422ZX JCB Service Manual 89 Paginas

Section E
Hydraulics
Service Manual - WLS 422ZX
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
14
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
20
Section F - Transmission
Section G - Brakes
Section H - Steering
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Publication No.
9813/3800-01
World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Notes:
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E-0 9813/3800-01 E-0

Section E - 1
Contents Page No.

Technical Data
422ZX ...................................................................................................... E - 1
Hydraulic Pump .................................................................................. E - 1
Relief Valve Operating Pressures ...................................................... E - 1
Loader valve ....................................................................................... E - 2
Basic System and Operation

General Description ................................................................................. E - 3
Introduction to Hydraulic Schematic Symbols ......................................... E - 4
General (Basic and Functional Symbols) ........................................... E - 4
Control Valves .................................................................................... E - 8
14
Example of Schematic Circuit ............................................................ E - 9
Schematic Circuits
...............................................................................................................E - 11
20
Component Key .................................................................................E - 11
Main Control Valve ........................................................................... E - 13
2 Spool Loader Valve ....................................................................... E - 15
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3 Spool Loader Valve ....................................................................... E - 17
Main Steer Hydraulics ...................................................................... E - 19
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Circuit Descriptions
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Loader Valve .......................................................................................... E - 21
Loader Valve - Arms Raise/Lower ......................................................... E - 22
Loader Valve .......................................................................................... E - 24
Shovel Tip ......................................................................................... E - 24
Shovel Return ................................................................................... E - 24
on aft
Load Hold Check Valve ......................................................................... E - 26

Auxiliary Service .................................................................................... E - 28
Auxiliary Relief Valve Operation ............................................................ E - 29
Introduction ....................................................................................... E - 29
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Pressure Relief ................................................................................. E - 29

Anti-Cavitation .................................................................................. E - 29
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Main Relief Valve Operation .................................................................. E - 31

Loader Valve - Unloader Operation 1 .................................................... E - 33
Loader Valve - Unloader Operation 2 .................................................... E - 35
Servo Control Valves ............................................................................. E - 37
Main Servo-Control Valve - Neutral .................................................. E - 37
Main Servo-Control Valve - Arm Spool Operation ............................ E - 39
Main Servo-Control Valve - Float Position ........................................ E - 41
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Service Procedures
Hydraulic Contamination ....................................................................... E - 43
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Hydraulic Fluid Quality ..................................................................... E - 43

Effects of Contamination .................................................................. E - 43
Cleaning Operation .......................................................................... E - 43
Contaminant Standards .................................................................... E - 44
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Filters ................................................................................................ E - 44
Servo Joystick ....................................................................................... E - 45
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Removal and Installation .................................................................. E - 45

Auxiliary Joystick ................................................................................... E - 47
Removal ........................................................................................... E - 47
Installation ........................................................................................ E - 47
E-i E-i
Section E - 1
Contents
Contents Page No.

Pressure Testing
.............................................................................................................. E - 48
Servo-Pressure ................................................................................ E - 48
Checking Steering Relief Valve Pressure ......................................... E - 48
Unloader Valve ................................................................................. E - 48
Main Relief Valve (M.R.V.) ................................................................ E - 49
Shovel Ram, Head Side ................................................................... E - 49
Shovel Ram, Rod Side ..................................................................... E - 49
Lift Ram, Head Side ......................................................................... E - 50
Auxiliary Valve, Head Side ............................................................... E - 50
Loader Valve - Pressure Testing ............................................................ E - 51
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Loader ARVs (Using Hand Pump) ................................................... E - 51
Hydaulic Gear Pump

Disassembly .......................................................................................... E - 56
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Sections ............................................................................................ E - 57
Second Section Components Disassembly ..................................... E - 58
Second Section Seals Disassembly ................................................. E - 58
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Second Section Seals Assembly ...................................................... E - 59
Second Section Components Assembly .......................................... E - 61
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First Section Components Disassembly ........................................... E - 61
First Section Seals Disassembly ...................................................... E - 62
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First Section Seals Assembly ........................................................... E - 63
Cover Seals Replacement ................................................................ E - 64
Component Reassembly .................................................................. E - 65
Components Reassembly ................................................................ E - 66
Final Bolting and Check ................................................................... E - 66
on aft
Loader Valve Block

Assembly Procedure ............................................................................. E - 68
......................................................................................................... E - 68
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Cleaning and Initial Set Up Of The Valve Body ................................ E - 70

VMR Kit Assembly ............................................................................ E - 70
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VR Kit (Load Check-valve) Assembly .............................................. E - 71

Load Sensing (LS) Valve Assembly ................................................. E - 71
P & T Plug Assembly ........................................................................ E - 72
Priority Inlet Spool Assembly ............................................................ E - 73
Main Relief Valve (MRV) Assembly .................................................. E - 73
Port Relief Valve Cavity Plug Assembly ........................................... E - 74
Port Relief Valve Assembly .............................................................. E - 74
Spool Assembly (for all type of spool) .............................................. E - 74
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Control Kit Assembly ........................................................................ E - 74

Pneumatic Dip Test .......................................................................... E - 76
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Rams
Precautions During Use ......................................................................... E - 78
Installation ........................................................................................ E - 78
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Caution During Use .......................................................................... E - 78

Maintenance, Inspection Points ....................................................... E - 78
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Typical Ram ........................................................................................... E - 80

Disassembly and Assembly ............................................................. E - 81
JCB Ram Sealing Procedure ........................................................... E - 83
E - ii E - ii
Technical Data
422ZX
Hydraulic Pump
Table 1.
Pump Data Pump 1 Pump 2
Direction of rotation (looking on Clockwise (D)
driveshaft)
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Cylinder Displacement 39.27 (cm3/rev) 34.56 (cm3/rev)
Inlet pressure range for pump 0.7 - 3 bar
Maximum continous pressure P1 260 bar 260 bar
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Mximum intermittent pressure P2 280 bar 280 bar
Maximum peak pressure P3 300 bar 300 bar
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Speed minimum P1 350 (min-1)
maximum P2 3000 (min-1)
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Weight 25.783 kg
Seals type HNBR/Shaft seals FPM
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Minimum temperature
Maximum temperature
Viscocity range
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peak
recommended
-250C
+1100C
+1250C
12 to 100 mm2/s (cst)
on aft
permitted maximum 750 mm2/s (cst)
Relief Valve Operating Pressures

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Table 2.
bar kgf/cm2 lbf/in2
Main Relief Valve 245 250 3553
Steering Relief 190 194 2756
Servo 30 31 435
Auxiliary Relief Valve
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– Shovel ram head side 285 291 4134

– Shovel ram rod side 315 321 4569
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– Lift ram, head side 275 280 3989

– Auxiliary ram, head side 285 291 4134
Unloader Valve 195 199 2828
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E-1 9813/3800-01 E-1

Technical Data
422ZX
Loader valve
Table 3.
Description 2 Spool 3 Spool
Nomial flow 160 l/min 160 l/min
Operating pressure (maximum) 315 bar 315 bar
Viscocity range 2
12 mm /s - 400 mm /s2 12 mm2/s - 400 mm2/s
Maximum level of contanimation 19/16 - ISO 4406 19/16 - ISO 4406
Internal leakage 3 to 9 cm3/min @ 100 bar 400C and 3 to 9 cm3/min @ 100 bar 400C and
46mm2/s 46mm2/s
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Continous temperature -20 to 800C -20 to 800C
Intermittent temperature -30 to 960C -30 to 960C
Seal material NBR NBR
Fluid Mineral based oil Mineral based oil
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Back pressure (maximum) 25 bar 25 bar
Ambient temperature -40 to 60 C 0 -40 to 600C
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E-2 9813/3800-01 E-2


General Description
The main components of the Wheeled Loader hydraulic When the servo control valve is operated it causes the
systems are the pumps, loader valve block, priority valve, selected service valve spool in the loader valve block to
servo-valve, steering valve, brake valve, tank, rams and direct pressurised oil from the pump to the selected service
filters. For descriptions of the steering and brake valves, ram. Pressurised oil forces the piston along the bore to
refer to the relevant sections. cause a service movement. As the piston moves, oil is
pushed from the opposite end of the ram and returns to
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The pumps (PI and P2) are installed as a single unit and tank by way of a filter.
driven by the engine to supply pressurised oil to the
system. P1 supplies the system and the loader block Relief valves in the system prevent undue pressure rises
spools to give the lift and bucket services. P2 supplies the through internal and external sources.
loader block auxiliary (if installed) and Quickhitch service
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spools only. The output from P2 can be sent to the tank by
the operation of the loader block unloading spool and this
lets the engine power to be fully applied to P1.
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A pressure regulated outlet from the priority valve is sent
to the servo-valve, which sends it to the loader valve
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service spools as control inputs. When the servo-control
valve is operated it causes the selected service valve
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spool in the loader valve block to send the pressurised oil
from the pumps to the selected service ram. The
pressurised oil forces the piston along the bore to give a
service movement. As the piston moves, the oil is pushed
from the opposite end of the ram and returns to the tank
through a filter.
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The relief valves in the system prevent undue pressure

increases through internal and external sources.
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When the valve blocks are assembled, tighten the tie-rods

to 67 lbf ft (91 Nm).
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The main components of the 416 Wheeled Loader

hydraulic system are the pump, loader valve block, priority
valve, servo valve, steering valve, tank, rams and filters.
For descriptions of the steering and brake valves, refer to
the relevant Sections.
A separate gear pump supplies the brake circuit.

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The variable flow piston pump is driven by the engine and

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delivers pressurised oil to the priority valve section of the

loader valve block. The priority valve ensures that the
steering circuit has first demand on pump flow and
pressure. A pressure regulated outlet from the loader valve
is routed to the servo valve which in turn is redirected to the
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loader valve service spools as control inputs.

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E-3 9813/3800-01 E-3

Introduction to Hydraulic Schematic Symbols

TE-001
General (Basic and Functional Symbols) Table 5. Rams
Complex hydraulic components and circuits can be Single acting

described to the engineer by using graphical symbols. The
following pages illustrate and give a brief description for
some of the more common symbols used.
Double acting
There are many symbols in use and it would be impossible
to include them all here. However it should be noted that
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most are only variations or refinements on the basic
principles explained here. If more detailed information is Double ended
required you are recommended to obtain a copy of
BS2917 or IS01219.
Double acting with damping
20
Once familiar with the symbols, the engineer can use at rod area end
hydraulic circuit diagrams as an aid to fault finding. It will
be possible to see the complete hydraulic circuit and
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decipher the relationship between hydraulic components. Table 6. Pumps and Motors
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Table 4. General
Variable capacity pump two
Spring directions of flow
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Flow restriction affected by
viscosity
Direction of flow
Fixed capacity motor one
direction of flow
on aft
Fixed capacity motor two

directions of flow
Indication of rotation
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Variable capacity motor one

Indication of direction and direction of flow
paths of flow
Variable capacity motor two

Variable control directions of flow
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E-4 9813/3800-01 E-4

Table 7. Control Valves
Used to enclose several Throttling orifice - normally

valves indicating they are closed
supplied as one unit
3-Position, 4-port spring Throttling orifice - normally

centered pilot operated valve open
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3-position, 6-port spring
centered pilot operated valve
Relief valve
3-Position, 4-port spring
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centered solenoid & pilot
pressure operated valve
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3-Position, 4-port spring
centered detent hand Variable restrictor
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operated valve
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Non-return valve
Non-return valve with back

pressure spring
on aft
Pilot operated non-return

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valve
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One way restrictor
High pressure selector

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(shuttle valve)
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E-5 9813/3800-01 E-5

Table 8. Energy Transmissions and Conditioning
Working line, return or feed Reservoir - return line below
fluid level
Pilot control
Drain lines
Header tank
Flexible pipe
Pressure sealed tank
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Line junction
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Accumulator
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Crossing lines Filter or strainer
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on aft
Air bleed
Cooler - with no indication of
Line plugged, also pressure coolant flow
test point
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Line plugged with take off line Cooler - indicating direction

of coolant flow
Quick release couplings -

connected
Heater
Quick release couplings -
disconnected
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Reservoir - return line above

fluid level
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E-6 9813/3800-01 E-6

Table 9. Control Mechanisms
Solenoid one winding
Rotating shaft - one direction
Rotating shaft - two directions Solenoid two windings
Detent Electric motor operated

M
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Locking device Internal pressure pilot
operated
Over centre device
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External pressure pilot
operated
Simple linkage
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release
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General control
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Pilot operated by solenoid
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Push button operated
pilot valve
Pilot operated by a solenoid

or seperate pilot valve
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Lever operated
Pressure guage
Pedal operated
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Pressure switch
Stem operated
Spring operated
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Roller operated
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Roller trip operated (one

directional)
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E-7 9813/3800-01 E-7

Control Valves
Control valves are usually represented by one or more
square boxes.
K Fig 1. ( T E-8) shows a control valve represented by

three boxes. The number of boxes indicates the number of
possible valve operating positions, (3 boxes - 3 positions
etc).
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Fig 4.
It must be noted that not all spools are of the same type.
Fig 1.
Their operating designs can be seen by following the path
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the flow arrows take in their respective operating squares.
K Fig 2. ( T E-8) - In circuit diagrams the pipework is
usually shown connected to the box which represents the
Three typical JCB style spools are known as 'D' spools, 'F'
unoperated condition. (Hydraulic circuit diagrams are
spools and 'N' spools.
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usually shown in the unoperated condition).
The 'D' spools generally control rams because when in the
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neutral position the outlet ports are blocked, preventing
ram movement. K Fig 4. ( T E-8) shows a 'D' type spool.
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Fig 2.
K Fig 4. ( T E-8) shows a valve described as a 3-position,

K Fig 5. ( T E-8) - 'F' spools are often shown as four
position spools with the three normal positions for neutral
and service control; and the forth position, which has a
detent, connects both sides of the ram together to allow the
service to 'float'.
on aft
4-port control valve. Port describes the openings to and

from the valve by which the hydraulic fluid enters or leaves.
In the fig shown, Position 2 indicates that in an unoperated
condition all 4 ports are blocked.
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Fig 5.
K Fig 6. ( T E-8) - 'N' spools are sometimes used to

control hydraulic motors, and it can be seen from the flow
arrows, that in neutral position both service ports are
connected to the exhaust oil port
Fig 3.
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If the valve spool was moved to Position 1, movement of

the spool would connect Port P1 to Port P2, and Port P3 to
Port P4. K Fig 4. ( T E-8).
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If the valve spool was moved to Position 3, movement of

the spool would connect Port P1 to Port P4, and Port P3 to Fig 6.
Port P2. K Fig 4. ( T E-8).
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E-8 9813/3800-01 E-8

Example of Schematic Circuit
A
B
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C G
D E
20
F
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Fig 7. Simple Schematic Circuit
Some of the symbols described on the preceding pages Example Circuit Key
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have been arranged into a simple schematic circuit.

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K Fig 7. ( T E-9).
7-A Hydraulic Tank
Hydraulic tank 7-A is a pressurised tank with an internally 7-B Strainer
mounted strainer 7-B on the suction line to the fixed 7-C Fixed Displacement Pump
displacement pump 7-C. System pressure is limited to the
setting of relief valve 7-D. 7-D Relief Valve
7-E Spool
Valve spool 7-E is an open-centre spool that is in neutral 7-F One Way Valve
position; flow from the pump passes through the spool and
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returns to the hydraulic tank. 7-G Double Acting Hydraulic Ram

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If the lever operated spool is moved away from neutral

position hydraulic fluid is directed to either head side or rod
side of hydraulic ram 7-G. Notice that the fluid must first
open one way valve 7-F before flowing to the ram.
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E-9 9813/3800-01 E-9

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E - 10 9813/3800-01 E - 10
Schematic Circuits
E - 11
14
K Fig 8. ( T E-12)
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Component Key
1 Hydraulic Tank
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2 Dual Gear Pump
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3 Hydraulic Filter Assembly
4 Breather
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5 Cooler - Hydraulic
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6 Cooler Bypass Valve
7 Brake Charge Manifold
9813/3800-01
8 Piston Accumulator
9 Brake Valve
on aft
10 Front Axle Brake
11 Rear Axle Brake
12 Main Control Valve (2 Spool)
13 Lift Rams
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14 Shovel Ram
15 Steer Ram
16 Steer Valve
17 Joy Stick
Schematic Circuits
18 Pressure Reducer With Accumulator
19 Teat Points
ed
20 Suction Strainer
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E - 11
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E - 12
15 13 14
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12 10 11
B1 A1 P1 M
L R B2 A2 Q=86 I/min
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12 275 bar 285 bar 315 bar
9
250 BAR
T
8
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Q=76 I/min
V3 V1
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P2
0.75 mm
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STEERING
CONTROL 7
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190 BAR 1.25 mm
UNIT 245 bar
V2
LS 190 bar
CF
EF V4
9813/3800-01
200 bar
LIFT TILT
on aft
P PRIORITY
VALVE
24 VDC
17
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1 4 T P 3 2
39.27cc/rev 34.56cc/rev
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2 Bar
PRESSURE PRESSURE 5
CHECK POINT CHECK POINT 6
0
+5
60 bar
Schematic Circuits
COOLER
19 BREATHER 2
3
0
+5
4
30 bar
18
ed
FILLER
20 1
STRAINER
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E - 12
D070900-01
Fig 8.
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Schematic Circuits
Main Control Valve
C H
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H
20
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V3
V5 V1
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A3 A1 A2
P1
T P2
H
H
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B3 B1 B2
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V6 V2 V4
A B A
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D070760-22
Fig 9.
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Item Description
A Main relief valve
B Input Supply Connections
C Output Supply Connections
H Relief Valves
E - 13 9813/3800-01 E - 13
Schematic Circuits
334-l1521-2-sheet1
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20
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Fig 10. Hydraulic Circuit
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E - 14 9813/3800-01 E - 14
2 Spool Loader Valve
E - 15
14
Z
T Q
20
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X
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AF
9813/3800-01
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F G
A Y
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D X
Schematic Circuits
T
Q
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333-P3269-4-sheet2 (HC)
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E - 15
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Schematic Circuits
Item Description
A 2 Spool valve block
B Set screw
C Washer
D Adapter
E Bonded washer
F Adapter
G Bonded washer
H Hose
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I Hose
J Hose clamp
K Bolt
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L Plain washer
M Rivet
N Body clamp
O
P
Cover plate
Bolt
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Q Hose
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R Lift ram
W
S
T
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Set screw
Plain washer
Hose
Hose
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Z Hose
AA Bonded washer
AB Servo control
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AC Rubber
D
AD Grommet
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E - 16 9813/3800-01 E - 16
3 Spool Loader Valve
E - 17
14
D H
20
L
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9813/3800-01
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F G
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Schematic Circuits
H
334-l1515-2-sheet2
ed

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E - 17
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Schematic Circuits
Item Description
A 3 Spool valve block
B Hose
C Hose
D Hose
E Bolt
F Plain washer
G Rivet nut
H Clamp body
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I Cover plate
J Bolt
K Hose
20
L Lift ram pipe work
M Set screw
N Plain washer
O
P
Locknut
Hose
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Q Hose
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R Servo control
W
S
T
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Joystick lever
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Loader end hydraulics
Hose
Clamp
on aft
Z Clamp plate
AA Bolt
AB Grommet
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AC 3 Spool servo hoses

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AD 3 Spool joystick
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E - 18 9813/3800-01 E - 18
Schematic Circuits
Main Steer Hydraulics
A B, H
H, C
F H, K
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20
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H, J
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D, L G
333-P4729-2-Sheet1.eps
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Fig 13.
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Item Description
A Steering valve
B Adapter
C Adapter 1/2-3/4 mm
D Adapter G3/4A*1-1/16SAE
E Hose
F Hose-08 BSP HP680 mm
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G Hose-3/4BSp ST/45-1690
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H Bonded washer
J Tee adapter
K Elbow adapter
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L O-ring
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E - 19 9813/3800-01 E - 19
Schematic Circuits
14
20
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E - 20 9813/3800-01 E - 20
Loader Valve
Loader Valve
The Loader Valve LV is a 2-spool monoblock (Walvoil) with The valve section spools are:
an integral Pressure Unloader PU. The valve block is
configured for open circuit operation and has two or three LV3 (S3) Auxiliary. Double acting A to B, double acting B
service valve sections LV1, LV2, LV3 (optional) with an to A.
integral main relief valve.
LV2 (S2) Bucket. Hydraulic pilot.
14
When its operated, the designated valve section controls
the direction of oil flow to each service through the service LV1 (S1) Loader Arms. Hydraulic pilot and detent float.
ports A and B. The valve spools in each service section
are held in a neutral position by spring-loading. In the PU Integral unloader valve.
neutral position the supply to the service is blocked and oil
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flows through the valve galleries back to the tank.
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LV3
LV2
LV1
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D070790-22
Fig 14.
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E - 21 9813/3800-01 E - 21
Loader Valve - Arms Raise/Lower
When the raise operation is selected, servo-pressure is

applied to the Loader Valve section LV1.
The spool A is moved from the neutral position. Oil is sent

to the waisted section at B through an open load check
valve at C to port B.
From port B the oil is sent to the ram. Simultaneously the

line from the rod side of the ram enters the loader valve at
port A and is connected to exhaust at D.The rams extend
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and raise the arms.
When the lower operation is selected, servo-pressure

moves the spool so that the pressure and return line
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galleries are interchanged.
Pressure oil is sent from port A and port B is connected to

the exhaust. The rams retract to give a controlled lowering
of the arms.
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E - 22 9813/3800-01 E - 22
D024250
D
14
B
20
LV1
PORT A
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PORT B
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Fig 15.
on aft
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PORT B
PORT B
PORT A
PORT A
LOWER
RAISE
V3
V3
V4
V4
C
C
E - 23 9813/3800-01 E - 23
Loader Valve
Loader Valve
Shovel Tip
When selected, the Loader Valve section LV2 controls the
shovel tip and close operation.
The spool A is moved by servo-pressure, oil is sent around

its waisted-section to the shovel rams.
Because the A and B ports are interconnected on both
14
sides of the ram pistons, the operating area is the piston-
rod and this causes the ram to extend at speed.
K Fig 16. ( T E-25).
Shovel Return
20
When the shovel return servo-pressure is applied to the
Loader Valve section LV2 the spool A is moved to separate
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the ram pressure and the return lines. K Fig 16. ( T E-25).
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The pressure oil is sent to port B and the exhaust line to
port A. The higher pressure is now on the rod side of the
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piston and this causes the ram to retract.
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The service lines are protected by ARV1 and ARV2. The
function of the A.R.V.s is in K Auxiliary Relief Valve
Operation ( T E-29).
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Loader Valve
14
20
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PORT A
Fig 16.
PORT B
on aft
DUMP
V1
V2
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C
PORT A
D
PORT B
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CROWD
V1
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V2
C
E - 25 9813/3800-01 E - 25
Load Hold Check Valve
When the Loader Valve section LV1 raise service is

operated, the weight of the load lifted gives a higher
pressure than that made by the pump.
This pressure difference causes the load hold check valve

A to close and prevent the load from dropping. Refer
K Fig 17. ( T E-27).
As the neutral circuit is blocked at B, the pump pressure

increases in the gallery until it is more than in the service
14
line.
The load hold check valve A will open (inset A2) to let the
oil flow through into the service line and continue with the
20
lift ram operation. Refer K Fig 17. ( T E-27).
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E - 26 9813/3800-01 E - 26
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on aft
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E - 27 9813/3800-01 E - 27
Auxiliary Service
Auxiliary Service
With the B port power selected for the Auxiliary Services Simultaneously the line from the rod side of the ram
(optional) servo pressure is applied to loader valve section entering the valve at port A is connected to exhaust at C.
LV3.
When port A power is selected servo pressure moves the
The spool A is moved from the neutral position which spool so that the service line galleries are reversed.
blocks the neutral gallery and directs oil over the waisted
section at B to port B. Pressure oil is directed from port A and port B is connected
to exhaust.
From port B oil is directed to the piston heads of the
service rams.
14
20
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D070790-21
Fig 18.
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E - 28 9813/3800-01 E - 28
Auxiliary Relief Valve Operation
Introduction
The two A.R.V.s in the Loader Valve section LV2 release
the excessive pressure in the service lines caused by
external forces and also supply an anti-cavitation function.
Pressure Relief
The figure inset 2 shows that the pressure in the service
14
gallery A has reached the setting of the A.R.V.
The pressure cancels the effect of the spring H on the

poppet B and lifts it from its seat.
20
The oil in the chamber C is moved through the drillings at
D. The excess service pressure from A (through port A) is
released into the exhaust gallery E. Refer
K Fig 19. ( T E-30).
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If the shovel is fully tipped when the arms are being raised
and the shovel cannot tip further, this causes back
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pressure to the head side of the shovel rams and cavitation
on the rod side.
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As the arms continue to rise, the back pressure increases
until it reaches the setting of ARV2 which opens to release
the pressure to the exhaust and prevents damage to the
on aft
rams and linkage.
Anti-Cavitation
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The figure inset 1 shows that when the ARV1 senses a

higher pressure in the exhaust gallery E it cancels the force
D
of the spring F that restrains the anti-cavitation cone G.
The cone and its assembly move down to let the oil from
the exhaust gallery into the service gallery A.
This oil is sent to the rams (through port B) to limit the effect
of the rod side cavitation. When the ram stops cavitating,
the compressed spring F will return the anti-cavitation
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cone G back to its seat. Refer K Fig 19. ( T E-30).

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E - 29 9813/3800-01 E - 29
14
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on aft
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E - 30 9813/3800-01 E - 30
Main Relief Valve Operation
The Main Relief Valves MRVs are attached to the Loader

Valve LV on the Pressure Unloader PU and inlet LV6
sections.
When the service is in neutral and there is no excessive

pressure, the service pressure at A is felt on the lower face
of the poppet B and in the valve through the hollow piston
C.
The springs D and F combine with the service pressure to
14
keep B and E in position.
The spring F can be adjusted by means of screw G.
20
As the service pressure increases at A and reaches the
pilot setting of the MRV, the poppet E opens to let the oil
release from H to J and the pass sleeve K to the exhaust
gallery L.
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As service pressure at A increases and oil continues to
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release from J the pressure differential on the piston C
causes it to rise and seat on the point of the pilot poppet E.
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The pressure oil to H is stopped and this causes a
pressure drop above the main poppet B.
The poppet B opens and vents the service oil pressure into
the exhaust gallery L to control the system pressure. Refer
on aft
K Fig 20. ( T E-32).

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E - 31 9813/3800-01 E - 31
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E - 32 9813/3800-01 E - 32
Loader Valve - Unloader Operation 1
The loader valve Unloader PU is used to decrease the

engine-down during the loading cycle, to give the
maximum available power to the transmission.
It does this by dumping the oil from the pump section P2 to

the tank, to fully apply the engine power to the main pump
section P1.
In operation 1 hydraulic oil from pump P2 enters the

pressure unloader PU and flows around the centre section
14
of spool A.
This oil goes through the check valve B and combines with
the flow from the pump P1.
20
The combined oil flows from P1 and P2 to fill the inlet
gallery C and is sent as pressure oil to the loader valve
service sections LV1 and LV2.
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The pressure in the inlet gallery C is sensed by the pilot
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valve D through the cross-drilling of spool A at A1.
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At a pressure below the setting of the pressure unloader,
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both the pilot valve D and spool A are closed.
The exhaust gallery E is connected to the tank. Refer

K Fig 21. ( T E-34).
on aft
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E - 33 9813/3800-01 E - 33
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20
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on aft
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E - 34 9813/3800-01 E - 34
If the pressure in the inlet gallery C increases, for example

because of increased demand on the lift service, the
setting of pilot valve D is reached and will open.
This causes a pressure differential between the spring

cavity F and gallery C.
The higher pressure in the gallery C is applied to the face

of the spool A at A2 and causes the spool to move.
14
The oil that enters the pressure unloader from the pump P2
now flows across the waisted section of the spool directly
to the tank.
20
The high pressure in the gallery C also holds the check
valve B closed and prevents the oil from the pump P1 from
being dumped.
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When the pressure in the gallery C decreases, the pilot
valve D will close.
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This means that oil in the spring cavity F will be at the same
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pressure as the oil in the gallery C and the force of the
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spring will move spool A back to close the pump P2
connection to the tank. Refer K Fig 22. ( T E-36).
on aft
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E - 35 9813/3800-01 E - 35
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on aft
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E - 36 9813/3800-01 E - 36
Servo Control Valves
Main Servo-Control Valve - Neutral

The Servo-Control Valve SCV operates as a direct
operated pressure reducing valve to apply the spool
actuating servo-pressures to the loader valve LV.
Contained in the valve are four spools that control the four
service ports.
In the neutral position, the oil from the pump P1 flows to the
14
pressure gallery P.
The plungers A and B are equally extended by the spring

S to hold the control lever in the central position.
20
The spools C and D are set to block the pressure oil to the
service ports.
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The service ports are connected to the exhaust gallery T
through the drillings in the spools C and D. Refer
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K Fig 23. ( T E-38).
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E - 37 9813/3800-01 E - 37
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FROM PUMP
TO TANK
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Fig 23.
on aft
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E - 38 9813/3800-01 E - 38
Main Servo-Control Valve - Arm Spool

Operation
When the control lever is moved (the illustration shows the
float position is selected), the operating-plate E pushes the
plunger A.
The return-spring S below the plunger is compressed and

the spool C is moved to align the waisted section F with the
pressure gallery P.
At the same time the exhaust gallery T is closed. The
14
servo-pressure oil is sent from the servo-control valve SCV
to the loader valve LV selected service spool.
The servo-line oil from the opposite end of the service

spool is sent back to the tank through the drilling in the
20
spool D.
All four service ports of the servo-control valve are
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selected as above. K Fig 24. ( T E-40).
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E - 39 9813/3800-01 E - 39
SCV
14
A
C
E
S
T
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G
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FROM PUMP
TO TANK
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Fig 24.
on aft
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E - 40 9813/3800-01 E - 40
Main Servo-Control Valve - Float

Position
When the control lever is moved (the illustration shows the
float position is selected), the operating-plate E pushes the
plunger A.
The return-spring S below the plunger is compressed and

the spool C is moved to align the waisted section F with the
pressure gallery P.
At the same time the exhaust gallery T is closed. The
14
servo-pressure oil is sent from the servo-control valve SCV
to the loader valve LV selected service spool.
The servo-line oil from the opposite end of the service

spool is sent back to the tank through the drilling in the
20
spool D.
All four service ports of the servo-control valve are
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selected as above.
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Electromagnetic locks are on the SCV arms lower position.
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A permanent 24 Volt supply is connected to the arm down
solenoid.
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The spring G gives increased resistance near the end of
the operating lever movement where a ring H contacts a
solenoid armature J.
on aft
The control lever is held at the end position until the

contact is physically broken or the solenoid is de-
energised. K Fig 25. ( T E-42).
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E - 41 9813/3800-01 E - 41
SCV
14
A
C
E
S
T
20
ELECTROMAGNETIC LOCK
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G
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FROM PUMP
TO TANK
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Fig 25.
on aft
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E - 42 9813/3800-01 E - 42
Service Procedures
Hydraulic Contamination
TE-002_3
Hydraulic Fluid Quality cleaning unit. K Fig 26. ( T E-43). General Bulletin 011
also refers.
This machine uses a large volume of fluid in the hydraulic
system for power transmission, equipment lubrication, rust Procedure
prevention and sealing. According to a survey conducted
by a pump manufacturer, seventy per cent of the causes of Connect the cleaning unit in place of the hydraulic filter.
14
problems in hydraulic equipment were attributable to K Fig 26. ( T E-43). Run the system for sufficient time to
inadequate maintenance of the quality of the hydraulic pump all the hydraulic fluid through the unit. Disconnect
fluid. Therefore, it is obvious that control of the quality of the cleaning unit and reconnect the filter. Top up the
the hydraulic fluid helps prevent hydraulic equipment system with clean hydraulic fluid as required.
problems and greatly improves safety and reliability.
20
Furthermore from an economic angle it extends the life of
the hydraulic fluid if quality is maintained.
Effects of Contamination
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Once inside the system, hydraulic circuit contaminants
greatly effect the performance and life of hydraulic
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equipment. For example, contaminants in a hydraulic
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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
on aft
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:
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1 Solid Particles - sand, fibres, metallic particles,

D
welding scale, sealing materials and wear particles

etc. S168050-1
Fig 26. Cleaning Unit
2 Liquid - usually water and incompatible oils and
greases.
3 Gases - Air, sulphur dioxide etc. which can create

corrosive compounds if dissolved in the fluid.
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These contaminants can appear during manufacture,

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

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E - 43 9813/3800-01 E - 43
Service Procedures
Hydraulic Contamination
Contaminant Standards
Dirt that damages your system is in many cases too small
to be seen with the eye. The particle size is measured in
microns.
1 micron = 0.001 mm (0.0000394 in).
Listed below are a few typical comparisons:
– Red Blood Cell = 8 microns (0.008 mm, 0.000315 in)

– Human Hair = 70 microns (0.07 mm, 0.00275 in)
14
– Grain of Salt = 100 microns (0.1 mm, 0.00394 in)
Smallest particle visible to the naked eye is 40 microns

(0.00157) approximately.
20
Standards will often be quoted to ISO (International
Standards Organisation) for which literature can be
obtained.
Filters
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The filter assembly fitted to all product ranges is designed
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to filter all the contamination that is generated through use
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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

on aft
important that the machines hydraulic system is serviced

periodically in accordance with the manufacturers
requirements.
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E - 44 9813/3800-01 E - 44
Service Procedures
Servo Joystick
Servo Joystick
Removal and Installation

Removal
Make sure that the engine is stopped and all the hydraulic
pressure is released from the system. K Fig 27. ( T E-46)
!MWARNING
14
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
20
publication.
HYD-1-5
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1 Remove the screws D and the cover plate C.
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2 Loosen the nut B that attaches the servo handle A.
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3 Remove the servo handle A.
5
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Remove the rubber bellow E.
Disconnect the controls and remove the joystick body

kit F.
on aft
6 Disconnect and put caps on the hydraulic hoses.

Make a record of the position of the hoses.
Installation
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D
The installation procedure is the reverse of the removal

procedure.
Note: During installation, use a new cover plate C.

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E - 45 9813/3800-01 E - 45
Service Procedures
Servo Joystick
B
H
14
E
G
20
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J
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F
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D070900-03
Fig 27.
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E - 46 9813/3800-01 E - 46
Service Procedures
Auxiliary Joystick
Auxiliary Joystick
Removal
Make sure that the engine is stopped and all the hydraulic
pressure is released from the system. K Fig 27. ( T E-46).
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
14
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
20
1 Park the machine and make it safe. Obey the care
and safety procedures.
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Remove the screws D and the cover plate C.
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3 Remove the bolts G that attaches the mounting
bracket H.
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4
5
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Remove the mounting bracket H.
Disconnect and put caps on the hydraulic hoses.

Make a record of the position of the hoses.
on aft
6 Remove the auxiliary servo joystick J.
Installation
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The installation procedure is the reverse of the removal

D
procedure.
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E - 47 9813/3800-01 E - 47
Pressure Testing
Servo-Pressure 9 If a pressure loss occurs check the seating of the non-

return valve and the accumulator.
1 Connect a 0-40 bar (600 lbf/in2) pressure gauge to the
servo-pressure test point A. Checking Steering Relief Valve Pressure
!MWARNING
14
Make sure the articulation lock is in the transport
position before you transport the machine. The
articulation lock must also be in the transport position
if you are carrying out daily checks or doing any
20
maintenance work in the articulation danger zone.
A
B If the articulation lock is not in the transport position
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chassis.
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4-3-5-7
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1 Connect a 0-400 bar (6000 lbf/in2) pressure gauge to
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Fig 28.
D070790-19
2
the test connector B. Refer K Fig 28. ( T E-48).
Turn the steering wheel and check that the pressure

shown is the same as in the K Technical
Data ( T E-1).
on aft
2 Start the engine and read the servo-pressure. 3 If the recorded pressure varies from the specified
pressure, adjust the relief valve accordingly.
3 If the recorded pressure is not as specified in the
K Technical Data ( T E-1) check if the pressure is Unloader Valve
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high or low.
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1 Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge

4 If the recorded pressure varies from the specified to the test connector B. Refer K Fig 28. ( T E-48).
pressure, adjust accordingly.
2 Run the engine at maximum speed.
5 Turn the screw clockwise to increase the pressure
and anti-clockwise to decrease the pressure. 3 To check the unloader valve pressure, slowly move
the shovel to its full extent.
6 Tighten the locknut, when the pressure is correct.
4 Release the lever to the neutral position.
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7 If necessary, do the procedure again, until you get the

correct pressure. 5 Slowly move the lever to operate the close function.
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8 Leave the gauge connected for 3 minutes to check if 6 The gauge pressure should increase to the pressure
the circuit holds its pressure. specified in the K Technical Data ( T E-1) and then
return to zero.
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E - 48 9813/3800-01 E - 48
Pressure Testing
7 To make sure of a consistent reading do the operation 3 To check the M.R.V. pressure, operate the shovel
2 or 3 times. close function until the rams are fully closed.
8 If the gauge does not return to zero, check the non- 4 Make a record of the maximum gauge pressure,
return valve for correct seating. which should be as sepecified in the K Technical
Data ( T E-1).
Main Relief Valve (M.R.V.)
5 If the pressure is incorrect, remove the locknut M and
1 Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge adjust the screw N.
to the test connector B. Refer K Fig 28. ( T E-48).
6 Turn the screw clockwise to increase the pressure
2 Run the engine at maximum speed. and anti-clockwise to decrease the pressure. When
the pressure is correct, tighten the locknut M.
14
20
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N
on aft
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D070790-20
Fig 29.
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Shovel Ram, Head Side 5 Tighten the locknut M to make sure that the pressure
stays at the value specified in K Technical
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1 Connect a 0-400 bar (6000 lbf/in2) pressure gauge to Data ( T E-1).

Shovel Ram, Rod Side
2 Start the engine and operate the shovel until the rams
s
are fully extend. 1 Connect a 0-400 bar (6000 lbf/in2) pressure gauge to
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3 Check that the pressure gauge shows the value as

specified in K Technical Data ( T E-1). 2 Start the engine and operate the shovel close function
until the rams are fully closed.
4 If an adjustment is necessary, release the locknut M
and adjust the screw N to get the correct pressure. 3 Check that the pressure gauge shows the value as
Refer K Fig 29. ( T E-49). specified in K Technical Data ( T E-1).
E - 49 9813/3800-01 E - 49
Pressure Testing

and adjust the screw N to get the correct pressure.
Refer K Fig 29. ( T E-49).
5 Tighten the locknut M to make sure that the pressure

Data ( T E-1).
Lift Ram, Head Side

1 Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge
14
2 Start the engine and operate the lift ram fully.

specified in K Technical Data ( T E-1).
20
and adjust the screw N until the gauge shows the
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correct pressure. Refer K Fig 29. ( T E-49).
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Data ( T E-1).
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Auxiliary Valve, Head Side
1
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Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge
on aft
2 Start the engine and operate the attachment kit

(optional).

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specified in K Technical Data ( T E-1).

D

and adjust the screw N until the gauge shows the
correct pressure.

Data ( T E-1).
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E - 50 9813/3800-01 E - 50
Pressure Testing
Loader Valve - Pressure Testing
Loader ARVs (Using Hand Pump)

To pressure test and set the auxiliary relief valve (A.R.V.),
use the service kit specified in K Service Tools ( T 1-21).
The service kit comprises; a test block 1, a setting-body 2

with adjusting-pin 3, a special spanner 4 and an anti-
cavitation lockout bung 5. The A.R.V. cartridge removal
tool contains an extractor cap 11 and a C-washer 12.
14
20
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Fig 31.
2 Put the special spanner 4 in the cross-holes A and
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separate the A.R.V. sub-assembly 7 from its cap 8.
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Fig 30.
on aft
1 Remove the complete A.R.V. assembly from the

valve block. If the A.R.V. sub-assembly 7 stays in the
valve blocks:
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a Put the cap 11 over the A.R.V. sub-assembly 7,

D
into the valve block E.
b Put the C-washer 12 on top of the cap, but below

the anti-cavitation spring seat as shown.
c Remove the cap, then remove the A.R.V. sub- Fig 32.
assembly.
3 Put the adjusting-pin 3 into the setting-body 2.
d
Note: The early type service kits have two types of

adjusting-pin, one has a screwdriver form and the other an
ue
hexagonal form (see inset). Put the applicable adjusting-

pin in the A.R.V. adjusting-screw. The newtype kits have a
single adjusting-pin that can be used on all A.R.V.'s.
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E - 51 9813/3800-01 E - 51
Pressure Testing
14
Fig 35.
Fig 33.
20
6 Connect a hydraulic hand pump to the port P (pump)
4 Install the A.R.V. sub-assembly into the setting-body
of the test block 1. Make sure that the hand pump is
2. Make sure that the adjusting-pin 3 engages
filled with JCB Hydraulic fluid.
correctly in the adjusting-screw 9.
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Make sure that the locknut 10 is put correctly in the Connect a 0 to 400 bar (0 to 6000 lbf/in2) pressure test
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setting-body socket, the anti-cavitation cone must be gauge to port G (gauge) of the test block 1.
closed, as shown at B.
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When a a hydraulic hand pump is used, the port T
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on aft
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Fig 34.
D
5 Install the A.R.V. sub-assembly and setting-body into

the test block 1. Make sure that the assembly is
installed in the port RV (relief valve).
Fig 36.
7 Raise the pressure at the valve inlet with the hydraulic

d
hand pump, when the A.R.V. 'cracks' and oil comes

from the port T the pressure gauge shows the A.R.V.
ue
setting.
If the A.R.V. setting is correct, move to step 12.

s
If the A.R.V. setting is not correct, move to step 8.

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E - 52 9813/3800-01 E - 52
Pressure Testing
Note: The anti-cavitation lock-out bung seals and locks
the A.R.V. anti-cavitation function. The bung is only
suitable for the test block application and must not be
installed to the excavator valve block.
The bung can be extracted with a 3/8 - 16 UNC

threaded bolt.
14
Fig 37.
20
8 Use the hand pump to increase to approximately 172
bar (2500 lbf/in2) the pressure at the valve inlet.
Note: A pressure increase at the valve inlet locks the anti-
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cavitation cone C onto its seat, this which lets you loosen
the A.R.V. adjusting-screw locknut 10 (step 10).
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If the pressure is maintained move to step 10.
24 Co
Fig 39.
Ju
If the pressure decreases quickly, or if there is no
pressure, it is possible that the anti-cavitation cone is
not seating correctly, in this condition move to step 9.
10 Release the A.R.V. adjusting-screw locknut.
Engage the nut at the end of setting-body 2, use the

slot in the special spanner 4, to turn the nut anti-
on aft
clockwise to release the A.R.V. adjusting-screw

locknut.
Note: Remember, it will not be possible to release the

locknut if there is not approximately 172 bar (2500 lbf/in2)
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pressure at the valve inlet.

d D
Fig 38.
ue
9 If there is no pressure (see step 8) at the valve inlet,

remove the A.R.V. assembly and install the anti-
cavitation lock-out bung 5 in the port RV, make sure
that the bung O-ring face seal D is facing out. Install
the A.R.V. assembly.
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E - 53 9813/3800-01 E - 53
Pressure Testing
12 When you get the correct A.R.V. setting, release the
pressure in the test block. Remove the A.R.V. sub-
assembly and its setting body from the test block.
Separate the A.R.V. sub-assembly from its setting

body.
Install the A.R.V. sub-assembly into its cap.
14
20
Fig 40.
11 Put an Allen key into the adjusting-pin 3. Push the
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adjusting-pin down and make sure it has engaged
with the A.R.V. adjusting-screw.
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Turn the Allen key clockwise to increase the pressure
24 Co
setting and anti-clockwise to decrease the pressure
setting.
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After adjustment, use the slot in the spanner 4 to lock
the A.R.V. adjusting-screw locknut (see note).
on aft
Note: Remember, pressure must be maintained at the

valve inlet to make sure the locknut is tightened.
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Fig 41.
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E - 54 9813/3800-01 E - 54
Pressure Testing
14
20
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E - 55 9813/3800-01 E - 55
Hydaulic Gear Pump

Disassembly
E
G
14
K
20
F
B A
D
th py J
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C I
24 Co
Ju
on aft
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D d
D
ue
D070760-05
Fig 42. Hydraulic Gear Pump
s
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E - 56 9813/3800-01 E - 56
Hydaulic Gear Pump
Disassembly
Item Description
A Hydraulic gear pump
B Suction pipe
C Suction hose
D Wormdrive clip
E Set screw
F O-ring
G O-ring
H Spring washer
14
I Screw D024680
J Spring Fig 44.
K Washer hard metric 3 Put the pump on the work bench and remove the
washers and the screws C. K Fig 44. ( T E-57).
20
Sections
4 Remove the front section A from the rear section B.
Use the slots on the casting as a guide.
th py K Fig 45. ( T E-57).
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24 Co
Ju
on aft
D070790-01
Fig 45.
D024670
Fig 43.
Remove the connecting hub D. K Fig 46. ( T E-58).
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5
A Front Section
D
B Rear Section
1 Use some aluminium protection on the vice so that it

does not damage the machined surface.
2 Put the pump in horizontal position and grab the

pump by the body. Loosen the screws C.
K Fig 44. ( T E-57).
d
s ue
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E - 57 9813/3800-01 E - 57
Hydaulic Gear Pump
Disassembly
14
D070790-02
Fig 46.
20
Second Section Components
Disassembly
1
th py
Draw a reference mark on the plate and the body. It
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will be used later during assembly.
K Fig 47. ( T E-58).
24 Co
Ju
on aft
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D
D024810
Fig 48.
Second Section Seals Disassembly

1 Remove the static seal E from the body.
K Fig 49. ( T E-59).
d
ue
D070790-03
Fig 47.
2 Remove the gears and the thrust plates.

s
K Fig 48. ( T E-58).

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E - 58 9813/3800-01 E - 58
Hydaulic Gear Pump
Disassembly
14
D070790-06
Fig 51.
20
4 Remove from the thrust plate the back-up seal 1 and
the seal 2. K Fig 52. ( T E-59).
th py
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24 Co
2
hou singwith a
Ju
Fig 49.
socket head
D070790-04
Remove the allen plug H and the O-ring J from the

screw.
on aft
K Fig 50. ( T E-59).

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D024850
Fig 52.
D
Second Section Seals Assembly

1 Apply grease on the pressure plate.
K Fig 53. ( T E-60).
d
ue
D070790-05
Fig 50.
3 Then remove the O-ring J from the allen plug H.

K Fig 51. ( T E-59).
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E - 59 9813/3800-01 E - 59
Hydaulic Gear Pump
Disassembly
14
D024860
Fig 53.
20
2 Fit the new thrust plate seal 1 and back-up seal 2 on
the plate. K Fig 54. ( T E-60).
th py
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24 Co
Ju 4
Fig 55.
D070790-04
Place the new O-ring J on the allen plug H and apply

grease on the O-ring J to prevent the damage during
on aft
assembly. K Fig 56. ( T E-60).

r
D024850
D
Fig 54.
3 Apply grease on the new static seal E and install the

static seal E on the on the body. K Fig 55. ( T E-60).
d
ue
D070790-06
Fig 56.
5 Install the allen plug H and the O-ring J assembly in

the body. K Fig 57. ( T E-61).
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E - 60 9813/3800-01 E - 60
Hydaulic Gear Pump
Disassembly
First Section Components Disassembly

1 Remove the front cover K. K Fig 59. ( T E-61).
14
D070790-05
Fig 57.
D070790-08
6 Torque the allen plug H to 90 Nm.
20
Fig 59.
Second Section Components Assembly 2 Draw a reference mark on the plate and the body. It
will be used later during assembly.
1
reference the
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Reassemble the gears and the plates. Use as
mark made previously.
K Fig 60. ( T E-61).
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K Fig 58. ( T E-61).
24 Co
Ju
on aft
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D
D070790-07
Fig 58.
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D070790-09
ue
Fig 60.
3 Remove the gears and the thrust plates assembly G.

K Fig 61. ( T E-62).
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E - 61 9813/3800-01 E - 61
Hydaulic Gear Pump
Disassembly
First Section Seals Disassembly

1 Remove the static seal E from the body.
K Fig 62. ( T E-62).
14
20
th py
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24 Co
Ju
on aft
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D070790-11
D070790-10
Fig 61. Fig 62.
2 Remove the back-up seal 1 and seal 2 from the plate.

K Fig 63. ( T E-63).
d
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E - 62 9813/3800-01 E - 62
Hydaulic Gear Pump
Disassembly
14
D024850 D024850
Fig 63. Fig 65.
20
First Section Seals Assembly 3 Apply grease on the new static seal E and install the
static seal E on the on the body. K Fig 66. ( T E-64).
1 Apply grease on the thrust plate. K Fig 64. ( T E-63).
th py
ly
24 Co
Ju
on aft
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D024860
Fig 64.
2 Fit the new back-up seal 1 and back-up ring 2 on the

plate. K Fig 65. ( T E-63).
d
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E - 63 9813/3800-01 E - 63
Hydaulic Gear Pump
Disassembly
1 Put the cover on the working bench. Paying attention
not to damage the seat remove with a screw driver
(flat head) the shaft seals.(2 - 3) Remove the snap
ring (1) Put some clean grease into the seal seat.
K Fig 68. ( T E-64).
14
20
th py
D04930
Fig 68.
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2 Insert the second shaft seal. Pay attention to the
assembling direction of the shaft seal.
24 Co
K Fig 69. ( T E-64).
Ju
on aft
D070790-11
Fig 66.
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D
Cover Seals Replacement
D024940
Fig 69.
3 Insert the snap ring.

d
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d024920
Fig 67.
E - 64 9813/3800-01 E - 64
Hydaulic Gear Pump
Disassembly
Component Reassembly
1 Put the connecting hub D into the second section
shaft. K Fig 71. ( T E-65)
14
20
D024950
Fig 70.
th py Fig 71.
D070790-12
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2 Install the bushes M. K Fig 72. ( T E-65).
24 Co
Ju
on aft
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D070790-13
Fig 72.
3 Put the front section A and the back section B

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together.
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E - 65 9813/3800-01 E - 65
Hydaulic Gear Pump
Disassembly
4 Put the appropriate CASAPPA tool L on the drive Final Bolting and Check
shaft or protect with adhesive tape to avoid damaging
the shaft seal. K Fig 73. ( T E-66). 1 Put the pump in the vice. K Fig 75. ( T E-66).
2 Use some aluminum protection on the vice to avoid

any damage of the machined surfaces.
3 Put the pump in horizontal position. Grab the pump by

the body. Tighten the bolts with a torque wrench.
14
20
th py
ly
D070790-14
Fig 73.
24 Co
D25010
Components Reassembly
1
K Fig 74. ( T E-66).
Ju
Install the the bushes M and the cover K.
4
5 Recommended sequence
K Fig 76. ( T E-66).
Fig 75.
Torque the bolt to 140 Nm.
for bolts tightening.

on aft
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d D
D025020
Fig 76.
s
6 Put the pump on the work bench and make sure the
Is
pump can rotate on in both directions.
D070790-15
Fig 74.
2 Remove the CASAPPA tool L.
E - 66 9813/3800-01 E - 66
Hydaulic Gear Pump
Disassembly
14
D070790-16
Fig 77.
20
7 If the shaft is locked this means that some of the seals
have come out of their seats during assembly. If this
happens the whole operation must be done again and
th py
the damaged seals must be replaced.
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24 Co
Ju
on aft
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d D
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E - 67 9813/3800-01 E - 67
Loader Valve Block
Assembly Procedure
Loader Valve Block

Assembly Procedure
14
20
th py
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24 Co
Ju
on aft
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D070810-33
Fig 78.
Table 10.
S. No. Description
d
1 Inlet Cover
ue
2 Main Pressure Relief Valve

3 Working Section
4 Port Relief
5 Load Check valve
s
6 Outlet Cover
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E - 68 9813/3800-01 E - 68
Loader Valve Block
Assembly Procedure
Table 11.
S. No. Malfunction Cause Remedy
1 External leakage Spool seal (O-ring) worn out due to – Replace the seal
from lever box or mechanical actuation or high back – Check the back pressure level
control kit side pressure
2 Excessive internal Increased clearance between spool and – Replace the working section
leakage from body due to high bore – Check the oil contamination level
working ports
3 Dropping load High leakage on the load check valve Remove the load check valve and clean
during transition the seat, verify that if there is any dent at
while raising seating area
14
4 Inability to build – Pressure relief valve block or setting – Remove and clean or replace the
pressure on lowered Lower relief valve
working ports – pump pressure and flow – Check the pump and circuit
20
th py
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24 Co
Ju
on aft
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d D
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E - 69 9813/3800-01 E - 69
Loader Valve Block
Assembly Procedure
Cleaning and Initial Set Up Of The Valve

Body
1 Clean the assembly table.
2 Place the valve body on the table.
3 Verify that the valve body is in compliance with the

description.
4 Place the valve body on the assembly bench with inlet

at the left side when viewed from operator side.
14
5 Clean the valve body by blowing compressed air to
remove any dust or dirt.
D070810-03
Fig 81.
20
3 Assemble the BSP ½” plug C and the O-ring D.
th py C D
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24 Co
Ju
on aft
D070810-05
D070810-01
Fig 79. Fig 82.
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4 Install the plug C and the O-ring D and torque plug

VMR Kit Assembly
D
assembly to 42 Nm.
1 Insert the poppet A in the manometer cavity.
d
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D070810-04
Fig 83.
D070810-02
Fig 80.
5 Assemble the BSP 1/4” plug E and torque the plug to
24 Nm.
2 Insert the spring B in the poppet.
E - 70 9813/3800-01 E - 70
Loader Valve Block
Assembly Procedure
2 Torque the VR kit F to the 42 Nm.
Load Sensing (LS) Valve Assembly

1 Insert orifice G (1.25 mm dia) in the LS cavity.
14
D070810-06
20
Fig 84.
VR Kit (Load Check-valve) Assembly

1
O-ring.
th py
Insert the VR kit plug F into the VR kit cavity with an
Fig 87.
D070810-09
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2 Assemble the LS valve H into the LS cavity.
24 Co
Ju
on aft
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D
D070810-07 D070810-10
Fig 85. Fig 88.
3 Torque the LS valve H to 24 Nm.

d
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D070810-08
Fig 86.
E - 71 9813/3800-01 E - 71
Loader Valve Block
Assembly Procedure
14
D070810-11 D070810-14
Fig 89. Fig 92.
20
P & T Plug Assembly 4 Torque the plug K to 42 Nm.
1 Assemble the plug J in the top side inlet port.
th py
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24 Co
Ju
on aft
D070810-15
Fig 93.
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D
5 Assemble the spring L and plug M.
D070810-12
Fig 90.
2 Torque the plug to 42 Nm.

d
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D070810-13
D070810-16
Fig 91.
Fig 94.
3 Assemble the plug K into the side outlet port.
E - 72 9813/3800-01 E - 72
Loader Valve Block
Assembly Procedure
6 Insert the plug assembly in the inlet port.
K Fig 94. ( T E-72).
14
D070810-20
Fig 96.
20
th py
D070810-17
Fig 95.
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Priority Inlet Spool Assembly
24 Co
1
Ju
Insert orifice N (0.75 mm Dia) in the spool.
on aft
D070810-21
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Fig 97.
D
2 Lubricate the spool cavity with hyspin VG46. Main Relief Valve (MRV) Assembly
3 Insert the spool P into the spool cavity. 1 Assemble the main relief valve R into the main relief
valve cavity.
d
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4 Make sure that the orifice face should go inside. D070810-22

Fig 98.
5 Install the plug Q into the spool cavity.
E - 73 9813/3800-01 E - 73
Loader Valve Block
Assembly Procedure
2 Torque the plug to 42 Nm. Spool Assembly (for all type of spool)
Port Relief Valve Cavity Plug Assembly 1 Lubricate the spool bore with proper quantity of
hyspin VG46.
1 Assemble the plug S in port relief valve cavity.
14
20
th py Fig 101.
D070810-25
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2 Place the O-ring onto the spool cavity.
24 Co
2 Ju
Fig 99.
Torque the plug to 42 Nm.
Port Relief Valve Assembly

D070810-23
3 Insert spool T in the first section from the inlet with
lever kit end facing the operator.
on aft
1 Assemble the port relief valve S1 into the port relief 2nd S
ec
valve cavity A1.
r
D
1st S
ec
T
d
D070810-26
Fig 102.
ue
4 Insert spool T in the second section from the inlet with

lever kit end facing the operator.
K Fig 102. ( T E-74).
s
D070810-24
5 Move the spools in and out two to three times for free
Fig 100.
movement.
Is

Control Kit Assembly
3 Follow the same procedures for the B1 and A2 ports.
K Fig 100. ( T E-74). 1st Section
1 Lubricate the spool end with proper quantity of

Castrol Spheerol TM grease or equivalent.
E - 74 9813/3800-01 E - 74
Loader Valve Block
Assembly Procedure
2 Install the control kit spring V, placed between two 2nd Section
bushes U which are assembled into the spool.
1 Lubricate the spool bore with proper quantity of
hyspin VG46.
V
14
U
D070810-27
Fig 103.
20
th py
D070810-30
Fig 106.
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2 Apply a drop of locktite 270 to the control kit screw X.
24 Co
Ju
on aft
D070810-28
Fig 104.
3 Install the end cap W with M6 screws.

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D
D070810-31
Fig 107.
3 Install the control kit and torque the control kit to 9.8
Nm.
d
4 Install the control kit spring, placed between two

bushes which are assembled into the spool.
ue
K Fig 103. ( T E-75).
5 Install the end cap with M6 screws.

s
6 Tighten the control kit cap.

Is
D070810-29
7 Torque the control kit cap to 9.8 Nm.
Fig 105.
4 Tighten the control kit cap. K Fig 105. ( T E-75).
5 Torque the control kit cap to 9.8 Nm.
E - 75 9813/3800-01 E - 75
Loader Valve Block
Assembly Procedure
Pneumatic Dip Test
14
20
D070810-32
Fig 108.
Do the pneumatic dip test to find out any leakage in the

loader valve block assembly.
th py
ly
Follow the below procedures:
24 Co
1 Connect the Pneumatic supply to the valve (Pressure
2 Dip the valve

K Fig 108. ( T E-76).
in Ju
6 Bar). K Fig 108. ( T E-76).
Castrol Honoil 981.

on aft
3 Allow the valve for a minute in the oil until the oil gets
still.
4 If there is leakage, air bubble will leak from the

defective area.
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E - 76 9813/3800-01 E - 76
Loader Valve Block
Assembly Procedure
14
20
th py
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24 Co
Ju
on aft
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D
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E - 77 9813/3800-01 E - 77
Rams
Precautions During Use
TE-006
Installation Special seal materials are necessary so check to

see if the ram that you are using is suitable or not.
1 Precautions when installing the ram on the machine.
c The number one cause of ram oil leakage is rod
a When installing and removing from the machine, damage. Be careful not to damage the rod.
suspend the ram safely.
14
2 Warm up sufficiently before beginning work.
b Suspending the ram by the piping is not only
dangerous, but can also cause damage to the a In cold conditions the rod seals may be frozen, so
cylinder. if the ram is operated at maximum pressure and
maximum speed, the seals will be damaged.
20
c Secure the piston rod with a band. It is very
dangerous if the rod extends unexpectedly. Also, b There is a large amount of air in a new ram or one
the rod can be damaged and become unusable. which has been left for a long time, so the ram will
th py
not operate smoothly. Also, if pressure is applied
2 Welding after installing the ram may result in damage. suddenly without bleeding the air, high
ly
temperatures will be generated due to adiabatic
a If electric welding is done even at a point away compression and the seals may burn.
24 Co
from the ram, there may be sparking inside the
3
Ju
ram and it will become necessary to replace the
ram with a new one.
When painting the machine, mask the ram.

3
c Before beginning work, always move the ram at
full stroke with no load and expel air from the
cylinder.
When stopping or storing, do it at a safe and fixed

position.
on aft
a If paint adheres to the rod surface or to the wiper

ring and the ram is operated, the wiper ring will not
function properly and foreign matter and paint can a The installed ram cannot maintain the same
easily enter the ram. This will cause damage to position for a long period of time, because the oil
the seals, drastically shortening the life of the ram. inside the ram may leak and the hydraulic oil
r
volume decreases as it cools. Stop or store the

D
4 Install the ram only when it is clean. machine in a safe and fixed position.
Caution During Use Maintenance, Inspection Points
1 Use only under designated conditions. 1 Carry out daily maintenance and inspection.
a If hydraulic oil other than the designated oil is a The key point for correct long-term ram function is
used, the seals quickly degenerate and become daily maintenance and inspection. Carry out
damaged. If the relief valve is set at a value higher maintenance and inspection so that the ram
d
than specified, it may cause ram damage and is functions fully at all times. Always remove any
dangerous. mud, water, dust or oil film adhering to the rod and
ue
keep it in normal condition. However, when

b In high temperature environments (approx. 90°C cleaning the wiper ring and seals, do not get them
and above) or low temperature environments wet with water but wipe clean with a rag. To
(below -20°C), seals quickly become damaged. prevent rust forming during storage, the amount of
s
exposed ram piston rod should be kept to a

Is
E - 78 9813/3800-01 E - 78
Rams
Precautions During Use
minimum. If leaving for more than one week,
apply a light coating of suitable grease or
petroleum jelly to the exposed part of the ram
piston rod.
2 Use genuine JCB parts when replacing parts.
a If parts other than genuine JCB parts are used,

the desired results may not be obtained. Use only
genuine JCB parts.
3 Caution during dismantling and reassembly.
14
a Dismantling the ram while it is still installed on the
machine can be dangerous as unexpected
movements of the machine can occur. Remove
the ram from the machine and then dismantle.
20
b If reassembled with dirty hands, foreign matter
can enter the ram causing a shorter life span and
also the other hydraulic equipment may be
th py
damaged. Reassemble in a clean state.
ly
c Follow the instructions in the diagrams regarding
torque tightening for screwed parts. If the torque is
24 Co
too high or too low, it can cause damage.
Ju
on aft
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d D
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E - 79 9813/3800-01 E - 79
Rams
Typical Ram
Typical Ram
17
14
18
16
19
20
3
7
2
th py
5
8
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10
1
24 Co
12
11
Ju 4
6
on aft
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D
13
d
15
14
ue
Fig 109.
s
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E - 80 9813/3800-01 E - 80
Rams
Typical Ram
Disassembly and Assembly Use the sleeve C to protect the gland-seal from damage
and put the end-cap on the piston-rod 9.
Disassembly
The numerical sequence shown on the illustration is a

guide to the disassembly procedure.
Put the ram assembly on a locally manufactured strip/

rebuild bench as shown.
Use the correct size spanner to remove the end-cap 1,

then remove the piston-rod assembly 9 from the cylinder.
14
!MWARNING
If air or hydraulic pressure is used to force out the
piston assembly, ensure that the end cap is securely
20
fitted. Severe injury can be caused by a suddenly
released piston rod.
HYD-1-2
th py
Put the piston-rod assembly on the bench. Remove the
Fig 110.
ly
seals 5, 6 and the wear-rings 4, 7 from the piston-head 3.
Thread the applicable sized screw into the extractor hole,

24 Co
Ju
then remove the dowel 2 from the piston-head.
Use the correct size spanner to remove the piston-head 3

from the piston-rod 9, then remove the O-ring 8.
Make sure that metal components are not scored, nicked

on aft
or burred. A damaged piston-rod will decrease the life of

the gland-seal.
Assembly
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D
The assembly procedure is the reverse of the disassembly

procedure. Fig 111.
Clean the threads of the piston-rod, piston-head, end-cap Apply Loctite Activator-T to the threads of the end cap and
and cylinder with a wire brush. cylinder. Let the Activator-T dry for 15 minutes before the
Loctite is applied.
Use JCB Cleaner and Degreaser to remove the grease,
hydraulic oil and old Loctite from all the threads. Wait 15 Note: The Loctite and Activator-T must not come into
minutes for the solvent to dry before the Loctite is applied. contact with the seals or O-rings.
d
Make sure that lubricants used during assembly do not Install a new O-ring 8 into the piston-head 3.
ue
come into contact with Loctite.

Assemble and torque the piston-head 3 to the piston-rod.
Install the new seals 10, 11, 12 into the end-cap 1, make
sure the seals 11 and 12 are installed correctly, as shown Attach the dowel 2 to the piston:
at A and B.
s
Is
E - 81 9813/3800-01 E - 81
Rams
Typical Ram
1 Existing piston-head and piston-rod: align the holes,
Ram Diameter X Depth Y
then install the dowel with the tapped extractor-hole in
size
view.
90 x 50 8.02mm - 8.10mm 27.0mm - 28.0mm
2 New piston-head and piston-rod: drill and ream the 60 x 30 6.02mm - 6.10mm 22.0mm - 23.0mm
piston-head and the piston-rod to the diameter and
100 x 60 8.02mm - 8.10mm 27.0mm - 28.0mm
depth shown in the table. Remove all the swarf and
contamination. Put the dowel in position, with the 70 x 40 6.02mm - 6.10mm 22.0mm - 23.0mm
tapped extractor-hole in view. 80 x 50 6.02mm - 6.10mm 22.0mm - 23.0mm
3 Existing piston-head and new piston-rod: drill through 50 x 25 6.02mm - 6.10mm 22.0mm - 23.0mm
the existing hole in piston-head to the diameter and
depth shown in the table. Remove all the swarf and Table 12. Torque Settings
14
contamination. Put the dowel in position with the Ram size Item Nm kgf m lbf ft
tapped extractor-hole in view. All except 60 x 30 & 50 1 678 69 500
x 25
4 New piston-head and existing piston-rod: same as
All except 60 x 30 & 50 3 405 41 300
20
step 2 but at 90 degrees to the existing hole in the
piston-rod. x 25
60 x 30 only 1 450 46 332
Note: Make sure that the top of the dowel is below the
th py
60 x 30 only 3 300 31 221
level of the bearing ring-groove. Use an smaller pilot drill
before you drill to the size shown in the table. 50 x 25 only 1 400 41 295
ly
50 x 25 only 3 250 25 184
Put the piston-seal 6 on the piston-head 3, then put the
24 Co
outer seal 5 over the piston-seal 6.
Ju
Note: Make sure that the piston-seal 6 is put in the correct
position and is square in the piston-head, before the outer
seal 5 is attached.
on aft
Put the seal wear-rings 4 and 7 on the piston-head.
Put the cylinder on bench, then install the piston-rod

assembly into cylinder.
r
Apply Loctite 932 to threads of cylinder, then torque the

D
end-cap 1.
Note: If the hydraulic oil touches the uncured Loctite the

bond will weaken. The cure times can change according to
the ambient temperature. The approximate cure times that
follow apply at 20 degrees C and are the minimum periods
between assembly and filling the ram with oil. Fig 112.
Loctite 262 or 932 with Activator N - 1 hour

d
Loctite 262 or 932 with Activator T - 2 hours

ue
Note: Cold weather operation. When you operate in

conditions which are consistently below freezing, operate
the rams slowly to their full extent before you start normal
s
work.
Is
E - 82 9813/3800-01 E - 82
Rams
Typical Ram
JCB Ram Sealing Procedure

TE-005_2
1 Fit new rod seals.
Use seal fitting tool 113-A to fit rod seals, the size
(diameter) and position of pins 113-B is determined
by the diameter and radial width of the rod seal being
fitted.
153212-1
14
Fig 115.
b Close the tool. K Fig 116. ( T E-83). The seal

must form a reniform (kidney shape).
20
S216250-1
Fig 113. Seal Fitting Tool
The pins are screwed into threaded holes in the tool
th py
body, the spacing of the holes is designed to suit
small or large diameter rod seals.
ly
a Open the tool and insert the new rod seal 114-A.
24 Co
S161750 Y-1
The seal must be fitted behind the two front pins Fig 116.
Ju
but in front of the rear pin as shown.
c Before fitting the rod seals check the seal grooves
are free of contamination and sharp edges.
d Locate the seal in the end cap groove.

on aft
K Fig 117. ( T E-83). When the seal is in position,

open the tool to release the seal. Make sure the
seal is correctly installed in its grooved and
remove the tool.
r
D
S161750 X-1
Fig 114.
Note: Later ram end caps and piston heads are metric
threads. The seals are also different, make sure the
correct seals are fitted. On metric threaded rams make
sure the seals are fitted the correct way round, as shown
d
at 115-A and 115-B.

ue
S161750 Z-1
Fig 117.
e Fit rod wiper seal 115-A into seal groove. Make

sure the seal is correctly installed as shown.
s
Is
E - 83 9813/3800-01 E - 83
Rams
Typical Ram
Note: Some rod wipers, i.e. power track rod, may use a b Fit outer seal 119-C using the same procedure as
metal encased seal which is pressed into the housing. stated for seal 119-B. Check the external grooves
Care must be taken to ensure the seal is square before it are visible.
is pressed in.
c Ensure the O-ring is fitted into the internal seal
f Sleeve 118-A must be used to protect the rod groove on the piston head. Screw the piston head
seals from damage when fitting end cap onto the onto the thread of the piston rod, refer to the
piston rod. There are various sizes of sleeve, see relevant section for torque figure and completion
Service Tools, Section 1. Make sure the of ram assembly.
hexagon on the end cap is towards the eye end of
the rod. d Fit the piston head retaining dowel, refer to the
relevant section for torque figure and completion
of ram assembly.
14
e Fit wear rings 120-A and 120-B. Rotate the wear
rings so that the piston retention dowel is covered
by the wear ring, Not as shown at 120-C.
20
th py
ly
187361-1
Fig 118.
24 Co
2 Fit new head piston seals.
a Ju
Use a blunt instrument 119-A (Part no. 892/
01027) to lever the inner seal 119-B into the
piston head seal groove. Do not let the seal twist.
There are identification marks on the outer
on aft
diameter of the seal, make sure the marks are

visible and the seal is free to rotate, if not remove
the seal and refit. 338490-1
Fig 120.
r
3 Fit the piston rod and head assembly into the cylinder.
D
a Insert the piston/rod assembly into the cylinder.

Align the rod and head assembly until parallel with
the cylinder then push the assembly into the
cylinder.
b Fit the end cap, refer to the relevant section for

torque figure and completion of ram assembly.
d
s ue
338480-1
Fig 119.
Is
E - 84 9813/3800-01 E - 84
Rams
Typical Ram
14
20
th py
ly
24 Co
Ju
on aft
r
D
ue
d
s
Is
E - 85 9813/3800-01 E - 85

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Section E

E-0 9813/3800-01 E-0

Contents Page No.

Basic System and Operation

Load Hold Check Valve ......................................................................... E - 26

Pressure Relief ................................................................................. E - 29

Main Relief Valve Operation .................................................................. E - 31

Hydraulic Fluid Quality ..................................................................... E - 43

Removal and Installation .................................................................. E - 45

Contents Page No.

Hydaulic Gear Pump

Loader Valve Block

Cleaning and Initial Set Up Of The Valve Body ................................ E - 70

VR Kit (Load Check-valve) Assembly .............................................. E - 71

Control Kit Assembly ........................................................................ E - 74

Caution During Use .......................................................................... E - 78

Typical Ram ........................................................................................... E - 80

permitted maximum 750 mm2/s (cst)

Relief Valve Operating Pressures

– Shovel ram head side 285 291 4134

– Lift ram, head side 275 280 3989

E-1 9813/3800-01 E-1

E-2 9813/3800-01 E-2

Basic System and Operation

The relief valves in the system prevent undue pressure

When the valve blocks are assembled, tighten the tie-rods

The main components of the 416 Wheeled Loader

A separate gear pump supplies the brake circuit.

The variable flow piston pump is driven by the engine and

delivers pressurised oil to the priority valve section of the

loader valve service spools as control inputs.

E-3 9813/3800-01 E-3

Introduction to Hydraulic Schematic Symbols

General (Basic and Functional Symbols) Table 5. Rams

Complex hydraulic components and circuits can be Single acting

Fixed capacity motor two

Variable capacity motor one

Variable capacity motor two

E-4 9813/3800-01 E-4

Used to enclose several Throttling orifice - normally

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

Non-return valve with back

Pilot operated non-return

One way restrictor

High pressure selector

E-5 9813/3800-01 E-5

Pressure sealed tank

Line plugged with take off line Cooler - indicating direction

Quick release couplings -

Reservoir - return line above

E-6 9813/3800-01 E-6

Rotating shaft - two directions Solenoid two windings

Detent Electric motor operated

Over centre device

th py Pressure operated spring

Pilot operated by a solenoid

Roller trip operated (one

E-7 9813/3800-01 E-7

K Fig 1. ( T E-8) shows a control valve represented by

K Fig 4. ( T E-8) shows a valve described as a 3-position,

4-port control valve. Port describes the openings to and

K Fig 6. ( T E-8) - 'N' spools are sometimes used to

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

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