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

 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

Section E - Hydraulics
C072210
Fig 15.

Excavator Valve
The illustration shows the bucket spool 4F selected to When this pressure reaches the setting of A.R.V. 4P,
operate the service against an immovable object. this valve opens, relieving the pressure into the

Operation
Fig 15. ( E-26) This forces the dipper away from exhaust gallery. Cavitation occurs in the rod side of
the obstruction and pressurises the head side of the the dipper service. A.R.V. Pressure Relief
dipper ram. Operation ( E-27)
E-26

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.

Section E - Hydraulics
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.

Transmission in Neutral
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

Operation
Pa Charge Valve swash plates of pumps P1 and P2.
Pb Pressure Relief Valve
With the engine running but no drive selected, oil from
E-32

Pc Pressure Relief Valve pump P3 is fed through the loader valve 2, excavator
 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.

Section E - Hydraulics
Key Key Key

Transmission in Forward Drive

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

Operation
Pa Charge Valve 8b Joystick Control Spool
Pb Pressure Relief Valve 2 Loader Valve 8c Joystick Control Spool
E-34

Pc Pressure Relief Valve 2X Pressure Test Point 8d Joystick Control Spool

 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
9803/9960-1

33 Stabiliser Ram
S1 Suction Strainer 4G Auxiliary Spool
34 Slew Ram
T Tank 4H
35 Slew Ram
1 Loader Joystick 4J Slew ARV
36 Boom Ram

Standard Machines - Single Lever Drive Control

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
4P Dipper Ram Head Side ARV

Section E - Hydraulics
2D Main Relief Valve (MRV) 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
'X' control pattern. For ISO '+' control pattern,

Schematic Circuits
2G Lift Ram Head Side ARV 4S Auxiliary 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
E-36
E-37
9803/9960-1

Standard Machines - Single Lever Drive Control

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

Table 2. Component Key ( E-36)

 From Machine no. 752463 4B Boom Spool
E-38

34 Slew Ram
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
9803/9960-1

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
2C Auxiliary Spool 5
2D Main Relief Valve (MRV) 6 Manually Operated Dump Valve

Standard Machines - Single Lever Drive Control

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

Section E - Hydraulics
2J Auxiliary ARV 8C Forward Spool
2X Pressure Test Point (Main Relief Valve) 8D Right Turn Spool
2Y Pressure Test Point (Transmission

Schematic Circuits
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
E-38

4A Slew Spool 33 Stabiliser Ram

E-39
9803/9960-1

Standard Machines - Single Lever Drive Control

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

Table 3. Component Key ( E-38)

 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.
9803/9960-1

1 Left Hand Joystick 4M Boom Ram Rod Side ARV

2 Loader Valve Block 4N Dipper Ram Rod Side ARV
2A Crowd Spool 4P Dipper Ram Head Side ARV
2B Lift Spool 4Q Bucket Ram Rod Side ARV

Standard Machines - Dual Lever Drive Control

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

Section E - Hydraulics
2G Lift Ram Head Side ARV 6 Manually Operated Dump Valve
2H Auxiliary ARV 7 Lift Rams

Schematic Circuits
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
E-40
E-41
9803/9960-1

Standard Machines - Dual Lever Drive Control

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

Table 4. Component Key ( E-40)

 From Machine no. 752463 4B Boom Spool
E-42

38 Bucket Ram
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
9803/9960-1

2A Crowd Spool 4S Auxiliary ARV

2B Lift Spool 4T Auxiliary ARV
2C Auxiliary Spool 5
2D Main Relief Valve (MRV) 6 Manually Operated Dump Valve

Standard Machines - Dual Lever Drive Control

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)

Section E - Hydraulics
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

Schematic Circuits
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
E-42

4A Slew Spool 37 Dipper Ram

E-43
9803/9960-1

Standard Machines - Dual Lever Drive Control

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

Table 5. Component Key ( E-42)

 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
9803/9960-1

S2 High Flow Suction Strainer 30

4H
T Tank 32 Stabiliser Ram
4J Slew ARV
1 Loader Joystick 33 Stabiliser Ram
4K Slew ARV

High Flow Machines - Single Lever Drive Control

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

Section E - Hydraulics
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

Schematic Circuits
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

E-44

8A Reverse Spool