TLT35D Section e - Hydraulic

Section E
Hydraulics
Service Manual - Teletruk
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section D - Controls
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering
Section K - Engine
Publication No.
9803/9510-08
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:
E-0 9803/9510-08 E-0

Contents Page No.

Service Tools
Numerical List ........................................................................................... E-1
Technical Data
Specifications ........................................................................................... E-5
4x4 Additional Components ...................................................................... E-7
Basic Operation
Description .............................................................................................. E-12
Hydraulic System ............................................................................... E-12
Steering System ................................................................................. E-12
Braking System .................................................................................. E-12
Transmission System ......................................................................... E-13
Introduction to Hydraulic Schematic Symbols ........................................ E-14
General (Basic and Functional Symbols) ........................................... E-14
Control Valves .................................................................................... E-18
Example of Schematic Circuit ............................................................ E-19
4 Wheel Drive (3.0D 4x4 Machines) ....................................................... E-20
2 Speed Operation ............................................................................. E-24
4 Wheel Drive Operation (3.5D 4x4 Machines) ...................................... E-25
Integrated Pump Mounted 4x4 System (3.0D/3.5D 4x4 Machines) ....... E-30
General Description ............................................................................ E-30
Service Procedures
Hydraulic Contamination ........................................................................ E-38
Hydraulic Fluid Quality ....................................................................... E-38
Effects of Contamination .................................................................... E-38
Cleaning Operation ............................................................................ E-38
Contaminant Standards ...................................................................... E-39
Filters .................................................................................................. E-39
`Positional Type' Hydraulic Adaptors ...................................................... E-40
Fitting Procedure ................................................................................ E-40
Connecting/Disconnecting Hydraulic Hoses ........................................... E-41
Flow and Pressure Tests ........................................................................ E-42
Pressure Tapping Points .................................................................... E-42
Schematic Circuits
Machines up to Serial No. M788390 ...................................................... E-44
Component Key .................................................................................. E-44
Transmission and Valve Hydraulic Circuit .............................................. E-46
Component Key .................................................................................. E-46
3.0D 4x4 Drive Circuit ............................................................................. E-49
Component Key .................................................................................. E-49
Transmission and Valve Block Circuit- 2 Wheel Drive Machines ........... E-51
Component Key .................................................................................. E-51
3.5D 4x4 Machines Priority, Steering, Drive and Fan Circuit .................. E-54
Component Key .................................................................................. E-54
Machines from Serial No. 1541224 ........................................................ E-58
E-i E-i
Contents
Contents Page No.

Hydraulic Pump
Steering/Main Hydraulic Pumps ............................................................. E-60
Removal ............................................................................................. E-60
Replacement ...................................................................................... E-61
Dismantling ......................................................................................... E-62
Inspection ........................................................................................... E-62
Assembly ............................................................................................ E-62
Steering Flow/Relief Valve (Double Pump) ............................................. E-65
Dismantling ......................................................................................... E-65
Assembly ............................................................................................ E-65
Steering Flow/Relief Valve (Triple Pump) ............................................... E-67
Dismantling ......................................................................................... E-67
Assembly ............................................................................................ E-67
Hydraulic Valves
Control Valve - Earlier Machines ............................................................ E-68
Removal ............................................................................................. E-68
Replacement ...................................................................................... E-68
Dismantling ......................................................................................... E-70
Assembling ......................................................................................... E-70
Control Valve Spool - Earlier Machines .................................................. E-72
Dismantling ......................................................................................... E-72
Assembly ............................................................................................ E-72
Control Valve - Later Machines .............................................................. E-73
Removal ............................................................................................. E-73
Replacement ...................................................................................... E-73
Main Relief Valve (MRV) ........................................................................ E-75
Testing ................................................................................................ E-75
Auxiliary Relief Valve (ARV) ................................................................... E-76
Testing - Removed ............................................................................. E-76
Testing - Fitted .................................................................................... E-77
Unloader Valve ....................................................................................... E-78
Description ......................................................................................... E-78
Adjustment ......................................................................................... E-79
Removal ............................................................................................. E-81
Replacement ...................................................................................... E-81
Anti-Slip Valves - 4WD (3.0D 4x4 Machines) ......................................... E-82
Removal ............................................................................................. E-82
Replacement ...................................................................................... E-83
Flow Divider Valve 2.5D/G, 3.0D/G and 3.5D 2 Wheel Drive Machines . E-84
Description ......................................................................................... E-84
Removal ............................................................................................. E-85
Replacement ...................................................................................... E-85
Flow Divider Pressure Switch 2.5D, 3.0D and 3.5D Machines ............... E-87
Description ......................................................................................... E-87
Removal ............................................................................................. E-87
Replacement ...................................................................................... E-87
Flow Divider Valve 3.5D 4x4 (Hydraulic Integrated Circuit) (HIC) .......... E-88
Removal ............................................................................................. E-88
Replacement ...................................................................................... E-88
Hydraulic Oil Cooler

Air Blast Type ......................................................................................... E-90
Removal ............................................................................................. E-90
Replacement ...................................................................................... E-90
E-ii E-ii
Contents
Contents Page No.

Liquid to Liquid Cooler ............................................................................ E-92
Description ......................................................................................... E-92
Removal ............................................................................................. E-92
Replacement ...................................................................................... E-93
Hydraulic Rams
Lift Ram .................................................................................................. E-94
Removal ............................................................................................. E-94
Replacement ...................................................................................... E-94
Compensating Ram ................................................................................ E-96
Removal ............................................................................................. E-96
Replacement ...................................................................................... E-96
Extension Ram ....................................................................................... E-98
Removal ............................................................................................. E-98
Replacement ...................................................................................... E-98
Tilt/Crowd Ram ..................................................................................... E-100
Removal ........................................................................................... E-100
Replacement .................................................................................... E-101
Assemble and Dismantle ...................................................................... E-102
Typical Ram ...................................................................................... E-102
E-iii E-iii
Contents
Contents Page No.
E-iv E-iv
Service Tools
Numerical List
The tools listed in the table are special tools required for details of all tools, including the content of kits and sets,
carrying out the procedures described in this manual. refer to Tool Detail Reference, Section 1.
These tools are available from JCB Service.
Note: Tools other than those listed will be required. It is
Some tools are available as kits or sets, the part numbers expected that such general tools will be available in any
for parts within such kits or sets are not listed here. For full well equipped workshop or be available locally from any
good tool supplier.
Part Number: Description:

1406/0011 Bonded Washer
1604/0003 Adaptor
1604/0004 Adaptor
1604/0006 Adaptor
1606/0003 Adaptor
1606/0004 Adaptor
1606/0007 Adaptor
1606/0008 Adaptor
1606/0009 Adaptor
1612/0006 Adaptor
816/00189 Blanking Cap
816/15118 Pressure Test Adaptor
816/20008 Adaptor
816/50043 T adaptor
816/55038 Pressure Test T adaptor
816/55040 Pressure Test T adaptor
816/60096 T adaptor
892/00047 T adaptor 3/8 in. BSP (A) x 1/4 in. BSP (B)
892/00048 T adaptor 1/2 in. BSP (A) x 1/4 in. BSP (B)
E-1 9803/9510-05 E-1

Service Tools
Numerical List

892/00055 Blanking Plug 1/4 in. BSP
892/00074 Female Connector 3/8 in. BSP x 3/8 in. BSP
892/00137 Hose
892/00223 Hand Pump
892/00252 ARV Test Block - Husco
892/00255 1/4 in BSP x Test Point
892/00259 1 in BSP x Test Point
892/00260 1.1/4 in BSP x Test Point
892/00261 5/8 in UNF x Test Point
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
892/00265 1 in M BSP x 1 in F BSP x Test Point
892/00268 Flow Monitoring Unit
892/00270 Load Valve
892/00271 Adaptor
892/00272 Adaptor
892/00074 Adaptor 3/8 in. BSP x 3/8 in. BSP
892/00278 Gauge
892/00279 Gauge
892/00923 ARV Test Block - Commercial Hydraulics
992/09300 Spanner 55 mm A/F
E-2 9803/9510-05 E-2

Service Tools
Numerical List
The following parts are replacement items for kits and
would normally be included in the kit numbers quoted
above.

Replacement items for kit number 892/00253
892/00201 Replacement Gauge
892/00254 Replacement Hose
E-3 9803/9510-05 E-3

Service Tools
Numerical List
Page left intentionally blank
E-4 9803/9510-05 E-4

Technical Data
Specifications
Relief Valve Operating Pressures (Oil temperature at 50 °C)

Main Relief Valve (at 2800 rev/min.) 245 bar (3553 lbf/in2)
Auxiliary Relief Valves 255 bar (3698 lbf/in2)
Brake Pressure Reducing Valve 25 bar (363 lbf/in2)
Unloader Valve (if fitted)
2.5 tonne At idle 80 bar (1160 lbf/in2) At max rpm110-120 bar
(1595-1740 lbf/in2)
3.0 tonne At idle 95 bar (1377 lbf/in2) At max rpm190 bar
(2755 lbf/in2)
3.5 tonne At idle 90-100 bar (13305-1405 lbf/in2) (0 amps)At
flight (2800rpm) 190 bar (2755 lbf/in2) (1.2 amps)
Check Valve 3 bar (43.5 lbf/in2)
Steering Orbitrol Unit 150 bar (2175 lbf/in2)
Rams (2.0T, 2.5T machines) Bore Rod Dia Stroke

mm in mm in mm in
Boom Lift 100 3.94 60 2.36 769 30.0
Carriage Tilt
Bi-ram 70 - Inner 2.75 40 1.57 35 1.38
Bi-ram 70 - Outer 171 3.73
Conventional Ram 70 2.75 40 1.57 246 9.69
Boom Extension 70 2.75 50 1.97 1496 58.9
Compensating 70 2.75 40 1.57 365 14.4
Rams (3.0T machines) Bore Rod Dia Stroke

mm in mm in mm in
Boom Lift 120 4.72 60 2.36 755 29.7
Carriage Tilt 80 3.15 50 1.97 244 9.61
Boom Extension 70 2.75 50 1.97 1496 58.9
Compensating 80 3.15 50 1.97 360 14.4
Rams (3.0D HL machines) Bore Rod Dia Stroke

mm in mm in mm in
Boom Lift 110 4.33 60 2.36 801 31.5
Carriage Tilt 90 3.54 50 1.97 241 9.48
E-5 9803/9510-06 E-5

Technical Data
Specifications
Rams (3.0D HL machines) Bore Rod Dia Stroke

mm in mm in mm in
Boom Extension 70 2.75 50 1.97 1955 77.0
Compensating 80 3.15 50 1.97 384 15.1
Rams (3.5T machines) Bore Rod Dia Stroke

mm in mm in mm in
Boom Lift 110 4.33 60 2.36 755 29.7
Carriage Tilt 90 3.54 50 1.97 241 9.48
Boom Extension 70 2.75 50 1.97 1645 64.76
Compensating 90 3.54 50 1.97 360 14.4
Ram Torque Settings Nm lb ft Kgf m

Piston head
- Boom Lift 405 299 41.3
- Carriage Tilt 450 332 45.9
- Boom Extension 405 299 41.3
- Compensating 405 299 41.3
Ram Torque Settings Nm lb ft Kgf m

End cap
- Boom Lift 678 500 69.2
- Carriage Tilt 678 500 69.2
- Boom Extension 450 332 45.9
- Compensating 678 500 69.2
E-6 9803/9510-06 E-6

Technical Data
4x4 Additional Components
Anti-Slip Valves (3.0D)

Maximum Flow Rate at Inlet port P 125 litres/min. (27.5 gal/min.)
Maximum System Pressure 480 bar (6960 lbf/in2)
Control Pressure at Port X3 35 bar (507 lbf/in2) @ max. RPM
Control Solenoid @ standby No drive
Control Solenoid @ idle (no slip) 500 mA
Control Solenoid @ max at any wheel (full slip) 1000 mA
Front Drive Motors (Twin Speed (Braked) Rexroth

MCR 05)
Displacement 635 cc/rev / 228 cc/rev
Maximum Speed 220 rpm
Maximum Flow 136 litres/min. (30 gal/min.)
Maximum Working Pressure 430 bar (Peak) (6236 lbf/in2)
Rear Drive Motors (Single Speed Rexroth MCR 03

3.0T 4x4)
Displacement 400 cc/rev
Maximum Flow 40 litres/min. (8.8 gal/min.)
Rear Drive Motors (Single Speed Rexroth MCR 04

3.5T 4x4)
Maximum Speed TBA
Maximum Flow TBA
Drive Motors Poclain MSE 05-0 TLT30)

Drive Motors (Poclain MSE 05-1 TLT35)

E-7 9803/9510-06 E-7

Technical Data
Drive Motors (Poclain MSE 05-1 TLT35)

Combined 2 Speed/Brake Valve

Rated Flow 11 litres/min. (2.4 gal/min.)
Relief Valve Pressure 25 bar (363 lbf/in2)
Inlet Pressure 210 bar (3045 lbf/in2)
Purge Valve
Relief Valve Pressure 18 bar (261 lbf/in2)
Flow Rate 25 litres/min. (5.5 gal/min.)
Transmission Pump
Charge Pressure - Oil Temperature @ 50 0C, 1220F 32 bar (464 lbf/in2) @ max rpm
Unloader Valve (Computer Controlled)

Unloader Settings
- @ flight (2600 rpm) (0A) 90-100 bar (1305-1450 lbf/in2)
- @ flight (2600 rpm) (1.2A) 190 bar (2756 lbf/in2)
Flow Divider Valve (3.5D)

Maximum Flow Rate at Inlet port P 220 litres/min. (48.4 gal/min.)
Maximum System Pressure 350 bar (5076 lbf/in2)
Control Pressure at Port X3 TBA bar (TBA lbf/in2) @ max rpm
Control Solenoid @ idle (no slip TBA mA
Main/Steer/Fan Pump (3.5T 4x4)

Type Triple Gear Pump
Displacement
Main Pump 21 cc/rev
Fan Pump 12 cc/rev
Steer Pump 12 cc/rev
Fan Motor (3.5T 4x4)

Displacement 8.4 cc/rev
Relief Valve Pressure - High Speed 95 bar (1378 lbf/in2) @ High Idle
(Approx. 3000 rpm)
E-8 9803/9510-06 E-8

Contents Page No.
E-9 9803/9510-06 E-9

Technical Data
Fan Motor (3.5T 4x4)

Relief Valve Pressure - Low Speed 55 bar (797 lbf/in2) @ High Idle
(Approx. 2250 rpm)
Direction Of Rotation Clockwise
E-10 9803/9510-06 E-10

Technical Data
E-11 9803/9510-06 E-11

Basic Operation
Description
The machine hydraulic system supplies the services that lifting a heavy weight on the forks. This reduces the load
follow: on the engine.
Hydraulic System Note: Later 3.5T machines machines fitted with a tandem
hydraulic pump do not include an unloader valve.
The main components of the hydraulic circuit are the tank,
pumps, control valve, filter, oil cooler, rams and unloader Pump section P1 priorities flow to the steering system
valve. using steer priority valve A. The priority valve supplies oil
to meet the steer circuit demand. Surplus flow passes to
The hydraulic pump is driven by the engine and has 2 or 3 the control valve block.
sections depending on machine model.
Steering System
A The steering pump 1-P1 delivers pressurised oil to the
P1 hydraulic steer unit then to the steering ram. The hydraulic
P2 steer unit directs the flow to the appropriate side the ram to
steer the machine. The steer unit has an internal valve
which when rotated by the steering wheel opens and
closes ports to divert the oil as applicable. Oil from the
opposite end of each track rod returns to tank via the steer
unit.
For steering system components, see Section H-

Steering.
Braking System
P3 Each front wheel motor has an integral brake pack. The
Fig 1. Hydraulic Pump brake is of the “always on” type. Hydraulic pressure from
the hydraulic pump 1-P1 is used to supply the brake port
– Pump Section P1 - This section supplies oil to the of the motor viathe brake release valve to release the
steering system and hydraulic system. K Steering brake. When the brake port receives no pressure supply
System ( T E-12) the brake comes on.
– Pump Section P2 - This section supplies oil to the
hydraulic system via unloader valve. For braking system components, see Section G - Brakes.
– Pump Section P3 (if fitted) - This section supplies oil
to the cooling fan motor.
Pump P2 delivers pressurised oil to the control valve, via

the unloader valve if fitted. When a valve is operated by a
control lever, it delivers the oil to one end of the appropriate
ram. The pressurised oil forces the ram's piston along the
bore of the ram. The MRV prevents system pressure from
rising too far. The unloader valve, if fitted, dumps flow back
to tank when pressure from the valve block increases
above a preset level due to the load on the circuit, e.g.
E-12 9803/9510-05 E-12

Basic Operation
Description
Transmission System flow of oil to the spinning motor to slow it down. Once the
wheel speed returns to a value that is within acceptable
The transmission pump is driven by the engine and is limits the flow to the motor resumes.
electronically operated via the drive controls. The
transmission pump delivers pressurised oil to the wheel The front wheel motors have two speeds. The speed is
motors. selected by directing the hydraulic flow to the motor 1st
speed or 2nd speed port.
The transmission pump is a variflow type and adjusts its
output in relation to the load demand and the input from the The first speed section of the motor, is a high capacity
drive control computer. motor which gives a slow speed operation and maximum
torque.
The 2nd speed section of the motor is a low capacity motor

which gives higher speeds.
The ASC system operates at both wheel motor speeds as

front and rear wheels are the same diameter.
3.5 D 4x4
A HIC (Hydraulic Integrated Circuit) valve is used to divide

the flow to all the wheel motors when in 1st speed only.
When 1st speed is selected the HIC makes sure that both
front wheel motors receive an equal flow as well as splitting
the flow between front and rear disproportionately to match
the flow capacity of the motors.There is no flow divider
between the two rear wheel motors. This gives a
Fig 2. Transmission Pump “differential lock” effect. The differential lock prevents one
wheel from spinning and reducing the flow to the other
For transmission system components, see Section F - motors.
Transmission.
When the 2nd speed is selected there is no flow restriction
The machine can have one of three types of transmission to and from the wheel motors. Therefore there is no
system. “differential lock” effect to prevent wheel spin. If the
operator is operating in conditions where the wheels may
2 Wheel Drive spin then the operator should return to 1st speed.
2 wheel drive machines have only 2 front drive motors. A small amount of flow is able to bypass the HIC to
compensate for the small difference in wheel speeds when
3.0 D 4x4 ASC the machine is cornering.
This system has 4 wheel motors, anti-slip valves, wheel

speed sensors on each wheel motor and a steer angle
sensor. The steer angle sensor monitors the steering
angle.
An Anti Slip Control system (ASC) is fitted to improve

traction. An Electronic control unit monitors wheel speed
and steering angle data. This reading is used to calculate
whether the wheel is spinning or if it is just travelling faster
than the other wheels due to the machine cornering. If the
controller decides that the wheel is spinning it controls the
E-13 9803/9510-05 E-13

Basic Operation
Introduction to Hydraulic Schematic Symbols

TE-001
General (Basic and Functional Symbols) Table 2. 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
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
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
decipher the relationship between hydraulic components. Table 3. Pumps and Motors
Table 1. General
Variable capacity pump two
Spring directions of flow
Flow restriction affected by

viscosity Fixed capacity motor one
direction of flow
Direction of flow
Fixed capacity motor two

directions of flow
Indication of rotation
Variable capacity motor one

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

Variable control directions of flow
E-14 9803/9510-05 E-14

Basic Operation
Table 4. 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
3-position, 6-port spring

centered pilot operated valve
Relief valve
3-Position, 4-port spring
centered solenoid & pilot
pressure operated valve
3-Position, 4-port spring

centered detent hand Variable restrictor
operated valve
Non-return valve
Non-return valve with back

pressure spring
Pilot operated non-return

valve
One way restrictor
High pressure selector

(shuttle valve)
E-15 9803/9510-05 E-15

Basic Operation
Table 5. 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
Line junction
Accumulator
Crossing lines Filter or strainer
Water trap
Air bleed
Cooler - with no indication of
Line plugged, also pressure coolant flow
test point
Line plugged with take off line Cooler - indicating direction

of coolant flow
Quick release couplings -

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

fluid level
E-16 9803/9510-05 E-16

Basic Operation
Table 6. Control Mechanisms
Solenoid one winding
Rotating shaft - one direction
Rotating shaft - two directions Solenoid two windings
Detent Electric motor operated

M
Locking device Internal pressure pilot

operated
Over centre device

External pressure pilot
operated
Simple linkage
Pressure operated spring
release
General control
Pilot operated by solenoid
pilot valve
Push button operated

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

directional)
E-17 9803/9510-05 E-17

Basic Operation
Control Valves
Control valves are usually represented by one or more
square boxes.
K Fig 3. ( T E-18) 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).
Fig 6.
It must be noted that not all spools are of the same type.
Fig 3.
Their operating designs can be seen by following the path
the flow arrows take in their respective operating squares.
K Fig 4. ( T E-18) - 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.
usually shown in the unoperated condition).
The 'D' spools generally control rams because when in the
neutral position the outlet ports are blocked, preventing
ram movement. K Fig 6. ( T E-18) shows a 'D' type spool.
K Fig 7. ( T E-18) - '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
Fig 4. detent, connects both sides of the ram together to allow the
service to 'float'.
K Fig 6. ( T E-18) shows a valve described as a 3-
position, 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.
Fig 7.
K Fig 8. ( T E-18) - '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 5.
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 6. ( T E-18).
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 8.
Port P2. K Fig 6. ( T E-18).
E-18 9803/9510-05 E-18

Basic Operation
Example of Schematic Circuit
A
B
C G
D E
Fig 9. Simple Schematic Circuit
Some of the symbols described on the preceding pages Example Circuit Key
have been arranged into a simple schematic circuit.
K Fig 9. ( T E-19).
9-A Hydraulic Tank
Hydraulic tank 9-A is a pressurised tank with an internally 9-B Strainer
mounted strainer 9-B on the suction line to the fixed 9-C Fixed Displacement Pump
displacement pump 9-C. System pressure is limited to the
setting of relief valve 9-D. 9-D Relief Valve
9-E Spool
Valve spool 9-E is an open-centre spool that is in neutral 9-F One Way Valve
position; flow from the pump passes through the spool and
returns to the hydraulic tank. 9-G Double Acting Hydraulic Ram
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 9-G. Notice that the fluid must first
open one way valve 9-F before flowing to the ram.
E-19 9803/9510-05 E-19

4 Wheel Drive (3.0D 4x4 Machines)
E-20
FWD.
11
1 1A FWD.
1 1C 14
14A
1 1B
REV . REV .
9 A X3 B 2
2A
9E 9E
2B
9A 9B A B
9D 9C
3
P L
3A
10 L P 3B
4
9803/9510-05
10D 10C
10A 10B
6 T
B 10E X3 10E A 6B
6A
X L 12
12A 6C FWD. 13
12B
Z
13A
B 5
12C 12D P1 S1 BRAKE S2 2SPD
A 6D TEST
POINT 6E TEST
POINT REV .
Fig 10. 4 Wheel Drive Operation (3.0D 4x4 Machines)

E-20
Basic Operation
Basic Operation
K Fig 10. ( T E-20),
K Fig 11. ( T E-21),K Fig 12. ( T E-21) and
K Fig 13. ( T E-21).
P
The illustrations on this page and the following pages are
B A P A
to assist with the identification of components and their B
ports. The schematics are for illustration only.
With the engine running, forward selected in 1st gear with

all wheels pointing straight ahead and no wheel spin,
pressure from transmission pump 10-2B is fed, via port A,
to the anti slip valves 1 and 2 port 12-P. Pilot charge
pressure from transmission pump 10-2A (32 to 36bar; 464
to 522 lbf in2), is fed to the anti slip valves via port X3,
spring pressure holds spools 12-A/B open against pilot
pressure which is exhausted back to tank via port 12-L.
L
L
Pump pressure from the 12cc main pump P1 (see Section B A
E - Main Pump) is fed to the combined brake 2 speed
valve 10-6 via port P. The pressure reducing valve 10-6C
limits the maximum pressure to 25 bar (363 lbf in2), it only B
requires 17 bar (246 lbf in2) to release the brake. When the Fig 12. Anti Slip Valves
parking brake switch is released and the direction is
selected, the solenoid 10-6B is energised which allows
hydraulic pressure to both front wheel brake valves 10-11A
and 10-12A which overcomes spring pressure and S2
releases the parking brakes.
A B
L
BRAKE
PORT
S1
X
Fig 11. Wheel Motor Fig 13. Brake Valve
Only the full hydraulic schematic for the front left wheel Pump pressure via their respective spools in the anti slip
motor 10-12 is shown. valves K Fig 12. ( T E-21) is fed to the four 4 wheel drive
motors through ports A and B. When 1st is selected,
The front wheel motors are of a two speed type. Refer to pressure is fed to both front wheel motors 10-11 and 10-12.
K 2 Speed Operation ( T E-24). The following applies to both front motors, spring pressure
E-21 9803/9510-05 E-21

Basic Operation
holds spool 10-12B open, oil is fed to both wheel motors
10-12C and 10-12D, the large capacity gives slow speed
with maximum tractive effort.
Oil is also fed to the rear motors, these are single speed
with no brakes.
The returning `low pressure òil from the wheel motor

closed loop is `purged' of a controlled amount of oil. This
makes sure that the return line from the motor is always
kept pressurised. The returning oil flows through valve 10-
3, the oil cooler and back to tank.
E-22 9803/9510-05 E-22

E-23
FWD.
11
1 1A FWD.
14
1 1C
14A
1 1B
REV . REV .
9 A X3 B 2
2A
9E 9E
2B
9A 9B A B
9D 9C
3
P L
3A
10 L P 3B
4
10D 10C
9803/9510-05
10A 10B
6 T
B 10E X3 10E A 6B 6A
BRAKE 2 SPEED
12
X L
12A 6C FWD. 13
Z
13A
B 5
12C 12D P1 S1 S2 2SPD
A 6D TEST
POINT 6E TEST
POINT REV .
12B

E-23
Basic Operation
Basic Operation
K Fig 14. ( T E-23).
2 Speed Operation
To operate the 2 speed low gear option, when selected
solenoid 14-6A is energised, hydraulic pressure via port
2SPD is fed to the two front drive motors. Spools 14-11B
and 14-12B move across, left front only illustrated.
Transmission pump pressure is now fed to the wheel motor
low capacity wheel motor 14-12D to give higher speed
drive. Any internal wheel motor leakage via port L case
drain is fed back to tank.
3rd is controlled electronically, when selected the machine

travels at the same speed as 2nd but with lower engine
revs for increased operator comfort and fuel efficiency.
If a wheel starts to slip, (lack of traction or one wheel off the

ground) the drive is controlled to the other 3 wheels. In the
illustration if the front right starts to slip, an electrical signal
from the speed sensor 14-11C is sent to the ASC
Electronic Controller, which energises proportional
solenoid 14-10C. This allows the pilot charge pressure to
build up and overcome spring pressure, spool 14-10B
moves across to proportionally meter the feed oil and flow
to the slipping wheel which will stop or rotate slowly until
the speed sensor is within the control band, then supply to
the wheel motor will be restored. Valves 14-9E and 14-10E
are fitted to prevent cavitation to the wheel motors.
When turning, a signal from the steering potentiometer,

fitted to the rear left axle hub, is sent to the Electronic
Controller. The Electronic Controller uses this signal to
help calculate if any wheels are spinning. If the machine is
cornering the two wheels on the inside of the corner will be
travelling faster than the outer wheels. The steering
sensors alert the Electronic controller that the wheel speed
may be due to cornering and not necessarily due to wheel
spin.
When reverse is selected, pressure from transmission

pump 14-2B is fed, via port B, to the four wheel drive
motors 14-11, 12, 13, 14. The anti slip valves 14-9 and 14-
10 still control wheel slip in the same manner as described
with forward selected, but controls the return oil rather than
the feed oil.
E-24 9803/9510-05 E-24

4 Wheel Drive Operation (3.5D 4x4 Machines)
E-25
FWD. 27
27C 27A FWD.
28
28A
27B
REV . REV .
G5 M3 M1 G2 19
19E
25M 25 19B
25J
B A
G3
25H
25B CHG
25G 23
DR
25C
25A 23A
25L 25F 25D
23B
25K 25E
31
9803/9510-05
24N
25P T
G4 M4 A M2 G1
26A 26
26B
L
P
X
29 FWD.
29A
29B 26C
B Z 30
30A
A 2
29C 29D P1 S1 BRAKE S2 2SPD
26D 26E REV .
4B

E-25
Basic Operation
Basic Operation
K Fig 15. ( T E-25), K Fig 16. ( T E-26), All the flow splitters and restrictors, 15-25E to 25L are
K Fig 18. ( T E-28) and K Fig 19. ( T E-29). therefore bypassed, and the oil flows unimpeded from port
A of the flow divider valve to port B of the transmission
The illustrations on this page and the following pages are pump.
to assist with the identification of components and their
ports. The circuit shown is for purposes of explanation only Valves 15-25M, 25N and 25P prevent cavitation in the
and is a simplified version of that shown in Section E - wheel motors.
Schematic Circuits.
Pump pressure from the 12cc pump P1 19-4B is fed to the A B

combined brake 2 speed valve 15-26 via port P. The
L
pressure reducing valve 15-26C limits the maximum
pressure to 25 bar (363 lbf in2), it only requires 17 bar (246
lbf in2) to release the brake. When the parking brake BRAKE
switch is released and direction is selected, solenoid 15- PORT
26B is energised which allows hydraulic pressure to both
front wheel brake valves 15-27A and 15-29A which
overcomes spring pressure and releases the parking
brakes.
With the engine running, forward drive selected and the

speed selector in position 2, pressure from transmission
pump 15-19B is fed, via port B, to the forward drive port A
on each of the hydraulic motors, items 15-27 to 30 on
illustration. X
Fig 16. Wheel Motor
Although only the full hydraulic schematic for the front left
wheel motor 15-29 is shown, the following applies to both Purge valve 15-23A is operated by the pressure
front motors, 15-27 and 29. differential between the `high pressure' and `low pressure'
sides of the wheel motor closed loop. As shown, the
When the speed selector is set to position 2, solenoid 15- greater pressure from port B of the transmission pump
26A is energised. Hydraulic pressure via port 2SPD is fed causes the valve spool to be moved to the position shown.
to the two front drive motors. Spools 15-27B and 15-29B The returning `low pressure òil is `purged' of a controlled
move across (left front only illustrated). Transmission amount of oil through valve 15-23A for cooling via the oil
pump pressure is now fed to the wheel motor low capacity cooler 15-31 and back to tank. For more information on the
wheel motor 15-29D only to give higher speed drive. Any purge valve operation see Section F - Transmission.
internal wheel motor leakage via port L case drain is fed
back to tank.
When the speed selector is set to position 1, spring

pressure holds spool 15-29B open, so oil is fed to both
wheel motors 15-29C and 15-29D. The large capacity
gives slow speed with maximum tractive effort.
Oil is also fed to the rear motors, these are single speed
with no brakes.
When the speed selector is set to position 2, solenoid valve

15-25A is de-energised, charge pressure from pump 15-
19E is blocked and valves 15-25B, 25C and 25D are held
open by spring pressure.
E-26 9803/9510-05 E-26

E-27
FWD. 27
27C 27A FWD.
28
28A
27B
REV . REV .
G5 M3 M1 G2 19
19E
25M 25 19B
25J
B A
25B G3
25H
25G CHG 23
25C
DR
25A
23A
25L 25F 25D
23B
25A
25K 31
24N
25P T
G4 M4 A M2 G1
26
26B
9803/9510-05
26A
X L
P
29B 29 FWD.
29A
26C
Z 30
B
30A
29C 29D P1 S1 S2 2SPD

2
BRAKE
A
26D 26E REV .
4B

E-27
Basic Operation
Basic Operation
K Fig 17. ( T E-27).
When the speed selector is selected to position 1, solenoid M2

17-26A is de-energised and the differential lock solenoid
17-25A is energised. Hydraulic pressure via port 2SPD is A
C
removed from the two front drive motors. Spools 17-27B DR
and 17-29B move across (left front only illustrated).
Transmission pump pressure is now fed to both wheel
motor sections 17-29C and 17-29D. The higher capacity M1
gives lower speed drive with greater traction, for a given oil
flow from the pump.
When solenoid valve 17-25A energises, charge pressure

from pump 17-19E is fed through to valves 17-25B, 25C M4 M3
and 25D, causing them to close.
V
The oil flow must now be through the flow dividers 17-25E, CHG
25F and 25G. Fig 18. Item 25
The flow is divided between the two front motors equally,

and between front and rear equally, giving a differential
lock effect.
A certain amount of oil is bypassed via restrictors 17-25H

and 25-K, further `fine tuned' by 17-25J and 25L to adjust
for oil flow differential required when turning.
When reverse is selected, pressure from transmission

pump 17-19B is fed, via port A, to the four wheel drive
motors 17-27, 28, 29 and 30. The flow divider 17-25 still
controls wheel slip in the same manner as described with
forward selected, but controls the feed oil rather than the
return oil.
Oil is returned to the transmission pump from port B of the

motor, via the flow divider valve 17-25.
Note: The flow divider is protected by relief valves. On

machines up to serial number M1174902 they are
mounted externally. On machines from serial number
M1174903 the relief valves are within the flow divider (HIC)
unit.
E-28 9803/9510-05 E-28

Basic Operation
1
7
R L
2 8
3A 3B
T LS P
4 6
2800 RPM 5C P1 V
P2
4C
105 bar
4A 4D LS
17A
EF 18
4B T1 T
20 bar 4F 17
18A
5A 50 bar
Y
Z
9 B A B A B A B A B A
800530
(853/80082-2)
Fig 19. Priority, Steering and Fan Circuit
E-29 9803/9510-05 E-29

Basic Operation
Integrated Pump Mounted 4x4 System (3.0D/3.5D 4x4 Machines)
General Description incorporates a pump mounted flow divider valve X. This

includes the brake valve solenoid and pilot port, the 2
K Fig 20. ( T E-30). K Fig 21. ( T E-31) speed solenoid and pilot port and the 4x4+ solenoid and
pilot port.
The Integrated Pump Mounted 4x4 system replaces the
Anti Slip Control System (ASC) on 3.0D 4x4 and the HIC The purge valve Y is also connected to the pump on the LH
on 3.5D 4x4. on both the machines the Integrated Pump side and helps in cooling the hydraulic oil.
Mounted 4x4 system operates identically. The system
P030650-10
Fig 20. Integrated Pump Mounted 4x4 System
X 3 Way Flow Divider Valve
Y Purge Valve
E-30 9803/9510-05 E-30

Basic Operation
A B
G
B
C A
T
C
D M1
P030650-06
Fig 21. 3 Way Flow Divider Valve
A 4x4 Plus (Optional)
B Two Speed Activation
C Brake Release
D Flow Divide Activation
E-31 9803/9510-05 E-31

Basic Operation
Integrated Pump Mounted 4x4 Hydraulic Drive
Schematic
Component Key
K Fig 22. ( T E-33).
1 Motor
2 Motor
3 2 Way Flow Divider Valve (4x4 Plus -
Optional)
4 3 Way Flow Divider Valve
5 Pump
6 Purge Valve
7 Brake
8 Tank and Filter
9 Cooler
10 Motor
11 Motor
E-32 9803/9510-05 E-32

E-33
LEVEL
F3 F2 F1
R
4x4
Y G
7 2 SPD PLUS L
1
A
1
8 R
T
M SE0 2-2
X NO N E
PH
10
4 9
C
1
B
A
3BAR
CHECKVALVE
p
M1 A L2 S L1 M4 M5
M1
G2 450
Bar
G1 36 Bar S2
FR ON T
P1 M3 RE AR
75cc
20cc
M3
A M
P M3
S1
B
T 450
Bar
5
M2
B
B
A
3
6
9803/9510-05
B1
X
B2 T R M SE0 2-2
NO N E
1 PH
A
1
L
Y
R
M SE05- A
NO N E E
PH
11
2
P030650-02
Fig 22. Integrated Pump Mounted 4x4 3.0D/3.5D Drive Circuit
E-33
Basic Operation
Basic Operation
3 Way Flow Divider 2nd Speed (Inactive) spools in each of the front drive motors. Front motors will
be in high speed low torque mode.
K Fig 23. ( T E-34).
Oil flow X from the main drive pump enters the flow divider
When the machine is in 2nd speed the flow dividers are valve at port P and is split three ways - two outlets to the
switched off. There is no charge pressure oil supply to the front motors Z and 1 outlet to the rear motors Y. As the oil
flow divider servo spool. There is a 12 V supply to the 2nd flow is not controlled, if one wheel is lifted from the ground
speed spool allowing charge pressure to the 2nd speed all the oil will flow to that wheel and the machine will lose
traction.
F3 F2 F1
G
S1 S2 S3 S4
B
A
Y
p
M1 A
X
P030650-C1
Fig 23.
S1 Flow Divider Solenoid
S2 Brake Release Solenoid
S3 2nd Speed Solenoid
S4 4x4 Plus Solenoid
X Flow from drive pump
Y To rear motors
Z To front motors
E-34 9803/9510-05 E-34

Basic Operation
3 Way Flow Divider 1st Speed (Active) Flow of oil X from the main drive pump enters the flow
divider valve at port P and is blocked by the flow divider
K Fig 24. ( T E-35) servo spool W diverting the oil through first the front / rear
flow divider cartridge then through the front L/front R flow
When 1st speed is engaged, this will send 12 V to the flow divider cartridge. If a wheel now loses traction the flow
divider solenoid, at the same time the 12 V supply to the divider cartridges will control the amount of flow going to
2nd speed solenoid will be removed and the front wheel that wheel, flow and pressure will still be maintained on the
motors will now change to low speed, high torque. Charge other wheels.
pressure is then connected to the servo spool for engaging
the two flow divider/combiner cartridges. The metering restrictors (shown in blue) allow a controlled
amount of oil to bypass the flow divider cartridges to allow
for the differential in wheel speeds due to steering.
F3 F2 F1
S1 S2 S3 S4
G
B
A
Y
p
M1 A
X
P030650-C2
Fig 24.
S1 Flow Divider Solenoid Y To rear motors
S2 Brake Release Solenoid Z To front motors
S3 2nd Speed Solenoid
S4 4x4 Plus Solenoid
W Flow divider servo spool
X Flow from drive pump
E-35 9803/9510-05 E-35

Basic Operation
4x4 Plus System the unloader valve that when engaged, using the switch in
the cab, evenly distributes the flow to each of the rear
K Fig 25. ( T E-36) wheels.
This option can be installed to both the 3.0T and 3.5T 4x4 Note: View X on the illustration shows the arrangement on
machines. It is a 2 way flow diverter A situated in front of machines without an unloader valve.
P030650-04T
Fig 25.
E-36 9803/9510-05 E-36

Basic Operation
Hydraulic Schematic for Optional 2 Way Flow
Divider (4x4 Plus)
K Fig 26. ( T E-37)
Note: The following description applies to machines with

and without an unloader valve.
When required the 4x4 Plus is activated by pressing the

activation button on the switch panel. This activates the
4x4 Plus solenoid on the 3 way flow divider/combiner valve
allowing charge pressure to flow to the PL port on the 2
way flow divider. This charge pressure acts on the servo
spool causing the by-pass ports to be closed. Oil flow from
the main loop now passes through the flow divider
cartridge with equal flow to each rear motor.
The metering restrictor (shown in blue) allows a controlled

amount of oil to bypass the flow divider / combiner
cartridge to allow for the differential in rear wheel speeds
due to steering.
There is a permanent charge pressure supply to the G2

port supplying two anti-cavitation valves in the outlet ports
A & B to the rear wheel motors. There is a tank return line
from port T connected to the valve to return any internal
leakage from the valve. As soon as the switch on the
dashboard is released the pressure is released from the
servo spool allowing the oil from port P to bypass the flow
divider/ combiner cartridge.
G2
G1
PL
A
P
B
T
P030650-C3
Fig 26. 2 Way Flow Divider (4x4 Plus)
E-37 9803/9510-05 E-37

Service Procedures
Hydraulic Contamination
TE-002_3
Hydraulic Fluid Quality cleaning unit. K Fig 1. ( T E-38). 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.
problems in hydraulic equipment were attributable to K Fig 1. ( T E-38). 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.
Furthermore from an economic angle it extends the life of
the hydraulic fluid if quality is maintained.
Effects of Contamination
Once inside the system, hydraulic circuit contaminants
greatly effect the performance and life of hydraulic
equipment. For example, contaminants in a hydraulic
pump develop internal wear to cause internal leakage and
hence lower discharges. Wear particles generated will
circulate with the hydraulic fluid to cause further
deterioration in the performance of this and other
equipment. Contaminants also enter principal sliding
sections of the equipment causing temporary malfunction,
scuffing, sticking and leakage and can lead to major
problems.The main contaminants can be classified as
follows:
1 Solid Particles - sand, fibres, metallic particles,

welding scale, sealing materials and wear particles
etc. S168050-1
Fig 1. 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.
These contaminants can appear during manufacture,

assembly and operation.
Cleaning Operation
The purpose of cleaning oil is to remove contaminants of
all types and sludge by filtering hydraulic fluid through a
E-38 9803/9510-06 E-38

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)
– Grain of Salt = 100 microns (0.1 mm, 0.00394 in)
Smallest particle visible to the naked eye is 40 microns

(0.00157) approximately.
Standards will often be quoted to ISO (International

Standards Organisation) for which literature can be
obtained.
Filters
The filter assembly fitted to all product ranges is designed
to filter all the contamination that is generated through use
to the required level of cleanliness. The filter must be
serviced to the requirements of the machine Service
Schedules.
To ensure optimum performance and reliability it is

important that the machines hydraulic system is serviced
periodically in accordance with the manufacturers
requirements.
E-39 9803/9510-06 E-39

Service Procedures
`Positional Type' Hydraulic Adaptors
`Positional Type' Hydraulic Adaptors
Fitting Procedure
On a typical machine, some hydraulic components may
utilise `Positional Type' SAE Hydraulic Adaptors. When
fitting `Positional Type' Hydraulic Adaptors it is important to
adopt the following procedure. If this procedure is not
followed correctly, damage to the Ò' ring seal 2A can
occur resulting in oil leaks.
1 Ensure the locknut 2B is screwed back onto the body

of the adaptor as far as possible as shown.
2 Check the Ò' ring backing washer 2C is a tight fit on

the adaptor. Note that the washer should not move
freely, if the washer is slack do not use the adaptor.
3 Check the Ò' ring 2A is fitted and that it is free from

damage or nicks. Before fitting the adaptor, smear the
Ò' ring with clean hydraulic fluid. Fig 2.
Note: The dimensions and shore hardness of the Ò' ring

is critical. Should it become necessary to replace the Ò'
ring, ensure that only JCB Genuine Parts are used.
4 Screw the adaptor into the port of the hydraulic

component as far as possible, so that ALL the threads
engage and the Ò' ring is correctly seated against
the sealing face.
5 Set the angular position of the adaptor as required,

then secure by tightening the locknut 2-B.
Note: When fitted correctly no more than one thread

should be visible at 3Z as shown.
6 Torque tighten the locknut to 81 Nm (60 lbf ft).
Fig 3.
E-40 9803/9510-06 E-40

Service Procedures
Connecting/Disconnecting Hydraulic Hoses
Connecting/Disconnecting Hydraulic Hoses
Refer to Section A, Connecting / Disconnecting

Hydraulic Hoses.
E-41 9803/9510-06 E-41

Service Procedures
Flow and Pressure Tests
Pressure Tapping Points Item Position Gauge Pressure Main Use

(bar) (bar)
K Fig 4. ( T E-42),K Fig 5. ( T E-43), K Fig 6. ( T E-43), 5 Purge Valve 380-450 At the High
K Fig 7. ( T E-43), and K Fig 8. ( T E-43) Pressure
Test Point
The hydraulic tapping points that are provided on the (Stalled)
Teletruk for maintenance, are listed in the table below:
Note: Hydraulic oil temperature should be at 50 degrees
Item Position Gauge Pressure Main Use oC.
(bar) (bar)
Charge
Pressure
1 Transmission 40 27.5 At idle
Filter
Housing
32 At max revs
27.5 (4x4) At idle
32 (4x4) At max revs 1
2 Hydraulic 400 See table Unloader
Pump unloader Pressure
description
3 Pump P1 400 245 MRV at max
revs
C053590
150 During
turning and Fig 4.
steering
“dead
ended”
17-18 At idle -
Stand-by
Pressure
4 Brake 40 25 With
hydraulic
service
“Dead
Ended”
17 At idle
On some machines the brake test point K Fig 7. ( T
position can vary. E-43)
K Fig 6. ( T
E-43)
E-42 9803/9510-06 E-42

Service Procedures
S2
2
4
S1
Fig 7. 3.0 and 3.5 4x4 Machines

3
Fig 5. 5
S1
Fig 8. 4x4 Purge Valve
Fig 6. 2 Wheel Drive Machines
E-43 9803/9510-06 E-43

Schematic Circuits
E-44
Machines up to Serial No. M788390
Component Key 9K Auxiliary Relief Valve 20D Multi-Function Valves

9L Auxiliary Relief Valve 20E Charge Pump
K Fig 1. ( T E-45).
9M Auxiliary Relief Valve 21A Drive Motor and Brake
1 Filter/Breather 9N Auxiliary Relief Valve 21B Drive Motor and Brake
2 Tank 9P Auxiliary Relief Valve 22 Parkbrake Valve
3A Suction Strainer - Main/Steering Pumps 10A Tilt/Crowd Ram
3B Suction Strainer - Transmission 10B Tilt/Crowd Ram
4A Demand Pump 10C Hose Burst Check Valve
4B Main Pump 10D Hose Burst Check Valve
4C Steering Priority Valve 11 Compensation Ram
4D Steering Pressure Relief Valve 12A Lift Ram
5A Test Point 12B Hose Burst Check Valve
5B Test Point 13A Extension Ram
9803/9510-06
5C Test Point 13B Hose Burst Check Valve
6 Unloader Valve 14A Quick Release Hoses (if fitted)
7 Steering Ram 14B Quick Release Hoses (if fitted)
8 Hydraulic Steering Unit 14C Quick Release Hoses (if fitted)
9 Valve Block 14D Quick Release Hoses (if fitted)
9A Main Relief Valve 15 Auxiliary Ram 1 (if fitted)
9B Tilt/Crowd Spool 16 Auxiliary Ram 2 (if fitted)
9C Lift Spool 17 Cooler
9D Extension Spool 18 Check Valve - 3 Bar
9E Auxiliary 1 Spool 19 Filter
9F Auxiliary 2 Spool 20 Transmission Pump Assembly
9G Auxiliary Relief Valve 20A Pump
9H Auxiliary Relief Valve 20B Charge Relief Valve
9J Auxiliary Relief Valve 20C Forward/Reverse Direction Control

Schematic Circuits
E-44
7
E-45
1 R L
19 5B
8 20 D E X3
2
S 20E M 3
3A 3B 20A 20B
18 M 4
M 5
T LS P L2
10C 11
10D
20C
M 2 M 1
17
6
10A 10B L1 20D
4
5C 1 2
4A
3 12A
4D LS 12B A B
P
4B
EF T
22
4C 13A
P B R
13B
9 B A B A B A B A B A
5A 15
14A 21A
9G 9J 9L 9N
9803/9510-06
14B
9H 9K 9M 9P
16
9A 14C
21B
14D
9B 9C 9D 9E 9F
714090-V1
Fig 1. Machines up to Serial Number M788390 - I.T. only

Schematic Circuits
E-45
Transmission and Valve Hydraulic Circuit
E-46
Component Key 9K Auxiliary Relief Valve 21A Drive Motor and Brake
9L Auxiliary Relief Valve 21B Drive Motor and Brake
K Fig 2. ( T E-47) & K Fig 3. ( T E-48).
9M Auxiliary Relief Valve 22 Parkbrake Valve
1 Filter/Breather 9N Auxiliary Relief Valve 23 Pressure Regulator Valve
2 Tank 9P Auxiliary Relief Valve 24 Accumulator
3A Suction Strainer - Main/Steering Pumps 10A Tilt/Crowd Ram 25 Inch Valve
3B Suction Strainer - Transmission 10B Tilt/Crowd Ram
4A Demand Pump 10C Hose Burst Check Valve
4B Main Pump 10D Hose Burst Check Valve
4C Steering Priority Valve 11 Compensation Ram
4D Steering Pressure Relief Valve 12A Lift Ram
5A Test Point 12B Hose Burst Check Valve
5B Test Point 13A Extension Ram
5D Test Point 14A Quick Release Hoses (if fitted)
9803/9510-06
5E Test Point 14B Quick Release Hoses (if fitted)
6 Unloader Valve 14C Quick Release Hoses (if fitted)
7 Steering Ram 14D Quick Release Hoses (if fitted)
8 Hydraulic Steering Unit 15 Auxiliary Ram 1 (if fitted)
9 Valve Block 16 Auxiliary Ram 2 (if fitted)
9A Main Relief Valve 17 Cooler
9B Tilt/Crowd Spool 18 Check Valve - 3 Bar
9C Extension Spool 19 Filter
9D Lift Spool 20 Transmission Pump Assembly
9E Auxiliary 1 Spool 20A Pump
9F Auxiliary 2 Spool 20B Charge Relief Valve
9G Auxiliary Relief Valve 20C Forward/Reverse Direction Control
9H Auxiliary Relief Valve 20D Multi-Function Valves
9J Auxiliary Relief Valve 20E Charge Pump

Schematic Circuits
E-46

Schematic Circuits
Fig 2. Transmission Circuit - 2WD P1 Brake Feed Valve
E-47 9803/9510-06 E-47

TILT RAMS
E-48
10A
10A
FILLER/
BREATHER
STEER RAM 7
1 10C
3/8 3/8
R L
8
3A 3B DANFOSS 10D
LOAD SENSING
STEER VALVE
90cc/REV
60cc/REV
T LS P
1-1/2" BORE
COMPENSATION RAM
SUCTION
1-3/4"
5B 6
VARIABLE UNLOADER
BORE
SUCTION
11
TEST
POINT
4A P1 V
2800 RPM 13B
P2
20cc/r
PRESSURE REGULATOR
12cc/r
4D
LS EXTENSION RAM
REG PIL
P
P
4B 13A
EF
23 T1 T
R
ACCUMULATOR 24
TEST
15
5A POINT
12B
LIFT RAM
12A
9803/9510-06
9
B A B A B A B A B A
14A
9G 9J 9L 9N AUX 1
15
9H 9K 9M 9P
14B
MRV
245 BAR
AUX 2
TANK 14C
16
14D
9B 9C 9D 9E 9F
TILT EXTEND LIFT AUX 1 AUX 2

853/30068-2
714060
Fig 3. Valve Block Circuit

Schematic Circuits
E-48

3.0D 4x4 Drive Circuit
E-49
Component Key 10A Supply Spool, Rear L.H.
10B Supply Spool, Front R.H.
K Fig 4. ( T E-50) & K Fig 5. ( T E-52).
10C Pilot Pressure Control Solenoid A
1 Test Point 10D Pilot Pressure Control Solenoid B
2 Transmission Pump Assembly 10E Anti-Cavitation Valves
2A Charge Pump 11 Front R.H. Drive Motor
2B Pump 11A 2 Speed Valve
2C Charge Valve 11B Brake Valve
2D Proportional Solenoid 11C Speed Sensor
2E Multi-Function Valves 12 Front L.H. Drive Motor
2F Charge Relief Valves 12A Brake Valve
3 Purge Valve 12B 2 Speed Valve
3A Return Spool 12C Speed Sensor
3B Relief Valve 13 Rear L.H. Drive Motor
4 Oil Cooler 13A Speed Sensor
9803/9510-06
5 Hydraulic Tank 14 Rear R.H. Drive Motor
6 Combined Brake and 2 Speed Valve 14A Speed Sensor
6A 2 Speed Spool
6B Brake Spool
6C Relief Valve
6D Brake Pressure Test Point
6E 2 Speed Pressure Test Point
9 Anti-Slip Valve 2
9A Supply Spool, Front L.H.
9B Supply Spool, Rear R.H.
9C Pilot Pressure Control Solenoid A
9D Pilot Pressure Control Solenoid B
9E Anti-Cavitation Valves
10 Anti-Slip Valve
Schematic Circuits
E-49
Schematic Circuits
Fig 4. 3.0D 4x4 Drive Circuit - ASC

2F
E-50 9803/9510-06 E-50

Transmission and Valve Block Circuit- 2 Wheel Drive Machines
E-51
Component Key 9H Auxiliary Relief Valve 20D Multi-Function Valves
9J Auxiliary Relief Valve 20E Charge Pump
K Fig 6. ( T E-53).
9K Auxiliary Relief Valve 21A Drive Motor and Brake
1 Filter/Breather 9L Auxiliary Relief Valve 21B Drive Motor and Brake
2 Tank 9M Auxiliary Relief Valve 22 Parkbrake Valve
3A Suction Strainer - Main/Steering Pumps 9N Auxiliary Relief Valve 25 Inch Valve
3B Suction Strainer - Transmission 9P Auxiliary Relief Valve
4A Demand Pump 10A Tilt/Crowd Ram
4B Main Pump 10B Tilt/Crowd Ram
4C Steering Priority Valve 10C Hose Burst Check Valve
4D Steering Pressure Relief Valve 10D Hose Burst Check Valve
5A Test Point 11 Compensation Ram
5B Test Point 12A Lift Ram
5D Test Point 13A Extension Ram
9803/9510-06
5E Test Point 13B Hose Burst Check Valve
6 Electric Unloader Valve 14A Quick Release Hoses (if fitted)
7 Steering Ram 14B Quick Release Hoses (if fitted)
8 Hydraulic Steering Unit 14C Quick Release Hoses (if fitted)
9 Valve Block 14D Quick Release Hoses (if fitted)
9A Main Relief Valve 15 Auxiliary Ram 1 (if fitted)
9B Tilt/Crowd Spool (loading pattern) 16 Auxiliary Ram 2 (if fitted)
Extension Spool (placing pattern) 17 Cooler
9C Extension Spool (loading pattern) 18 Check Valve - 3 Bar
Tilt/Crowd Spool (placing pattern) 19 Filter
9E Auxiliary 1 Spool 20A Pump
9G Auxiliary Relief Valve 20C Forward/Reverse Direction Control

Schematic Circuits
E-51
E-52
FILLER/
BREATHER 7 STEER RAM
19 5B
TEST
1 POINT
3/8 3/8
20 D E X3
R L
20cc 20E
S M3
2
8
2.8 DIA
RESTRICTOR
75cc
20B
20A
3A 3B M4
DANFOSS
LOAD SENSING 3 BAR
25
STEER VALVE CHECK VALVE
90cc/REV
60cc/REV
L2
18 M5
T LS P
M2
1-1/2" BORE
SUCTION
L1
1-3/4"
5C
ELECTRONIC UNLOADER 6
BORE 20D
SUCTION
TEST
POINT
P1 V
2800 RPM
4A P2
20cc/r
17
COOLER
4D
12cc/r 0.8 dia
A B
LS
P
4B
20 bar EF See note
PARKBRAKE
T1 T 22 VALVE
4C T
9803/9510-06
TEST BR TEST
5A POINT POINT
5E
9 21A
B A B A B A B A B A
9G 9J 9L 9N
9M 9P
9A
MRV
245 BAR 21B
TANK
9B 9C 9D 9E 9F
853/30068
TILT EXT LIFT AUX 1 AUX 2 764980-1
Fig 5. Transmission and Steering Circuit 2-Wheel Drive Machines - Electric Unloader - P1 Brake Release
Schematic Circuits
E-52
Schematic Circuits
Fig 6. Valve Block Circuit 3.5 Machines (Except 4x4) - Electric Unloader - 2WD P1 Brake Release
E-53 9803/9510-06 E-53

3.5D 4x4 Machines Priority, Steering, Drive and Fan Circuit
E-54
Component Key 9J Auxiliary Relief Valve 255 bar 19D Multi-Function Valves
9K Auxiliary Relief Valve 255 bar 19E Charge Pump
K Fig 7. ( T E-55),K Fig 8. ( T E-56),
K Fig 9. ( T E-57). 9L Auxiliary Relief Valve 255 bar 20 Inch Valve
9M Auxiliary Relief Valve 255 bar 21 Test Point - Charge Pump Pressure
1 Filter/Breather 9N Auxiliary Relief Valve 255 bar 22 Check Valve - 3 bar
2 Tank 9P Auxiliary Relief Valve 255 bar 23 Purge Valve
3A Suction Strainer - Main/Steering Pumps 10A Tilt/Crowd Ram 23A Test Point - Forward Loop Pressure
3B Suction Strainer - Transmission 10B Tilt/Crowd Ram 23D Test Point - Brake Release Pressure
3C Suction Strainer - Transmission Charge 10C Hose Burst Check Valve 23E Test Point - Speed Selection Pressure
Pump 10D Hose Burst Check Valve 24 Filter
4 Triple Pump 11 Compensation Ram 25 Flow Divider
4A Fan Pump 12A Lift Ram 26 Combined Brake/2 Speed Valve
4B Main/Steering Pump 12B Hose Burst Check Valve 26A Relief Valve
4C Demand Pump 13A Extension Ram 26B Brake Release Valve
4D Steering Priority Valve 13B Hose Burst Check Valve 26C 2 Speed Valve
9803/9510-06
4E Steering Pressure Relief Valve 14A Quick Release Hoses (if fitted) 27 Front Right Hand Motor
5A Test Point - Main/Steering Pump Pressure 14B Quick Release Hoses (if fitted) 28 Rear Right Hand Motor
5B Test Point 14C Quick Release Hoses (if fitted) 29 Front Left Hand Motor
6 Electric Unloader Valve 14D Quick Release Hoses (if fitted) 30 Rear Left Hand Motor
7 Steering Ram 15 Auxiliary Ram 1 (if fitted) 31 Cooler
8 Hydraulic Steering Unit 16 Auxiliary Ram 2 (if fitted) 32 Relief Valve (430 bar)
9 Valve Block 17 Fan 33 Relief Valve (430 bar)
9A Main Relief Valve - 245 bar 17A Relief Valve 105 bar
9B Tilt/Crowd Spool 18 Fan Solenoid Valve
9C Extension Spool 18A Relief Valve 50 bar
9E Auxiliary 1 Spool 19A Transmission Pump
9G Auxiliary Relief Valve 255 bar 19C Forward/Reverse Direction Control
9H Auxiliary Relief Valve 255 bar
Schematic Circuits
E-54
1
E-55
7
R L
2 8
3A 3B
T LS P
4 6
2800 RPM 5C P1 V
P2
4C
105 bar
4A 4D LS
17A
EF 18
4B T1 T
20 bar 4F
9803/9510-06
17
18A
50 bar
5A
Y
Z
B A B A B A B A B A
9
800530
(853/80082-2)
Fig 7. 3.5D Machines Priority, Steering and Fan Circuit - 2 Speed with Control Module
Schematic Circuits
E-55
E-56
10C 10D
10A 10B
11
13B
13A
12B
9803/9510-06
9 12A
B A B A B A B A B A
9G 9J 9L 9N
14A
9M 9P
9H 9K 14B 15
9A
TANK 14C
X
14D 16
9B 9C 9D 9E 9F
TILT EXTEND LIFT AUX 1 AUX 2

800540
2 (853/30082-3)
Fig 8. 3.5D 4x4 Machines Hydraulic Services Circuit

Schematic Circuits
E-56
Schematic Circuits
Fig 9. 3.5D 4x4 Machines Transmission Circuit - HIC
E-57 9803/9510-06 E-57

Schematic Circuits
Machines from Serial No. 1541224
332-T7843-1
Fig 10. 2.5D and 3.0D Machines
E-58 9803/9510-06 E-58

Schematic Circuits
333-S6778-1
Fig 11. 3.0D 4WD Machines
E-59 9803/9510-06 E-59

Hydraulic Pump
Steering/Main Hydraulic Pumps
Hydraulic Pump
Removal 1 Extend then lower boom to its lowest position.
!MWARNING 2 Make the machine safe by stopping the engine,

removing the key, and chocking the wheels.
Make the machine safe before working underneath it.
Park the machine on level ground, lower the 3 Open daily inspection cover, remove the front cover
attachments to the ground. Apply the park brake, put and tilt the cab (See Section B).
the transmission in neutral and stop the engine. Block
both sides of all four wheels. 4 Ensure that all hydraulic pressure is released from
the system by operating the steering wheel and the
Disconnect the battery, to prevent the engine being hydraulic levers.
started while you are beneath the machine.
GEN-4-1_1
Fig 1. Steering/Main Hydraulic Pump
E-60 9803/9510-05 E-60

Hydraulic Pump
!MWARNING Item Nm
Table 1. Torque Settings
Kgf m lbf ft
It is not possible to vent all residual pressure. Loosen 1-B 79 8 58
the connection one full turn and allow the pressure to
dissipate. Keep face and hands well clear of 1-E 90 9 66.5
pressurised hydraulic oil and wear protective glasses.
HYD-4-3 Triple Pump (3.5D 4x4 Only)
5 Disconnect and plug hydraulic hoses 1-A labelling 3.5D 4x4 machines are fitted with a triple pump. There is
each to ensure correct position on replacement. an extra section 2-P3 between the main pump 2-P2 and
steering pump 2-P1. This drives the hydraulic fan motor.
Note: On Diesel machines from Serial No. 892735 and
LPG machines from Serial No 892875, hose 1-P is Apart from the extra hydraulic connections, the procedures
retained using a split flange 1-C, washers 1-D and Bolts 1- for removal and replacement remain the same.
E. (Some machines with lower serial numbers may have
had a replacement pump fitted with the split flange
arrangement.)
A
6 Remove flange bolts 1-B. P1
P2
7 Make sure to retain the ‘O’ ring that is fitted between
the hydraulic pump assembly and the transmission
pump.
8 Remove the pumps from the transmission pump and

lift clear.
Replacement
Replacement is the opposite of the removal procedure.
During the replacement procedure do this work also:

P3
Fig 2. Triple Pump (3.5D 4x4 Only)
Make sure that the ‘O’ ring between the hydraulic pump
assembly and the transmission pump is fitted correctly.
Note: On Diesel machines from Serial No. 892735 and

LPG machines from Serial No 892875, retain hose 1-P
using a split flange 1-C, washers 1-D and Bolts 1-E. (Some
machines with lower serial numbers may have had a
replacement pump fitted with the split flange
arrangement.)
Torque tighten all bolts.
Before connecting the outlet hose from the pump, fill the
pump with clean hydraulic fluid, (See Section 3 - Routine
Maintenance) and allow to drain partially.
Connect the outlet hose.
E-61 9803/9510-05 E-61

Hydraulic Pump
Dismantling 9 Remove back-up seals 11, bush seal 12 and body Ò'
ring 13.
K Fig 3. ( T E-64).
10 Remove drive shaft 14, bushes 15 and 16 and idler
Note: Before removing and dismantling the unequal frame gear 17. Push out bushes 18 and 19 from the body
tandem pumps, check that its performance is as specified. 21. Note the position of bushes to ensure correct
If the pump performance is below that specified, the pump assembly.
should be renewed. Renewal of components such as
gears, bearings and housing will not effect a permanent 11 Remove circlip 20 and shaft seal 22. Take care not to
cure. If the pump output is satisfactory but there is external damage the shaft seal recess.
leakage, it should be dismantled for re-sealing only. Before
dismantling make sure that the pump exterior and working 12 Discard all seals and 'O' rings.
area are thoroughly cleaned and free from possible
sources of contamination. Inspection
Note: 3.5D 4x4 machines are fitted with a triple pump. K Fig 3. ( T E-64).
There is an extra section 2-P3 between the main pump 2-
P2 and steering pump 2-P1. This drives the hydraulic fan. 1 Inspect all 'O' ring grooves and shaft seal recesses in
adaptor flange 10 and mounting flange 24. Make sure
The procedures for dismantling and assembly remain they are free from burrs.
similar except for the extra set of items 7S to 21S. Although
the components of the fan pump may look similar to those 2 Check that the mating faces of the end cover 6, body
of the steering pump, they are not the same and care must 21S and adaptor flange 10 and adaptor flange 10,
be taken to keep all components of the two pumps body 24 and mounting flange 24 are not scored.
separated.
The pump must be renewed if any of the following faults
1 Remove sharp edges and burrs from drive shaft. are found:
2 Mark end cover 6, body 21 (S & M), flanged adaptor – The gear cut-in track in the body low pressure side is
10, and mounting flange 24 to ensure correct deeper than 0.08mm or has a scored and matt
assembly. appearance.
– The PTFE coated bearings in the body or flange are
3 Remove nuts 1 and washers 2 securing main pump to worn through so that the bronze base is visible.
flanged adaptor 10.
– The gear side faces or balance plates are scored.
4 Lightly tap flange adaptor to free it from the locating – The drive shaft has a wear groove where the shaft
dowels on body 21M then remove complete steering seal lips run.
pump.
Assembly
5 Undo bolts 4 and spring washers 5 and remove end
cover 6. Take care not to damage the machined faces K Fig 3. ( T E-64).
by prising them apart - use a soft faced hammer.
Note: Wash all components. Apply hydraulic oil
6 Strip both units (Same procedure applies to both immediately afterwards to prevent moisture collecting.
units).
Renew all seals and 'O' rings using JCB Special Hydraulic
7 Remove back-up seal 7, bush seal 8 and body 'O' ring fluid as a lubricant.
9.
1 Fit shaft seal 22 into the mounting flange 24 with
8 Remove adaptor flange 10, (flange 24) slide the gaiter spring facing into the pump and secure with
flange off square to the shaft. Take care not to circlip 20. Grease the lips of the shaft seal with JCB
damage the machined faces by prising them apart - HP Grease.
use a soft faced hammer to free flange from dowels.
E-62 9803/9510-05 E-62

Hydraulic Pump
2 Fit bushes 18S and 19S in their original positions.
Place end cover 6 temporarily against body 21S and
stand assembly upright with dowels uppermost.
3 Fit drive shaft 14S and idler gear 17S. Fit bushes 15S
and 16S in their original positions. Fit 'O' ring 13S,
bush seal 12S and back-up seal 11S. Make sure that
the flat face of back-up seal is uppermost.
4 Locate adaptor flange 10 to body 21S with a square

fit on the dowels. Turn the assembly over and support
on the flange, not on the drive shaft. Remove end
cover.
5 Fit 'O' ring 9S, bush seal 8S and back-up seal 7S.
Make sure that flat face of back-up seal is uppermost.
Fit end cover 6 and secure with spring washers 5 and
bolts 4.
6 Assemble main body, bushes and gears. Fit seals to

mounting flange end.
7 Turn unit on its side and fit mounting flange stud

assembly.
8 Stand unit on mounting flange, ensuring it is not

supported on drive shaft.
9 Fit seals to open end of main pump and then fit

splined coupling 25.
10 Fit complete steering pump, turn drive shaft to align

splines, secure with washers 2 and nuts 1.
11 Put a small amount of clean hydraulic oil in the inlet

ports and check that the drive shaft can be turned by
hand without undue force.

Item Nm Kgf m lbf ft
1
4 47 4.8 35
E-63 9803/9510-05 E-63

Hydraulic Pump
Fig 3. Steering/Main Hydraulic Pump
E-64 9803/9510-05 E-64

Hydraulic Pump
Steering Flow/Relief Valve (Double Pump)
Dismantling Note: Ensure inlet to valve in rear face is over high

pressure side of pump (semi-circular cut out in bushes).
K Fig 4. ( T E-66).
4 Steer valve pressure will require setting on machine
1 Clean the valve externally. or in a test rig.
2 Remove end cover from pump.
3 Remove spool plug 1 and spring seat 13 followed by

spring 11 and spool 10.
4 Inspect spool and bore for damage. Remove Ò' rings

2 and 12 and replace with new.
5 Ensure orifice in the base of the spring recess in

spring seat 13 is clear and free of contaminant.
6 Hold spool 10 on non-ground surface, unscrew

damping orifice and remove filter.
7 Fit new filter, apply JCB Threadlocker and tighten

damping orifice to 14 Nm (10 lb ft).
8 Remove core plug 9 and unscrew pilot relief valve

seat 8.
Note: Seat is peened in position and it may be necessary

to drill locally to ease removal.
9 Remove relief valve 5 and spring 4. Inspect for wear

or damage.
10 Remove Ò' rings 6 and 7 and replace with new.
Assembly
Note: Thoroughly clean all components.
1 Replace relief valve components ensuring valve

remains located in valve seat. Screw in pilot relief
valve seat 8 to just take up load of spring 4.
2 Replace spool 10, spring 11 and spring seat 13,

tighten plugs 13 to 100-105 Nm (74-80 lb ft) and 1 to
75-80 Nm (55-59 lb ft).
3 Refit valve to pump.
E-65 9803/9510-05 E-65

Hydraulic Pump
1
3 4
2
5
6
7
8
9
10
11
12
13
A283050
Fig 4. Steering/Flow Relief Valve (Double Pump)
E-66 9803/9510-05 E-66

Hydraulic Pump
Steering Flow/Relief Valve (Triple Pump)
Steering Flow/Relief Valve (Triple Pump)
Dismantling
Note: The steering flow/relief valve 1 is a sealed unit. If
faulty the whole unit must be replaced.
K Fig 5. ( T E-67).
1 Clean the valve externally.
2 Remove the securing screws 2.
3 Remove the steering flow/relief valve 1 from the

pump assembly.
4 Remove Ò' rings and gaskets and replace with new.
Assembly
Assembly is the opposite of the dismantling procedure.
Make sure to use new gaskets and Ò' rings. Fit new
adapters 4 and seals 3.
Fig 5. Steering Flow/Relief Valve (Triple Pump)
E-67 9803/9510-05 E-67

Hydraulic Valves
Control Valve - Earlier Machines
Removal 10 Lift control valve clear from the space under the boom
area.
!MWARNING Replacement
Park the machine on level ground, lower the Replacement is a reversal of the removal procedure.
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block Torque tighten the securing bolts to 56 Nm (5.7 kgf m 42
both sides of all four wheels. lbf ft).
Disconnect the battery, to prevent the engine being Ensure sensors are correctly set (See Section D).
GEN-4-1_1
1 Raise boom to its highest position and make safe/

support.
2 Make the machine safe by stopping the engine,

3 Open daily inspection cover and tilt the cab (See

Section B).
!MWARNING
It is not possible to vent all residual pressure. Loosen
dissipate. Keep face and hands well clear of
HYD-4-3
4 Ensure that all hydraulic pressure is released from

the system by operating the steering wheel or
hydraulic levers.
5 Disconnect and plug hydraulic hoses 1-A labelling

each to ensure correct position on replacement.
6 Disconnect all electrical wiring.
7 Disconnect lever rods.
8 Support control valve.
9 Remove 3 bolts 1-B securing the control valve to the

mounting plate.
E-68 9803/9510-08 E-68

Hydraulic Valves
B
A283200-1
Fig 1. Control Valve Removal and Replacement
E-69 9803/9510-08 E-69

Hydraulic Valves
Dismantling
K Fig 2. ( T E-71).
Note: The exploded view shows a four spool control valve

block, containing auxiliary spool 2B, lift spool 2C, tilt spool
2D and extension spool 2E. The Main Relief Valve
(M.R.V.) 2A and the Auxiliary Relief Valves (A.R.V.s) 2F,
2G, 2H and 2J are screw adjustable, for pressures see
Pressure Settings this Section.
M.R.V. 2A and A.R.V.'s 2F, 2G, 2H and 2J may be

dismantled only for cleaning, inspection or pressure
adjustment as no parts are serviced. Take care not to
damage seal Y
Assembling
Ensure that valves 4 are located on tie rod 3 and that inter-
section seals are located in their grooves as at X.Shim 5 is
fitted between all sections including end sections but only
over tie bar 3.
Nuts 1 must be tightened evenly while the valve is lying on

a flat surface with the ports facing upwards. Tighten nut 1A
by hand, then tighten nuts 1 to the correct torque value and
finally tighten nut 1A to the correct torque value. This will
allow the spool sections to assume their correct positions.

1 26-28 2.6-2.9 19-21
1A 40.5 4.15 30
E-70 9803/9510-08 E-70

Hydraulic Valves
1A
Fig 2. Control Valve Block
E-71 9803/9510-08 E-71

Hydraulic Valves
Control Valve Spool - Earlier Machines
Control Valve Spool - Earlier Machines
Dismantling
The spools and their components can be removed without
separating the valve sections but tie rod 3-1 must be
removed to release load hold check valve plugs 3-2.
Check valves 3-3 are not fitted to all sections. Do not
remove back up ring 3-A as this cannot be renewed in
service.
It is important to identify the spools with their respective

bores to ensure correct replacement as some valve blocks
have half motor spools. Failure to fit spools correctly could
result in machines not operating correctly and damage to
components.
Assembly
Ensure the spools are fitted in their original bores.
Apply JCB Threadlocker and Sealer to screw 3-9.

7 5-8 0.5-0.8 4-6
17 5-8 0.5-08 4-6
Fig 3. Control Valve Spool
E-72 9803/9510-08 E-72

Hydraulic Valves
Control Valve - Later Machines
Removal 10 Lift control valve clear from the space under the boom
area.
Park the machine on level ground, lower the Replacement is a reversal of the removal procedure.
the transmission in neutral and stop the engine. Block Tighten the securing bolts to their correct torques, see
both sides of all four wheels. Section 1.
Disconnect the battery, to prevent the engine being Ensure sensors are correctly set, see Section D.
GEN-4-1_1
1 Raise boom to its highest position and make safe/

support.

3 Open daily inspection cover and tilt the cab (See

Section B).
!MWARNING
HYD-4-3

the system by operating the steering wheel or
hydraulic levers.
5 Disconnect and plug hydraulic hoses, labelling each

to ensure correct position on replacement.
K Fig 4. ( T E-74)
6 Disconnect all electrical wiring.
7 Disconnect lever rods 6.
8 Support control valve.
9 Remove 3 bolts 1, together with nuts 4, resilient

mounts 3 and washers 2 securing the control valve to
the mounting plate.
E-73 9803/9510-08 E-73

Hydraulic Valves
6
5
7
3
2
1 C135820
C135820
Fig 4. Control Valve Removal and Replacement
E-74 9803/9510-08 E-74

Hydraulic Valves
Main Relief Valve (MRV)
Main Relief Valve (MRV)
!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under B
pressure and wear protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately. A
INT-3-1-10_2
Testing
Operate control levers to vent residual pressure.
Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to

test point. See Section E - Service Procedures.
Start engine and run at idle rev/min.

Fig 5. MRV
Operate the machine to normal operating temperature (50
degrees C) before checking the following.
Select boom lower service and hold ram fully closed.

Increase engine speed to max rev/min. while checking
maximum gauge reading which should be as specified in
Technical Data. If pressure should exceed specified data
before max rev/min. is reached, return the control lever to
the neutral position and reduce engine speed to idle.
Raise the boom and make secure/safe, see Section 3 -

Machine Safety.
Switch OFF the engine, vent residual pressure and adjust

the M.R.V. 6-2.
2
If necessary, adjust the M.R.V. by releasing locknut 5-A
and screwing body 5-B in or out as required. Retighten
locknut.
Screwing the M.R.V adjuster 5-B inwards increases the Fig 6. MRV Location
pressure. Screwing the adjuster outwards decreases the
pressure.
E-75 9803/9510-08 E-75

Hydraulic Valves
Auxiliary Relief Valve (ARV)
!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
INT-3-1-10_2
Testing - Removed
With the use of a test block and hand pump the ARV's can
be tested when removed from the valve block. The
advantage of using this method is, it is more accurate,
hoses do not need to be disconnected, blanks and gauges
fitted
!MWARNING
Take care when disconnecting hydraulic hoses and
fittings as the oil will be HOT.
TRANS-1-2
Switch OFF the engine and remove the starter key.

Operate the controls to vent residual pressure.
Remove the relevant ARV.
Fit the A.R.V. into the test block, part no. 892/00923.
Connect hand pump 892/00223 and a 0 - 400 bar (0 - 6000
lb/in2, 0 - 422 kg/cm2) pressure gauge to the pressure port
7-P.
Pressurise until oil begins to escape from the drain hole 7-

T. At this point the gauge will indicate the crack pressure
of the A.R.V.
The pressure should be as given in Section E - Technical

Data.
If required, adjust the pressure by slackening locknut 7-A

and turning cap 7-B
E-76 9803/9510-08 E-76

Hydraulic Valves
A
B
Fig 7. ARV Test Equipment
Testing - Fitted Operate the switches to vent residual hydraulic pressure,

adjust the A.R.V's. as detailed for M.R.V.
If the test block or hand pump are not available then the
A.R.V's can be tested in situ. The Auxiliary A.R.V's which Note: On completion ensure that M.R.V. is reset at the
are set below the M.R.V. pressure can be tested simply by operating pressure specified in Pressure Settings.
operating the relevant service. For tilt ram A.R.V's. which
are set above the M.R.V. pressure, the M.R.V should be
temporarily set at 260 bar.
Note: The engine must not be run at maximum speed as a

significant increase in pressure will be recorded.
Operate the machine to normal operating temperature

before carrying out the following procedures.
With the pressure gauge connected to test point, run

engine at idle and operate the service to full travel. Hold
while checking the maximum gauge reading which should
equal the A.R.V. operating pressure. Refer to Settings and
Pressure Tapping Points.
With the engine stopped, turn the starter switch to ON.
E-77 9803/9510-08 E-77

Hydraulic Valves
Unloader Valve
Unloader Valve
Description It is not possible to adjust the maximum pressure

mechanically on the 2.5 tonne machine.
The Teletruk utilises an unloader valve to control the
hydraulic load on the engine and maintain maximum The 3.0 unloader valve assembly incorporates an
engine power. The unloader valve is automatically adjustable regulating valve, this limits the maximum
adjusted with variations of engine speed, the pressure unloader pressure and prevents overloading the engine.
required to open the unloader valve (dump hydraulic load) The maximum unloading pressure on the 3.0 tonne
increases with engine speed. machine is adjustable.
The unloader valve used on the Teletruk differs between The 3.5 Tonne and 4x4 unloader valve is electrically set by
models. the Susmic controller, and is therefore mechanically
unadjustable.
Both the 2.5 and 3.0 tonne machine unloader valves must
be adjusted at idle. For adjustment of the unloader valve see the relevant
procedure for each machine.
Machine tonne Engine Speed Pressure Adjustable

2.5 Idle 2
80 bar (1160 lbf in ) Yes
Max 2
110-120 bar (1595-1740 lbf in ) No
3.0 Idle 2
95 bar (1378 lbf in ) Yes
Max 2
185-190 bar (2683-2755 lbf in ) Yes
3.5 & 4x4 Idle 90-100 bar (1305-1450 lbf in2) No
Max 190 bar (2755 lbf in2) No
E-78 9803/9510-08 E-78

Hydraulic Valves
Unloader Valve
Adjustment 5 Ensure hydraulic oil is at 50°C (122°F). Gradually

dead end the extension service with the engine at
2.5 Tonne Machine idle. Note the highest gauge reading before the
needle drops to zero. This should be 80 bar (1160 lbf/
in2).
!MWARNING
6 If the valve requires adjustment, screw the adjuster 9-
B in to increase, or out to decrease the pressure
Park the machine on level ground, lower the
setting. Note that this adjustment is very sensitive,
one quarter turn being equal to approximately 7.5 bar
(110 lbf/in2). Repeat steps 5 and 6 as necessary until
both sides of all four wheels.
the pressure is correctly set.
Disconnect the battery, to prevent the engine being
7 With the engine at maximum rpm gradually dead end
the extension service. Note the highest gauge
GEN-4-1_1
reading before the needle drops to zero. This should
be 110 to 120 bar (1595 to 1740 lbf/in2).
1 Fully extend the boom and lower to the ground.
Note: The unloader pressure at maximum engine speed is
not adjustable. It is pre-set, being proportional to the
pressure set when the engine is at idle.
3 Remove the bottom front cover.
Fig 8. Pump Pressure Test Point (2.5 T) C053450

Fig 9. Unloader Valve Adjustment (2.5 T)
4 Connect 200 bar (3000 lbf/in2) pressure gauge to
hydraulic pump pressure test point 8-A.
E-79 9803/9510-08 E-79

Hydraulic Valves
Unloader Valve
3.0 Tonne Machine 5 Ensure hydraulic oil is at 50°C (122°F). To test lower
limit Gradually dead end the extension service with
!MWARNING the engine at idle. Note the highest gauge reading
before the needle drops to zero. This should be 80 -
Make the machine safe before working underneath it. 90 bar (1160 - 1450 lbf/in2).
attachments to the ground. Apply the park brake, put 6 If the valve requires adjustment, screw the adjuster B
the transmission in neutral and stop the engine. Block in to increase, or out to decrease, the pressure
both sides of all four wheels. setting. Repeat steps 5 and 6 as necessary until the
pressure is correctly set.
started while you are beneath the machine. 7 To test upper limit, set the engine at full rpm, gradually
GEN-4-1_1 dead end the extension service. Note the highest
gauge reading before the needle drops to zero. This
1 Fully extend the boom and lower to the ground. should be 180 - 200 bar (2610 - 2900 lbf/in2 @ 2600
rpm). The engine should be heard to drop
2 Make the machine safe by stopping the engine, approximately 600 to 800 rpm before the hydraulic
removing the key, and chocking the wheels. pressure indication drops.
3 Remove the bottom front cover. 8 If necessary, adjust the pressure setting by turning
screw C, (in to increase, or out to decrease). Note that
this adjustment is very sensitive, one quarter turn
being equal to approximately 7.5 bar (110 lbf/in2).
Repeat steps 7 and 8 until the pressure setting is
correct.
Fig 10. Pump Pressure Test Point (3.0 T)
4 Connect 200 bar (3000 lbf/in2) pressure gauge to

hydraulic pump pressure test point 10-A.
E-80 9803/9510-08 E-80

Hydraulic Valves
Unloader Valve
Removal !MWARNING
!MWARNING It is not possible to vent all residual pressure. Loosen
Make the machine safe before working underneath it. dissipate. Keep face and hands well clear of
Park the machine on level ground, lower the pressurised hydraulic oil and wear protective glasses.
attachments to the ground. Apply the park brake, put HYD-4-3
both sides of all four wheels. 4 Ensure that all hydraulic pressure is released from
the system (by operating the lift lever).Disconnect
Disconnect the battery, to prevent the engine being the electrical wiring at harness plug 11-B.
5 Disconnect and plug all hydraulic hoses, labelling
GEN-4-1_1
1 Extend and lower boom to the ground
6 Remove two screws 11-A and remove unloader
2 Make the machine safe by stopping the engine, valve.
Replacement
Replacement is a reversal of the removal procedure.
Check and adjust the unloader valve pressure as detailed

on the previous pages.
B
A
V A
P2
P1
A437840
Fig 11.
E-81 9803/9510-08 E-81

Hydraulic Valves
Anti-Slip Valves - 4WD (3.0D 4x4 Machines)
Removal
!MWARNING

GEN-4-1_1
1 Extend and lower boom to the ground.

!MWARNING
HYD-4-3

the system (by operating the lift lever).

6 Remove four screws 12-C from the brackets securing

the valves and connecting manifold to the machine,
lift the assembly clear of the machine to a clean
working area.
E-82 9803/9510-08 E-82

Hydraulic Valves
Replacement 12-1A Yellow

12-1B Blue
12-2A Red
Note: Label each hydraulic hose, using the correct colour 12-2B Green
cable ties:
1A
2A
1B 2B
A437650
Fig 12.
E-83 9803/9510-08 E-83

Hydraulic Valves
Flow Divider Valve 2.5D/G, 3.0D/G and 3.5D 2 Wheel Drive Machines
Description The flow divider function should only be selected when

required, as it can induce tyre scrubbing and the effect of
The flow divider valve 13-A acts as a differential lock for torque 'wind up'.
the hydrostatic transmission system, equally dividing the
hydraulic flow between the front two wheels. Note: Do not select the flow divider function whilst driving
the machine. Ensure the controls are in the neutral position
before selecting.
4 5
2 3
G1 C1 C2 G2
CT3 CT2
CT5 CT6
OPTIONAL
ORIFICE
CT4
IN DR
8 10 9
Fig 13.
1 Flow Divider Valve 7 Charge Pressure (Top of Transmission Pump)
2 Check Valve 8 Pressure Switch Reverse (120 bar)
3 Check Valve 9 Pressure Switch Forward (120 bar)
4 R/H Wheel Motor 10 Transmission Pump (Forward Loop)
5 L/H Wheel Motor
E-84 9803/9510-08 E-84

Hydraulic Valves
Removal 8 Unscrew the two bolts 15-C and remove the flow
divider from the machine.
Clothing
You can be injured if you do not wear the proper Replacement is the reversal of the removal procedure.
clothing. Loose clothing can get caught in the
machinery. Wear protective clothing to suit the job. Note: Ensure check valves are correctly orientated when
Examples of protective clothing are: a hard hat, safety fitted. Check vlave should stop flow out of the flow divider,
shoes, safety glasses, a well fitting overall, ear- but allow flow in for anit-cavitation purposes.
protectors and industrial gloves. Keep cuffs fastened.
Do not wear a necktie or scarf. Keep long hair
restrained. Remove rings, watches and personal 2
jewellery.
INT-1-3-6_2
1 3
!MWARNING
Park the machine on level ground, lower the Fig 14.
attachments to the ground. Apply the park brake, put 1 Charge Pressure
2 Direction of Flow
3 Flow Divider Valve
GEN-4-1_1
1 Extend boom and lower to its lowest position.

3 Open the daily inspection cover and tilt the cab. (See
Section B).
4 Remove the step 15-B.

the system.
!MWARNING
HYD-4-3
6 Label and disconnect and plug all hydraulic

connections and hoses.
7 Disconnect the electrical wiring at the harness plug.
E-85 9803/9510-08 E-85

Hydraulic Valves
Fig 15.
E-86 9803/9510-08 E-86

Hydraulic Valves
Flow Divider Pressure Switch 2.5D, 3.0D and 3.5D Machines
Flow Divider Pressure Switch 2.5D, 3.0D and 3.5D Machines
Note: Only applicable to TCR machines, fitted with the 6 Lift pressure switch clear.
optional Flow Divider valve.
Replacement
Description
When fitted to TCR Machines, the Flow Divider option
includes a 120 Bar pressure switch 16-A within both the Note: Flow divider pressure switches are supplied pre-set
forward and reverse loops. The pressure switches are at 120Bar and no adjustment is necessary.
located on either side of the transmission pump 16-B.
To reduce the possibility of the machine stalling when

driving up a gradient, the pressure sensors switch off the
electrical signal to Pin 17 of the Susmic controller.
Removal
!MWARNING

GEN-4-1_1
1 Extend then lower boom to its lowest position.
2 Make the machine safe by stopping the engine, B

A C
!MWARNING C076980-C1
Fig 16.
HYD-4-3

the system (By operating the lift lever).
4 Disconnect electrical harness at plug 16-C.
5 Unscrew pressure switch 16-A and plug hydraulic

pipework.
E-87 9803/9510-08 E-87

Hydraulic Valves
Flow Divider Valve 3.5D 4x4 (Hydraulic Integrated Circuit) (HIC)
Make the machine safe before working underneath it. Replacement is a reversal of the removal procedure.

GEN-4-1_1
Removal
1 Extend and lower boom to the ground.

!MWARNING
HYD-4-3

the system.

6 Disconnect the electrical wiring to solenoid valve 17-

V at the harness plug.
7 Unscrew the three bolts 17-C and remove the flow

divider from the machine
Note: The flow divider is protected by relief valves. On

machines up to serial number M1174902 they are
mounted externally as shown at 17-D and need to be set
to 350 bar (5076 lbf/in2). It is not necessary to remove
these to remove the flow divider. On machines from serial
number M1174903 the relief valves are within the flow
divider (HIC) unit.
E-88 9803/9510-08 E-88

Hydraulic Valves
M2 C
DR
A
M4 M1
M3
V
CHG
D
Fig 17.
E-89 9803/9510-08 E-89


Air Blast Type
Removal Replacement
!MWARNING Replacement is a reversal of the removal procedure.


GEN-4-1_1

3 Open daily inspection cover and tilt the cab. (See

Section B)
!MWARNING
HYD-4-3

the system (By operating the lift lever).
!MWARNING
Beware of the hot exhaust system even with the
engine stopped.
ENG-4-3
5 Disconnect hydraulic pipework 1-A and plug all ends.
6 Support cooler.
7 Remove 4 bolts 1-B.
8 Lift cooler clear.
E-90 9803/9510-05 E-90

Air Blast Type
A283190
Fig 1.
E-91 9803/9510-05 E-91

Liquid to Liquid Cooler
Description 3 Open daily inspection cover and tilt the cab. (See
Section B)
The Cooler contains a bank of parallel tubes fixed in a
perforated plate at either end. Water flows through the
tubes and oil across the tubes, the latter guided in its flow
!MWARNING
path through the shell by baffle plates. It is not possible to vent all residual pressure. Loosen
Item K Fig 2. ( T E-92). pressurised hydraulic oil and wear protective glasses.
A Oil Out HYD-4-3
B Oil In
C Water Out the system (By operating the lift lever).
D Water In
E Cooler (Liquid/Liquid) !MWARNING
X Tubes Beware of the hot exhaust system even with the
Y Baffles engine stopped.
ENG-4-3
5 Disconnect hydraulic pipework 3-3 and 3-5. Plug all

ends.
B A
!MWARNING
C D
The cooling system is pressurised when the coolant is
hot. When you remove the cap, hot coolant can spray
out and burn you. Make sure that the engine is cool
X Y before you work on the cooling system.
A437810
9-3-3-1_2
Fig 2.
Removal !MWARNING
Antifreeze can be harmful. Obey the manufacturer's
!MWARNING instructions when handling full strength or diluted

antifreeze.
Make the machine safe before working underneath it. 7-3-4-4_1
attachments to the ground. Apply the park brake, put 6 Disconnect the bottom hose from the engine radiator
the transmission in neutral and stop the engine. Block 3-2 to drain system.
7 Remove cooler retaining clips 3-7.
started while you are beneath the machine. 8 Support cooler.
GEN-4-1_1
9 Remove cooler hoses 3-6 and 3-8.
10 Lift cooler 3-4 clear.
E-92 9803/9510-05 E-92

Replacement 1 Check that the coolant level is within the High and
Low marks on the expansion tank 3-9.
Top up the system with a suitable mixture. (See Section 3
- Routine Maintenance).
1 2 3 4 5
7
8
A437970
Fig 3.
E-93 9803/9510-05 E-93

Hydraulic Rams
Lift Ram
!MWARNING 6 Drive out pin 1-D and carefully lower the ram.
Make the machine safe before working underneath it. 7 Remove pin 1-E (requires a puller or sliding hammer).
attachments to the ground. Apply the park brake, put 8 Remove the lift ram using suitable lifting equipment.
both sides of all four wheels. Replacement
Disconnect the battery, to prevent the engine being Replacement is a reversal of the removal procedure.
started while you are beneath the machine. Torque tighten the securing bolts to 56 Nm (5.7 kgf m 42
GEN-4-1_1 lbf ft).
!MWARNING
Lifting Equipment
You can be injured if you use faulty lifting equipment.
Make sure that lifting equipment is in good condition.
Make sure that lifting tackle complies with all local
regulations and is suitable for the job. Make sure that
lifting equipment is strong enough for the job.
INT-1-3-7
Removal
1 Raise retracted boom to 30% of its highest position
and support the boom.


the system.
!MWARNING
HYD-4-3
4 Disconnect and plug hydraulic hoses 1- A labelling

5 Remove securing bolts 1-B and 1-C from pins 1-D

and 1-E.
E-94 9803/9510-05 E-94

Hydraulic Rams
Lift Ram
B
B
D
D
A
A
C
C
A283090
Fig 1.
E-95 9803/9510-05 E-95

Hydraulic Rams
Compensating Ram
Compensating Ram
!MWARNING 7 Remove pin 2-E (requires a puller or sliding hammer.
Make the machine safe before working underneath it. 8 Remove the compensating ram using suitable lifting
Park the machine on level ground, lower the equipment.
the transmission in neutral and stop the engine. Block Replacement
Disconnect the battery, to prevent the engine being Torque tighten the securing bolts to 56 Nm (5.7 kgf m 42
started while you are beneath the machine. lbf ft).
GEN-4-1_1
!MWARNING
Lifting Equipment
You can be injured if you use faulty lifting equipment.
Make sure that lifting equipment is in good condition.
regulations and is suitable for the job. Make sure that
INT-1-3-7
Removal
1 Raise retracted boom to 30% of its highest position
and support the boom.


the system.
!MWARNING
HYD-4-3
4 Disconnect and plug hydraulic hoses 2-A labelling

5 Remove securing bolts 2-B and 2-C from pins 2-D

and 2-E.
6 Drive out pin and lower the ram.
E-96 9803/9510-05 E-96

Hydraulic Rams
Compensating Ram
B
B
D
D
C
C
E
E
A
A283080
Fig 2.
E-97 9803/9510-05 E-97

Hydraulic Rams
Extension Ram
Extension Ram
!MWARNING 7 Remove securing bolt 3-B and withdraw pin 3-C,

using sliding hammer.
Park the machine on level ground, lower the 8 Remove hose burst check valve 3-H.
the transmission in neutral and stop the engine. Block 9 Disconnect and plug hydraulic hoses labelling each to
both sides of all four wheels. ensure correct position on replacement.
Disconnect the battery, to prevent the engine being 10 Remove cap screws 3-D, and cover 3-E.
GEN-4-1_1 11 Slacken grub screw 3-F.
!MWARNING 12 Use dummy pin to withdraw pivot pin 3-G so that

dummy is just clear of ram.
Lifting Equipment
You can be injured if you use faulty lifting equipment. 13 Fully withdraw pivot pin 3-G and fit second dummy pin
Make sure that lifting equipment is in good condition. to support the boom.
regulations and is suitable for the job. Make sure that 14 Pull the extension ram out, using suitable lifting
lifting equipment is strong enough for the job. equipment to take the weight.
INT-1-3-7
Replacement
Removal
1 Extend ram by distance recorded before removal and
1 Park on firm level ground and apply parking brake. remove hose burst check valve 3-H, if fitted.
2 Remove screws and lift boom end cover plate A clear. 2 Refit extension ram.
3 Extend boom approximately 600 mm (record figure). 3 Grease pivot pins 3-C and 3-G.
4 Raise retracted boom to just above horizontal and 4 Remove second dummy pin and fit pivot pin 3-G, with
support boom and under forks. all wear pads 3-J.
5 Make the machine safe by stopping the engine, 5 Secure pin 3-G using cap 3-E, cap screws 3-D, and
removing the key, and chocking the wheels grub screw F.
6 Ensure that all hydraulic pressure is released from 6 Fit hoses in correct positions and tighten.
the system by operating the boom extension control
lever. 7 Use bar to align front pin 3-C or fit hose burst check
valve 3-H and tighten. Start engine and work
!MWARNING extension service to align front pin 3-C.
It is not possible to vent all residual pressure. Loosen 8 Fit pivot pin 3-C securing bolt 3-B and tighten nut.
dissipate. Keep face and hands well clear of 9 Fit hose burst check valve 3-H and tighten. (if not
pressurised hydraulic oil and wear protective glasses. fitted at step 7).
HYD-4-3
E-98 9803/9510-05 E-98

Hydraulic Rams
Extension Ram
H J
E
F
A283440
Fig 3.
E-99 9803/9510-05 E-99

Hydraulic Rams
Tilt/Crowd Ram
Tilt/Crowd Ram
!MWARNING !MWARNING
Make the machine safe before working underneath it. Lifting Equipment
Park the machine on level ground, lower the You can be injured if you use faulty lifting equipment.
attachments to the ground. Apply the park brake, put Make sure that lifting equipment is in good condition.
the transmission in neutral and stop the engine. Block Make sure that lifting tackle complies with all local
both sides of all four wheels. regulations and is suitable for the job. Make sure that
Disconnect the battery, to prevent the engine being INT-1-3-7
GEN-4-1_1 Removal
D,B
A
C054860-C2
E,C
Fig 4.
1 Extend boom and lower to its lowest position. 4 Disconnect and plug hydraulic hoses 4-A labelling
removing the key, and chocking the wheels. 5 Remove securing bolts 4-B and 4-C from pins 4-D
and 4-E.
the system by operating the tilt control lever. Note: The pin on the left hand side can be driven out, but
the right hand side pin requires a puller or sliding hammer
!MWARNING 6 Remove pin 4-D and lower the ram.
the connection one full turn and allow the pressure to 7 Drive out pin 4-E.
pressurised hydraulic oil and wear protective glasses. 8 Remove the tilt/crowd ram.
HYD-4-3
E-100 9803/9510-05 E-100

Hydraulic Rams
Tilt/Crowd Ram
Replacement
Note: Ensure tilt/crowd ram is mounted the correct way
up.

Torque tighten the securing bolts to 56 Nm (5.7 kgf m 42
lbf ft).
E-101 9803/9510-05 E-101

Hydraulic Rams
Assemble and Dismantle
Typical Ram When Assembling
When Dismantling Renew all seals and 'O' rings.
Place the ram assembly on a locally manufactured strip/ Thoroughly clean the threads of piston head 6, piston rod
rebuild bench. 2, end cap 1 and cylinder with a wire brush. Ensure that all
threads are free from grease, hydraulic oil and old locking
Slacken the end cap 1 using a special spanner (See fluids using JCB Cleaner/Degreaser. Allow solvent to dry
Section 1 - Service Tools) and remove the piston rod for 15 minutes before applying JCB Activator.
assembly from the cylinder.
Ensure that lubricants used during assembly do not come
K Fig 6. ( T E-105). into contact with the locking fluids.
!MWARNING Fit rod and wiper seals 8 and 9 into end cap 1, ensuring
that they are not twisted. Fit Ò' ring 3 into its external
To avoid burning, wear protective gloves when groove.
handling hot components. To protect your eyes, wear
goggles when using a wire brush to clean Before fitting the end cap 1 onto the piston rod 2, wrap tape
components. around the piston rod threads or use a suitable sleeve, as
shown at 5-F, to protect the seals and threads from oil and
HYD-1-3
grease.
Position the piston rod assembly on the bench in place of
the ram cylinder. Remove the piston head seals 4. Note: Threadlocker and Activator must not contact seals,
bearing rings or 'O' rings.
Extract dowel 5 from the piston head using a metric screw
(M3) threaded into the extractor hole. Fit the locking dowel 5 to the piston head/rod as follows:
Note: Any attempt to remove the piston head without 1 New rod and piston head.
removing the dowel will cause damage to both the piston
head and rod. If both are required, the following procedure should
be followed:
Remove piston head 6 from rod 2 using a special spanner
(see Section 1 - Service Tools). Remove the piston head a Drill through the piston head into the piston rod,
internal 'O' ring 7. shown at 5-Z. Use an undersized diameter drill
first as a guide and then drill using the correct size
Remove the end cap 1 from the piston rod and remove the diameter drill to suit: refer to the table overleaf for
inner and outer seals 8, and 9 and Ò' ring 3. drill diameters and depths.
Ensure that all metal components are free from scoring, b Remove all swarf and contamination. Insert dowel
nicks and burrs. A damaged rod will impair the life of the 5-C into the drilled hole, making sure that the
inner rod and wiper seals. tapped extractor hole is to the outside.
Discard all seals and 'O' rings. 2 New piston head fitted to a pre-drilled piston rod.
Note: The lift ram end cap is fitted with an end damping a Redrill and dowel BOTH the piston head and
spring and collar (not illustrated) which should be checked piston rod at 90° from the existing drilled dowel
for wear or damage. hole in the piston rod. Follow the procedure
described in step 1.
E-102 9803/9510-05 E-102

Hydraulic Rams
3 New piston rod fitted to a pre-drilled piston head. two together and then torque-tighten the end cap into the
cylinder.
Use the pre-drilled hole in the piston head. Care must
be taken not to elongate the existing hole in the piston Note: If hydraulic oil contacts uncured Threadlocker, a
head. weakening of the bond will result. Cure times vary
according to the ambient temperature. Allow
a Use a drill of the same diameter as the pre-drilled approximately 1 hour at 20 °C between assembly and
hole in the piston head to make a 'centre mark' in filling the ram with oil.
the piston rod. DO NOT drill the piston rod at this
stage. Note: When fitting cylinder and piston eye bushes 10,
ensure that the split in the bush is set at 90° to the
b Use an undersized diameter drill as a guide and longitudinal centreline of the cylinder.
drill into the piston rod to the required depth (see
the table overleaf), making sure that the drill has Table 1. Torque Settings
centred correctly on the 'centre mark' made in Item Item Nm kgf m lbf ft
step 3a. No.
Lift Ram 6-1 678 69 500
c Use the correct size diameter drill to suit the dowel
and drill to the required depth (see the table 6-6 405 41 300
overleaf). Compensating 6-1 450 46 332
Ram
d Remove all swarf and contamination. Insert the
6-6 300 31 221
dowel C into the drilled hole, making sure that the
tapped extractor hole is to the outside. Crowd Ram 6-1 678 69 500
6-6 405 41 300
Tilt Ram 6-1 678 69 500
Fit piston head seals 4. When fitting seal 4A, ensure that 6-6 405 41 300
internal seal 4B remains seated squarely in its groove and
not twisted. Note: Cold weather operation. When operating in
conditions which are consistently below freezing, it is
Position the cylinder on the bench and install the rod recommended that the rams are operated slowly to their
assembly into the cylinder. full extent before commencing normal working.
Taking care to retain the end cap 1 at the further end of the Drilling details for piston head retention (all dimensions
piston rod from the cylinder, coat the thread of the cylinder in mm)
with JCB Activator. Next apply JCB Threadlocker to the
thread of the end cap. Wait 15 minutes before bringing the
Table 2.
Ram Size Dowel Guide Guide Drill Dowel Drill Dowel Drill
Size Dia Drill Dia Depth Dia (5-X) Depth (5-Y)
50 x 25 20 x 6 4 19 6.1/6.02 23/22
60 x 30 20 x 6 4 19 6.1/6.02 23/22
70 x 40 20 x 6 4 19 6.1/6.02 23/22
70 x 50 20 x 6 4 19 6.1/6.02 23/22
80 x 50 20 x 6 4 19 6.1/6.02 23/22
110 x 60 30 x 12 8 28 12.02/12.10 32/33
E-103 9803/9510-05 E-103

Hydraulic Rams
Fig 5.
E-104 9803/9510-05 E-104

Hydraulic Rams
Fig 6.
E-105 9803/9510-05 E-105

Hydraulic Rams
E-106 9803/9510-05 E-106

TLT35D Section e - Hydraulic

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TLT35D Section e - Hydraulic

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Section E

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Contents Page No.

Contents Page No.

Hydraulic Oil Cooler

Contents Page No.

Contents Page No.

Part Number: Description:

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Part Number: Description:

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Part Number: Description:

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Relief Valve Operating Pressures (Oil temperature at 50 °C)

Rams (2.0T, 2.5T machines) Bore Rod Dia Stroke

Rams (3.0T machines) Bore Rod Dia Stroke

Rams (3.0D HL machines) Bore Rod Dia Stroke

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Rams (3.0D HL machines) Bore Rod Dia Stroke

Rams (3.5T machines) Bore Rod Dia Stroke

Ram Torque Settings Nm lb ft Kgf m

Ram Torque Settings Nm lb ft Kgf m

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4x4 Additional Components

Anti-Slip Valves (3.0D)

Front Drive Motors (Twin Speed (Braked) Rexroth

Rear Drive Motors (Single Speed Rexroth MCR 03

Rear Drive Motors (Single Speed Rexroth MCR 04

Drive Motors Poclain MSE 05-0 TLT30)

Drive Motors (Poclain MSE 05-1 TLT35)

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Drive Motors (Poclain MSE 05-1 TLT35)

Combined 2 Speed/Brake Valve

Unloader Valve (Computer Controlled)

Flow Divider Valve (3.5D)

Main/Steer/Fan Pump (3.5T 4x4)

Fan Motor (3.5T 4x4)

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Contents Page No.

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Fan Motor (3.5T 4x4)

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For steering system components, see Section H-

Pump P2 delivers pressurised oil to the control valve, via

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The 2nd speed section of the motor is a low capacity motor

The ASC system operates at both wheel motor speeds as

A HIC (Hydraulic Integrated Circuit) valve is used to divide

This system has 4 wheel motors, anti-slip valves, wheel

An Anti Slip Control system (ASC) is fitted to improve

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Introduction to Hydraulic Schematic Symbols

General (Basic and Functional Symbols) Table 2. Rams

Complex hydraulic components and circuits can be Single acting

Flow restriction affected by

Fixed capacity motor two

Variable capacity motor one

Variable capacity motor two

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