Partie 3

Section D Controls Section D
i i
Contents Page No.
* Servo Hand Controllers

Description and Operation 1-1
Dismantling and Assembly 2-1
Fault Finding 3-1
Maintenance Specification 3-2
9803/9300 Issue 2*
1-1 Servo Hand Controllers 1-1
Description
This section deals with the Remote Control Valve which provides pilot pressure for the hydraulic control valve and electrical
switching to flow-control solenoids.
The remote control valve is a pressure reduction valve used to control the pilot pressure operated system. Four pressure
reduction valves used to control the pilot pressure are located in the main housing. Direction of the output pilot pressure is
controlled by selective movement of the control lever. The valves and control levers are mounted in the arm rests on both sides
of the operator’s seat.
P T
1 2 3 4
10
5
11
9
28
16
12
15
14
17
18
26
13
27
24
21 25
23
20
32
19 418910
9803/9300 Issue 2
Operation
The pressure reduction unit comprises spools 26, pressure
control springs 18, return springs 13 and spring seats 17.
The spools 26 are held against the plungers 16 by the return
springs 13.
The lower end of the main body 21 contains the main inlet
port P fed from the pump, exhaust port T connected to tank
and the pilot pressure outlet ports 1, 2, 3 and 4.
The pilot pressure controls the stroke and direction of the

main control valve spools.
Oil supplied by the hydraulic pilot pump enters at port P and

the function of the spools 16 is to direct oil from the inlet
port P to the output ports 1, 2, 3 and 4 or alternatively, to the
exhaust port T to tank. The pressure control springs 18 act
on the spools 26 to determine pressure at each port.
Plungers 16 slide in the guides 15 to vary the compression in
the springs 18. The control handle, fixed to the adjusting nut
10 and circular rocker plate 11 is operated to move the
plungers 16. The control handle is able to rotate 360° around
the knuckle joint 9.
The return springs 13 operate between the casing 21 and

the seats 17, regardless of the outlet pilot pressure, returning
the plungers 16 to their outer positions, ensuring the spools
26 return to their neutral (closed) positions. The springs 13
also provide a resistive force, giving the operator a ‘tactile
feel’ of the controls.
The control handles contain electrical push button and

rocker switches which are used to operate auxiliary services.
When the control handle is tilted, the plungers 16 move

down, depressing the return spring seats 17, simultaneously
compressing the pressure control springs 18, moving the
spool, allowing hydraulic oil to flow to the designated pilot
port.
If the handle is held in the tilted position, the pressure in the

outlet ports rises to equal the force of pressure control
spring 18; the oil pressure and spring force become
balanced. If the outlet pressure exceeds the set pressure,
the spool moves to allow port T to open. If the outlet
pressure falls below the set pressure, port T is closed and
port P is opened.
9803/9300 Issue 2
5
13
13
18
18
27
27
11
26
5A 26
9
6
7 21
8 12
10
28
28
15
24 25
15
14 23
14
16
16 22
17 20
17
19 20
19
418920
9803/9300 Issue 1
Dismantling and Assembly

Notes:
1 All parts are precision made and require the utmost 7 Clean the valve exterior using approved solvent and
care when being handled. using soft metal pads for protection, clamp the valve
body into a vice.
2 During dismantling, do not use excessive force to
separate components which could cause scratches or 8 If the return springs 13 are weak, the sliding resistance
burrs on bearing surfaces. Failure to observe this of the seal 14 will cause the guides 15 to stick in the
instruction will cause oil leaks leading to poor casing. Using a screw driver, carefully ease out the
performance. guides 15 and plungers 16.
3 Label all parts during dismantling to ensure correct Note: Care must be taken to prevent damage to the guides
assembly. when removing. Ensure the guides do not fly out due to the
force of the return springs.
4 Storing the valve when dismantled could cause rusting
of parts. Ensure they are suitably protected by anti-rust 9 Remove spring seats 17, return springs 13, pressure
treatment. control springs 18 and spools 26.
5 During assembly, ensure all parts are clean and free Note: Identify each set of parts and their locations for
from burrs and scratches. Remove minor damage by assembly.
lapping.
10 Slacken and remove body assembly screws 19.
6 Renew all ‘O’ rings, seals and back-up rings. Take care Remove and discard ‘O’rings 20.
to install seals the correct way around.
11 Separate upper and lower body sections 21 and 22.
7 During assembly apply hydraulic oil to ‘O’ rings and Remove dowel pins 23 and bush 24.
seals.
12 Remove and discard ‘O’ring 25.
8 Ensure all screws and bolts are tightened to the torque
settings given. 13 Hold spool 26 firmly, depress spring seat 17 and flex
spring 18 to allow the spring seat to slide sideways and
Dismantling be removed from the spool via the larger aperture.
1 Push down upper section of gaiter 5 and remove roll Note: Avoid scratching the surface of the spools. Do not
pin 6. depress the spring seats more than 6 mm (0.24 in).
2 Remove control handle 5A from mounting knuckle 7. 14 Separate spools 26, spring seats 17, springs 18 and
washers 27.
Note: Take care when removing handle to avoid damage to
wiring loom and switches. These should be removed by 15 Remove plungers 16 from guides 15.
separating the line connectors in the control handle and
below the valve body. 16 Remove seals 28 and 14 from guides 15 and discard.
3 Remove gaiter 5 from valve housing. Note: Leave all parts to soak in suitable solvent until dirt is
loosened. Using clean solvent, wash all parts and allow to air
4 Slacken locknut 8 and remove mounting knuckle 7. dry. Apply rust inhibitor to all parts.
5 Slacken and remove joint nut 10 and rocker plate 11.
! CAUTION
When unscrewing the knuckle joint 9, ensure retaining plate
12 is held firmly against the force of springs 13 to make sure
parts do not fly out and cause injury.
6 Unscrew knuckle joint 79, releasing retaining plate 12.
9803/9300 Issue 1
5
13
13
18
18
27
27
11
26
5A 26
9
6
7 21
8 12
10
28
28
15
24 25
15
14 23
14
16
16 22
17 20
17
19 20
19
418920
9803/9300 Issue 1
Dismantling and Assembly (cont’d)
Assembly
Reverse the dismantling procedure, noting the following

details:
1 Locate retaining plate 12 onto plunger guides 15 and

screw knuckle joint 9 into position. Torque tighten to 4.
6 Nm (0.5 kgf m, 40 lbf in).
2 Locate rocker plate 11 and tighten until it makes

contact with the plungers 16. Ensure the plungers are
not depressed at this stage.
3 Holding the rocker plate 11 in this position, screw down

joint nut 10. Torque tighten to 6.7 Nm (0.7 kgf m, 60 lbf
in).
4 When fitting the body assembly screws 19, torque

tighten to 1.9 Nm (0.2 kgf m, 17 lbf in).
5 Ensure the switch cable is free from obstruction and the

line connectors are securely fastened.
9803/9300 Issue 1
Fault finding
Symptom Possible cause Remedy
1 Low secondary pressure. a Primary pressure is low. Check servo pressure maintenance
valve.
b Spring 18 is damaged. Renew the spring.
c Clearance between the spool Renew the remote control valve

and seating is too large. assembly.
d The handle unit is loose. Dismantle, reassemble or renew the

handle unit.
2 Unstable secondary pressure. a Sliding parts are sticking. Release the sticking part.
b Fluctuations in the tank line Check return line and filter for
pressure. blockage.
c Air is trapped in the piping. Operate the valve several times to

remove the air.
3 High secondary pressure. a The tank line pressure is too Check retur n line and filter for
high. blockage.
b Sliding parts are sticking. Release the sticking part.
9803/9300 Issue 1
Maintenance Specification
Maintenance Item Standard Note
Leakage Amount Replace if the leakage exceeds 1.0 Condition:

litre/min (0.22 UKgal/min, 0.26 US gal/min) Primary pressure 26 bar
with the handle in the neutral position or (377 lbf/in2).
2.0 litre/min (0.44 UK gal/min, 0.5 US Oil viscosity 23 cSt.
gal/min) during operation.
Spool Replace when the sliding contact faces The conditions are approximately
are worn more than 0.01 mm (0.0004 in) or the same as for the leakage
more than the non-sliding contact faces. above.
Plunger Replace if the

tip is wor n
more than 1
mm (0.039 in).
JS02060
Loose movement in the Replace the parts if the wear in the pin
operating controls. and joint produces free travel of more than
2 mm (0.079 in).
Investigate if abnormal noises, jerky

Actuation stability. operation or drops in primary pressure are
experienced during operation. Replace the
valve if the problem cannot be solved.
Note: Ensure that ‘O’-rings and other seals are renewed during reassembly. If the body assembly screw 19 is loosened, always
renew the ‘O’-ring 20.
9803/9300 Issue 1
Section E Hydraulics Section E
i i
Contents Page No
Technical Data 1-1
Hydraulic Circuit (Schematic) 2-1

Descriptions 2-2
Hydraulic System
General Fault Diagnosis 3-1
Hydraulic Pump
Operation 4-1
* Track Motor
Description and Operation 5-1
* Slew Motor
Description 6-1
Removal and Replacement 6-2
* Hydraulic Pump
Flow Testing 7-1
Removal and Replacement 7-3
* Hose and Pipe Connections

Servo Circuit - ISO 10 - 1
Servo Circuit - SAE 10 - 2
Boom, Dipper and Bucket Circuits 10 - 3
Slew and Swing Circuits 10 - 4
Track and Dozer Circuits
- Control Valve to Rotary Coupling 10 - 5
- Undercarriage 10 - 6
Return to Tank Circuits 10 - 7
Control Valve
Component Location 12 - 1
Removal and Replacement 12 - 2
Dismantling and Assembly 13 - 1
- Valve Sections 13 - 2
* Vaves
Removal and Replacement
Main Relief Valves 14 - 1
Auxiliary Relief Valves 14 - 2
Pressure Maintenance Valve 14 - 3
Dual Solenoid Valve 14 - 3
* Pressure Testing
Main Relief Valves 15 - 1
Auxiliary Relief Valves 15 - 2
Servo Pressure 15 - 3
Dipper Boost Dump Valve 15 - 3
Cross Line Relief Valves 15 - 4
Boom, Dipper and Bucket rams

9803/9300 Issue 2*
ii ii
Contents Page No
Dozer ram
Swing ram
Rams
Typical Dismantling and Assembly 16 - 5
Inspection 16 - 7
* Rotary Coupling
Dismantling and Assembly 17 - 1
Hydraulic Oil Cooler

9803/9300 Issue 2*
1-1 Technical Data 1-1
Pump
Type Single variable displacement piston type with two equal outlet flows in
tandem with single gear type, driven directly from the engine crankshaft.
Flow Rates at 2420 rev/min

and at neutral circuit pressure
Pump P1 26.8 litres/min. (5.9 UK gal/min., 7.1 US gal/min.).
Pumps P2 and P3 29 litres/min. (6.4 UK gal/min. 7.6 US gal/min.).
* Relief Valve Operating Pressures (at hydraulic oil temperature of 50 oC (122 oF)
8027Z 8032Z
bar lbf/in2 bar lbf/in2
Main Relief Valves (M.R.V.)
Swing/Slew/Dozer/Dipper Boost 185 2683 185 2683
Tracks/Dipper/Boom/Bucket/Auxiliary 207 3000 240 3480
* Servo Pressure
Maintenance Valve 26 377 26 377
Auxiliary Relief Valves (A.R.V.)

Boom rod and head side 290 4200 290 4200
Dipper rod and head side 290 4200 290 4200
* Dozer rod side 220 3190 220 3190
* Bucket head side 290 4200 290 4200
Swing rod and head side Anti-cavitation valve
Slew Crossline Relief Valves 165 2393 165 2393
* Dipper Boost Dump Valve 150 2175 150 2175
Rams
Bore Rod Dia Stroke

mm in mm in mm in
Boom 80 3.15 40 1.57 465 18.31
* Dipper 65 2.56 40 1.57 570 22.44
Bucket 75 2.95 50 1.97 374 14.72
Swing 80 3.15 40 1.57 520 20.47
Dozer 90 3.54 45 1.77 165 6.50
* Track Motors 8027Z 8032Z

Model PHV-290-45-5-8541A PHV-290-45-5-8196A
Type Axial piston motor with dual displacemnt
Displacement 23.6/12.0 cm3/rev 22.1/10.9 cm3/rev
Reduction ratio 45.2 : 1 45.2 : 1
Tracking speed
Low 2.1 km/hr (1.3 mile/hr) 2.2 km/hr (1.4 mile/hr)
High 3.9 km/hr (2.4 mile/hr) 4.2 km/hr (2.6 mile/hr)
Weight 36 kg (79.4 lb) 44 kg (97 lb)
Slew Motor Piston Piston

Slew Speed 9.5 rev/min 9.5 rev/min
Filtration
Main Bypass pressure 1.5 bar (22 lbf/in2) 1.5 bar (22 lbf/in2)
9803/9300 Issue 2*
2-1 Schematic 2-1
Hydraulic Circuit
2 3
4 5 6 7 8
B A B A
18
17
17A
10
16
16
1
P3 2 4 P T 3 1
10A
1K 10B
10C
1F 10D
1A 1H 10E
1C 1D 1J 1L 1M 1N
1B
P T
11
1E 1G
1 3 2 4 11A
11B
1R 1P 1P 1P 1Q 1P 1P 1S 11C
11D
B1 B2
T1 T2
12
P1 C1 P2 C2
12A
13 12B
12C
13B
14 12D
13F
13A
13E
13G
13F
15
13C 13D
P3 P2 P1 E
T 19
9803/9300 Issue 2
2-2 2-2
Hydraulic Circuit 13 Pressure Maintenance Valve Auxiliary relief valves (A.R.V.) 1P are fitted to protect the Servo Circuit
13A Pressure Reducing Valve dipper, boom and the head side only on the dozer ram from
Component Key 13B Shuttle Valves damage that might be generated through over-pressure The Servo Pressure Maintenance Valve 13 is fitted with a
13C Servo Isolation Solenoid Valve conditions during operation. single adjustable pressure reducing valve 13A and solenoid
P Pump 13D Two-Speed Tracking Solenoid Valve valves for servo isolation 13C and two speed tracking
P1 Pump Section 1 - (Gear Pump) 13E Non-Return Valves When the A.R.V.’s are open, over pressure fluid is routed to selection 13D. The system is supplied from pumps P1 and
P2 Pump Section 2 13F Pressure Test Points the control valve exhaust chamber and back to tank T. P2 via a servo signal hose from each of the pump pressure
P3 Pump Section 3 13G Accumulator pipes, into a shuttle valve system 13B.
T Tank 14 Oil Cooler The service lines to the dozer ram, the track motors and the
E Engine 15 Return Filter With Bypass Valve pilot line from the high speed selector to the track motors With the isolator solenoid energised, neutral circuit pressure
1 Valve Block 16 Non-Return Valve are routed through a rotary coupling 18. This device allows from the pumps connects to the hand controllers 10 and 11.
* 17 Auxiliary Couplings (Single/Double Acting) the machine upper structure to turn without damaging hoses As the hand controllers are operated, the neutral circuit
1A Track Right Spool
* 17A Changeover Valve (Single/Double Acting) connected to services mounted on the undercarriage.
1B Dipper Spool pressure is directed to and begins to select the desired
1C Boom Boost Spool 18 Rotary Coupling excavator spool, which in turn pressurises the supplying
1D Auxiliary Spool 19 Suction Strainer The remaining service lines connect directly to their relevant pump flow. This increase in pressure is available in the servo
1E Dipper Boost Spool devices. Return fluid from services or from the neutral system via shuttle valves 13B to enable full excavator
1F Dipper Boost Dump Valve Hydraulic Circuit pressure circuit is routed back to tank through an exhaust operation, but is limited and maintained to correct servo
1G Slew Spool line and return filter 15. levels by the relief valve cartridge 13A.
1H Dozer Spool Note: Circuit and description are for ISO Machines.
1J Swing Spool Neutral Pressure Circuit Servo pressure can be measured at pressure point 13F
1K Main Relief Valve The hydraulic circuit is fed from a hydraulic oil tank T, which is located in the forward position on the top face of
Dozer Circuit located to the right of the operator’s cab. With the engine running, but no service selected, the pump the valve.
Swing Circuit flows are routed from pump sections P1, P2 and P3 to their
Slew Circuit The system is powered by a three section pump P, respective sections of the control valve. Because the signal lines from all three pump flows are
Dipper Boost Circuit connected directly to the engine crankshaft. capable of being pressurised to full system pressure, a
1L Bucket Spool The valve spools are spring loaded to the neutral position, single pressure test tapping PT (rear test point on top face
1M Boom Spool Sections P1 and P2 are constant horsepower variable allowing fluid to pass through the valve’s neutral circuit and of valve) is fitted which can be used to monitor all main
1N Track Left Spool displacement pumps, section P3 is a fixed displacement returned to tank through the return line. hydraulic pump pressures.
1P Auxiliary Relief Valves gear pump.
1Q Non-Return Valves Excess pressure in the selected circuit opens the M.R.V.
1R Main Relief Valve When the engine is running, the pump draws fluid from the associated with the valve section supplied and vents excess
Track Right Circuit tank and routes it through the main control valve block 1. pressure back to tank T.
Dipper Circuit
Boom Boost Circuit Pump section P1 supplies the control valve sections for: Dipper Boost
Auxiliary Circuit
1S Main Relief Valve - Dozer ram, 1H Dipper speed is increased by an automatic dipper boost
Track Left Circuit - Swing ram, 1J system. Dipper boost is achieved by adding a fifth spool 1E
Boom Circuit - Slew motor, 1G between the slew and auxiliary spools in the valve block 1,
Bucket Circuit - Dipper boost, 1E the spool is arranged in series to the slew spool to maintain
2 Track Right Motor ‘preferred’ slew operation, The boost supply from pump P1
3 Track Left Motor Pump section P2 supplies the control valve sections for: via this fifth spool is piped through relief valve 1F and joins
4 Dozer Ram the main dipper spool 1B flow to the ram 5.
5 Dipper Ram - Left hand track motor, 1N
6 Swing Ram - Boom ram, 1M * Relief valve 1F limits the boost pressure to a preset level
7 Bucket Ram - Bucket ram, 1L (see Technical Data) and is pilot operated from pressure
8 Boom Ram developing in the main dipper feed pump P3. This dump
9 Slew Motor Pump section P3 supplies the control valve sections for: valve ensures that when dipper tearout is utilised the boost
10 R.H. Joystick Controller supply is off-loaded back to tank by valve 13, enabling full
10A Bucket Crowd - Right hand track motor, 1A system pressure to be generated at the main excavator
10B Bucket Rollback - Dipper ram, 1B pumps P2 and P3 without overloading the engine.
10C Boom Lower - Boom boost, 1C
10D Boom Raise - Auxiliary, 1D
10E Boom Boost
11 L.H. Joystick Controller Supply from all three pumps is also directed to the Pressure
11A Dipper Boost Maintenance Valve 13, fitted with a single adjustable
11B Dipper Out pressure reducing valve 13A, Servo Isolation Solenoid Valve
11C Dipper In 13C and Two Speed Tracking Solenoid 13D. Supply from
11D Dipper Boost the pumps is via a servo signal hose directed into shuttle
12 Dual Solenoid Valve valves 13B.
12A Slew Right
12B Swing Right Main relief valves (M.R.V.) 1K, 1R and 1S are fitted in the
12C Slew Left main control valve blocks to vent hydraulic pressure, venting
12D Swing Left excess flow to tank T.
9803/9300 Issue 2*
3-1 Hydraulic System - General Fault Diagnosis 3-1
Before carrying out the following checks, ensure that where applicable:
1 The correct hydraulic fluid is used and the system filled to the correct level.
2 The hydraulic fluid, filter and suction strainer are clean.
3 There are no visible leaks in the system.
4 Engine maximum speed and condition is as specification
5 Hydraulic pressures for each service are correct to specification
If possible the machine should be operated to identify the fault and to bring the systems to their normal working temperature.
After completing these initial checks, proceed as follows:
A If all the hydraulic services are at fault start at check 1.

B If servo controllers only are at fault start at check 13.
C If tracking services only are at fault start at check 16.
D If slew service only is at fault start at check 21.
Check Action
1 Is the fault in all services or one only? ALL : Check 2

ONE : Check 6
2 Are the hydraulics inoperative or lacking in power? INOPERATIVE : Check 4

POOR PERFORMANCE :Check 3
3 Is the servo pressure to specification? YES : Check 4.

NO : Adjust
4 Is the pump operating correctly? YES : Check M.R.V's.

NO : Check 5.
5 Is the pump noisy in operation? YES : Purge air from pump casing.
NO : Check 6
6 Is the pump drive broken? YES : Renew

NO : Check 7.
7 Is one service only down on pressure? YES : Check 8.

NO : Check 9.
*8 Is the cable adjustment correct? (Tracks, dozer & auxiliary services only) YES : Check 9.
NO : Adjust cable.
9 Is the control valve spool sticking? YES : Overhaul valve block section
NO : Check 10.
10 Is the service A.R.V. operating correctly? YES : Check 11.

NO : Reset or renew
11 Is the valve block section cracked? YES : Renew section and check
valve block mounting
12 Are the rams faulty? YES : Overhaul or renew
13 Is the fault in all servo operated services or only one? ALL : Check servo isolator microswitch,
check servo solenoid valve, check
14.
ONE : Check 15.
14 Is the servo system operating correctly? YES : Check 15

NO : Check servo pressure maintenance
valve.
9803/9300 Issue 2*
3-2 Hydraulic System - General Fault Diagnosis 3-2
Check Action
15 Is the hand controller plunger leaking/sticking? YES : Service hand controller, see Section D.
16 Is the tracking fault in both tracks and in one or both ONE : Check control linkage, check 17.
directions? BOTH : Check 4.
17 Is the tracking fault in one track in one or both ONE : Swap hoses between pumps P2 & P3, If the fault
directions? changes to other track, service pump. If fault stays
check 18. Check for sticking motor counterbalance
spool.
BOTH : Check 18.
18 Is the fault in one track only and in both directions? YES : With track stalled measure lubrication return to tank
flow (1) at top of rotary joint and (2) out of track
motor.
If (1) high and (2) normal service rotary joint. If (1)
high and (2) high check track motor.
19 Is high speed engaging? YES : Check 20.

NO : Check operation of high speed solenoid valve, rotary
joint seals or motor high speed selector spool.
20 Is the track motor high speed selector servo hose YES : Correct connections
crossed with motor lubrication drain hose?
21 Is the slew motor performance/braking poor? YES : Check for correct pressure settings of cross line
relief valves. Check slew motor anti-cavitation check
valves are closing.
22 Does the slew motor performance improve if bucket YES : Check servo pressure maintenance valve non return
service stalled? valves are closing.
9803/9300 Issue 1
4-1 Hydraulic Pump 4-1
P3
P1
9803/9300 Issue 1
Variable Displacement
Operation
The hydraulic pump is a small lightweight compact unit The constant horsepower control, or summator, is a simple
containing single piston pump A components, which is able design incorporating a trunnion mounted 'swash plate' F
to supply two equal flows to the hydraulic system. Mounted which governs the stroke of the pistons in the pump barrel.
on the back of the pump body is a gear pump B supplying This swash plate is spring loaded to an angle matching the
oil to the dozer, slew and swing circuits. maximum piston stroke hence maximum flow position. As
the pistons G and barrel D rotate, driven by the engine, the
P1 swash plate draws the pistons out of the barrel, filling the
vacated space on top of the piston with oil, once past top
S P2 dead centre the swash plate pushes the pistons back into
the barrel displacing the oil out into the hydraulic circuits of
the machine.
When the machine starts to dig the pressures in the circuits

begin to rise, this is sensed back to the pump and registers
against the crown of the pistons G as the barrel rotates. The
C force of the pressure felt on the piston crowns is transmitted
onto the swash plate and once the spring force of the
summator is exceeded, the swash plate angle progressively
A395070 decreases. This in turn decreases the piston stroke reducing
the volume of oil pumped into the hydraulic circuits.
The piston pump rotating group of components seal against
a fixed valve plate C in the pump casing. The valve plate has The gear pump is a fixed displacement pump, and should
a single groove S machined for suction, but two concentric this come under pressure whilst the machine is digging, the
pressure grooves P1 & P2 both bridging the piston bores in horsepower demands on the engine will increase. However,
the rotating barrel D, the outer groove supplies one hydraulic there is a pilot gallery H sensing gear pump pressure,
circuit whilst the inner groove supplies the second, both running through the main pump housing to a plunger J
circuits receive equal flows. behind the swash plate. This increases the load against the
summator springs E decreasing the angle of swash plate
The piston pump has a constant horsepower control E further and so reducing the piston pump flows thus
which responds to hydraulic system pressure demands, as maintaining a constant horsepower demand on the engine.
pressure in the circuits rise so the volume of oil being
pumped into the circuits decreases, maintaining the
horsepower demands within the power output of the engine
and preventing an engine stall situation.
9803/9300 Issue 1
5-1 Track Motor 5-1
9803/9300 Issue 1
5-2 Track Motor 5-2
Operation
General Counterbalance Operation
The track motor consists of a fixed section, made up of a When the machine is on an incline it will tend to travel under
hydraulic motor and valve unit, and a rotary section which is gravity. Under such conditions the motor overspeeds, acting
a simple double-step planetary speed reduction. as a pump, increasing outlet pressure and lowering inlet
pressure.
When both tracks are selected to operate, the pump section
P3 feeds the valve block section for the RH travel motor, P2 Differential pressure causes the counterbalance plunger Z to
feeds the valve block section for the LH travel motor. Track shift and restrict flow from the counterbalance valve.
feeds from the selected spools flow through the rotary Restricted flow from counterbalance valve to motor causes
coupling to the respective track motors. motor inlet pressure to rise and balance outlet pressure
compensating for gravitational action.
The motor valve plate A has two sets of ports B and C and
is in contact with the swash plate D. Braking
B and C are connected to the motor inlet and outlet lines via When control valve is reset to neutral, ports X and Y are
the counterbalance valve. When pressurised fluid is connected to the tank return line. Pressure on both ends of
introduced through A, pistons E, on the B side are forced the plunger is reduced to exhaust value and the plunger is
against the swash plate D. re-centred. The metering notches on the plunger gradually
limit the flow of return fluid from the motor and machine
Reaction force from the swash plate generates radial force speed is smoothly reduced.
causing rotation of the cylinder block F. Torque generated at
the cylinder block is transmitted to the output shaft G,
through splines on the cylinder block.
The end of the output shaft G has a spline connected gear

which drives two sets of planetary gears H. These reduce
output speed in two steps and transmit rotation to the rotary
section of the motor via an integral ring gear J. Y X
Working fluid is discharged from C. When the control valve, Z
on the main valve block, is selected to opposite position, C
becomes inlet port, B becomes outlet and rotation is X
Y
reversed.
Z
For low speed operation, the 2-speed control valve supplies
fluid to all ports on the port B side (or port C side),
producing maximum torque.
Normal Operation
When travel is selected, pressure is fed from the main pump

to one of the motor control valve ports, either X or Y
depending on the direction of travel. Each port provides a
restricted feed to either end of plunger Z via a small drilling
from the port into the plunger bore. Pressure from the inlet
port causes the plunger to move across, allowing flow to
enter the motor via the control valve to port C. Oil is returned
through the other port back to the tank.
B C
BB AA
9803/9300 Issue 1
5-3 Track Motor 5-3
H50220
9803/9300 Issue 1
5-4 Track Motor 5-4
Motor Low Speed, High Traction Selected
With the high speed button deselected on the dozer lever,

the return spring A above two speed selector spool B
returns the spool to the low speed position.
Service ports C and D are connected via the rotary coupling

to the track spool in the valve block. Depending on whether
track forward or track reverse is selected either port C or D
may be pressurised, the other port then returns exhaust oil
back to tank via the rotary coupling and the track spool.
The illustration shows the upper service port A pressurised.

Because the two speed tracking selector is not selected, the
return spring A holds the selector spool B down allowing
this pressurised oil to cross the spring cavity and on to two
inlet ports in the valve plate E as well as across the top
waisted section of the spool into the centre port of the valve
plate. This means that at least four of the motor pistons
receive high pressure oil, driving the motor at maximum
torque (tractive effort) although at the lower speed.
The opposite four pistons of the track motor are connected

to tank via the lower waisted section of the two speed
selector spool.
9803/9300 Issue 1
5-5 Track Motor 5-5
h50230
9803/9300 Issue 1
5-6 Track Motor 5-6
Motor High Speed, Low Traction Selected
With the high speed button selected on the dozer lever,

servo pressure from the servo pressure maintenance valve
via the rotary coupling fills the cavity under the two speed
selector spool B and lifts it against the return spring A.
Service ports C and D are connected via the rotary coupling

to the track spool in the valve block. Depending on whether
track forward or track reverse is selected either port C or D
may be pressurised, the other port then returns exhaust oil
back to tank via the rotary coupling and the track spool.
* The illustration shows the upper service port C pressurised.

Because servo pressure has lifted spool B, pressurised oil
crosses the top waisted section only of the spool into the
centre port of the valve plate E, supplying a maximum of two
of the motor pistons, driving the motor at maximum speed
(minimum torque/tractive effort).
The opposite two pistons of the track motor displace the oil
to tank via the lower waisted section of the two speed
selector spool.
9803/9300 Issue 2*
5-7 Track Motor 5-7
8
10
9 7
13
14
15
16
11
17
12
18
19
20
21
22
9803/9300 Issue 1
5-8 Track Motor 5-8
Motor and Brake Valve Asembly

The numerical sequence shown on the illustration is

intended as a guide to dismantling.
For assembly the sequence should be reversed.
Note: See Brake Valve Dismantling and Assembly for

components of item 2.
When Dismantling
Remove pistons 10 for inspection. If pistons or cylinder

bores are worn, renew the complete cylinder block and
pistons assembly 6.
When Assembling
Renew all O-rings and oil seals.
Before fitting the oil seal 22, fill the inside of the lip with
grease.
Install the oil seal 22 and the bearing 21 with a compression

force of approximately 500 kgf (1100 lbf).
Before fitting the body 2 to body 3, pour hydraulic fiuid into

body 3.
9803/9300 Issue 1
5-9 Track Motor 5-9
Brake Valve

When Dismantling
Note: Cover all open orifices to prevent dirt entering the

hydraulic system.
When removing the valve spools, note their orientation; they

must be refitted correctly or the valve will not operate
properly.
When Assembling
Renew all the ‘O’ rings supplied in the seal kit.
5 19
4
3 5 20
2 21
1
18
10
6
9 14
8
7
13
12
11
17
16
15
9803/9300 Issue 1
6-1 Slew Motor 6-1
Description
The slew motor consists of a reduction gearbox A, hydraulic The motor located by dowels D to the mainframe and
motor B and hydraulic cross-line relief valve assembly C. secured by setscrews E which may be used as jacking
screws when removing the motor from the mainframe.
The hydraulic motor is an axial piston type and converts
hydraulic energy supplied from the hydraulic pump into a
rotary motion.
The hydraulic valve consists of cross-line relief valves, which

in conjunction with a D/A spool fitted to the valve block
ensures that the inertia produced when stopping the
machine is absorbed through the cross-line relief valves
producing a smooth machine stop also preventing the
hydraulic motor becoming overloaded.
The gearbox is a single step planetary type, the gearing

converts high speed rotary motion from the hydraulic motor
into low-speed high torque transmitted to the pinion shaft.
H18550
9803/9300 Issue 1
6-2 Slew Motor 6-2
Slew Motor
It is not necessary to remove the motor/gearbox complete to

service either the motor A or the cross-line relief valve
assemblies B and C.
Gain access to the slew motor by removing operator’s seat

and cab floor plates. Label, then disconnect three hydraulic
hoses D from the motor head, plug hoses and blank open A
ports to prevent the ingress of dirt.
!CAUTION
Lubrication drain hose is a direct connection to hydraulic
tank, consequently it must be plugged immediately to
prevent excessive oil loss.
D B
Slew Motor Removal
Mark gearbox casing E and motor casing A to aid re-

D
assembly.
A
Remove ring of capscrews F locating motor casing to F
gearbox casing.
E
Lift motor clear of gearbox and remove to a clean area for
dismantling.
Protect open gearbox from ingress of dirt.
Replacement
Remove protective cover from gearbox, position slew motor

over gearbox, ensuring correct engagement of drive shaft
splines.
Align marks made prior to dismantling, fit capscrews F and

tighten to 29 Nm (21 lbf ft).
Cross-line Relief Valve Removal
Mark adjacent housing to aid re-assembly.
Unscrew valve housing A or B and remove. Cover open

motor port to prevent ingress of dirt.
Replacement
Renew 'O' ring seals, ensure valve is correctly positioned

and fit valve to motor.
Check relief valve setting (see Pressure Testing).
9803/9300 Issue 1
6-3 Slew Motor 6-3
6
5 7
13
14
15
16
18
17
19
12
11
20
10
21
9
9803/9300 Issue 1
6-4 Slew Motor 6-4
Motor and Valve Asembly


Note: See Slew Motor Removal and Replacement for

instructions on cross-line relief valves B.
When Dismantling
Remove pistons 10 for inspection. If pistons or cylinder

bores are worn, renew the complete cylinder block and
pistons assembly 6.
When Assembling
Renew all O-rings and oil seals.
Before fitting the oil seal 21, fill the inside of the lip with
grease.
9803/9300 Issue 1
9803/9300 Issue 1
Pump Flow Testing Variable Displacement Pumps
To achieve accurate flow figures it is recommended that the Before the following flow testing is attempted all hydraulic
following procedure is adopted. pressures should be checked for accuracy. It may be an
incorrectly set relief valve causing engine over load or poor
When variable displacement pump flow testing the results machine performance.
are critical to assessing the pumps performance and
therefore the flow meter must be checked for accuracy. If during normal excavating duties the engine excessively
lugs down and black smokes or the hydraulic system
appears to be slow, it may be due to incorrect calibration of
! WARNING the variable displacement pump. To prove this, the pump
Accurate pump performance can only be measured with must be accurately flow tested as follows.
the hydraulic system at normal operating temperature.
Consequently various hose connections may be required With the hydraulic system at the correct working
with HOT hoses, pipes and fittings. Care must be taken temperature, park the machine with the excavator end
to avoid touching metallic fittings with bare hands and resting on the ground. Stop the engine, leave the isolator
prevent hot oil dripping onto the skin. lever in the 'down' position and ignition switch 'on', operate
all excavator services to vent residual pressure.
Remove ignition key for safety, open the engine cover and
disconnect pumps P3 and P2 pressure hoses from the
pressure testing steel pipes. Connect suitable lengths of
hose to both steel pipes and join together with a Tee piece
A. Run another 1 metre (36 in) length of hose B (to prevent
oil turbulence interfering with the flow meter). Connect a
suitably accurate reading flow meter C ideally with an inbuilt
pressure gauge and manual pressure loading restrictor
valve. Run a length of hose from the meter to a second Tee
D piece then divide the flows along the correct neutral circuit
paths E & F of pumps P3 and P2.
Ensure load valve on the flow meter is released so that no

hydraulic pressure is imposed on engine start. Start the
engine and set the throttle to rated speed as detailed in
Technical Data, slowly and progressively screw load valve
in until 207 bar (3000 lbf/in2) for the 8027Z, or 240 bar (3480
lbf/in2) for the 8032Z is recorded on the pressure gauge,
and check engine speed. Note recorded flow figure on
meter.
With 190 bar (2750 lbf/in2) still loaded on system, raise and
stall dozer service, again record flow meter reading. Release
dozer service and reduce system pressure imposed by the
load valve to 185 bar (2683 lbf/in2) and record flow. Stall
dozer service and record flow.
Continue these flow checks through 150 bar (2175 lbf/in2)

and 100 bar (1450 lbf/in2) pressure settings always re-
checking engine speed and adjusting.
Contact Service department of JCB Compact Products Ltd

for calibration instructions.
9803/9300 Issue 1
1
K
2 5
4
3
B
9803/9300 Issue 1
! WARNING
Fine jets of hydraulic oil at high pressure can penetrate
the skin. Do not use your fingers to check for hydraulic
oil leaks. Do not put your face close to suspected leaks.
Hold a piece of cardboard close to suspected leak and
then inspect the cardboard for signs of hydraulic oil. If
hydraulic oil penetrates your skin, get medical help
immediately.
HYD-001
Removal Replacement
Gain access to the engine compartment. Renew filtered adaptor B fitted to gear pump.
Select the starter switch to the ON position. Fill pump body with clean hydraulic fluid through suction
port adaptor A. Cap adaptor to prevent oil draining whilst
Relieve pressure from the hydraulic system. pump is refitted to flywheel housing.
Select the starter switch to the OFF position and Engage the pump driveshaft into coupling K, ensuring the
remove the key. Disconnect the battery. shaft gearteeth mesh correctly with the splines in the
coupling. Torque set bolts 5 (see Technical Data).
Drain the hydraulic tank into a clean container of suitable
capacity, for reuse. Replace pump connections 1, 2, 3 and 4.
Disconnect hydraulic hoses and pipes 1, 2, 3 and 4 from the Refit suction hose 1 to adaptor A as quickly as possible to
pump, cap open ports to prevent dirt ingress. prevent oil loss, tighten worm drive clips.
Remove the screws and washers 5 securing the pump to the Refill Hydraulic tank with oil to the correct level.
engine flywheel housing.
Ensure maximum no load engine speed does not exceed the
figure specified in Engine Technical Data.
Running-in
A new pump is correctly bedded in by the manufacturer and

will require no further running in after fitting.
9803/9300 Issue 1
10 - 1 Hose and Pipe Connections 10 - 1
Servo Circuit - ISO
Port numbers for hose connections are shown in brackets

after item numbers on the illustration.
Note: The ISO control pattern has the boom controlled by the
right hand controller and the dipper controlled by the left hand
controller. The difference between this circuit and the SAE
version is that hoses 21, 25, 26 and 29 are connected to
different ports on the main control valve.
28(P9) 26(P1)
27(P3)
28(P13)
51
4(P5)
5(P7) 27(P1)
25(P13) 2(T) 50
21(P2)
1(P11)
22(P3)
59 15(P)
30
26(P4) 10(P3) 25(P4)
29(P2)
17(P) 9(P1)
11(T)
52 22(P4) 18(P1)
21(P2) 60
53 19(P2)
7(P6)
20(P3)
24(P12)
29(P14) 30(T)
6(P8) 59
2 54
23(P10)
16
3 23(P14)
16(P8)
5(A1)
1
8(P7)
9(P1)
14(ACC)
57
3
18(P1) 7(B1)
17(PR) 11
14
8(BV) 15(PR)
19(P2) 12 6(A2) 4(B2) 10(P2)
31
20(P3) 32
31
13(T)
33
55
56 418650
9803/9300 Issue 1
Servo Circuit - SAE
Port numbers for hose connections are shown in brackets

after item numbers on the illustration.
Note: The SAE control pattern has the dipper controlled by

the right hand controller and the boom controlled by the left
hand controller. The difference between this circuit and the
ISO version is that hoses 21, 25, 26 and 29 are connected to
different ports on the main control valve.
28(P9) 29(P1)
27(P3)
28(P13)
51
4(P5)
5(P7) 27(P1)
21(P13) 2(T) 50
21(P2)
1(P11)
22(P3)
59 15(P)
30
26(P4) 10(P3) 25(P4)
29(P2)
17(P) 9(P1)
11(T)
52 22(P4) 18(P1)
25(P2) 60
53 19(P2)
7(P6)
20(P3)
24(P12)
26(P14) 30(T)
6(P8) 59
2 54
23(P10)
16
3 23(P14)
16(P8)
5(A1)
1
8(P7)
9(P1)
14(ACC)
57
3
18(P1) 7(B1)
17(PR) 11
14
8(BV) 15(PR)
19(P2) 12 6(A2) 4(B2) 10(P2)
31
20(P3) 32
31
13(T)
33
55
56 418660
9803/9300 Issue 1
Boom, Dipper and Bucket Circuits
Hose Connections
1 Valve port A9 to dipper ram head side

2 Valve port B9 to dpiper ram rod side
3 Valve port A8 to boom boost check valve 11
4 Valve port B2 to boom ram rod side
5 Valve port A3 to bucket ram head side
6 Valve port B3 to bucket ram rod side
7 Tee piece 9 to boom ram head side
8 Valve port A2 to boom boost check valve 11
Note: The flow direction of check valve 11 is shown by the

arrow.
4
6 8
5
2
3
1
1 2 8
7
5
6
4
7 12
12A
11
10A
10
9 418620
9803/9300 Issue 1
Slew and Swing Circuits

Hose Connections
9 Valve port B6 to slew motor port PB

10 Valve port A6 to slew motor port PA
11 Pump port P1 to valve port P1
12 Valve port A4 to swing ram head side
15 Valve port B4 to swing ram rod side
15
9 12
10 3
11 13
14 11
13
14
9
10
12
15
2
418630
9803/9300 Issue 1
Track & Dozer Circuit -

Control Valve to Rotary Coupling
Hose Connections
1 Valve port B5 to rotary coupling port P5

2 Valve port A5 to rotary coupling port P6
6 4
6
5
418640
9803/9300 Issue 1
Track & Dozer Circuit - Undercarriage
Hose Connections
Item Rotary Coupling Connected To Function Colour Code
1 Port 7 Track Motor PP 2-Speed White

2 Port 7 Track Motor PP 2-Speed White
3 Port 8 Track Motor DR1 Drain None
4 Port 8 Track Motor DR1 Drain None
5 Port 1 Track Motor (Bottom P) Track Left Grey
6 Port 2 Track Motor (Top P) Track Left Brown
7 Port 3 Track Motor (Top P) Track Right Light Blue
8 Port 4 Track Motor (Bottom P) Track Right Yellow/Green
9 Port 5 Dozer Ram Rod Side Dozer Up Red/Yellow
10 Port 6 Dozer Ram Head Side Dozer Down Blue/White
10
7
8
3 1
5
6 2
7
418670
1
9803/9300 Issue 1
Return to Tank Circuit
Key
1 Slew motor return

2 Tank branch pipe
3 Cooler bypass
4 Cooler return
5 Cooler to control valve port T2
6 Check valve
7 Excavator end auxiliary feed
8 Excavator end auxiliary return to control valve port T1
9 Control valve port T1 to tank branch pipe 2
Note: The flow direction of check valve 6 is shown by the arrow.
7
5
8 9
3
4
2
6 8
1
9
A408680
9803/9300 Issue 1
12 - 1 Control Valve 12 - 1
Component Locations
) ⁄
2
1
3 4 5
6
@ 7
$
^ ‹ 8 9 0
! ¤
B1
B2 *
B3
A1 B4
A2 B5
A3 B6
A4
A5 B8
A6 B9
B10
B11
£ A8 A9
A10
T1
T2 % A11
&
379682
SPOOLS AUXILIARY RELIEF

& ANTI-CAVITATION VALVES PORT
1 LH Track Spool
2 Boom Spool Boom
3 Bucket Spool 12 ARV, Rod side B2
4 Swing Spool 13 ARV/Anti-cavitation valve, Head side A2
5 Dozer Spool Bucket
6 Slew Spool 14 ARV/Anti-cavitation valve, Head side B3
7 Dipper Boost Spool Swing
8 Auxiliary Spool 15 Anti-cavitation valve, Rod side A4
9 Boom Boost Spool 16 Anti-cavitation valve, Head side B4
10 Dipper Spool Dozer
11 RH Track Spool 17 Relief valve, Rod side A5
Dipper
SERVICE PORTS 18 ARV, Rod side B10
(For details see Hose and Pipe Connections) 19 ARV, Head side A10
A1 to A11 MAIN RELIEF VALVES

B1 to B11
20 MRV, LH Track, Boom, Bucket
TANK PORTS 21 MRV, Dozer, Swing, Slew, Dipper boost
22 MRV, Dipper, Boom Boost
T1 Tank Line
T2 Tank Line 23 Dipper Boost Dump Valve
9803/9300 Issue 2
Removal Replacement
! WARNING Check the condition of rubbers C and renew if necessary.

Replacement is a reversal of the removal procedure. On
completion, check the cables for freedom of operation, top
up the hydraulic system and test the circuits for circuit
Hold a piece of cardboard close to suspected leaks and
operation, leakage etc. When installing bracket B ensure
that it is forced down to compress rubbers C.
immediately.
HYD-001
The valve is mounted on upper and lower brackets. To

remove the valve the upper bracket must be removed. See
below.
1 Position the machine on firm level ground.

Stop the engine and vent the hydraulics.
2 Unlock and open the engine cover, open the side

(hydraulic) cover by operating the cover release cable
located in the right hand side of the engine bay.
3 In order to avoid draining the complete hydraulic

system, remove and blank the three feed hoses from
the main pump and release the hydraulic filter cover to
avoid syphoning.
4 Disconnect and blank the hydraulic pipes and hoses

from the valve. Note positions of pipes and hoses for
reassembly.
5 Disconnect all control cables. (You may find it more

convenient to disconnect the cables at the ‘control’ end
rather than at the valve.) Support the valve with a sling.
6 Remove bolts A and bracket B and lift the valve clear.
A395960
9803/9300 Issue 2

Note: The individual valve sections are shown on the When Assembling
following pages.
Notes:
When Dismantling
1 Use new seals and ‘O’ rings, smeared with hydraulic
Caution: Absolute cleanliness is essential when stripping fluid on assembly.
and assembling hydraulic components.
2 If a load check valve has been dismantled then when
* Note: It is not necessary to separate valve sections to assembling check the valve poppet and seat for
remove valve spools, connections, relief valves etc. from the scratches, damage and cleanliness. Begin assembly
valve block. If spools are removed, label them to make sure with the poppet, followed by the spring and finally the
they are assembled in their original positions and facing the plug. Screw the unit in by hand to feel for any
correct direction as each one is machined to match its bore. misalignment or cross threading.
1 Remove the nuts A from one end of the valve tie rods. * 3 If a spool is removed, when assembling ensure that the
‘O’ ring and wiper seal (if fitted) are correctly seated
2 Stand the valve vertically on the other end of the tie and not damaged. Pay particular attention to
rods. cleanliness and the smooth finish of the spool. Ensure
that the spools are fitted in their correct positions.
3 Withdraw the sections one by one, discarding the
intersection ‘O’ rings as you proceed. Note the position 4 Torque figures for the valve section components are
and orientation of the sections before removing them. given on the following pages.
Inspection Assembly
1 Check the mating faces of the valve sections for 1 Ensure all sections are returned to their original
scratching, pitting, burrs and/or corrosion. Renew valve location. Assembly must be carried out on a clean,
sections as necessary. smooth surface.
2 Check the ‘O’ ring seatings, check valve locations and 2 Screw the nuts to one end of each tie rod (to the end
check valves for scratching, pitting, burrs and/or with the shortest length of thread).
corrosion. Renew control valve sections or check
valves as necessary. 3 Insert the tie rods into the first section of the valve.
Place the section on the bench with the free length of
the tie rod uppermost.
4 Lubricate the necessary ‘O’ rings and place on the

required seats. Add the elements to the tie rods
ensuring that mating surfaces are thoroughly clean.
5 After all elements are installed screw the nuts into the
tie rods and tighten to 50% of the required torque.
6 Tighten the tie rods to a torque of 25 Nm (18.5 lbf ft)

using a torque wrench.
379680
9803/9300 Issue 2*
Control Valve Sections

Track Left and Track Right
Note: These sections are not 7 1

interchangeable.
6 2 2A
A
* Torque Settings and Key
Note: Torque setting of the MRV is very critical to ensure

correct MRV pressure and prevent oil leakage. The adjuster
cap 1 can removed and refitted once only using the existing
washer 1A and then tightened to 25 Nm (18 lbf ft). If the cap
is removed and refitted again, a new washer must be fitted
and the cap tightened to 22 Nm (16 lbf ft).
3
Item
A Head side port
B Rod side port
4
1 MRV Adjuster Cap See Note
2 MRV 50 Nm (37 lbf ft)
3 Capscrew 4.5 Nm (40 lbf in)
4 Locknut 4.5 Nm (40 lbf in)
5 Plug 20 Nm (15 lbf ft)
7 Spring Adjuster 4.5 Nm (40 lbf in)
9803/9300 Issue 2*

Boom
5 A
6
4 6
7
1
Item 2
A Head side port
B Rod side port
3 Cap 22 Nm (16 lbf ft)
4 ARV 50 Nm (37 lbf ft)
5 Check Valve Plug 20 Nm (15 lbf ft)
6 ARV/Anti-cavitation Valve 50 Nm (37 lbf ft)
9803/9300 Issue 2*

Bucket
4 B
4
Item 2
A Head side port
B Rod side port
3 Connector 40 Nm (30 lbf ft)
4 Boom Priority Valve Plug 20 Nm (15 lbf ft)
5 ARV/Anti-cavitation Valve 50 Nm (37 lbf ft)
9803/9300 Issue 2*

Swing
9 1
8
2
2
B
7
7
6
6 8
5 3
Item
A Head side port 4

B Rod side port
1 MRV Adjuster Cap 22 Nm (16 lbf ft)
2 MRV 50 Nm (37 lbf ft)
6 Anti-cavitation Valve 30 Nm (22 lbf ft)
8 Anti-Cavitation Valve 30 Nm (22 lbf ft)
9803/9300 Issue 2*

Dozer
7 2
B
6
7
A
5
5
3
Item
A Head side port 4
B Rod side port
7 Blanking Plug 30 Nm (22 lbf ft)
9803/9300 Issue 2*

Slew
B
3
Item
A Head side port 2
B Rod side port
9803/9300 Issue 2*

Dipper Boost
6
1
2 6
1
4
Item
1 Plug 35 Nm (26 lbf ft) 5
2 Check Valve (Dipper Boost) 20 Nm (15 lbf ft)
3 Shuttle Valve 12 Nm (106 lbf in)
5 Spring Aduster 4.5 Nm (40 lbf in)
6 Dump Valve 50 Nm (37 lbf ft)
9803/9300 Issue 2*

Auxiliary
1
Item 2
A Head side port
B Rod side port
2 Locknut 4.5 Nm (40 lbf in)
9803/9300 Issue 2*

Boom Boost
Item
2 Spring Adjuster 4.5 Nm (40 lbf in) 2
9803/9300 Issue 2*

Dipper
B
6
5 7
5 2
* Torque Settings and Key 4
Item
A Head side port 3
B Rod side port
9803/9300 Issue 2*
14 - 1 Valves 14 - 1
Main Relief Valves

Removal * Replacing
! WARNING Note 1: Seals are made from special material, ensure

Fine jets of hydraulic oil at high pressure can penetrate correct replacements are used.
oil leaks. Do not put your face close to suspected leaks. Note 2: Torque setting of the M.R.V. is very critical to ensure
Hold a piece of cardboard close to suspected leaks and correct M.R.V. pressure and prevent oil leakage. The
then inspect the cardboard for signs of hydraulic oil. If adjuster cap D can removed and refitted once only using
hydraulic oil penetrates your skin, get medical help the existing washer E and then tightened to 25 Nm (18 lbf ft).
immediately. If the cap is removed and refitted again, a new washer must
HYD001 be fitted and the cap tightened to 22 Nm (16 lbf ft).
1 Relieve hydraulic pressure, if necessary disconnect and 1 Screw the M.R.V. assembly into the valve block and
blank hydraulic hoses from the valve block. tighten to 50 Nm (37 lbf ft).
2 Unscrew the M.R.V.(s) from the valve block, covering 2 Reconnect hydraulics and set the valve.
the port(s) to prevent the ingress of dirt.
Remove to a clean working area. 3 Refit the components removed to gain access to the
valve(s).
M.R.V. Location and Identification
The M.R.V.’s are located in the two track sections and the
swing section of the control valve.
A Track Left Section

Track left, boom, bucket
B Swing Section
Dozer, swing, slew, dipper boost
C Track Right Section

Dipper, boom boost
A
D
B
E
9803/9300 Issue 2*
14 - 2 Valves 14 - 2
Auxiliary Relief Valves
Removal Inspection
1 Check valve components for scratching, pitting,

! WARNING distortion and/or corrosion.
the skin. Do not use your fingers to check for hydraulic Note: If any part other than O-rings and washer are
oil leaks. Do not put your face close to suspected leaks. damaged the entire valve must be renewed.
then inspect the cardboard for signs of hydraulic oil. If If the valve has been dismantled it should be pressure tested
hydraulic oil penetrates your skin, get medical help before refitting.
immediately.
HYD001
ARV’s are located in the folowing sections of the main

control valve:
Boom
Bucket
Dipper
* Dozer
See Control Valve - Spool and Auxiliary Relief Valve
Locations also Dismantling and Assembly.
1 Obtain access to the control valve.
2 Relieve hydraulic pressure, disconnect and blank any

hoses or pipes which may interfere with the removal of
the relief valve(s).
3 Unscrew the auxiliary relief valve(s) from the control

valve and remove to a clean working area.
9803/9300 Issue 2*
14 - 3 Valves 14 - 3
Pressure Maintenance Valve and Dual

Solenoid Valve
Removal Note: It is possible to remove a valve cartridge for cleaning
or resealing without removing the complete valve from the
! WARNING machine.
3 To remove the valve, mark hoses for correct
replacement and remove. plug hoses to prevent the
ingress of dirt. On the dual solenoid valve, disconnect
the cables.
4 Remove the bolts holding the valve to the slew frame.
immediately.
HYD001
If there is evidence of damage to the valve or its seat
caused by debris then the cartridges will require
1 Stop the machine on level ground with the bucket
renewing. If a cartridge or valve complete is renewed it
resting on the ground. Stop the engine and vent
is recommended that the filtered adapters in the feed
residual pressure from the servo accumulator by
ports of the valve are also renewed.
turning the ignition on and lowering the L.H. arm rest to
the excavator operate position. Operate both excavator
control levers in all directions until stored servo
pressure in the accumulator has been exhausted.
2 Remove the key. Remove the left side skirt to gain

access to the pressure maintenance valve A and dual
solenoid valve B.
A396040
9803/9300 Issue 1
15 - 1 Pressure Testing 15 - 1
Main Relief Valves
1 Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge A B

to port PT on the pressure maintenance valve.
2 With the engine running at maximum speed and

hydraulic fluid at normal working temperature,
operate to full travel one of the rams in the circuit
served by the valve under test. (See services listed at A, C
B and C below.
The M.R.V.’s are located in the two track sections and the
swing section of the control valve.
A Track Left Section

Track left, boom, bucket
B Swing Section
Dozer, swing, slew, dipper boost
C Track Right Section 379682
Track right, dipper, boom boost
3 Check the gauge reading is as detailed in Technical D

Data. If incorrect, use a spanner to prevent body
E
F from turning and remove cap nut D. With the ram
held at full travel and body F still prevented from
F
turning, use a screwdriver to adjust the M.R.V. by
means of the screw E until the gauge reads the correct
pressure.
4 Fit cap nut D and tighten to 25 Nm (18 lbf ft). Do not

overtighten. Check gauge reading is correct. Repeat
procedure as necessary. If body F is disturbed, tighten
to 50 Nm (37 lbf ft).
Note: Torque setting of the MRV is very critical to ensure

correct MRV pressure and prevent oil leakage. The adjuster
cap nut D can removed and refitted once only using the
existing washer and then tightened to 25 Nm (18 lbf ft). If the
cap is removed and refitted again, a new washer must be
fitted and the cap tightened to 22 Nm (16 lbf ft).
5 Switch off engine. Remove pressure gauge and refit

blanking cap.
PT
A397740A
9803/9300 Issue 2
Auxiliary Relief Valves

1 Remove the auxiliary relief valve from the control valve
and plug the valve port.
* 2 Install the auxiliary relief valve into the test block B part
number 331/31069.
3 Connect a 0 - 400 bar (0 - 6000lbf/in2) pressure gauge

and hand pump, number 892/00223, to test block.
4 Operate pump and adjust pressure setting plug C until

valve opens at correct pressure, refer to Technical
Data.
5 Lock the pressure setting plug with the locknut D and

retest. Remove auxiliary relief valve from test block and
refit to control valve.
418590
9803/9300 Issue 2*
Servo Pressure
1 Remove the blanking cap and connect a 0 - 40 bar (0 -
600 lbf/in2) pressure gauge to the test point PV on the
pressure maintenance valve (PMV) B. GP
2 With the engine running at maximum speed and
hydraulic fluid at normal working temperature,
operate the dipper service and check the gauge
reading.
3 If the servo pressure is incorrect (see Technical Data), B

adjust as follows: Slacken lock nut C and turn adjusting
screw D clockwise to increase the pressure or anti- PV
clockwise to decrease. Tighten lock nut to 25 Nm (18 lbf
ft). Recheck the pressure as described in step 3.
4 Switch off engine. Remove pressure gauge and refit D

blanking cap.
C
Dipper Boost Dump Valve A397740B
1 Remove the blanking cap and connect a 0 - 400 bar (0 -

6000 lbf/in2) pressure gauge to the test point GP on the
pressure maintenance valve (PMV) B.
2 With the engine running at half speed and hydraulic

fluid at normal working temperature, ensure that the
dipper is partly out. Very slowly and progressively
operate dipper IN. The pressure recorded on the gauge G
will gradually rise. When the gauge reaches the current
setting of the dipper dump valve the needle will drop F
suddenly to zero.
For accurate valve setting the reading MUST be taken

at the exact point the pressure drops off, so care must
be taken when raising the pressure.
Note: If a pressure reading is not recorded at the first

attempt, the dipper must be sent out again before trying to
recheck the pressure as described above.
4 If the dump valve pressure is incorrect (see Technical

Data), adjust as follows: Slacken lock nut F and turn
adjusting screw G clockwise to increase the pressure or
anti-clockwise to decrease. Tighten lock nut to 25 Nm
(18 lbf ft). Recheck the pressure as described in step 3.
5 Switch off engine. Remove pressure gauge and refit

blanking cap.
9803/9300 Issue 2
Cross Line Relief Valves

There is a single relief valve A and B for each direction of
slew. These valves are located in the head of the slew B
motor. The pressures should be checked to the values
quoted (refer to Technical Data) using the method
described below.
Ensure the hydraulic system is at correct operating

A
temperature.
Cross Line Relief Valves A and B
1 Remove floor mat and necessary floor plates to gain

access to the slew motor.
2 Connect a 0 - 400 bar (0 - 6000lbf/in2) pressure gauge

at test point PT on the pressure maintenance valve.
3 Engage slew lock. With the engine running at maximum

speed and the hydraulic fluid at working temperature
(refer to Technical Data), fully select slew left and hold
whilst checking the pressure gauge reading.
4 Check that the pressure gauge reading equals the cross

line relief setting (refer to Technical Data). The relief
valve cartridges are not pressure adjustable, if the
recorded pressure is low, remove the valve from the
motor and check for debris or failed seals. Clean valve
components and renew seals if necessary, refit to
motor and retest. if the correct pressure is still not
obtainable the relief valve should be changed for a new
one.
5 Repeat the test fully selecting slew right.
6 Stop the engine, remove the pressure gauge and fit

blanking cap.
PT
A397740A
9803/9300 Issue 2
16 - 1 Rams 16 - 1
Boom, Dipper and Bucket Rams
Removal and Replacement When Removing
1 With the engine idling, set the machine with the bucket
! WARNING on the ground.
the skin. Do not use your fingers to check for hydraulic 2 Support the excavator under the angle between the
oil leaks. Do not put your face close to suspected leaks. dipper and boom to ensure it will not move when the
Hold a piece of cardboard close to suspected leaks and ram is removed.
hydraulic oil penetrates your skin, get medical help 3 On boom and bucket rams, remove the protection
immediately. plate. Support the ram under the gland bearing and
HYD001 remove locknut A and bolt B from the pivot at the eye
end of the ram. Drive out the pivot pin C.
! WARNING
4 With the engine idling, gently retract the ram rod into
A raised and badly supported machine can fall on you.
the cylinder by operating the relevant service.
Position the machine on a firm, level surface before
raising one end. Ensure the other end is securely
5 Run the engine at idle and with the servo isolator lock in
chocked. Do not rely solely on the machine hydraulics or
the operate position move the control lever rapidly in
jacks to support the machine when working under it.
both directions to vent any trapped pressure. Stop the
Disconnect the battery, to prevent the engine being
engine.
started while you are beneath the machine.
GEN001
!CAUTION
This operation may not fully release all the trapped pressure.
! WARNING Consequently, when removing the hoses, progressively
slacken the fittings to vent any residual pressure to
If air or hydraulic pressure is used to force out the piston
atmosphere
assembly, ensure that the end cap is securely fitted.
Severe injury can be caused by a suddenly released
6 Support the ram and remove the locknut A and the bolt
piston rod.
B from the pivot at the base of the piston.
HYD002
Drive out the pivot pin C. Disconnect the hoses.
Remove the ram from the machine.
Z Z
Z
Z Z B
C
Z
A
A390950
9803/9300 Issue 1
16 - 2 Rams 16 - 2
Boom, Dipper and Bucket Rams (cont’d)

Removal and Replacement (cont’d)
When Replacing
1 Locate the pivot point on the ram into the location on

the machine structure. Fit the pivot pin C and secure
using the bolt B and new locknut A.
2 Support the ram under the gland end of the cylinder,

reconnect the hoses. With the engine idling, slowly
extend the ram until the eye end locates correctly in the
machine structure. Fit pin C. Secure using the bolt B
and new locknut A.
3 Apply grease to the pivot points through the grease

nipples. For grease specification see Lubricants and
Capacities.
4 Connect the hoses to the cylinder, see Hydraulic

Fittings and Torque Settings.
5 On the bucket and boom rams, fit the protection plate

and secure using the bolts.
Z Z
Z
Z
Z B
C
Z
A
A390950
9803/9300 Issue 1
16 - 3 Rams 16 - 3
Dozer Ram
When Removing When Replacing
1 Set the machine in the posture shown with the dozer 1 Locate the pivot point on the base of the ram into the
grounded onto suitable supports. dozer frame.
2 With the starter switch turned OFF, relieve residual 2 Fit pivot pin F and secure with bolt E and new locknut
hydraulic pressure by operating the hydraulic controls. D.
3 Disconnect the hydraulic hoses. Blank off the hoses 3 Fit the pivot point at the rod end of the ram to the
and the open ports of the ram. machine.
4 Remove locknut A and the bolt B from the pivot at the 4 Fit the pivot pin C and secure using the bolt B and new
rod end of the ram. Support the ram and drive out the locknut A.
pin C. Lower the ram end onto a suitable support.
5 Apply grease to the pivot points through the grease
5 Remove locknut D and bolt E. Support the ram and nipples G.
drive out pin F. Carefully remove the ram from the
machine. 6 Connect the hoses to the cylinder, see Hydraulic
Fittings and Torque Settings.
B G
C
A
G
E
F
D
A395950
9803/9300 Issue 1
16 - 4 Rams 16 - 4
Swing Ram
Removal & Replacement
When Removing
1 Position the machine with upper structure slewed at 90º 8 Remove the pivot pin .
right to the tracks.
9 Withdraw ram with hoses attached.
2 Swing the machine dig end fully to the right and lower
the excavator to the ground. When Replacing
3 Remove keep plate A at the rod end of the ram. 1 Connect hoses to new/serviced ram. Locate the ram
into the machine upper structure and align the base
4 Support the cylinder and drive out the pivot pin B. With pivot point with the mating location in the machine
the engine idling, slowly retract the ram until the eye frame.
end clears the king post C. Stop the engine.
2 From underneath the upper structure fit the pivot pin
5 Operate the swing pedal in both directions to vent any and secure with bolt, washer and keep plate.
residual pressure.
3 Reconnect the hoses.
6 Remove floor mat and floorplates. Disconnect the ram
feed hoses at the valve block, Plug the hoses and cap 4 With the engine idling, slowly extend the ram until the
the open ports of the valve. eye end locates into the kingpost C, stop the engine
7 Locate the ram from underneath the upper structure. 5 Fit the pivot pin B. Refit and secure keep plate A.
Remove the bolts and the spring washers securing the
keep plate at the base end of the cylinder. Note: See section 1 for torque tightening and sealant
information.
9803/9300 Issue 1
16 - 5 Rams 16 - 5
Typical Dismantling and Assembly
! WARNING
If air or hydraulic pressure is used to force out the
piston assembly, ensure that the end cap is securely
fitted. Severe injury can be caused by a suddenly
released piston rod.
HYD002
Illustrations for the Dismantling and Assembly sequences

are of typical rams, slight variations may occur in parts used.
The numerical sequences shown in the figures are intended

as a guide to dismantling.
Note: The numerical sequences shown in the figures on this

and the following page are intended as a guide to
dismantling. For assembly the sequence should be reversed.
Try to lay out the parts in the correct sequence for assembly.
Support the ram as shown. Discard all seals and O-rings.
SWING RAM
4 3
5
6
7
9
1
380420
9803/9300 Issue 2
16 - 6 Rams 16 - 6
BUCKET RAM BOOM RAM
3
4
5 4 3
6 5
6
7 7
1
8 1 9
8
2 2
380410 419900
DIPPER RAM DOZER RAM
2
3 8 9
4 1
5
7
6
7 4
9 5
1 6
8
2
3
380430
380400
9803/9300 Issue 2
16 - 7 Rams 16 - 7
Typical Dismantling and Assembly

(continued)
Inspection
Piston Rod Warp
1 Support the piston rod on a pair of 'V' blocks.
2 Set a dial test indicator (D.T.I.) at the approximate

centre of the rod. Set the D.T.I. to zero.
3 Rotate the piston rod in its blocks, noting any variation

in D.T.I. reading.
4 If warp (half the difference between maximum and

minimum readings) exceeds 0.5 mm (0.02 in) the piston
rod must be replaced.
When Assembling
Completely remove oil, grease, dirt and hardened locking

compound from all threads. Remove all traces of rust using
a wire brush.
* Apply JCB Activator to threads of piston rod and cylinder.

Apply JCB High Strength Threadlocker & Sealer to threads A B
of piston head 5 and gland bearing 1. Wait 15 minutes
before assembly, using torque figures specified below.
Use new seals and ‘O’ rings, lubricated with hydraulic fluid
before assembly.
Take care not to damage seals during assembly.
Make sure that the wiper A and gland B seals are fitted the
correct way around as shown.
* Apply JCB Threadlocker and Sealer to threads of locking

screw 4.
* Allow one hour at 20 deg C before filling the ram with oil. H13160
* Torque Settings Nm (lbf ft)
Piston Head (5) Locking Screw (4) Gland Bearing (1)
Boom Ram 600-650 (440-480) 20-25 (15-18) 320-370 (235-270)
Dipper Ram 400-450 (295-330) 20-25 (15-18) 280-310 (205-230)
Bucket Ram 680-730 (500-540) 20-25 (15-18) 310-360 (230-265)
Swing Ram 660-710 (485-525) 20-25 (15-18) 320-370 (235-270)
Dozer Ram 880-930 (650-685) 20-25 (15-18) 380-430 (280-315)
9803/9300 Issue 2*
17 - 1 Rotary Coupling 17 - 1
L
D
K
H
B
B
J
B
C
C B
F B
G
9803/9300 Issue 1
17 - 2 Rotary Coupling 17 - 2
Removal & Replacement Dismantling & Assembly

Removal Note: Although the illustration shows ORFS seals, the seals
fitted are BSP.
Note: Before removing a suspected leaking coupling,
ensure that the leak is from the coupling core and not a hose Dismantling
adaptor. Ensure all adaptors are tight.
1 Note the positions and remove the adaptors A and B
from the coupling. Discard the O-rings.
! WARNING
2 Remove the four capscrews retaining cover plate F.
3 Remove the external circlip and spacer ring G from the
base of the coupling.
4 From the top of the coupling carefully withdraw the
coupling core H from the shell J.
immediately.
HYD001
5 Remove and discard back-up rings and O-rings K from
! WARNING the core.
A raised and badly supported machine can fall on you.
Inspection
Position the machine on a firm level surface before
raising one end. Ensure the other end is securely
1 All rotary coupling core O-rings and back-up rings K
chocked. Do not rely solely on the machine hydraulics or
must be replaced with new and are only available as a
jacks to support the machine when working under it.
set.
Disconnect the battery, to prevent the engine being
started while you are beneath the machine. 2 If the core H or shell J show signs of wear replace the
GEN001
complete rotary coupling.
Assembly
1 Remove the floor plate
1 Assemble in reverse order of dismantling, fitting new O-
2 Disconnect the hydraulic hoses from the rotary coupling rings and back-up rings, lightly lubricate with hydraulic
adaptors A, blank off the hoses and adaptors. fluid.
3 From under the machine, remove the rotary coupling 2 Fit lip seals L in the positions and attitudes shown.
cover plate.
Replacement
4 Disconnect the remaining hydraulic hose from the rotary
coupling adaptors B, Blank off the hoses and adaptors. 1 Replace in reverse order of removal.
5 Remove the bolts, washers and nuts C securing the 2 Reconnect hydraulic hoses using new lightly lubricated
coupling flange to undercarriage. O-rings.
6 Lift the coupling, allowing the reaction pin D to clear the

cut-out in the mainframe floor, turn the coupling 90º.
and lower clear of the machine to a clean working
surface.
9803/9300 Issue 1
21 - 1 Hydraulic Oil Cooler 21 - 1

! WARNING
Note: The hydraulic oil cooler is mounted directly in front of
the radiator, and under normal circumstances should require
no attention. However, periodically debris collected between
the radiator and cooler should be removed. In this event the
cooler can be dismounted and carefully moved clear of the
radiator without disconnecting the hydraulic pipework.
Whilst dismounted, the cooler should be inspected for
immediately.
damage and leaks.
HYD001
Removal Replacement
1 Position the machine on firm level ground with the Replacement is a reversal of the removal procedure.
bucket resting on the ground. Stop the engine and vent
residual pressure from the system by fully operating all On completion, fill the hydraulic tank, run the engine and
control levers. check for leaks.
2 Remove the hydraulic oil filler cap and drain the

hydraulic tank.
3 Disconnect the top and bottom hoses from the cooler.
4 Remove bolts and washers securing the upper A and

lower B oil cooler mounting lugs to the top radiator
bracket and lower mount.
5 If a new cooler is to be fitted, separate the upper and

lower oil cooler brackets from the old cooler by
removing bolts, nuts and washers at C and D.
Note: Ensure the space between the radiator and oil cooler
is clean and free from debris.
A395440
9803/9300 Issue 1

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Section D Controls Section D

Contents Page No.

* Servo Hand Controllers

The pilot pressure controls the stroke and direction of the

Oil supplied by the hydraulic pilot pump enters at port P and

The return springs 13 operate between the casing 21 and

The control handles contain electrical push button and

When the control handle is tilted, the plungers 16 move

If the handle is held in the tilted position, the pressure in the

Dismantling and Assembly

5 Slacken and remove joint nut 10 and rocker plate 11.

6 Unscrew knuckle joint 79, releasing retaining plate 12.

Dismantling and Assembly (cont’d)

Reverse the dismantling procedure, noting the following

1 Locate retaining plate 12 onto plunger guides 15 and

2 Locate rocker plate 11 and tighten until it makes

3 Holding the rocker plate 11 in this position, screw down

4 When fitting the body assembly screws 19, torque

5 Ensure the switch cable is free from obstruction and the

Symptom Possible cause Remedy

b Spring 18 is damaged. Renew the spring.

c Clearance between the spool Renew the remote control valve

d The handle unit is loose. Dismantle, reassemble or renew the

c Air is trapped in the piping. Operate the valve several times to

b Sliding parts are sticking. Release the sticking part.

Maintenance Item Standard Note

Leakage Amount Replace if the leakage exceeds 1.0 Condition:

Plunger Replace if the

Investigate if abnormal noises, jerky

Technical Data 1-1

Hydraulic Circuit (Schematic) 2-1

* Hose and Pipe Connections

Boom, Dipper and Bucket rams

Hydraulic Oil Cooler

Flow Rates at 2420 rev/min

Auxiliary Relief Valves (A.R.V.)

Slew Crossline Relief Valves 165 2393 165 2393

* Dipper Boost Dump Valve 150 2175 150 2175

Bore Rod Dia Stroke

* Track Motors 8027Z 8032Z

Slew Motor Piston Piston

After completing these initial checks, proceed as follows:

A If all the hydraulic services are at fault start at check 1.

1 Is the fault in all services or one only? ALL : Check 2

2 Are the hydraulics inoperative or lacking in power? INOPERATIVE : Check 4

3 Is the servo pressure to specification? YES : Check 4.

4 Is the pump operating correctly? YES : Check M.R.V's.

6 Is the pump drive broken? YES : Renew

7 Is one service only down on pressure? YES : Check 8.

10 Is the service A.R.V. operating correctly? YES : Check 11.

12 Are the rams faulty? YES : Overhaul or renew

14 Is the servo system operating correctly? YES : Check 15

19 Is high speed engaging? YES : Check 20.

When the machine starts to dig the pressures in the circuits

The end of the output shaft G has a spline connected gear

When travel is selected, pressure is fed from the main pump

Motor Low Speed, High Traction Selected

With the high speed button deselected on the dozer lever,

Service ports C and D are connected via the rotary coupling

The illustration shows the upper service port A pressurised.

The opposite four pistons of the track motor are connected

Motor High Speed, Low Traction Selected

With the high speed button selected on the dozer lever,