the reverse of the Shovel Lift procedure.
the shovel 'crowds' or lifts. Oil from the other side of
the ram returns to the exhaust line via the control
E-19

valve.
 Section E - Hydraulics
Operation
Loader Valve

Relief Valve Operation

C072180
Fig 9.

Main Relief Valve
The main relief valve (M.R.V.) 6 is situated in the loader
valve block. Fig 5. ( E-16) It provides control of both
loader and excavator pressures.
Oil continues to escape from the cavity E but the incoming
flow to the cavity has been cut off. This produces a
pressure drop above poppet G, causing the poppet to lift
and release service pressure into the exhaust gallery D.

View X
As service pressure reaches the pilot setting of the valve,
pilot poppet A lifts, allowing oil to escape into cavity B and
pass down the sides of sleeve C into the exhaust gallery D.
The auxiliary relief valves work in exactly the same manner
as the main relief valve although the operating pressures
are different.

View Y.

As service pressure continues to rise and oil escapes from

cavity E, the pressure differential between the upper and
lower surfaces of piston F causes this piston to rise and
seat on the point of pilot poppet A.

E-20 9803/9960-1 E-20

 Excavator Valve
E-21

Neutral Circuit
9803/9960-1

Section E - Hydraulics
C072150
Fig 10.
Note: Machines with ISO control pattern have the
boom and dipper spools interchanged.
4A Slew Spool
4B Boom Spool Oil from the loader valve enters the excavator valve at
A and flows through the neutral gallery and around the
4C Stabiliser Spool
waists of the solid spools. It also fills the parallel

Excavator Valve
4D Stabiliser Spool gallery X but is not at a high enough pressure to open

Operation
4E Dipper Spool the load hold check valves B.
4F Bucket Spool
E-21

4G
 Section E - Hydraulics
Operation
Excavator Valve

Operation

C072160
Fig 11.

The excavator services all operate in a similar manner.

The boom service is shown as an example. When the
boom spool 4B is selected for lift, initially back pressure
exceeds system pressure which closes the load hold
check valve Y.

When pressure in the feed line exceeds back pressure, the

load check valve Y opens and oil is allowed to flow to the
boom ram piston, as shown, and the pressure causes the
boom ram to lift. Oil from the other side of the piston
returns to the exhaust line via the control valve.

The remaining load hold check valves are also opened by

system pressure but the galleries are dead-ended
because the spools are in neutral. When lower is selected,
the spool directs the flow in the reverse direction.

E-22 9803/9960-1 E-22

 Section E - Hydraulics
Operation
Excavator Valve

Excavator Valve - Bi-Restrictor Operation

C072170
Fig 12.

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.

To prevent this from happening, the boom service is fitted

with bi-restrictor E.

E-23 9803/9960-1 E-23

 Section E - Hydraulics
Operation
Excavator Valve

Slew Operation

C072190
Fig 13.

The illustration shows right hand slew selected. The lower

port C has been pressurised by the spool. Oil flows from
the parallel gallery X, out past A.R.V. 4K to the left hand
side of the slew actuator. The boom therefore slews to the
right as seen from the operators viewpoint. Displaced oil
from the right hand side of the slew actuator flows back
through the upper service port D and back to tank.

When the actuator is approaching the end of its travel, the

damper piston P contacts the end of the slew pot and is
pushed into the slew rack. This causes the flow of oil to be
restricted, so slowing down the slew action.

E-24 9803/9960-1 E-24