Section E: Service Manual - JS200, JS140 & JS205

Section E
Hydraulics
Service Manual - JS200, JS140 & JS205
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body & Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section J - Track and Running Gear
Section K - Engine
Publication No.
9813/0400-2
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 9813/0400-2 E-0

Contents Page No.

Technical Data
General Data ............................................................................................ E-1
Slew Motor ........................................................................................... E-1
Hydraulic Pump .................................................................................... E-1
Main Control Valve ............................................................................... E-1
Track Motor .......................................................................................... E-1
Filtration ................................................................................................ E-2
Hydraulic Cylinders .............................................................................. E-2
Cab ....................................................................................................... E-2
ECU4 Control ....................................................................................... E-2
Controls ................................................................................................ E-2
Basic System Operation

Introduction to Hydraulic Schematic Symbols .......................................... E-3
General (Basic and Functional Symbols) ............................................. E-3
Control Valves ...................................................................................... E-7
Example of Schematic Circuit .............................................................. E-8
Circuit Descriptions
Hydraulic Schematic ................................................................................. E-9
JS200, JS205 ....................................................................................... E-9
JS140 ..................................................................................................E-11
Servo/Pilot Line ...................................................................................... E-13
Components ....................................................................................... E-13
Servo/Pilot Pressure and Return Line .................................................... E-16
Components ....................................................................................... E-16
Component Location .............................................................................. E-19
Neutral Circuit ......................................................................................... E-21
Travel - Single Speed ............................................................................. E-23
Straight Line Travel ................................................................................. E-25
Boom Up ................................................................................................ E-27
Boom Down ............................................................................................ E-29
Dipper Out .............................................................................................. E-31
Dipper In ................................................................................................. E-33
Bucket Opening ...................................................................................... E-35
Bucket Closing ........................................................................................ E-37
Swing ...................................................................................................... E-39
Main Control Valve

Description .............................................................................................. E-41
Hydraulic Pump/Regulator
Hydraulic Pump Operation ..................................................................... E-55
Main Pumps (P1 and P2) ................................................................... E-55
Pump Hydraulic Circuit Diagram ........................................................ E-56
Hydraulic Pump/Regulator Exploded View ........................................ E-57
Hydraulic Pump/Regulator Plan View ................................................ E-58
Hydraulic Pump Removal and Replacement .......................................... E-59
Removal ............................................................................................. E-59
Replacement ...................................................................................... E-60
Hydraulic Pump Dismantling and Assembly ........................................... E-61
Dismantling ......................................................................................... E-61
Assembly ............................................................................................ E-64
E-i E-i
Contents
Contents Page No.

Regulator Dismantling and Assembly ..................................................... E-67
Dismantling ......................................................................................... E-67
Assembly ............................................................................................ E-71
Remote Control Valve (Hand Control)

Operation ................................................................................................ E-75
Function .............................................................................................. E-75
Removal and Replacement .................................................................... E-77
Removal ............................................................................................. E-77
Replacement ...................................................................................... E-77
Dismantling and Assembly ..................................................................... E-79
Dismantling ......................................................................................... E-79
Inspection ........................................................................................... E-83
Assembly ............................................................................................ E-83
Fault Finding ....................................................................................... E-84
Travel Pedal Valve

Dismantling ......................................................................................... E-85
Inspection ........................................................................................... E-87
Assembly ............................................................................................ E-87
Slew Motor
Motor Operating Principles ..................................................................... E-89
Slew Brake Operation ............................................................................. E-90
Fault Finding ........................................................................................... E-91
Motor Does Not Rotate ....................................................................... E-91
Motor Rotates in the Reverse Direction ............................................. E-91
Motor Speed is Low ............................................................................ E-91
Motor Brake Working Poorly .............................................................. E-92
Motor is Driven by Exterior Torque ..................................................... E-92
Oil Leakage ........................................................................................ E-92
Removal and Replacement .................................................................... E-93
Removal ............................................................................................. E-93
Replacement ...................................................................................... E-94
Slew Motor Configuration ....................................................................... E-95
Dismantling ......................................................................................... E-98
Inspection ......................................................................................... E-103
Assembly .......................................................................................... E-105
Relief Valves ...................................................................................... E-111
Slew Gearbox
Reduction Gear Structure and Working Principles ................................ E-113
Description ............................................................................................. E-114
Component Identification ...................................................................E-115
Disassembly and Assembly ................................................................... E-116
Disassembly ......................................................................................E-116
Inspection ..........................................................................................E-117
Assembly ...........................................................................................E-118
Rotary Coupling
Description ............................................................................................ E-121
E-ii E-ii
Contents
Contents Page No.

Removal and Replacement .................................................................. E-123
Removal ........................................................................................... E-123
Replacement .................................................................................... E-124
Dismantling and Assembly ................................................................... E-125
Dismantling ....................................................................................... E-125
Assembly .......................................................................................... E-126
Hydraulic Rams
Precautions During Use ........................................................................ E-129
Installation ........................................................................................ E-129
Caution During Use .......................................................................... E-129
Maintenance, Inspection Points ....................................................... E-129
Removal and Replacement .................................................................. E-131
Typical Bucket Ram .......................................................................... E-131
Typical Boom Ram ........................................................................... E-135
Typical Dipper Ram .......................................................................... E-140
Assembly and Disassembly .................................................................. E-145
Cylinder Disassembly ....................................................................... E-145
Cylinder Assembly ............................................................................ E-151
Do’s in a Hydraulic Cylinder ............................................................. E-157
Dont’s in a Hydraulic Cylinder .......................................................... E-157
Service Procedure
Make the Machine Safe ........................................................................ E-158
Pressure Testing - General ................................................................... E-159
Confirmation of the Oil Temperature ................................................ E-159
Warming-up Procedure .................................................................... E-159
Pressure Testing Points .................................................................... E-160
Pressure Relief Valve Location ............................................................. E-162
Main Relief Valve (MRV) Pressure ....................................................... E-164
Servo Relief Pressure ........................................................................... E-166
Auxiliary Relief Valves .......................................................................... E-167
General ............................................................................................. E-167
Boom Ram ....................................................................................... E-168
Dipper Ram ...................................................................................... E-170
Bucket Ram ...................................................................................... E-171
Option ARV (Monoboom) ................................................................. E-172
Slew Motor Pressure Relief .................................................................. E-173
Travel Motor Relief Pressure ................................................................ E-175
Fault Finding
Hydraulic Contamination ...................................................................... E-176
Hydraulic Fluid Quality ..................................................................... E-176
Effects of Contamination .................................................................. E-176
Cleaning Operation .......................................................................... E-176
Contaminant Standards .................................................................... E-177
Filters ................................................................................................ E-177
Main Control Valve ............................................................................... E-178
Relief Valve ........................................................................................... E-179
Hydraulic System .................................................................................. E-180
Slew Motor ............................................................................................ E-181
Hydraulic Pump .................................................................................... E-183
Hydraulic Rams .................................................................................... E-184
Hydraulic Ram Faults and Remedies ............................................... E-184
E-iii E-iii
Contents
Contents Page No.
E-iv E-iv
Technical Data
General Data
Technical Data
General Data
Slew Motor Main Control Valve

Table 1. A combined four and five spool control valve with auxiliary
Swing motor Axial piston type service spool as standard. When required twin pump flow
is combined to boom and dipper services for greater speed
Swing brake Automatic spring applied disc type
and efficiency K Table 4. ( T E-1).
parking brake
Final drive Planetary reduction Table 4.
Swing gear Large diameter, internally toothed fully ARV Setting
sealed oil bath lubricated Boom/Arm/Bucket 343 bar
Swing circuit 289 bar
Hydraulic Pump
Travel circuit 343 bar
A variable flow negative control system with flow on Pilot control 40 bar
demand, variable power output and servo operated, multi Arm In 392 bar
functional. K Table 2. JS200, JS205 ( T E-1)
Arm Out 392 bar
Table 2. JS200, JS205 Bucket In 392 bar
Main pumps 2 variable displacement axial piston Bucket Out 392 bar
Max. Flow 2 x 220 l/min Boom Up 392 bar
Servo pump Gear type Boom Down 264 bar
Displacement 2 x 110 cu. cm/rev Track motor 353 bar
Table 3. JS140 A separate restriction valve in the system provides smooth

Main pumps 2 variable displacement axial piston operation of the boom and dipper spools selection.
Max. Flow 2 x 130 l/min
Servo pump Gear type
Track Motor
Displacement 2 x 59 cu. cm/rev Table 5.
Type Fully hydrostatic
Travel motors Axial piston type, fully guarded within
undercarriage frame
Final drive Planetary reduction, bolt-on
sprockets
Service brake Hydraulic counter balance valve to
prevent over-speeding on gradients
Park brake Disc type, spring applied, automatic
hydraulic release
Grade ability 70% (35 deg.) continuous
Travel speed Single, 4 Km/h
E-1 9813/0400-2 E-1

Technical Data
General Data
Filtration Controls
The hydraulic components are protected by the highest Table 7.
standard of filtration to ensure long hydraulic fluid and Excavator All servo lever operated.
component life K Table 6. ( T E-2).
Tracks Servo operated by foot pedal or hand
lever.
Table 6.
In tank 150 Micron, suction strainer Control Via gate lock lever at cab entrance or
isolation panel switch.
Main return line 10 Micron
Engine speed Easy Pull type with mode change
Plexus bypass line 1.5 Micron control.
Pilot line 10 Micron Engine stop Ignition key operated/Stop cable
operated
Hydraulic Cylinders Horn Operated via servo lever mounted
button.
Double acting type, with bolt-up end caps and hardened
steel bearing bushes. End cushioning is fitted as standard
on boom and dipper. EMS bushes at boom mtg. and
Dipper mtg. allows greasing at every 1000 hrs K Table 5.
( T E-1).
Cab
Pressed steel with high strength rolled section frame. All
tinted safety glass windows with fully opening two-piece
windscreen and in screen stowage. Gas strut assisted.
Opening door windows. Fan forced fresh air ventilation
Fully adjustable deluxe suspension seat with armrest and
back rest recline. Radio cassette player with digital tuning
as an optional.
ECU4 Control
2-Modes i.e. “E” Economy & “P” Power mode operational.
ECU4 allows the fool proofing of the hour meter recording,

at gauge and itself by ECU4 K Table 7. ( T E-2).
E-2 9813/0400-2 E-2


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-3 9813/0400-2 E-3

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-4 9813/0400-2 E-4

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-5 9813/0400-2 E-5

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-6 9813/0400-2 E-6

Control Valves
Control valves are usually represented by one or more
square boxes.
K Fig 1. ( T E-7) 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 4.
It must be noted that not all spools are of the same type.
Fig 1.
Their operating designs can be seen by following the path
the flow arrows take in their respective operating squares.
K Fig 2. ( T E-7) - 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 4. ( T E-7) shows a 'D' type spool.
K Fig 5. ( T E-7) - '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 2. detent, connects both sides of the ram together to allow the
service to 'float'.
K Fig 4. ( T E-7) 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 5.
K Fig 6. ( T E-7) - 'N' spools are sometimes used to

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

the spool would connect Port P1 to Port P2, and Port P3 to
Port P4. K Fig 4. ( T E-7).
If the valve spool was moved to Position 3, movement of

the spool would connect Port P1 to Port P4, and Port P3 to Fig 6.
Port P2. K Fig 4. ( T E-7).
E-7 9813/0400-2 E-7

Example of Schematic Circuit
A
B
C G
D E
Fig 7. 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 7. ( T E-8).
7-A Hydraulic Tank
Hydraulic tank 7-A is a pressurised tank with an internally 7-B Strainer
mounted strainer 7-B on the suction line to the fixed 7-C Fixed Displacement Pump
displacement pump 7-C. System pressure is limited to the
setting of relief valve 7-D. 7-D Relief Valve
7-E Spool
Valve spool 7-E is an open-centre spool that is in neutral 7-F One Way Valve
position; flow from the pump passes through the spool and
returns to the hydraulic tank. 7-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 7-G. Notice that the fluid must first
open one way valve 7-F before flowing to the ram.
E-8 9813/0400-2 E-8

Hydraulic Schematic
JS200, JS205 Item Description

29 Solenoid Valve
The item numbers in the following table are identified on
the hydraulic schematic diagrams. K Fig 1. ( T E-10) 30
31 Accumulator
Table 1. Component identification
32
Item Description
33 Line Filter
1 Slew Motor
34 Hyd Pump
2 Arm Ram
35 Remote Control Valve
3
36* Remote Control Valve
4 Travel Motor
37 Check Valve
5 Centre Joint
38
6 Bucket Ram
39 Remote Valve
7 Boom Ram
40
8 Boom Ram
41
9
42* Quick Release Coupling
10 Valve Control
43* Valve C/over
11
44* Relief Valve
12
45* Line Filter
13 Main Control Valve
46
14 Check Valve
47
15 Check Valve
48 Quick Release Coupling
16 Radiator
49
17 Slew Gearbox
50
18 Air Breather
51 Remote Valve RH
19 Sump Tank
52 Auto Idler
20
53 Proximity Switch 12 Bar
21 Strainer
54 Proximity Switch 20 Bar
22 Relief Valve
23 Return Filter * Option
24 Stop Valve
25 Plexus Filter
26
27
28
E-9 9813/0400-2 E-9

Hydraulic Schematic
Fig 1. 229/01100 issue 5
E-10 9813/0400-2 E-10
Hydraulic Schematic
JS140 Item Description

34 Switch 12 Bar
The item numbers in the following table are identified on
the Hydraulic Schematic diagrams. K Fig 1. ( T E-10) 35 Switch 20 Bar
Table 2. Component identification * Option

Item Description
1 Slew Motor
2 Arm Ram
3 Travel Motor
4 Centre Joint
5 Bucket Cylinder
6 Boom Ram LH
7 Boom Ram RH
8 Control Valve
9 Filter
10 Check Valve 1 Bar
11 Check Valve 3 Bar
12 Radiator
13 Air Breather
14 Tank
15 Strainer
16 Relief valve
17 Return Filter
18 Stop Valve
19 Filter
20 Solenoid Valve
21 Accumulator
22 Filter
23 Hydraulic Pump
24 Remote Valve
25* Check Valve
26* Remote Valve LH
27* Remote Valve RH
28* Control Remote Valve
29* Quick Relief Coupling
30 Relief Valve
31 Filter
32 Quick Relief Coupling
33 Auto Idler Mechanism
E-11 9813/0400-2 E-11

E-12
1
2 3 3 5 6
7
33
9
11 12 10
20
13
14
17 18
15 16
21
9813/0400-2
19
22
35 34
24
23
25
27 26
Hydraulic Schematic
28
29
31
32
30
Fig 2. 229/02700 issue 4

E-12
Servo/Pilot Line
Servo/Pilot Line
Components
1 Centre Joint
2 Slew Motor
3 Solenoid Valve
4 Main Pump
5 Cab Manifold
6 Tank Manifold
7 Main Control Valve
8 Pilot Pump
9 Plexus Filter
Hose Colour
BL Blue
BR Brown
CI Colourless
G Green
GR Grey
LB Light Blue
O Orange
P Pink
R Red
V Violet
W White
Y Yellow
LG Light Green
DG Dark Green
Oil from the servo pump is filtered and passes to the pilot
valve and Pp port of the main control valve. Oil is stopped
at the pilot valve if the hydraulic control is locked by the
Hydraulic Lever and Rocker Switch lock solenoid and P1
port of the cab Manifold. From the cab Manifold oil is
available to the P port of the LHS/RHS joysticks and Travel
valve. When any service selected, oil is supplied to the
respective spools of the main control valve.
K Fig 3. ( T E-14)
E-13 9813/0400-2 E-13

E-14
DR2
DR4 Ps1 Ps2
DR1
Pi2
Pp
BACK RIGHT
W/BL FRONT PH LEFT
5 T T7 T1 P1
6
T
T
T1 T2 T3 T4 T5 T6 T7 T8
2
P
-
-
- -
1 -
T
P
9813/0400-2
- - -
-
C2 C3
ACC
3 T2
P2
P1
-
- Ps1 Ps2 Pp Dr1 Dr2
Pt Pa Pr
-
-
R
8
Pt2 Pt1 Pf
Servo/Pilot Line
Psv
Fig 3. Servo/Pilot Line Schematic 229/01272 issue 12-JS200, JS205

E-14
Servo/Pilot Line
9
7
6
Fig 4. Servo/Pilot Line Schematic 229/02548 issue 14-JS140

-
5
4
1
2
E-15 9813/0400-2 E-15
Servo/Pilot Pressure and Return Line
Components
1 Right joystick
2 Left joystick
3 Cab manifold
4 Pilot check valve
5 Hydraulic Pump
6 Main control Valve
7 Centre Joint
8 Slew Motor
9 Solenoid Valve
10 Tank Manifold
11 Pilot Pump
Hose Colour
BL Blue
BR Brown
CL Colourless
G Green
GR Grey
LB Light Blue
O Orange
P Pink
R Red
V Violet
W White
Y Yellow
LG Light Green
DG Dark Green
E-16 9813/0400-2 E-16

E-17
Y O/W
CL
W G
O/W
1 4
R BL O/G
O BL
9813/0400-2
V BL/GR P
O/R
2
O BL/W
6
W O
P
CL

3
CL LB
Y/G
W GR
Fig 5. Servo/Pilot Pressure and Return Line Schematic 229/01271 issue 13 JS200, JS205
E-17
10
3
8
11
Fig 6. Servo/Pilot Pressure and Return Line Schematic 229/01272 issue 12 JS140
E-18 9813/0400-2 E-18

Component Location
Component Location
Note: The illustration(s) show a typical machine model; 25 Engine Oil Pan
your machine may look different from the model shown.
26 Servo (Pilot Line) Filter
1 Bucket
27 Main Fuel Filter/Sedimenter
2 Bucket Link
28 Engine Oil Filter
3 Dipper Link
29 Return Filter
4 Bucket Ram
30 Suction Filter
5 Dipper
31 Drain Line Filter
6 Tipping Ram
32 Air Filter
7 Boom
33 Slew Ring
8 Boom Ram
34 Plexus Filter
9 Operators Cab
35 Breaker Filter
10 Hydraulic Tank Breather
36 Counterweight
11 Fuel tank
37 Primary Fuel Filter/Sedimenter
12 Hydraulic Oil Tank
13 Engine
14 Main Valve Block
15 Slew gearbox
16 Battery
17 Air Pre Cleaner (option)
18 Track Plate
19 Track Gearbox
20 Lower Roller
21 Upper Roller
22 Recoil Spring
23 Idler Wheel
24 Front Attachment Pin
E-19 9813/0400-2 E-19

Component Location
Fig 7.
Fig 8.
E-20 9813/0400-2 E-20

Neutral Circuit
Neutral Circuit
With all the controls in the neutral position, flow from pump
A1 enters the main control valve at port P1 and flow from
pump A2 enters the main control valve at port P2.
Oil is allowed to flow across all of the spools via the neutral
gallery when all controls are in the neutral position. Oil from
pump A1 exits port Ps1 and oil from pump A2, exits port
Ps2 at the top of the main control valve. Both flows of oil
meet a separate restrictor and relief valve. Some oil will
pass through the restrictor and back to tank, creating back
pressure in the line. Oil is exhausted across the relief
valves at 40 bar (580 lb/in2). The back pressure is sensed
at ports Ps1 and Ps2 and ports Pt1 and Pt2 of the pumps,
holding the pumps on minimum flow.
Flow from the servo pump enters the valve block at port
Pp, where it meets 3 restrictors. These maintain the
pressure on the input side at full servo pressure. Oil that
crosses the restrictors is allowed back to tank after passing
over the neutral gallery of the spools. No pressure is
created in this line whilst all controls are in neutral, allowing
all pressure switches to remain in the open position.
K Fig 9. ( T E-22)
E-21 9813/0400-2 E-21

E-22
P S1 T3 T1 D1 D2 T2 P S2
P C1
A5
B5
ARM(1) f ARM(2)
P b5 a P b9
P a9
a 3
P c2
A1 Psv A2
P a5 A8
P c3
B8
a 1 a 2
(FRONT) (REAR)
P b4
BOOM(2) b g BOOM(1) P b8
P a4 P a8
B7
SWING
P b3 c BUCKET A 7
h P b7
9813/0400-2
Pm 1 Pm 2 P a3
P i2 P a7
Pt 1 Pt 2 Dr4
B2 B6
A2 TRAVEL(R) A
6
A1 A2 P b2
OPTION d i P b6
M P4
P a2 P a6
B1
a 4
A 1 TRAVEL(L) k
P b1 e
Dr B1 B3 A3
P a1
P1 PT PP PA PH P3 P2
Keyto Oil Flow & Pressure
Full Pressure
Pressure
Servo
Neutral
Exhaust
Cavitation
Lock Up
Fig 9. Neutral Circuit
Neutral Circuit
E-22
Travel - Single Speed
When both tracks are selected, servo pressure from port 2

(LH travel lever), and port 4 (RH travel lever) enters the
main control valve at Pa1 and Pa6 respectively, selecting
the left and right hand travel spools K Fig 10. ( T E-24).
Flow from pump A1 is available at the LH travel spool and

is directed to the LH travel motor via port A1 of the Main
control valve, through the rotary coupling and into port P1
on the LH travel motor. Exhaust oil from the motor enters
the main control valve at port B1 and is directed by the LH
travel spool to the tank port.
E-23 9813/0400-2 E-23

E-24
P S1 T3 T1 D1 D2 T2 P S2
P C1
Keyto Oil Flow & Pressure A5

B5
Full Pressure ARM(2)
P b5
ARM(1) a f P b9
Pressure
Servo
Neutral P a9
Exhaust P c2
Cavitation P a5 A8
Lock Up P c3
B8
BOOM(1)
P b4
BOOM(2)
b g P b8
P a4 P a8
B7
SWING A7
P b3 c BUCKET
h P b7
P a3
P i2 P a7
Dr4
B2 A6
A2 OPTION P b6
P b2 d i
P4
TRAVEL(R)
P a2 P a6
B1
A1 k
P b1 e
9813/0400-2
P a1 TRAVEL(L)
R2
R3 R1
A1 A2
1 2 T P 4 3

Fig 10. Travel Circuit
E-24
Straight Line Travel
Refer to Travel speed for travel circuit servo function and

Boom Up for servo function of Boom up. Servo pressure
entering at port Pp on the main control valve 10 is blocked
by the Travel spool and Boom (2) spool, this causes back
pressure which selects the travel linear travel spool.
Flow from pump A1 is available to the left hand Travel

spool and the Linear travel spool which diverts the flow to
the right hand Travel motor.
Flow from pump A2 is available to all the functions on the

left hand side of the Main control valve via the parallel
gallery. If any excavator function is selected at slow speed
and does not require the full flow from pump A2, then the
extra flow is used in the travel circuit via (as long as the
travel circuit is at a lower pressure) the check valve at the
right hand travel spool, a restrictor gives low priority to the
travel circuit. If the Boom up is selected, both Boom 1 and
2 spools are fed from the pump A2 through the left and
right hand parallel gallery. When both Travel spools are
selected, the loss of pressure in the neutral gallery is
sensed at the pumps through ports Ps1 and Ps2 on the
main control valve. The pumps come onto full flow
K Fig 11. ( T E-26).
E-25 9813/0400-2 E-25

E-26
P S1 T3 T1 D1 D2 T2 P S2

P C1
Full Pressure
Pressure A5
Servo B5
Neutral P b5
ARM(1) a f ARM(2) P b9
Exhaust
Cavitation P a9
Lock Up
P c2
P a5 A8
P c3
B8
BOOM(2)
b g P b8
P b4
BOOM(1)
P a4 P a8
B7
SWING BUCKET A 7
P b3 c h P b7
P a3
P i2 P a7
Dr4
B2 B6
A2 A6
P b2
OPTION d i P b6
P4
TRAVEL(R)
P a2 P a6
B1
A1 k
P b1 e
9813/0400-2
P a1 TRAVEL(L) LINEARTRAVEL
A1 A2
Fig 11. Straight Line Travel Schematic
E-26
Boom Up
Boom Up
For schematic, K Fig 12. ( T E-28).
Servo pressure from the hand controller enters the servo

restriction valve and is divided between the Boom (1) spool
valve port Pa8 and the boom (2) spool on the main control
valve 10. The servo restriction valve provides a smoothing
effect to the service circuits.
Flow from pump A2 is stopped by the Boom (1) spool and

diverted via the parallel gallery to the Boom (1) spool. The
oil passes through the spool and merges with the flow from
pump A1. Flow from pump A1 in the neutral gallery is
stopped by the Boom (2) spool and diverted via the parallel
gallery to the Boom (2) spool. The oil passes through the
spool and merges with the flow from pump A2.
The pressure lifts the Boom holding valve BHV off its seat
allowing oil to leave the main control valve at port B8 to
enter the Boom rams 7 and 8. Exhaust oil enters the Main
control PS1and P2 at port B8 and crosses the Boom (1)
spool to tank.
Pressure is lost on both negative control ports Ps1 and

Ps2, which is sensed at the pumps which come onto full
flow.
E-27 9813/0400-2 E-27

E-28
6 6
P S1 T3 T1 D1 D2 T2 P S2
C2 C2
C2 C2
P C1
A5
B5
ARM(2)
P b5
ARM(1) a f P b9
V2 E BL P P BL E V2
P a9
P c2
P a5 A8
P c3
B8
BOOM(2)
P b4 b g P b8
BOOM(1)
P a4 P a8
B7
SWING c A7
P b3 h BUCKET P b7
P a3
P i2 P a7 P T
Dr4
B2 B6
A 2
i TRAVEL(R) A 6
P b2
OPTION d P b6
P4
9813/0400-2
P a2
P a6
B1
A 1 TRAVEL(L) k BUCKET BOOM
P b1 e OPEN CLOSE UP DOWN
1 3 2 4
P a1
A1 A2
Full Pressure
Pressure
Servo
Neutral
Exhaust
Cavitation
Lock Up
Fig 12. Boom Up Schematic
Boom Up
E-28
Boom Down
Boom Down
Servo pressure from the Hand controller enters the Servo

Shuttle valve 30 at port A4 and is distributed to:
1 Port C2 to the Main control valve at port Pc2. The

Boom holding spool valve is moved across allowing
pressure at the top of the Boom Holding Valve BHV to
exhaust to tank.
2 Port B4 to port E of the Cushion control valve 34. The

oil flows across the unrestricted part of the spool and
out of port G to the main control valve at port Pb8,
moving the spool to the down position.
Flow from pump A2 travels through the neutral gallery to

the Boom (1) spool. The flow is restricted allowing a
reduced pressure at port Ps2 which is sensed at Pm2 of
the pump A2 which increases flow (less than full flow). Oil
flow also passes through the parallel gallery to the Boom
(1) spool and is directed to the Boom rams 6 via port B8.
Exhaust oil passes through to the Main control valve at 10
port A8, lifts the Boom Holding Valve BHV off its seat and
passes through the Boom (1) spool and exhausts to tank.
Exhaust oil passing through the spool can be regenerated

into the feed side of the rams. A check valve in the spool
allows oil to enter the pressure side of the spool, if the
returning oil is at a higher pressure, due to the weight of the
boom or load, item A. The restrictor creates back pressure,
causing the check valve to open K Fig 13. ( T E-30).
E-29 9813/0400-2 E-29

E-30
T2 P S2
ARM(2)
f P b9
P a9
P c2
A8
B8
g BOOM(1)
P b8
P a8
B7
A7
h BUCKET
P b7
P a7
B6
Keyto Oil Flow & Pressure i TRAVEL(R) AP 6
b6
Full Pressure P a6
Pressure
k
Servo
Neutral P T
Exhaust
9813/0400-2
Cavitation
Lock Up
P3 P2
BUCKET BOOM
OPEN CLOSE UP DOWN
1 3 2 4
A1 A2
Pm2
Fig 13. Boom Down Schematic
Boom Down
E-30
Dipper Out
Dipper Out
Servo pressure from the Hand controller 39 is sent directly

to port C3 and port Pa 9 of the main control valve 10, to
activate the dipper spool, and through restriction valve to
port Pa5 on the main control valve 10, activating the Dipper
(1) spool.
Flow from pump A1 is available at the Dipper (1) spool via

the left hand neutral passage and the Linear travel spool
via the parallel gallery. Flow from pump A2 is blocked at the
Dipper (2) spool and joins the flow from pump A1 just after
the Dipper (1) spool.
Exhaust oil from the ram enters the Main control valve at
port B5 and has a path to tank via the Dipper (1) and
Dipper (2) spools K Fig 14. ( T E-32).
E-31 9813/0400-2 E-31

E-32

T
Full Pressure
4
C2
C2
Pressure
Servo M
D D
Neutral
Exhaust
Cavitation
P BL E V2
Lock Up P S1 T3 T1 D1 D2 T2 P S2
P C1
A5
B5 ARM(2)
ARM(1)
P b5 a f P b9
P a9
P c2
P a5 A8
P c3
B8
BOOM(1)
P b4
BOOM(2) b g P b8
P T
P a4 P a8
B7
SWING c A7
h BUCKET
9813/0400-2
P b3
P b7
SWING ARM P a3
LEFT RIGHT IN OUT P i2 P a7
1 2 3 4
Dr4
B2 B6
A2 A6
P b2
OPTION
d i TRAVEL(R) P b6
P4
P a2 P a6
B1
LINEARTRAVEL
A 1 TRAVEL(L) k
P b1 e
P a1
A1 A2
Dipper Out
Fig 14. Dipper Out Schematic
E-32
Dipper In
Dipper In
Servo pressure from the Hand controller 39 is distributed

to C4 Port Pb9 on the Main control valve. From the out port
of the restriction valve, it flows to port Pb5 and port Pc1 on
the Main control valve 10 and to the Dipper (1) spool and
the dipper load hold check valve DHV respectively.
Flow from pump A1 is available at the Dipper (1) spool via

the left hand neutral gallery or after passing over the
straight line travel spool via the parallel gallery. At the
Dipper spool flow is diverted to the Dipper ram 2. Pressure
is sensed at the regeneration spool RGS and moves it to
the lesser restricted position.
Flow from pump A2 is blocked at the Dipper (2) spool and

joins the flow of pump A1 just after the Dipper (1) spool.
Exhaust oil from the ram passes to the Main control valve
10 at port A5 through Dipper hold check valve DHV (that
has been released by servo pressure) to the Dipper (1).
This can be at a higher pressure than the feed oil due to
the effect of gravity on the dipper arm when first selected.
This causes the regeneration check valve RG to open,
feeding a proportion of exhaust oil into the feed side. The
remaining exhaust oil returns to tank passing over the
regeneration spool RGS. The regeneration spool has two
restrictors, one more restrictive than the other. The
restrictors cause back pressure, encouraging the
regeneration check valve to open. As the pressure drops
the regeneration spool moves across to the more
restricted position. When the feed pressure is greater than
the exhaust pressure the regeneration check valve will
close.
Exhaust oil from the Dipper (1) spools travels over

restrictors R2 and R 3 and to tank via the unselect travel
spool K Fig 15. ( T E-34).
E-33 9813/0400-2 E-33

E-34
Full Pressure
Pressure
Servo
Neutral
Exhaust
P S1 T3 T1 D1 D2 T2 P S2
Cavitation
Lock Up
P C1
A5
B5
P b5
ARM(1) a f ARM(2)
P b9
P T P a9
P c2
P a5 A8
P c3
B8
BOOM(1)
b g P b8
P b4
SWING ARM
BOOM(2)
LEFT RIGHT IN OUT P a4 P a8
1 2 3 4 B7
P b3
c h BUCKET
A7
P b7
SWING
P a3
P i2 P a7
Dr4
9813/0400-2
B2 B6
A2 TRAVEL(R) A 6
P b2
OPTION d i P b6
P4
P a2 P a6
B1
A 1 TRAVEL(L) k
P b1 e
P a1
R2
R3 R1
P C1
DHV
A5
B5 A1 A2
ARM(1)
P b5
RG
RGS
Fig 2
Dipper In
Fig 15. Dipper In Schematic
E-34
Bucket Opening
Bucket Opening
Servo pressure from port 2 of the Hand controller 33

selects the bucket spool open position via port Pa7 of the
Main control valve.
Flow from pump A2 is available to the Bucket spool via the

parallel gallery. At the spool the flow is diverted to port B7
of the Main control valve 10 to the Bucket ram 6. Returning
oil enters the Main control valve 10 at port A7 and is
diverted by the Bucket spool to the tank. Pressure in the
neutral circuit drops after the Bucket spool is selected. This
is sensed at the port Ps2 and at the pump, bringing it onto
full flow K Fig 16. ( T E-36).
E-35 9813/0400-2 E-35

E-36
D1 D2 T2 P S2
Full Pressure
Pressure
Servo
Neutral
Exhaust
Cavitation
Lock Up
f ARM(2) P b9
P a9
P c2
A8
B8
g BOOM(1)
P b8
P a8
B7
BUCKET A 7
h P b7
9813/0400-2
P a7 P T
B6
TRAVEL(R) A 6
i
P b6
BUCKET BOOM
CLOSE OPEN DOWN UP
1 2 3 4
P a6
PT PH P3 P2
PP
A2
Bucket Opening
Fig 16. Bucket Opening Schematic
E-36
Bucket Closing
Bucket Closing
Servo pressure from the hand controller is sent from port 1

to port Pb7 of the Main control valve and moves the Bucket
spool into the bucket close position.
Flow from pump A2 is available at the Bucket spool via the

parallel gallery. Flow is diverted to port A7 of the Main
control valve to the Bucket ram 6.
Returning oil from the Bucket ram enters the Main control
valve at port B7 and is diverted to tank by the Bucket spool.
When returning oil from the Bucket ram enters the spool it
crosses a restrictor which causes back pressure. If the
pressure in the return line is greater than that of the feed
line, the valve will open allowing return oil to be
regenerated into the feed line K Fig 17. ( T E-38).
E-37 9813/0400-2 E-37

E-38
Fig 3
BUCKET
P S1 T3 T1 D1 D2 T2 P S2
P C1
A5
B5
P b5
ARM(1) a f ARM(2) P b9
Full Pressure
P a9 Pressure
Servo
P c2
Neutral
P a5 A8
Exhaust
P c3
B8 Cavitation
P b4
BOOM(2) b g BOOM(1) P b8 Lock Up
P a4 P a8
B7
SWING c A7
P b3 h BUCKET
P b7
P a3
P i2 P a7
D r4
9813/0400-2
B2 B6
A2 A6
P b2
OPTION d i TRAVEL(R)
P b6
P4
P a2 P a6
B1
A 1 TRAVEL(L) k
P b1 e
P a1
P T
BUCKET BOOM
CLOSE OPEN DOWN UP
A1 A2 1 2 3 4
Bucket Closing
A406070
Fig 17. Bucket Close Schematic

E-38
Swing
Swing
When Ignition is ON, the swing lock solenoid is energized

and allows 40 bar pressure to go to the swing brakes to
release them. The machine is still locked hydraulically.
Servo pressure from the Hand controller 51 enters port B2

to the slew spool at port Pa3 on the Main control valve 10
to move the spool across. Flow from the pump A1 is
stopped in the neutral gallery by the slew spool. The flow
passes through the linear travel into the parallel gallery to
the slew spool. The spool flow is then directed via port A3
to the slew motor 1.
Exhaust oil enters the main control valve at B3 to the slew

spool and to tank through a restriction K Fig 18. ( T E-40).
E-39 9813/0400-2 E-39

E-40
Key to Oil Flow & Pressure
Full Pressure
Pressure
Servo
P
Neutral
Exhaust
Dr Cavitation
Lock Up
P S1 T3 T1 D1 D2 T2 P S2
P C1
Mu A5
B5
RIGHT B A LEFT
ARM(1) ARM(2)
P b5 P b9
P a9
P c2
SDV A8
oil servo pump P a5
P c3
B8
BOOM(2) BOOM(1)
P b4 P b8
P a4 P a8
9813/0400-2
B7
P b3 A7
BUCKET
P b7
SWING
P a3
P i2 P a7
Dr4
B2 B6
A2 A6
OPTION TRAVEL(R)
P b2 P b6
P4
P a2 P a6
B1
A 1 TRAVEL(L)
P b1
P a1
SWING
LEFT RIGHT A1 A2
Fig 18. Slew Circuit
Swing
E-40
Main Control Valve

Description
For location diagram K Fig 1. ( T E-42). For Schematic K Fig 2. ( T E-43).
Key
A Negative Control Valve Ps1
B Restrictor Orifice
C Negative Control Valve Ps2
D Shuttle Valve
E Load Hold Check Valves (x7)
F Priority Valve
F2 Boom over Slew
G Blank
H -
I Main Relief Valve (MRV)
J Restrictors, J1 Travel, J2 Linear Travel, J3 Excavator Pressure Switch
K Auxiliary Relief Valves (ARV)
K1 Dipper out, K2 Option, K3 Boom Up, K4 Bucket Open, K5 Boom Down, K6 Bucket Close, K7 Dipper In,
K8 Option
L Load Holding Valve
L1 Dipper, L2 Boom
M Regeneration Valves
N Spool (x 10)
O Shuttle Valve
P P1 - Pump 1pressure in, P2 - Pump 2 pressure in
Q1, Q2 Blank (For option spool only when not used, to centralise the option spool)
R Slew over Dipper Priority Valve
S End Cap
V V1 Merge Out, V2 Merge In
W MRV Shuttle Valve (x2)
E-41 9813/0400-2 E-41

E-42
E
K
N6 R
O
K5 E4
N1 F
N7
K7
K6 E5
N2
N8
N3 F2
N9
H2
N4 E6
N10 H3
K8 B
N5 E7 A
S C D
V2
P1
Q2
9813/0400-2
M
N L
N1 E1
E
N6
K1 K3
N2 E2
L
N7
N3 L1 F1
K2
N8 F
K
N4 E3
K4
N9
N5 G
N V1
Q
N10
J1 J2 J3
Q1 I
P2
Main Control Valve

H1
Description
Fig 1. Main Control Valve
E-42
For description, K Main Control Valve ( T E-41).

Main Control Valve
Description
P s1 T3 T1 D1 D2 T2 P s2
A C
P C1 L1
A5
L1
B5 K7 N6
DIPPE
R2
P b5
Dipper D P b9
K1
N E1
P a9
M L2
P c2
P a5
E4 R B L2 A8
P c3
B8
BOOM(2) N2 O K3 K5 BOOM(1)
P b4 P b8
P a4 E5 N7 P a8
N3 K4 B7
SWING A7
P b3 K6 BUCKET
P b7
P a3 F2 N8 P a7
P i2
D r4
B2 B6
N9
A2
P b2
OPTION N4 K8 TRAVEL(R)
A6
P b6
V2 P4 K2
P a2 E6 E3 P a6
B1
E7 N10
A 1 TRAVEL(L) N5
P b1
P a1
J2 I
J1 J3
V1
Fig 2. Main Control Valve Schematic
E-43 9813/0400-2 E-43

Main Control Valve
Description
9 10
11
8
12
7
pb9 pb5 13
6 pb8 pb4
14
pb7 pb3 15
5
pb6 pb2
16
4
pb1
3
2 17
1
18
A405940
Fig 3. Main Control Valve viewed from rear of machine
For port identification, K Table 1. ( T E-45).
E-44 9813/0400-2 E-44

Main Control Valve
Description
Table 1. Port Identification
Item Port Function
1
2 pba Linear Travel Spool
3 pb6 Travel (R) Backwards spool
4 pb7 Bucket Close Spool
5 ARV Bucket Close
6 ARV Bucket Down
7 pb8 Boom Down Spool
8 pb9 Dipper (1) In Spool
9
10 pc3 Slew over Dipper Priority Valve
11 Shuttle Valve
12 pb5 Dipper (1) In Spool
13 ARV Dipper In
14 pb4 Boom 2 Up Spool
15 pb3 Slew Right Spool
16 ARV Option
17 pb2 Option Spool
18 pb1 Travel (L) Backwards Spool
For port location, K Fig 3. ( T E-44).
E-45 9813/0400-2 E-45

Main Control Valve
Description
25 26 27 28
29
30
T1
ps1
31
24 B5
A5
B4 32
23
B3 A3
33
22 Pi2
21
B2 P4 A2
B1 A1 PT
20
PA 34
P1
19
1
A405950
40 39 38 37 36 35
Fig 4. Main Control Valve viewed from right hand side of machine
For port location, K Table 2. ( T E-47).
E-46 9813/0400-2 E-46

Main Control Valve
Description
Item Port Function
19 B1 Travel (L) Backwards
20 B2 Option
21 B3 Slew Left
22 B4 Not Used
23 B5 Dipper In
24 Pc3 Swing over Dipper Priority
25 T1 Tank
26 Load Hold Check Valve
27 ps1 Negative Control Port
28 Load Hold Check Valve
29 A5 Dipper out
30
31
32 A3 Slew Right
33 A2 Option
34 PT Travel Pressure Switch
35 PA Excavator Pressure Switch
36 A1 Travel Left
37 Pi2 Boom Priority
38 P1 Pump 1
39 Load Hold Check Valve (Travel)
40 P4 Merge In (if fitted)
E-47 9813/0400-2 E-47

Main Control Valve
Description
51 52
50 53
T3
54
49 DR1
pa5 pa9
55
48
pc1 56
47
pa4 pa8
46 pc2 57
45 pa3 pa7 58
pa2 pa6
44 59
pa1
43 60
PA PORT
PP
1
pr 61
42
PH
62
41
A405960
64 63
Fig 5. Main Control Valve Viewed from front of machine
For port location, K Table 3. ( T E-49)
E-48 9813/0400-2 E-48

Main Control Valve
Description
Item Port Function
41 pa1 Travel (L) Forward Spool
42 pp Servo Pressure In (Pressure switches
only)
43 pa2 Option Spool
44 ARV Option
45 pa3 Swing Left Spool
46 DR2 Drain (Slew over Dipper Priority)
47 AVR Dipper Out
48 pa4 Tank
49 pc1 Dipper Holding Valve
50 pa5 Dipper Out Spool
51 Blank
52 T3 Tank
53 DR1 Boom Hold Drain
54 pa9 Dipper In Spool
55 ARV Boom Up
56 pa8 Boom Up Spool
57 pc2 Boom Holding Valve
58 ARV Bucket Open
59 DR3 Drain (Boom Bucket)
60 pa7 Bucket Open Spool
61 pa6 Travel (R) Forward Spool
62 Linear Travel Spool
63 pr Auto Power Boost Pressure Switch
64 PH MRV
E-49 9813/0400-2 E-49

Main Control Valve
Description
70 71 72
73
69
74
ps2 pc3
T2
75
68
A8 B8 76
67 pc2
A7 Pi1 B7
77
A6 B6
78
P3
79
P2
66
80
81
65
82
A405970
Fig 6. Main Control Valve viewed from left of machine
For port location, K Table 4. ( T E-51)
E-50 9813/0400-2 E-50

Main Control Valve
Description
Item Port Function
65 Blank
66 A6 Travel (R) Forwards
67 A7 Bucket Close
68 Blank
69 A8 Boom Up
70 T2 Tank
71 ps2 Negative control port
72 Dipper 2 Check Valve
73 Boom1 Check Valve
74 pc3 Slew over Bucket Priority
75 B8 Boom Down
76 Pi1 -
77 B7 Bucket Open
78 Drain (Boom over Bucket)
79 B6 Travel (R) Backwards
80 Travel (R) load hold valve
81 P3 Merge Port Out
82 P2 Pump 2
E-51 9813/0400-2 E-51

Main Control Valve
Description
86 86
85
84
pc3 PORT
DR2
83 DR4
88
Fig 7. Main Control Valve viewed from above machine

Item Port Function
83 Blank
84 Ps1 Negative control Valve
85 Restrictor
86 Ps2 Negative control Valve
87 Shuttle Valve
88 DR4 Drain (Slew over Dipper Priority)
E-52 9813/0400-2 E-52

Main Control Valve
Description
DR3
89 A405980
Fig 8. Main Control Valve viewed from below machine

Item Port Function
88 Dr3 Drain (Boom, Bucket)
E-53 9813/0400-2 E-53

Main Control Valve
Description
Page left intentionally blank
E-54 9813/0400-2 E-54

Hydraulic Pump Operation
TE-029_2
Main Pumps (P1 and P2)

The rotary group consists of the drive shaft 7, cylinder rod
19, piston shoe 4, 5, press plate 11, spherical bush 12,
spacer 13 and cylinder spring 14. The drive shaft is
supported on both sides by the bearings 8, 16. The shoe is
caulked on the piston and forms the spherical coupler, and
because it slides slightly on the shoe plate 6, it has a 6
pocket to balance the oil pressure.
The subgroup, which is made up of the piston and shoe is

held down on the shoe plate by the cylinder spring through
5
the press plate and spherical bush. In the same way, the
cylinder block is held down on the valve plate 15 by the
cylinder spring. 18
4
The swash plate group consists of the swash plate 10,
shoe plate 6, swash plate support 9 bush 2 pin 3 and servo 17
piston 1. The swash plate is supported by the swash plate
support at the cylindrical part formed by the side opposite
to the shoe sliding surface. The oil pressure controlled by 16
the regulator is guided to the hydraulic cavities on both
sides of the servo piston which moves the servo piston to
the left and right, causing the swash plate, through the
15
spherical portion of the pin, to press on the swash plate
support and changes the angle of the swash plate.
14
The valve cover group comprises of the valve block 17, 13
valve plate 13 and valve plate pin 18. The valve plate, 3
which has two oval shaped ports, is on the valve block and
delivers oil to and recovers oil from the cylinder block. The
12
oil directed by the valve plate flows through the valve block 2 11
and is connected to the outer piping.
1 10
When the drive shaft is driven by the engine, the cylinder
block rotates simultaneously with the spline coupling. 9
When the swash plate is leaning, the piston in the cylinder
block rotates simultaneously with the cylinder block and 8
causes reciprocal motion relative to the cylinder.
Therefore, during one rotation, the piston moves away 7

from the valve plate for 180° (enough for oil suction) and
A406500-1
approaches the valve plate for the remaining 180°. When
Fig 1.
the swash plate leaning angle is at the minimum 5° the
piston does not stroke and does not deliver oil.
E-55 9813/0400-2 E-55

Pump Hydraulic Circuit Diagram
A1 A2
a1 a2
Pi1 Pi2
Pm1 Pm2
a4
M
Psv
A3
Dr B1 B3 a3
C077790
Fig 2.
Table 1. Key
A1,2 Delivery port
B1 Suction port
Dr Drain port
Pi1,2 Pilot port
P1 Proportional pressure reducing valve
Pm1,2 Q max cut port
a1-3 Gauge port
a4 Gauge port
A3 Gear pump delivery port
B3 Gear pump suction port
E-56 9813/0400-2 E-56

Hydraulic Pump/Regulator Exploded View
4 3
2
24
26
27
25
31
22 5
21
16 17 15 14
14 16
32 30
20
X 8 32A
16
29 17A
28 5A
9 22A
12
31 10
19 1
23
13
11
18
803230
Fig 3.
E-57 9813/0400-2 E-57

Hydraulic Pump/Regulator Plan View
E-58
Pi1 Pm1 P1 P1
Dr Pm2 Pi2
9813/0400-2
Pi2
B3
CLOCKWISE
A3
A1 a1 A1 A2 a3 a2 A2
A357730-C2
Fig 4.
E-58
Hydraulic Pump Removal and Replacement
Removal
2
!MWARNING
Hydraulic Pressure 7
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
3
!MWARNING
This component is heavy. It must only be removed or
handled using a suitable lifting method and device.
BF-4-1_1
1 Make the machine safe, refer to Section E, Service

procedures.
2 Drain the hydraulic fluid from the hydraulic tank.
3 Disconnect all hydraulic hoses and pipes from the

hydraulic pump and plug all orifices to prevent ingress
of dirt.Label each hose before disconnecting, this will C080180
ensure correct position when refitting. Fig 5.
4 Disconnect electrical connection to proportion 8 Remove rubber flange 5 from pump coupling 4 by
solenoid on hydraulic pump. removing the two retaining bolts 6.
5 Attach lifting eyes to the pump. Support weight of the 9 Loosen the two grub screws on the pump coupling 4.
pump with suitable lifting apparatus, refer to Section Withdraw pump coupling from the pump's splined
E, Technical Data. shaft.
6 Remove engine exhaust muffler bracket from pump 10 Support the weight of the pump flange 2. Remove
flange 2 by removing three set pins 3. Remove the four cap screws 7 from the flange and pump. Remove
remaining nine set pins 3 and washers from pump flange from pump.
flange 2.
11 Remove the four studs 8 from the engine.
7 Withdraw the pump clear of the engine. When clear of
engine, lift pump clear of machine.
E-59 9813/0400-2 E-59

Replacement
Replacement is the reversal of removal procedure but note
the following:
– When fitting a new pump, the shaft end spline may be

coated with a anti-rust coating. Remove this coating
with a suitable cleaning agent and apply a lubricant to
the shaft being careful not to get either on to the oil
seal of the pump.
– The bevelled edge of the pump coupling 4 must be
fitted facing the pump.
– To prevent the rubber flange 5 from twisting on
installation, apply a small amount of lubricant to the
under face axial and radial screws
– Locate the rubber flange 5 of the pump into the four
engine studs 8.
– Before fastening pump flange 2 to engine, make sure
the mating surfaces are fully together.
– Apply JCB Threadlocker to bolts 3 and 6.
– Fill the pump casing inside fully with oil and operate
at low engine revs with no services selected for 3
minutes.
!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 and gloves.
Hold a piece of cardboard close to suspected leaks
and then inspect the cardboard for signs of fluid. If
fluid penetrates your skin, get medical help
immediately.
INT-3-1-10_3
– If there is any air left in the circuit or pump, this may

cause faulty operation or damage so be sure to bleed
the air completely.
– It is not desirable to leave the pump motor unused for
a long period of time (more than one year.) At
intervals, start the engine even if for short periods of
time. When left unused by itself, rotating the shaft end
by hand can be effective. If left unused for an
extended period of time, inspection for overhaul will
become necessary.
E-60 9813/0400-2 E-60

Hydraulic Pump Dismantling and Assembly
The working environment must be clean and the

workbench covered with a cloth or rubber sheet to prevent 3
damage to the components.
The illustration opposite shows both halves of the tandem 2

double axial piston pump, but the procedures refer mostly
to Pump 1. These procedures should also be applied to
Pump 2 except where indicated otherwise.
Note: The components from one pump section must not

be mixed up with the corresponding components from the 4
other section and should be returned to the section from
which they came.
The item numbers called up in the following procedures

correspond with those in the exploded view.
K Fig 3. ( T E-57).
5
Dismantling
Before dismantling, the pump ports should be plugged and
the external surfaces thoroughly cleaned to prevent the
ingress of dirt into the pump mechanism.
1 Remove drain plug 1 and let the oil drain into a 379380-C1
Fig 6.
suitable receptacle.
3 Remove the four socket head screws 7.
2 As an aid to re-assembly, match mark the mating
flanges of regulator 4 and pump casing 5. Remove
socket head screws 2 and 3 (2 off each) and lift off the
regulator. Put the regulator to one side in readiness
for dismantling if required. K Dismantling ( T E-67).
7
8 5
379540-C1
Fig 7.
E-61 9813/0400-2 E-61

4 Place the pump on the workbench with its regulator
mounting face downwards. Match mark the mating
flanges of pump casing 5 and valve block 8. Separate
the pump casing from the valve block.
5 Remove the piston/cylinder assembly Z comprising

cylinder 9, piston assemblies 10, set plate 11,
spherical bush 12 and cylinder springs 13 from pump
casing 5. Take care not to damage the sliding
surfaces of the components.
379560-C2
Fig 9.
7 Match mark the mating flanges of swash plate

support 17 and pump casing 5. Separate the swash
plate support from the pump casing by lightly tapping
the support around its flange using a plastic hammer.
Z
379550-C1
Fig 8.
6 Remove screws 14 and then remove servo pump X

(Pump 1) or seal cover 15 (Pump 2), taking care not 5A (5)
to damage the oil seal 16. This task can be simplified
by inserting a pull-out bolt into the tapped hole in the
cover.
17A
(17)
379570-C1
Fig 10.
8 Remove shoe plate 18 and swash plate 19 from pump

casing 5.
E-62 9813/0400-2 E-62

18 8
19
379580-C1
Fig 11.
9 Pump 1
Remove snap ring 20 and bearing spacer 21. Using a

plastic hammer, gently tap shaft 22 out of its support 23
bearing 32 to remove it from swash plate support 17. 379600-C2
Fig 13.
Pump 2
11 If necessary, remove plugs 24 and 25, servo piston 26
Gently tap shaft 22A, at the end nearest the mating and tilting pin 27 from pump casing 5.
flange of valve block 8, to separate it from swash
plate support bearing 32A. Note: When removing the tilting pin use a protector to
prevent damage to the pin head. Also take care not to
damage the servo piston as a result of the JCB
Threadlocker used to secure it.
32A 12 Remove needle bearings 28 and splined coupling 29

from valve block 8. K Fig 3. ( T E-57).
Note: Do not remove the needle bearing assembly unless

22A it needs renewing.
Note: To avoid the risk of changing the flow settings, do

not loosen nut 30 in valve block 8 or nut 31 in swash plate
support 17. K Fig 3. ( T E-57).
17A
379590-C1
Fig 12.
10 Remove valve plate 23 from valve block 8.
E-63 9813/0400-2 E-63

Assembly
Before assembling:
17
a Thoroughly clean all components with clean 5
hydraulic oil and dry with compressed air.
b Apply clean hydraulic oil to all sliding surfaces,

bearings, etc. 19
1 If previously removed from pump casing 5, install

tilting pin 27 and servo piston 26. Use a protector to
prevent damage to the tilting pin head and feedback
pin.
2 Take care to align the flange match marks and then fit
swash plate support 17 to pump casing 5 by gently
tapping it with a plastic hammer.
379620-C1
Fig 15.
4 Pump 1
5
17A From inside pump casing 5 install shaft 22 through its
(17) support bearing 32 and secure with bearing spacer 21
and snap ring 20.
Pump 2 (right)
From outside pump casing 5A, install shaft 22A, small

splined end first, through its support bearing 32A as
far as it will go.
379610-C1
Fig 14.
3 Place the pump casing on the workbench with its

regulator mounting face downwards. Attach swash
plate tilting bush 31 to tilting pin 27. Smear the sliding
surfaces of swash plate support 17 and swash plate
19 with grease. Install the swash plate against the
support and manually check that the swash plate
slides smoothly.
E-64 9813/0400-2 E-64

sure the internal splines of the cylinder and the
spherical bearing are aligned.
5A Insert the piston/cylinder sub-assembly into pump

casing 5.
32A 11 9
12
10
13
22A
379630-C1
Fig 16.
5 Grease oil seal 16 and fit seal cover 15 to swash plate Z

support 17. Secure it with socket head screws 14 379650-C1
tightened to a torque of 11.5 Nm (8.5 lbf ft). Fig 18.
7 Attach valve plate 23 to valve block 8, engaging the

location pin in the process. Check that the suction and
delivery ports of the plate are not transposed.
5A (5)
8 Insert splined coupling 29 into valve block 8.
17A K Fig 13. ( T E-63). Fit the valve block to pump
(17) casing 5, taking care to align the match marks.
Engage the spline on shaft 22 with the splined
15 coupling. Secure with the four socket head screws 7,
tightened to a torque of 130 Nm (94 lbf ft).
9 Refit regulator 4 to pump casing 5 taking care to

14 locate the feedback pin of tilting lever 27 with the lever
of the regulator. Secure the regulator with socket
head screws 2 and 3, tightened to a torque of 29.4
Nm (25.8 lbf ft).
379640-C2
Fig 17.
6 Assemble the piston/cylinder sub-assembly Z

comprising cylinder 9, piston assemblies 10, set plate
11, spherical bush 12 and cylinder springer 13. Make
E-65 9813/0400-2 E-65

379680-C1
Fig 19.
10 Refit servo pump assembly X, tighten the securing

screws to a torque of 6.9 Nm (5 lbf ft).
K Fig 13. ( T E-63).
11 Refit drain plug 1. K Fig 13. ( T E-63).
E-66 9813/0400-2 E-66

Regulator Dismantling and Assembly
The working environment must be clean and the ring 12. Do not interfere with the settings of any of
workbench covered with a cloth or rubber sheet to prevent these components as this could alter the pre-set flow
damage to the components. settings.

correspond with those in the exploded view. 5
K Fig 29. ( T E-70). 6
Dismantling
Before dismantling, remove dust, rust, etc. using clean
hydraulic oil.
Retain all washers, snap rings etc. for later re-use. O-rings
should be renewed.
1 If not already done, separate the regulator 1 from the

pump casing by removing socket head screws 2 and
3 (2 off each). Do not lose the large O-ring 4.
379390-C1
Fig 21.
3 3 From regulator body 1, withdraw outer spring 13,

inner spring 14 and spring seat 15. Also withdraw
adjusting ring 16 (refer to Note 1), pilot spring 17 and
2 spring seat 18.
Note: 1 Use an M4 screw Z attached to the end of

adjusting ring 16 to facilitate its easy removal.
13
14
15
1 16
1
17
379380-C2 18 Z
Fig 20.
379400-C1
2 Remove the four socket head screws 5 and lift off Fig 22.
cover 6 complete with adjusters 7/8, adjusting screw
9, two locking nuts 10, mounting nut 11 and adjusting
E-67 9813/0400-2 E-67

4 Remove socket head screws 19 and 20 and lift off
pilot cover 21. Take out set spring 22. 1
33
29
28
22
31
30 Y
379430-C1
20 Fig 25.
21 7 Remove lever 32 leaving pin 33A in position on the

19 lever.
379410-C1
Fig 23.
1
5 Remove snap ring 23 taking care not to allow the
components behind it to spring out. Take out spring
seat 24, return spring 25 and sleeve 26 (complete
with snap ring 27).
25
23
32
26 1 33A
379440-C1
Fig 26.
24
379420-C1
8 Knock out pin 34 (4 mm dia.) using a suitable metal
Fig 24. rod X and a plastic hammer.
6 Remove snap ring 28 and take out fulcrum plug 29,

complete with pin 33. Remove snap ring 30 and take
out adjusting plug 31.
Note: 2 Use an M6 screw Y attached to the ends of

fulcrum plug 29 and adjusting plug 31 to facilitate their
easy removal.
E-68 9813/0400-2 E-68

Note: 3 Piston case 40 can be removed by pressing
compensating rod 42 from the opposite side of regulator
body 1.
379450-C1
Fig 27.
9 Withdraw feedback lever 35.
35
379460-C1
Fig 28.
10 Remove lever 36 from pin 37 (in the regulator body)

leaving pin 37A in position on the lever.
11 Draw out pilot piston 38 and spool 39.
12 Withdraw piston case 40, compensating piston 41

and compensating rod 42.
E-69 9813/0400-2 E-69

E-70
14
13
15
12
42
D
41 B 36
40
35
F
34 16
32 17 5
37A 18
39 11
A
26 G
10
22 E
6
24 C
25 33A
23 10
7
8
9813/0400-2
38 3 2
9

37
3
F 29
G 28A
20 A
B 28
C
31
19
4 30A
21 30
379670-C1
E-70
Fig 29.
Assembly
Before assembling:
– Thoroughly clean all components with clean hydraulic

oil and dry with compressed air. 36 32
– Apply clean hydraulic oil to all sliding surfaces,
bearings, etc.
– Renew any damaged components.
– Renew all O-rings and other seals.

correspond with those in the exploded view 35
K Fig 29. ( T E-70).
1 Insert compensating rod 42 into hole B of regulator 379480-C1

body 1. Fig 31.
2 Locate pin 37A in lever 36 in the groove of 5 Insert pilot piston 38 into hole C of regulator body 1.
compensating rod 42. Locate lever 36 on pin 37 in Check that the piston slides freely without binding.
regulator body 1.
6 Locate pin 33A in lever 32 in the groove of pilot piston
3 Fit spool 39 and sleeve 26 into hole A of regulator 38. Position lever 32 in regulator body 1.
body 1. Check that the spool and the sleeve slide
smoothly in the body without binding. Check the 7 Fit fulcrum plug 29 so that integral pin 33 locates with
orientation of the spool with respect to feedback lever lever 32. Fit a new seal 28A and install snap ring 28.
35. K Fig 30. ( T E-71).
39 35
29
379470-C1
Fig 30.
4 Install feedback lever 35, orientating it as shown 1

below and aligning its pin hole with that of spool 39.
Insert pin 34.
379490-C1
Fig 32.
E-71 9813/0400-2 E-71

8 Insert adjusting plug 31. Fit a new seal 30A and install
snap ring 30.
1
Check that feedback lever 35 moves freely but does
not have excessive play. 22
9 Insert return spring 25 and spring seat 24 into hole A
of regulator body 1. Compress the spring and secure
with snap ring 23.
41
40
23 Fig 34.
379510-C1
24 11 Insert spring seat 18 (flat face first), pilot spring 17

and adjusting ring 16 into hole E of regulator body 1.
25 Insert spring seat 15 (flat face first) inner spring 14
and outer spring 13 into hole D of regulator body 1.
1
13
14
1 15
379500-C1
Fig 33.
10 Insert set spring 22 into hole A of regulator body. 16

17
Insert compensating piston 41 and piston case 40
into hole B of regulator body 1. 18
Fit pilot cover 21 and secure with socket head screws

19 and 20 tightened to a torque of 11.8 Nm (10.3 lbf
ft). 379520-C1
Fig 35.
12 Install the cover 6 assembly comprising adjusting

screws 7/8, adjusting ring 12, mounting nut 11, two
locking nuts 10 and adjusting screw 9.
Secure the cover using socket head screws 5

tightened to a torque of 11.8 Nm (10.3 lbf/ft).
E-72 9813/0400-2 E-72

7
379530-C1
Fig 36.
E-73 9813/0400-2 E-73

E-74 9813/0400-2 E-74


Operation
TE-008
The remote control valve is a pressure reduction valve springs also provide a resistive force, giving the operator a
used to control the servo pressure operated system. Four `tactile feel' of the controls.
pressure reduction valves used to control the servo
pressure are located in the main housing. Direction of the The control handles contain electrical push button and
output servo pressure is controlled by selective movement rocker switches which are used to operate auxiliary
of the control lever. The valves and control levers are services.
mounted in the arm rests on both sides of the operator's
seat.
The pressure reduction unit is comprised of spools 17,

pressure control springs, return springs and spring seats
13. The spools 17 are held against the plungers 11 by the
return springs 15. When the control handle is tilted, the
plungers 11 move down, depressing the return spring
seats 13, simultaneously compressing the pressure
control springs moving the spool, allowing hydraulic oil to
flow to the designated pilot port.
The lower end of the main body contains the main inlet port
P, outlet port T to tank and the servo pressure outlet ports
1, 2, 3 and 4.
The servo pressure controls the stroke and direction of the

main control valve spools. This is achieved by providing a
spring at one end of the main control valve spools and
applying pilot pressure to the opposite end. (In some
cases, pilot pressure is applied to both ends of the control
valve spool.)
Function
Oil supplied by the hydraulic servo pump enters at port P
and the function of the spools 17 is to direct oil from the
inlet port P to the output ports 1, 2, 3 and 4 or alternatively,
to the exhaust port T to tank. The pressure control springs
act on the spools 17 to determine pressure at each port.
Plungers 11 slide in the guides to vary the compression in
the springs. The control handle, fixed to the adjusting nut
24 and circular rocker plate 25 is operated to move the
plungers 11. The control handle is able to rotate 360°
around the knuckle joint 26.
The return springs operate between the casing and the

seats 13, regardless of the outlet pilot pressure, returning
the plungers 11 to their outer positions, ensuring the
spools 17 return to their neutral (closed) positions. The
E-75 9813/0400-2 E-75

Operation
24
26
25
11
11
13
13
T 17
2,4 1,3
A409170-C1
Fig 1.
T P
1 2 3 4
JS03240-C1
Fig 2.
E-76 9813/0400-2 E-76

Removal and Replacement
!MWARNING 9 Lift the remote control valve clear of the arm rest.
Hydraulic Pressure Note: Care should be taken when removing right arm rest,
Hydraulic fluid at system pressure can injure you. remove switches, using a thin flat bladed screw driver and
Before connecting or removing any hydraulic hose, disconnect electrical connections.
hose line must be vented. Make sure the hose service Replacement
hoses. Make sure the engine cannot be started while Replacement is the reversal of the removal sequence.
the hoses are open.
INT-3-1-11_2 Note: All hydraulic adapters that are installed together with
a bonded sealing washer must also have JCB Threadseal
!MWARNING applied to the threads of the adapter.

immediately.
INT-3-1-10_3
Removal
1 Lower dipper and place bucket on the ground
2 Turn off engine.
3 Operate both control joysticks back and forth and side

to side to vent residual pressure.
4 Remove the two screws A from each side, and loosen

screws B (one either side of the arm rest). Remove
front panel C.
5 Disconnect electrical connection to remote control

valve.
6 Disconnect all hydraulic hoses and pipes from the

remote control valve and plug all orifices to prevent
ingress of dirt. Label each hose before disconnecting,
this will ensure correct position when refitting.
7 Remove the two screws D, two screws E and loosen

the two screws F. Remove panel G.
8 Lift up gaiter H and remove the fours bolts holding the

valve to the arm rest.
E-77 9813/0400-2 E-77

G F
D B
A
C
A407780-C1
Fig 3.
Table 1.
Left hand Control Valve Right hand Control Valve
Port Hose Colour Port Hose Colour
1 Orange 1 Green
2 Green 2 Blue
3 Violet 3 Yellow
4 Pink 4 Red
P White P White
T - T -
E-78 9813/0400-2 E-78

Dismantling and Assembly
Dismantling Note: Ensure retaining plate moves freely to prevent

sudden release due to spring pressure beneath.
Note: All parts are precision made and require the utmost
care when being handled. 7 Clean the valve exterior using approved solvent and
using soft metal pads for protection, clamp the valve
Note: During dismantling, do not use excessive force to body into a vice.
separate components which could cause scratches or
burrs on bearing surfaces. Failure to observe this 8 If the return springs 15 are weak, the sliding
instruction will cause oil leaks leading to poor resistance of the seal 9 will cause the guides 8 to stick
performance. in the casing. Using a screw driver, carefully ease out
the guides 8 and plungers 11.
Note: Label all parts during dismantling, to ensure correct
assembly. Note: Care must be taken to prevent damage to the guides
when removing. Ensure the guides do not fly out due to the
Note: Storing the valve when dismantled could cause force of the return springs.
rusting of parts. Ensure they are suitably protected by anti-
rust treatment. 9 Remove spring seats13, split washers 12, return
springs 15, pressure control springs 14 and spools
Note: Refer to the illustration for part number identification 17.
K Fig 4. ( T E-81).
Note: Identify each set of parts and their locations for
1 Push down upper section of gaiter 19 and remove roll assembly.
pin 20.
10 Loosen the two hex bolts 27 on the base of the valve.
2 Remove control handle from mounting knuckle 3. Remove the base plate and Ò'-ring 30 from the valve
casing.
Note: Take care when removing handle to avoid damage
to wiring loom and switches. These should be removed by 11 Slacken and remove body assembly screw 6.
separating the line connectors in the control handle and Remove and discard Ò'-ring 7.
below the valve body.
12 Separate upper and lower body sections 1 and 2 and
3 Remove gaiter 19 from valve housing. remove dowel pins 5.
4 Slacken locknut 22 and remove mounting knuckle 23. 13 Remove and discard Ò'-rings 3 and 4.
5 Slacken and remove joint nut 24 and rocker plate 25. Note: The surface of spool 17 and spring 13 can be
damaged by mis-handling. Take care not to damage the
!MWARNING surface of the spool during removal and do not push the
spring seat down more than 6mm (0.24 in).
Always wear safety glasses when dismantling
assemblies containing components under pressure 14 Hold spools 17 firmly on the work bench and depress
from springs. This will protect against eye injury from spring seat 13 and remove split washers 12.
components accidentally flying out.
Note: Avoid scratching the surface of the spools. Do not
GEN-6-2
depress the spring seats more than 6 mm (0.24 in).
Note: The return spring 15, retaining plate 18 and plunger
11 will rise when knuckle joint 26 is loosened. 15 Separate spools 17, spring seats 13, springs 14 and
15 and shims 16.
6 Using a jig, slacken and unscrew knuckle joint 26,
releasing retaining plate 18. 16 Remove plungers 11 from guides8.
E-79 9813/0400-2 E-79

17 Remove seals 9 and 10 from guide 8 and discard.
Note: Leave all parts to soak in suitable solvent until dirt is

loosened. Using clean solvent wash all parts and allow to
air dry. Apply rust inhibitor to all parts.
E-80 9813/0400-2 E-80

21
26
18
8
19
9
10
2 11
20 12
23 3
4 13
5
14
22 1
15
24
16
25 7
17
6
30
29
28
27
A408130-C1
Fig 4.
E-81 9813/0400-2 E-81

Table 2.
Item Description Qty. Item Description Qty. Item Description Qty.
1 Lower body 1 11 Plunger 4 21 Control handle 1
2 Upper body 1 12 Split Washer 4 22 Locknut 1
3 Ò'-ring 1 13 Spring seat 4 23 Mounting knuckle 1
4 Ò'-ring 1 14 Compression spring 4 24 Joint nut 1
5 Dowel pin 2 15 Return spring 4 25 Rocker plate 1
6 Body assembly screw 1 16 Shims - 26 Knuckle joint 1
7 Ò'-ring 1 17 Spool 4 27 Hex Bolt 2
8 Plunger guide 4 18 Retaining plate 1 28 Washer 2
9 Seal 4 19 Gaiter 1 29 Base plate 1
10 Seal 4 20 Roll pin 1 30 Ò'- ring 1
E-82 9813/0400-2 E-82

Inspection
Note: Before assembling the remote control valve make
sure that a thorough inspection of all the components is
carried out. Remember that although a failed component
may be easy to identify, the cause may be less easy to
trace. It is also possible that a failed component may have
caused damage to other areas of the valve.
1 Carefully clean all components using a suitable

degreasing agent.
24
2 Carefully inspect all components for signs of
excessive wear or damage. If wear or damage is
evident, components must be renewed. 25
Note: Ò'-rings and other sealing materials should
preferably be replaced each time the valve is
disassembled but they may be re-used provided a careful
check is made that they are un-damaged. 26
Assembly
18
Note: During assembly, ensure all parts are clean and free
from burrs and scratches. Remove minor damage by
lapping.
Note: Renew all Ò'-rings, seals and back-up rings. Take 1

care to install seals the correct way around.
Note: During assembly apply hydraulic oil to Ò'-rings and

seals.
Note: Ensure all screws and bolts are tightened to the

torque settings given.
The numerical sequence given previously is a guide to

dismantling. For assembly the sequence should be P
reversed noting the following details:
1 Locate retaining plate 18 onto plunger guides 8 and

using the jig, screw knuckle joint into position. 6,7
JS03250-C1
2 Locate rocker plate 25 and tighten until it makes Fig 5.
contact with the plungers 11. Ensure the plungers are
Item Nm Kgf m lbf ft
not depressed at this stage.
6 40 4 29.5
3 Holding the rocker plate 25 in its position, screw down 24 68 7 50
joint nut 24.
25 30 3 22
4 Ensure the switch cable is free from obstruction and 26 30 3 22
the line connectors are securely fastened. 27 20 2 14.7
E-83 9813/0400-2 E-83

Fault Finding
Symptom Possible cause Remedy

Low secondary pressure. Primary pressure is low. Apply the correct primary pressure.
Spring 4 is damaged. Renew the spring.
Clearance between the spool and Renew the remote control valve
seating is too large. assembly.
The handle unit is loose. Dismantle, reassemble or renew the
handle unit.
Unstable secondary pressure. Sliding parts are sticking. Release the sticking part.
Fluctuations in the tank line pressure. Check return line and filter for
blockage.
Air is trapped in the piping. Operate the valve several times to
remove the air.
High secondary pressure. The tank line pressure is too high. Check return line and filter for
blockage.
Release the sticking part.
E-84 9813/0400-2 E-84

Travel Pedal Valve

TE-007
Note: Parts can be damaged by use of excessive force. 8 Remove plug 7 with the grease cap 12, packer 13 and
Parts can be damaged by corrosion caused by humidity Ò'-ring attached.
and dust if left in un-assembled.
9 Remove piston 14 and damping spring 8 from the
Note: For part number identification for the Travel Pedal casing.
Valve, K Fig 2. ( T E-86).
10 Remove spring washer 16 from the casing 10 using
Dismantling tweezers etc.
1 Clean the valve exterior using an de-greasing agent 11 Remove steel balls 17 using a magnet.
and using soft metal pads for protection, clamp the
valve body into a vice. 12 Fix the lower casing assembly in a vice and remove
the Ò'-rings 18, 19 from casing 20.
2 Remove the gaiter 1 from the cover 2.
13 Remove pressure reduction valve assembly and
3 Loosen the 5mm hex screw 3. return spring 21 from casing 20.
!MWARNING 14 Place cover 2 flat on a flat bench, apply special jig,

K Fig 1. ( T E-85) to bush 23 and tap with a hammer
Always wear safety glasses when dismantling to remove the bush
assemblies containing components under pressure
from springs. This will protect against eye injury from (A = 2 mm)
components accidentally flying out.
10mm -0.3
-0.4
GEN-6-2
8mm-0.2
-0.3
Note: Take care that push rod 4 does not fly out under
spring tension.
30
4 Remove pin 5 using a 7mm punch and remove cam
and steel balls 6.
20 mm 2
Note: Take care that push rod 4 and plug 7 are not thrown
30mm
out by damping spring 8 pressure.
A406320-1
5 Loosen hex bolt 9 and remove cover. Making a note Fig 1.
of the relative positions of the cover 2 and the
casing 10. The plug 7 will remain in casing 10 due to A Central Hole (2mm maximum)
friction of the Ò'-ring 11.
15 For disassembly of the pressure reduction valve,
6 Remove casing 10 and fix in vice using soft metal
press in spring washer 24, slide the spring washer
pads for protection.
sideways, bending secondary pressure spring 25,
then remove spool 26 from the larger hole.
7 Pull push rod 4 from plug 7 noting the relative
positions of plugs and push rods to the casing 10.
16 Separate spool 26, secondary pressure setting spring
25, shim 27 and washer 28.
E-85 9813/0400-2 E-85

Travel Pedal Valve
17 Remove grease cap 12 from plug 7. c Wipe clean de-greasing agent from all parts using
a lint-free cloth.
Remove packing 13 from plug 7 using a small flat
screw driver being careful not to scratch the plug. Note: Adhered dirt and grease may cause damage during
Remove Ò'-ring 11 from plug 7. the first washing; soak well to loosen and float these off.
Dirty de-greasing agent may cause damage to the parts.
18 Wash all parts: Monitor the cleanness of the de-greasing agent up to re-
assembly. Do not dry with compressed air as the dust and
a Place all parts in container with clean de-greasing moisture carried by the air may damage the parts or cause
agent (first washing). corrosion
b Place all parts in a finishing wash container with

clean de-greasing agent and rotate slowly to
ensure complete washing. (finish wash).
24 24
4
4 25 25
1 27 27
9 14 28 28
3
6 14 8 26 26
23
5 8
9 16 21 21
16 17
18 18
23 2 17 19
20
12 10
13 12
7 13 30
29
7
11
11
A406310-C4
Fig 2.
E-86 9813/0400-2 E-86

Travel Pedal Valve
Inspection 3 Fix casing 20 in a vice. Fit return spring 21 into

casing.
Before assembling the Directional control valve make sure
that a thorough inspection of all the components is carried 4 Fit the pressure reduction valve sub-assembly,
out. Remember that although a failed component may be assembled in 1 and 2 above, into casing 20. When
easy to identify, the cause may be less easy to trace. It is fitting the pressure reduction valve sub assembly,
also possible that a failed component may have caused take care not to hit the lower end of the spool against
damage to other areas of the valve. the edge of the casing, K Fig 3. ( T E-87).
1 Carefully clean all components using a suitable de-

greasing agent.
2 Carefully inspect all components for signs of

excessive wear or damage. If wear or damage is
evident, components must be renewed.
Note: Ò'-rings and other sealing materials should

preferably be replaced each time the valve is
disassembled but they may be re-used provided a careful A
check is made that they are undamaged.
Assembly
Note: Ò'-rings and other sealing materials should A406350-1
preferably be replaced each time the valve is Fig 3.
disassembled but they may be re-used provided a careful
check is made that they are undamaged. Note: Be careful of the casing edge A.
Note: When hexagonal socket (hex) bolts 29 are loosened 5 Fit Ò'-rings 18, 19 into the casing.
the seal washers 30 must be replaced.
6 Fix upper casing 10 in a vice and fit steel balls 17.
Note: Fit all components in the same positions as before
disassembly 7 Fit spring washer 16 into casing 10 using tweezers
etc.
!MWARNING 8 Fit damping spring 8 into casing 10.
Always wear safety glasses when dismantling
assemblies containing components under pressure 9 Fit piston 14 into casing 10.
from springs. This will protect against eye injury from
components accidentally flying out. 10 Fit Ò'-ring 11 to plug 7.
GEN-6-2
11 Fit packing 13 to plug 7. Be careful of the direction
1 Assemble washer 28, shim 27, secondary pressure when fitting the packing, K Fig 4. ( T E-88). Apply a
setting spring 25 and spring washer, in that order, light coating of grease before fitting packing.
onto spool 26
2 Push spool 26 through the larger hole of spring

washer 24 and assemble by sliding the spring washer
sideways while bending the secondary pressure
spring
E-87 9813/0400-2 E-87

Travel Pedal Valve
16 Fix the lower cover assembly, as assembled step 1-5,
in a vice and attach upper assembly, as assembled in
A steps 6-14
17 Fit cover 2 to casing 10.
18 Tighten the hexagonal socket bolt 9 to the specified

torque.
A406370-2
Fig 4. 19 Fit cam and steel balls 6 to cover 2. Press down cam
6 and insert cam shaft 5 from the outside.
A Packing
20 Apply JCB Threadlock or equivalent to the surfaces of
12 Fit grease cap 12 to plug 7. hexagonal socket screws 3.
13 Fit push-rod 4 to plug 7 Apply working oil to surfaces 21 Tighten hexagonal socket screw 3 to specified torque.
before fitting push-rod.There is a risk of damage to
the rib part of packing 13 do not use excessive force 22 Tilt cam 6, apply grease to the top of push-rod 4 and
when fitting. inject grease into grease cap 12 of plug 7. Grease is
to be applied and injected using a spatula made of
14 Fit the push-rod sub assembly, assembled in step 10, soft material and care it to be taken that the surfaces
11, 12 and 13, into casing 10. of the push-rod and plug are not damaged.
23 Fit the top of bellows 1 into cam 6 and then the bottom
Item Nm Kgf m lbf ft into the groove in cover 2.
125 21 2 15
24 Before fitting the bottom edge of the bellows into the
312 69 7 51
groove in the cover, apply anti corrosion oil inside the
301 47 5 35 bellows.Please note that if the bellows do not fit
precisely into the groove and are loose, resistance to
15 Place cover 2 flat on a flat bench, push on bush 23 dust and water will deteriorate.
using the special Jig K Fig 5. ( T E-88) and insert by
tapping with a hammer.
(A = 2 mm)
10mm -0.3
-0.4
8mm-0.2
-0.3
30
20 mm 2
30mm
A406320-1
Fig 5.
A Central Hole (2mm maximum)
E-88 9813/0400-2 E-88

Slew Motor
Motor Operating Principles
The following detailed description explains the operating piston expels low pressure hydraulic fluid T via the output
cycle of an individual piston. side A (b) of the control plate, port b and back to tank.
Driving force F2 varies according to the flow rate of the
High pressure hydraulic fluid P from the pump flows via high pressure hydraulic fluid input.
input port a and control valve A into cylinder B when it is
aligned with the input side A (a) of the control plate. The There are nine pistons equally spaced around the cylinder
force F against piston C generates a force F2 (shown block. As each one in turn goes through the cycle
vectorally) which acts on piston shoe D. The piston shoe described, a continuous even rotation of the output shaft is
moves against stationary swash plate E, causing cylinder produced.
block F and hence drive shaft G to rotate. This situation
exists for 180° of rotation of the cylinder block i.e. until the By reversing the hydraulic fluid flow direction i.e. high
cylinder aligns with the output side A (b) of the control pressure feed into port b, the motor rotation is reversed.
plate. For the next 180° of rotation of the cylinder block the
E D C F B P T P
G
F2 b a
F1
F
A(b) A(a)
C075110
Fig 1.
E-89 9813/0400-2 E-89

Slew Motor
Slew Brake Operation
Slew Brake Operation
Cylinder block F is splined to output shaft G. Two friction locking cylinder block F and casing E and preventing
plates A are splined to the outer edge of the cylinder block rotation.
and are interleaved between three counter plates B which
are fixed to the slew motor casing E. The brakes are released when hydraulic pressure is
applied to port X. Oil enters chamber Y and pushes brake
The brakes are applied when the hydraulic pressure at port piston D up, against the pressure of spring C, to release
X is zero. Spring C pressure forces piston D down to press the previously locked friction plates A and counter plates
the friction plates and the counter plates together, thereby B. Cylinder block F is now free to rotate within casing E.
C
E D
F
A B Y
X
C075120
Fig 2.
E-90 9813/0400-2 E-90

Slew Motor
Fault Finding
Fault Finding
Motor Does Not Rotate
Symptom Cause Remedy

The pressure is low. The relief valve is not set correctly. Set to the correct value.
The relief valve does not work properly.
Plunger sticking. Repair or renew the plunger.
Plunger orifice contaminated. Dismantle and clean.
Plunger not seating correctly. Renew the plunger seat.
The pressure is correct but no Overload protection operating. Remove the cause of overload.
rotation. The moving part is burnt. Check and repair the piston/shoe,
cylinder/valve plate, etc.
No release pressure acting on the brake. Check and repair the circuit.
The brake piston is sticking. Dismantle and clean/repair.
The brake friction plate is burnt and Dismantle and renew the damaged parts.
sticking to counter plate.
Motor Rotates in the Reverse Direction

Reverse rotation. The motor has been incorrectly Check step 16 of the assembly procedure
assembled. to verify that the valve housing 303 and
main housing 301 are in their correct
relative positions. Rectify if necessary.
Inlet/outlet hoses reversed. Re-locate hoses.
Motor Speed is Low

Slow rotation. The oil flow volume is low. Check the pump output and the circuit to
the motor.
The temperature is high and leakage is Check the oil cooling circuit.
serious.
The sliding parts are worn out or broken. Renew suspect parts.
E-91 9813/0400-2 E-91

Slew Motor
Fault Finding
Motor Brake Working Poorly

Low brake torque The friction plate is worn out Dismantle and renew worn parts
The brake piston is sticking Dismantle and clean
The brake releasing pressure is low Check and repair the supply circuit
The spline of the friction plate is broken Dismantle and renew the broken parts
Motor is Driven by Exterior Torque

Slip volume is high The relief valve is not set correctly Set to correct value or renew
Relief valve plunger not seating cleanly Renew
The reversal protecting valve does not Renew
work properly
Drain volume exceeds 500 cc/mm Dismantle and check for signs of wear.
Renew suspect parts
Oil Leakage

Oil leaking from around the drive Oil seal lip damaged. Renew the oil seal.
shaft oil seal. The shaft is damaged or worn. Repair or renew the shaft.
High pressure in casing, causing the lip of Clear the drain pipes.
the oil seal to become rolled.
The drive shaft is corroded. Dismantle and repair.
Oil leaking from mating surfaces of O-ring not fitted or damaged. Fit or renew the O-ring.
main housing and valve housing. The seal surface is damaged. Dismantle and repair.
The securing bolts are damaged or loose. Renew and/or tighten to the required
torque.
E-92 9813/0400-2 E-92

Slew Motor

TE-027
C078320
Fig 3.
Removal 3 Make an alignment line across the gearbox and motor

mounting flanges, to provide a reference during
!MWARNING
assembly.
Hydraulic Pressure 4 Remove bolts X.

Before connecting or removing any hydraulic hose, 5 Using suitable lifting equipment carefully lift slew
residual hydraulic pressure trapped in the service motor until clear of machine, refer to Section E,
hose line must be vented. Make sure the hose service Technical Data.
the hoses are open.
INT-3-1-11_2
1 Make the machine safe, refer to Section E, Service

Procedures.
2 Disconnect all hydraulic hoses from the slew motor

and plug all orifices to prevent ingress of dirt. Label
each hose before disconnection.
E-93 9813/0400-2 E-93

Slew Motor
Replacement
Replacement is a reversal of the removal sequence.
!MWARNING
immediately.
INT-3-1-10_3
1 Check slew gearbox oil level, refer to Section 3,

Routine Maintenance
2 After replacement check the main relief valve

(M.R.V.) and auxiliary relief valve (A.R.V.) pressure
settings.
E-94 9813/0400-2 E-94

Slew Motor
Slew Motor Configuration
Slew Motor Configuration
Slew Unit
Planetary 2-stage Reduction Gear Swash Plate Type Axial Piston Hydraulic Motor
Mechanical Brake
By-pass Valve Relief Valve
Make-up Valve
Fig 4.
E-95 9813/0400-2 E-95

Slew Motor
Fig 5.
E-96 9813/0400-2 E-96

Slew Motor
Key
a Drain port g Flow paths N A side seat
a1 Pilot port h Flow paths P B side seat
b1 Pilot port i Flow paths R Anti-pendulum valve
a2 Pilot hole j By pass valve S Anti-pendulum valve
a3 Pilot hole A Inlet port T Pilot hole
b Flow paths B Outlet port U Spring chamber
c Flow paths C Anti-cavitation check valve V Make-up port
d Flow paths D Mechanical brake W Piston
e Flow paths J Cross-line relief valve X Mechanical brake release port
f Piston bore K A side cavity Y Motor output shaft
L B side seat Z Slipper foot
M Intermediate cavity
E-97 9813/0400-2 E-97

Slew Motor
Dismantling
As a guide to dismantling and assembly, Refer to the
sectional drawing K Fig 5. ( T E-96).
26
Before attempting to dismantle the slew motor assembly,
the inlet and outlet ports should be blanked and the outer
surfaces washed down with a suitable solvent to remove
all dirt and dust. Dry using compressed air.
1 Remove the level gauge with a pipe wrench.
JS06110-C1
Fig 7.
3 Remove screws B with a 19 mm socket wrench and

remove the motor.
Note: Before removing the motor from the reduction gear,

it is advisable to make an alignment mark on the mating
faces to facilitate reassembly.
JS06100
Fig 6.
2 Remove plug 26 with an 8 mm allen key and drain the JS06120-C1

gear oil. Fig 8.
4 Remove the caps 37 with 14 mm A/F hexagonal key

and remove relief valves 34 from the motor.
Note: Record the position of relief valves 34 to ensure

correct reassembly.
5 Remove the caps 30 with a 14 mm A/F hexagonal key

and take out the springs 31 and check valves 29.
Remove by-pass valve assembly by unscrewing cap
28 using a 10 mm A/F hexagonal key.
E-98 9813/0400-2 E-98

Slew Motor
Note: Record the relative positions of the parts to ensure
correct reassembly.
27
6 It is advisable to make alignment marks on cover 17
and housing 25 with white paint, etc. to facilitate
reassembly.
17
30
31 25
17 29
28
JS05670-C1
29
34 Fig 10.
9 Remove snap ring 23 and remove the inner ring of

needle bearing 22.
10 Remove O-ring 13.
31 37 11 Remove balance plate 21. Remove the pins 15 from

30 the balance plate.
34
25
Note: The balance plate 21 must be reinstalled correctly
on cover 17. (The alignment of the hair groove and round
groove which select high and low pressure is very
important. Before removing the balance plate, note the
JS06130-C1 correct relationship with cover 17.)
Fig 9.
12 Remove the bushings 20 with Teflon rings 19 and the
7 Remove screws 27 attaching cover 17 to housing 25 plate springs 18.
with a 12 mm hexagonal key.
8 Place the motor with the main shaft downwards and

lift off cover 17.
E-99 9813/0400-2 E-99

Slew Motor
23 14
13
22
12
13
11
21 15 25
15 20
19
25
18
X
12
17
JS05680-C1
Fig 11.
JS05700-C1
13 Remove the springs 14 from brake piston 12. Fig 12.
Note: Keep the springs in the order in which they are to be 16 Remove friction plate 9 and mating plate 10.
re-inserted.
17 Hold the end of cylinder 24 by hand and pull out the
14 It may be difficult to remove brake piston 12 from cylinder assembly from housing 25.
housing 25 due to resistance caused by O-rings 11
and 13. Therefore remove brake piston 12 using the Note: The oil seal 2 and the outer ring of taper roller
tapped M6 holes X as shown in the illustration. bearing 3 remain in the housing.
15 Remove O-ring 11 from housing 25 and O-ring 13 The end face of the cylinder should be protected by
from brake piston 12. clean cloth to prevent it from being damaged.
Make alignment marks or write numbers on the piston

bores and the piston assemblies so that the piston
assemblies can be replaced in the same bores during
reassembly.
18 Remove the outer ring of taper roller bearing 3 from

the housing.
E-100 9813/0400-2 E-100

Slew Motor
10 9
10
9
10
24
JS06170-C1
Fig 14.
20 Attach a puller to the inner ring of taper roller bearing

25 3 at two places and on the end of cylinder 24 spline,
3 then extract bearing inner ring 1. Take out collar 53.
21 Remove swash plate 6, piston assemblies 8 and

retainer plate 7 together from cylinder 24.
JS05710-C1
Fig 13.
19 Tap oil seal 2 with a screwdriver and hammer to

remove it from housing 25.
Note: The oil seal cannot be reused.
E-101 9813/0400-2 E-101

Slew Motor
1 5
53
6
7 24
8
5
JS06140-C1
Fig 17.
24
JS06160-C1
Fig 15.
22 Slide swash plate 6 from the sliding faces of the

piston assemblies.
Note: Take care not to damage the swash plate during

handling.
JS06150-C1
Fig 16.
23 Remove spring 5 from cylinder 24.
E-102 9813/0400-2 E-102

Slew Motor
Inspection
1 Clean each part in a suitable solvent and dry using
compressed air.
2 Inspect all parts and act in accordance with the

following table.
3 Discard all used seals and O-rings and fit new ones
during assembly.
!MCAUTION
If the machine is operated at full load before its initial
run-in procedure is complete it may cause scuffing
and seizing which can adversely effect the life of the
machine.
8-3-1-5
!MWARNING
immediately.
INT-3-1-10_3
!MWARNING
Hydraulic Pressure
the hoses are open.
INT-3-1-11_2
E-103 9813/0400-2 E-103

Slew Motor
Item Inspection and Maintenance Standards

The crescent-shaped ports in the balance plate, which are in sliding contact with the
end face of the cylinder assembly shaft, act to switch between high and low oil
pressure. Any damage to the sliding contact face will increase leakage, causing a
decrease in volumetric efficiency and an increase in slip. Any seizure of the sliding
Balance plate 21
contact face causes a reduction in mechanical efficiency and can lead to further
damage. If the grooves or marks depths are less than 0.03 mm (.001 in), the plate can
be corrected using fine emery cloth. If the wear is greater than 0.03 mm (.001 in), the
plate should be renewed. The plate should be renewed if it shows any sign of seizure.
Correct any damage to the sliding contact face of the slipper feet by using fine emery
Piston assembly 8 slipper feet cloth. Renew the motor if the depth of any slipper foot oil groove is less than 0.45 mm
(.018 in) or if the slipper foot surfaces are seriously damaged.
The external surfaces of the piston assemblies should be practically unworn. The motor
Piston assembly 8 pistons
should be renewed if a piston assembly shows any sign of seizure.
Cylinder assembly 24 piston The piston bores should be practically unworn. The motor should be renewed if the
bores bores show any sign of seizure or are badly damaged.
Hydraulic motor
Taper roller bearing 3 The bearings should be renewed if any slight damage is noticed on the contact
surfaces of the rollers or needles.It is recommended that all bearings be renewed on
Needle bearing 22
reassembly of the motor because bearings can be damaged when the motor is
Self-aligning roller bearing 57 dismantled.
Roller bearing 62
Hydraulic motor
Oil seal 2 Renew any oil seal if damage to the lip is apparent. New seals must be used when
Reduction gear reassembling the motor.
Oil seal 61
Hydraulic Motor Renew any O-ring that appears to be damaged. New O-rings must be used when
O-rings 11, 13, 33, 36, 41, 45, 52 reassembling the motor.
Hydraulic Motor
The back-up rings must be renewed when reassembling the motor.
Back-up ring 32, 35, 46
E-104 9813/0400-2 E-104

Slew Motor
Assembly
As a guide to dismantling and assembly, Refer to the
sectional drawing K Fig 5. ( T E-96).
Check all parts before assembly and remove any

scratches with a fine oil stone or carborundum paper.
Wash with a suitable solvent and blow dry.
Replace all seals with new ones.
Apply clean hydraulic oil to all sliding faces during

assembly.
JS06190-C1
!MCAUTION Fig 19.
Cleaning
Cleaning metal parts with incorrect solvents can cause
corrosion. Use only recommended cleaning agents
and solvents.
INT-3-2-11
!MCAUTION
'O' rings, Seals and Gaskets
Badly fitted, damaged or rotted 'O' rings, seals and
gaskets can cause leakages and possible accidents.
Renew whenever disturbed unless otherwise
instructed. Do not use Triochloroethane or paint
thinners near 'O' rings and seals. JS06200-C1
INT-3-2-12 Fig 20.
1 Lap the sliding contact faces of piston assemblies 8, 2 Apply grease to the curved part of cylinder 24 (contact
balance plate 21 and swash plate 6 with very fine face with spring 5) and mount spring 5.
paste on a flat surface.
3 Position the piston assemblies 8 into the holes of
retainer plate 7.
4 Mount the piston assemblies 8 together with retainer

plate 7 into cylinder 24.
Note: Insert the piston assemblies into the same bores

from which they were removed.
Apply clean hydraulic oil to all cylinder 24 bores

before reassembling.
5 Apply clean hydraulic oil to piston assembly 8 shoe

sliding surface and mount the swash plate 6.
JS06180-C1
Fig 18. 6 Mount collar 53 and inner ring of taper roller bearing
1 on motor output shaft.
E-105 9813/0400-2 E-105

Slew Motor
7 Apply a thin coat of JCB retainer where the inner ring
is mounted on motor output shaft.
1
1
53
6
24
8 JS05730-C1
Fig 22.
7
9 Apply grease to the lip of seal 2 and use a press and
5 jig (see Special Tools, Section 1) to force fit the seal
into position.
24 2
JS05720-C1
JS05740-C1
Fig 21.
Fig 23.
8 Using a jig, (see Special Tools, Section 1) press
inner ring 1 on output shaft. 10 Mount the outer ring of the taper roller bearing into
housing 25.
11 Hold the end of cylinder 24 by hand and carefully

insert the cylinder assembly into housing 25. Use the
seal protector on the splines.
Note: The splines of the cylinder assembly protrude

beyond the housing, so use a guide of 30-50 mm (1.2-1.9
in) on the lower part of the housing. Verify that spring 5 is
inserted correctly into the back face of retainer plate 7.
12 Mount friction plate 9 and mating plate 10.
E-106 9813/0400-2 E-106

Slew Motor
Note: Apply hydraulic oil to both faces before mounting the
plates.
14
13 Mount O-ring 11 in housing 25 and O-ring 13 on
piston 12. 13
Note: Grease the O-rings before mounting. 12
14 Apply hydraulic oil to the sliding surface around piston
12 and slide it into housing 25. 9
9
10 10
Note: It is difficult to insert piston 12 into the housing due
to O'-rings 11 and 13. Hold the piston horizontally and 9
push it into the housing with one movement.
10
11
15 Insert the brake unit springs 14 back into brake piston
12.
Note: Insert the springs 14 in the same order as they were

found during dismantling. 24 7, 5
25
JS05690-C1
Fig 24.
16 Mount the bushings 20 with Teflon rings 19 and the

plate springs 18 into the bushing holes in cover 17.
Note: Apply a coating of grease to the end faces and

peripheries of the bushings 20 and to the Teflon rings 19
before mounting them, as this helps prevent them from
falling out when the cover is mounted onto the housing.
E-107 9813/0400-2 E-107

Slew Motor
17 Generously grease the pins 15 and insert into cover
17.
18 Mount balance plate 21 onto cover 17.
19 Press needle bearing 22 inner ring into cover 17 and

attach snap ring 23.
20 Apply grease to the O-ring and install O-ring 13 to

cover 17.
23
JS05650-C1
Fig 26.
22
22 Lift cover 17 and balance plate 21 by hand and mount
them carefully on housing 25.
13
Take care that balance plate 21 and bushings 20 do
21 15 not fall out while mounting cover 17. Align housing 25
15 20 and cover 17 alignment marks which were made
before dismantling.
19
23 Tighten the cap screws 27 (with a 12 mm A/F
18 hexagonal key) which attach cover 17 to housing 25
to a torque of 157 Nm (116 lbf ft).
17
27
JS05680-C1
Fig 25. 17
21 To prevent oil leakage from the cover bolt holes apply

JCB Multi-gasket to the surface. 25
JS05660-C1
Fig 27.
E-108 9813/0400-2 E-108

Slew Motor
24 Assembling the make-up and by-pass valves. Note: If the shaft does not turn, the unit has not been
assembled correctly so dismantle again and inspect.
Assemble the check valves 29 and springs 31 in
cover 17 and tighten the caps 30 (14 mm A/F 27 Degrease the mating faces of the gear unit ring gear
hexagonal sockets) to a torque of 137 Nm (101 lbf ft). 64 and motor housing 25 and apply Multi-gasket to
the ring gear.
Assemble by-pass valve assembly 28 to cover 17 and
tighten the caps (10 mm A/F hexagonal sockets) to a
torque of 79 Nm (58 lbf ft).
25 Insert the relief valve assemblies 34 into cover 17 and

tighten the caps 37 (14 mm A/F hexagonal sockets) 25
to a torque of 79 Nm (58 lbf ft).
Note: Ensure that the relief valves are replaced in their

original positions.
64
30
31 JS06220-C1
17 29 Fig 29.
28
28 Attach the motor with hexagonal bolts and spring
washers.
29
34
Size: 19 mm, Tightening torque: 103 Nm (76 lbf ft).
B
31 37
30 34
25
JS06130-C1
Fig 28.
26 Final checks after assembling. JS06120-C1
Fig 30.
Open the inlet and outlet ports and apply 30 kgf/cm2
(427 lbf/in2) pilot pressure to the brake release port. 29 Attach the level gauge A with a pipe wrench, setting
(Take care as oil will be discharged from the drain the height as shown.
port). Check that the drive shaft can be rotated
smoothly for at least one full revolution by applying a
torque of approx. 39 Nm (29 lbf ft).
E-109 9813/0400-2 E-109

Slew Motor
26
JS06110-C1
JS06210-C1
Fig 33.
Fig 31.
31 Apply grease (type and capacity is given in Fluids
and Lubricants).
Note: Bleed air in the chamber from the air bleed port
before filling with grease, as a build-up of internal pressure
can damage the oil seal.
After the unit is filled, run it for around 10-15 minutes

at zero load, and at low speed and verify that there is
no abnormal noise or vibration. Gradually bring the
system into high speed and loaded operation.
Item Nm Kgf m lbf ft

Fig 32. B 103 16 76
30 Fill with gear oil through the filler port. 26 39 4 29

27 157 16 116
Insert plug 26 with an 8 mm Allen key and tighten to 28 78.5 8 58
torque of 39 Nm (29 lbf ft).
30 137 14 101
Note: Fill the hydraulic motor case with hydraulic oil
before connecting the piping to the drain port.
See Fluids and Lubricants, Section 3, for type and

quantity of oil.
E-110 9813/0400-2 E-110

Slew Motor
Relief Valves
Disassembly 39
Refer to the sectional drawing as a guide to dismantling 44

and assembling.
Take steps during dismantling to ensure that all the parts

are returned to their original positions.
JS06240-C1
Clean the parts with a suitable solvent and blow them dry.
Fig 35.
Replace all used O-rings
1 If not already done, remove cap 37 (with a 14 mm A/

F hexagonal socket) from the relief assemblies 34
and remove piston 38, liner 51, shim 40, poppet 43
and spring 42.
34
40
43 38
42
51
37 JS06230-C1
Fig 34.
2 The seat 44 is press-fitted into sleeve 39. Remove it

using a soft object, taking care not to scratch the seat
face.
E-111 9813/0400-2 E-111

Slew Motor
Assembly
1 Press fit seat 44 into sleeve 39 which has an O-ring

41.
2 Mount poppet 43, spring 42, shim 40, piston 38, liner
51 onto sleeve 39.
3 Screw cap 37 (with a 14 mm A/F hexagonal socket)

with O-ring 36 and back-up 35 mounted, on to sleeve
39 and tighten to a torque of 157 Nm (116 lbf ft).
Check the relief set pressure.
The correlation between the set pressure of the relief

valve and the adjusting shims is shown below.
However, adjustment must not be attempted if the
pressure cannot be checked.
A 0.1 mm (0.003 in) shim equals 5 kgf/cm2 (71 lbf/in2)

approximately.
41
39
44
40
43 38
35
42
51
36
37
JS06250-C1
Fig 36.
E-112 9813/0400-2 E-112

Slew Gearbox
Reduction Gear Structure and Working Principles
Fig 1.
Table 1. Key Due to the severe conditions under which the output shaft
A A Chamber operates, an oil seal 61 is provided in the centre of gear
case 58 to protect the bearings from metal waste worn
B B Chamber
from the gears. The bearing in chamber A is lubricated with
C Torque path gear oil and the bearing in chamber B with grease.
Power transmitted by the hydraulic motor output shaft is

transmitted to second sun gear 77 via first sun gear 66,
planetary gear 69 and holder 65. Power is then transmitted
to output shaft 53 via second sun gear 77, planetary gear
72 and holder 76. The output shaft is constructed with an
integral pinion and is supported in gear case 58 by
bearings 57 and 62.
E-113 9813/0400-2 E-113

Slew Gearbox
Description
Description
K Fig 3. ( T E-116)
3 10
11
12
4
13
7 14
8 15
16
9
17
C041470
Fig 2.
E-114 9813/0400-2 E-114

Slew Gearbox
Description
Component Identification
Table 2.
Item Description
1 1st Reduction Sun Gear
2 1st Reduction Planet gear assembly
3 Bolt
4 Cover
5 2nd Reduction Sun Gear
6 O- ring Seal
7 Ring Gear
8 O- ring Seal
9 2nd Reduction planet gear assembly
10 Ring nut
11 Bearing
12 Seal
13 Gearbox housing
14 Bearing
15 Nylon ring
16 Spacer
17 Pinion Shaft
E-115 9813/0400-2 E-115

Slew Gearbox
Disassembly and Assembly
Disassembly
Cleanliness is of the utmost importance when servicing the
gearbox. All precautions to prevent any ingress of dirt, grit
etc. must be taken K Fig 3. ( T E-116).
Note: For the details of service tool referred to see

Service Tools, Section 1.
1 Remove the bolts 3 which hold the cover 4 to the ring

gear and gear box cover 13.
a Lift out 1st reduction sun gear 1

K Fig 4. ( T E-116).
Fig 4.
b Lift out 1st reduction planet gear assembly 2.
c Lift out 2nd reduction sun gear 5.
d Remove cover 4.
e Remove O-ring 6 from the ring gear
f Lift out 2nd reduction planet gear assembly 9.
g Remove ring gear 7
h Remove O-ring 8 from the ring.
2 Assemble the socket box wrench and nut adaptor

(see Service Tools, Section1) on the ring nut 10. By Fig 5.
using torque multiplier (1:25) loosen the ring nut 10.
Removing the nut K Fig 5. ( T E-116). 3 Using a 3 leg puller release gear box housing 13 from
pinion shaft 17 and bearing. Using suitable lifting
equipment, remove gearbox housing 13
K Fig 6. ( T E-117).
Fig 3.
E-116 9813/0400-2 E-116

Slew Gearbox
Fig 8.
Fig 6. Inspection
4 Assemble the bearing rig section 1 between the Before assembling the gear box make sure that a thorough
pinion shaft 17 and the bearing 14. Using suitable inspection of all the components is carried out. Remember
lifting equipment, place the unit in the tube provided that although a failed component may be easy to identify,
with the service tool. Using a press, push on the the cause may be less easy to trace. It is also possible that
pinion shaft 17 to separate it from the bearing 14. a failed component may have caused damage to other
Remove the bearing 14 nylon ring 15 from pinion areas of the gearbox.
shaft K Fig 7. ( T E-117)
Components that are subject to general wear and tear are
the following:
Gears 1,2,5,7,9
Pinion shaft 17
Bearings 11,14
Seals 10
1 Carefully clean all components using a suitable

degreasing agent.
2 Carefully inspect all gears, bearings and shafts for

Fig 7. signs of excessive wear or damage. If wear or
damage is evident, components must be renewed.
5 Turn gear box housing 13 upside down. Place seal
Ring tool on the seal 12 and, using a soft faced 3 In the case of damaged gears, for example a
hammer, tap service tool to remove seal 12. Remove planetary gear, do not proceed to replace the
bearing 11 from gear box housing 13 individual gears but the entire assembly.
K Fig 8. ( T E-117).
E-117 9813/0400-2 E-117

Slew Gearbox
Assembly
Note: Apply clean hydraulic fluid to all sliding contact faces
during assembly. New seal must be use on assembly.
1 Place seal 12 on its seat in the gearbox housing 13.
2 Use the ring seal tool A, see Service Tools and a soft
faced hammer to push the seal 12 against its seat.
3 Turn the gearbox housing 13 upside down and apply

with grease K Fig 9. ( T E-118).
Fig 10.
4 Place nylon ring 15 on the pinion shaft 17.
5 Place the bearing 14 on the pinion shaft

K Fig 10. ( T E-118).
6 Use tool, see Service Tools and a press to push the

bearing onto the pinion shaft and seated against the
shoulder.
7 Apply a coat of grease, on the bearing 14.
Fig 11.
8 Using suitable lifting equipment, lift the pinion shaft 17

into the tube of the bearing rig.
9 Using suitable lifting equipment, place the gearbox

housing 13 into the pinion shaft 17.
Using the stopper tool and a press push the gear

housing 13 against the pinion shaft and shoulder 17.
Fig 9. 10 Insert the bearing 11 into the pinion 17 and using the
stopper Tool and press, assemble the output unit
K Fig 11. ( T E-118)
11 Apply JCB threadlocked to the thread of a new ring

nut 10.
Assemble the socket box wrench and nut adapter

tools 18-B, see Service Tools on the ring nut 10.
tighten the ring nut 10 K Fig 12. ( T E-119).
E-118 9813/0400-2 E-118

Slew Gearbox
Fig 12.
12 Place 2nd reduction planetary gear assembly 9 over

the pinion shaft 17.
13 Replace O-ring 8 into its seat in the ring gear 7.
14 Place ring gear 7 into the gear box housing, 13

making sure bolt holes are aligned.
15 Replace O-ring 6 into its seat in the ring gear 7.
16 Insert the 2nd reduction sun gear 5 in the 2nd reduction

planetary gear assembly 9.
17 Assemble the cover 4 into the gear ring. Insert bolts 3

and tighten to 205 Nm torque.
18 Insert the 1st reduction planet gear assembly 2.
19 Insert 1st reduction sun gear 1.
Torque Settings
Table 3.
Item Nm kgf m lbf ft
10 1400 1032 143
3 205 21 151
E-119 9813/0400-2 E-119

Slew Gearbox
E-120 9813/0400-2 E-120

Rotary Coupling
Description
Fig 1.
Item Part no.
11 Axle
12 V- ring
13 Motor
14 O -ring
15 Packing ring
16 Thrust plate
17 Hexagonal socket head
18 O-ring
19 Cover
20 Plug
21 Plug
K Fig 2. ( T E-122)
E-121 9813/0400-2 E-121

Rotary Coupling
Description
Fig 2.
Item Part Number
1 High strength bolt
2 High strength washer
3 JCB threadlocker and sealer high strength
4 Lock bar
5 Seal washer
6 Seal cap
7 Rubber packing
8 Seal ring
9 Rotating joint assembly
E-122 9813/0400-2 E-122

Rotary Coupling
Removal !MWARNING
Refer to the sectional illustration on the previous page as Hydraulic Pressure
a guide to the dismantling and assembly procedures. Hydraulic fluid at system pressure can injure you.
Using the excavator, raise the machine as shown and residual hydraulic pressure trapped in the service
block the undercarriage. hose line must be vented. Make sure the hose service
the hoses are open.
INT-3-1-11_2
!MWARNING
Take care when disconnecting hydraulic hoses and
fittings as the oil will be HOT.
TRANS-1-2
3 Attach identification tags to the rotary coupling hoses

JS10510
for reconnection purposes. Remove the hoses and
Fig 3. install blind plugs and caps to prevent contamination
K Fig 5. ( T E-123).
1 Prepare the machine.
a Stop the machine and release the hydraulic

pressure, (See Releasing Tank Pressure).
2 Remove the access panel K Fig 4. ( T E-123).
Fig 5.
4 Remove the coupling.
JS10520 Remove the two bolts B and remove lock bar A.

Fig 4. Remove the three mounting bolts C and carefully lift
the rotary coupling out of the machine
K Fig 6. ( T E-124).
E-123 9813/0400-2 E-123

Rotary Coupling
!MWARNING
immediately.
INT-3-1-10_3
Fig 6.
Replacement
1 Align the coupling 9 to the lower frame and tighten the
rotating joint installation bolt 1 K Fig 7. ( T E-124).
Tighten the lock bar installation bolt 1 and washer 2

to the specified torque, 109-127 Nm (11.1-2.9 kgf m,
80.28-93.28 and install the lock bar.
Fig 7.
2 Reconnect the hoses and install the access cover.

Remove the wooden block and lower the machine to
the ground.
Start the machine and check for leaks.
E-124 9813/0400-2 E-124

Rotary Coupling
Dismantling
1 Remove the bolt 19 and cover 17
K Fig 8. ( T E-125).
Fig 10.
4 Remove seal F.
5 Using a jig push off the axle G from the rotor H

K Fig 11. ( T E-125).
Fig 8.
Do not hit with a hammer.
2 Remove the O-ring C.
Do not reuse the O-ring 18 K Fig 9. ( T E-125).
Fig 11.
6 Remove the V-ring J and nylon ring K from the axle H.
Note: Do not reuse the V-ring J and nylon ring K

Fig 9. K Fig 12. ( T E-125).
3 Remove bolts 16 and the thrust plate 17

K Fig 10. ( T E-125).
Fig 12.
E-125 9813/0400-2 E-125

Rotary Coupling
7 Remove the O-rings, and packing rings from the rotor a Set one packing ring in each groove starting from
G K Fig 13. ( T E-126) the 2nd groove from the top.
Note: Do not reuse O-rings and the packing rings. b Set the O-ring in the top groove
K Fig 15. ( T E-126).
Fig 13.
Assembly
Inspect the parts for signs of wear, pitting, scratching,
discolouration etc. Polish out scratches using a fine grade
oil stone.
Before assembly, thoroughly clean all parts using a

suitable solvent: Do NOT use solvents on O-rings, backup
rings and seals.
Fit new O-rings, backup rings and seals.
Lubricate all O-rings, backup rings and seals, with clean

hydraulic fluid before fitting.
1 Clean the rotor G with cleaning fluid or compressed

air K Fig 14. ( T E-126).
Fig 15.
3 After installing the O-ring, packing rings and packing,

check with a mirror to see if they are installed
correctly.
After checking, coat with grease then check once

more for any protrusion, twisting, etc.
K Fig 16. ( T E-127).
Fig 14.
After cleaning, check to see if there are any scratches

or roughness on the inner side of the rotor or grooves.
2 Check the number of packing rings and O-rings. Coat

with Vaseline and install in the order below.
E-126 9813/0400-2 E-126

Rotary Coupling
Fig 16.
Fig 18.
4 Install the V-ring 12 and nylon ring on the axle 11and
grease adequately. Take care to prevent 6 Install a new seal K Fig 19. ( T E-127)
contamination of the grease by water or dirt
K Fig 17. ( T E-127).
Fig 19.
Fig 17.
7 Install a new O-ring K Fig 20. ( T E-127).
5 Install the axle 11 to the rotor 13
K Fig 18. ( T E-127).
Note: Set the V-ring 12 so that it will not be cut or

scratched.
Fig 20.
8 Install the cover and bolts K Fig 21. ( T E-128).
E-127 9813/0400-2 E-127

Rotary Coupling
Fig 21.
E-128 9813/0400-2 E-128

Hydraulic Rams
Precautions During Use
TE-006
Installation Special seal materials are necessary so check to

see if the ram that you are using is suitable or not.
1 Precautions when installing the ram on the machine.
c The number one cause of ram oil leakage is rod
a When installing and removing from the machine, damage. Be careful not to damage the rod.
suspend the ram safely.
2 Warm up sufficiently before beginning work.
b Suspending the ram by the piping is not only
dangerous, but can also cause damage to the a In cold conditions the rod seals may be frozen, so
cylinder. if the ram is operated at maximum pressure and
maximum speed, the seals will be damaged.
c Secure the piston rod with a band. It is very
dangerous if the rod extends unexpectedly. Also, b There is a large amount of air in a new ram or one
the rod can be damaged and become unusable. which has been left for a long time, so the ram will
not operate smoothly. Also, if pressure is applied
2 Welding after installing the ram may result in damage. suddenly without bleeding the air, high
temperatures will be generated due to adiabatic
a If electric welding is done even at a point away compression and the seals may burn.
from the ram, there may be sparking inside the
ram and it will become necessary to replace the c Before beginning work, always move the ram at
ram with a new one. full stroke with no load and expel air from the
cylinder.
3 When painting the machine, mask the ram.
3 When stopping or storing, do it at a safe and fixed
a If paint adheres to the rod surface or to the wiper position.
ring and the ram is operated, the wiper ring will not
function properly and foreign matter and paint can a The installed ram cannot maintain the same
easily enter the ram. This will cause damage to position for a long period of time, because the oil
the seals, drastically shortening the life of the ram. inside the ram may leak and the hydraulic oil
volume decreases as it cools. Stop or store the
4 Install the ram only when it is clean. machine in a safe and fixed position.
Caution During Use Maintenance, Inspection Points
1 Use only under designated conditions. 1 Carry out daily maintenance and inspection.
a If hydraulic oil other than the designated oil is a The key point for correct long-term ram function is
used, the seals quickly degenerate and become daily maintenance and inspection. Carry out
damaged. If the relief valve is set at a value higher maintenance and inspection so that the ram
than specified, it may cause ram damage and is functions fully at all times. Always remove any
dangerous. mud, water, dust or oil film adhering to the rod and
keep it in normal condition. However, when
b In high temperature environments (approx. 90°C cleaning the wiper ring and seals, do not get them
and above) or low temperature environments wet with water but wipe clean with a rag. To
(below -20°C), seals quickly become damaged. prevent rust forming during storage, the amount of
exposed ram piston rod should be kept to a
E-129 9813/0400-2 E-129

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

the desired results may not be obtained. Use only
genuine JCB parts.
3 Caution during dismantling and reassembly.
a Dismantling the ram while it is still installed on the

machine can be dangerous as unexpected
movements of the machine can occur. Remove
the ram from the machine and then dismantle.
b If reassembled with dirty hands, foreign matter

can enter the ram causing a shorter life span and
also the other hydraulic equipment may be
damaged. Reassemble in a clean state.
c Follow the instructions in the diagrams regarding

torque tightening for screwed parts. If the torque is
too high or too low, it can cause damage.
E-130 9813/0400-2 E-130

Hydraulic Rams
Typical Bucket Ram

P11-E001_2
Removal
!MWARNING
Hydraulic Pressure
hose line must be vented. Make sure the hose service 803090
line has been vented before connecting or removing Fig 2.
the hoses are open. 3 Stop the engine, remove the key.
INT-3-1-11_2
Release the tank pressure, see Releasing the Tank
!MWARNING Pressure.
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
1 Lower the attachment to the ground.
709600
Fig 3.
4 Remove the nuts and bolts from the rod end of the
ram.
709670
Fig 1.
2 Place a wooden block under the bucket ram.
E-131 9813/0400-2 E-131

Hydraulic Rams
803091
803140
Fig 6.
Fig 4.
7 Remove the ram hoses and install plugs or caps to
5 Push the pin out using a bar and hammer. prevent contamination.
!MWARNING 8 Attach slings to support the ram.
Metal Splinters
You can be injured by flying metal splinters when
driving metal pins in or out. Use a soft faced hammer
or copper pin to remove and fit metal pins. Always
wear safety glasses.
INT-3-1-3_2
803095-1
Fig 7.
9 Remove the nuts and bolts from the cylinder end of

the ram. Push out the pin using a bar and hammer.
Lift the ram clear.
!MWARNING
Metal Splinters
803141
Fig 5. driving metal pins in or out. Use a soft faced hammer
6 Restrain the eye end of the ram piston rod to the ram wear safety glasses.
cylinder to prevent the piston rod from extending. INT-3-1-3_2
E-132 9813/0400-2 E-132

Hydraulic Rams
2 Install the pin, bolt and nuts to the cylinder end of the
ram.
803093
Fig 10.
803092
Fig 8.
Replacement
1 Attach slings to the ram and lift it into position on the

dipper.
Fig 11.
Note: When checking or refitting JS machine pivot pins,

the retaining nuts and bolts should not be fastened up tight
to the pivot boss but must have approximately 3mm of play
so that the pin is free from tension.
3 Connect the hoses.
803096-1
Fig 9.
E-133 9813/0400-2 E-133

Hydraulic Rams
A409820-C2
Fig 14.
803094
Fig 12. Note: When checking or refitting JS machine pivot pins,
803142
Fig 13.
4 Hoist the ram to align with the link.
Install the pin, bolt and nuts.
Note: Stroke the ram to release entrapped air. After

releasing the air, check for oil leakage.
E-134 9813/0400-2 E-134

Hydraulic Rams
Typical Boom Ram

P11-E002_2
Removal
!MWARNING
Hydraulic Pressure
the hoses are open.
INT-3-1-11_2
803210
!MWARNING
Fig 16.
3 Remove the nuts, bolt and collar.

Lifting Equipment
You can be injured if you use faulty lifting equipment.
Make sure that lifting equipment is in good condition. !MWARNING
regulations and is suitable for the job. Make sure that Metal Splinters
lifting equipment is strong enough for the job. You can be injured by flying metal splinters when
INT-1-3-7
1 Lower the attachment to the ground, as shown. wear safety glasses.
INT-3-1-3_2
Push out the pin, using a bar and hammer.
709670
Fig 15.
Stop the engine, remove the key.
2 Remove the grease tube and attach slings to the

boom ram.
803211
Fig 17.
4 Lower the ram and place it on a stand.
E-135 9813/0400-2 E-135

Hydraulic Rams
6 Release the tank pressure, see Releasing the Tank
Pressure.
709600
Fig 20.
7 Remove the hoses, and install plugs or caps to

prevent contamination.
803222-1
Fig 18.
5 Restrain the eye end of the piston rod to the ram

cylinder, to prevent movement of the rod.
803220-1
Fig 21.
8 Remove the nut and bolt and push out the pin with a
hammer and bar.
!MWARNING
Metal Splinters
INT-3-1-3_2
803221-1
Fig 19.
E-136 9813/0400-2 E-136

Hydraulic Rams
Replacement
1 Attach slings to the ram.
Align the ram to its installation position.
803223-1
Fig 22.
9 Lift the ram away from the unit.
803224-1
Fig 23.
2 Install the pin and then the bolt and nuts.
!MWARNING
Metal Splinters
INT-3-1-3_2
E-137 9813/0400-2 E-137

Hydraulic Rams
803226-1
Fig 26.
803225-1 4 Lift the ram and align the rod eye end with the pin
Fig 24. position.
A409820-C2
Fig 25.
803213-1
Fig 27.
the retaining nuts and bolts should not be fastened up tight 5 Install the pin with a bar and hammer.
!MWARNING
3 Install the hoses. Metal Splinters

INT-3-1-3_2
E-138 9813/0400-2 E-138

Hydraulic Rams
7 Connect the grease tube.
Note: Stroke the ram and release entrapped air. After

803212-1
Fig 28.
6 Install the collar and then the bolt and nuts.
803214-1
Fig 29.
A409820-C2
Fig 30.
E-139 9813/0400-2 E-139

Hydraulic Rams
Typical Dipper Ram

P11-E003_1
Removal
!MWARNING
Hydraulic Pressure
the hoses are open.
803190
INT-3-1-11_2 Fig 32.
!MWARNING 3 Stop the engine, remove the key.
Lifting Equipment Release the tank pressure, see Releasing the Tank
You can be injured if you use faulty lifting equipment. Pressure
Make sure that lifting equipment is in good condition.
regulations and is suitable for the job. Make sure that
lifting equipment is strong enough for the job.
INT-1-3-7
1 Lower the attachment to the ground, as shown.
709600
Fig 33.
709670
4 Remove the nuts and bolts from the rod end of the
Fig 31.
ram.
2 Place a wooden block under the dipper ram.
E-140 9813/0400-2 E-140

Hydraulic Rams
803151
Fig 34.
803150
!MWARNING Fig 35.
Metal Splinters 6 Restrain the eye end of the ram piston rod to the ram
You can be injured by flying metal splinters when cylinder to prevent the piston rod from extending.
INT-3-1-3_2
5 Push out the pin, using a bar and hammer.
803160
Fig 36.
7 Remove the ram hoses, and install plugs or caps to

prevent contamination.
Remove the grease tube.
E-141 9813/0400-2 E-141

Hydraulic Rams
!MWARNING
Metal Splinters
INT-3-1-3_2
803170
Fig 37.
8 Attach slings to support the ram.
803200-1
Fig 39.
Replacement
1 Attach slings and lift the ram onto the boom.
803180-1
Fig 38.
9 Remove the nuts and bolts from the cylinder end of

the ram, push out the pin using a bar and hammer. Lift
the ram clear.
E-142 9813/0400-2 E-142

Hydraulic Rams
803201
Fig 41.
803181-1
Fig 40.
2 Install the pin, bolts and nuts.
!MWARNING
Metal Splinters
INT-3-1-3_2 A409820-C2
Fig 42.

3 Install the grease tube and connect the hoses.
E-143 9813/0400-2 E-143

Hydraulic Rams
A409820-C2
803171
Fig 45.
Fig 43.
4 Hoist the ram to align the piston rod eye end with the
dipper pin position.
5 Install the pin, bolt and nuts.
Note: Stroke the ram to release entrapped air. After

!MWARNING
Metal Splinters
INT-3-1-3_2
803152
Fig 44.
E-144 9813/0400-2 E-144

Hydraulic Rams
Assembly and Disassembly
Cylinder Disassembly 6 Tap the head end cover out using nylon mallet as
shown in K Fig 47. ( T E-145)
1 Remove the cylinder from the equipment
Note: Do not hit the cylinder with hammer.
2 Drain the oil from the cylinder
Note: Do not heat the cylinder using welding flames for
Note: Do not open the cylinder or pull the piston rod out opening the head end cover.
unless the oil is drained.
Note: Do not chisel the head end cover
3 Put the cylinder on a wooden V-block
4 Clean the cylinder with clean cotton cloth
5 Clamp the cap end using rod and de-torque the

hexagonal bolts. SeeK Fig 46. ( T E-145)
D065410
Fig 47.
Disassembly of Piston Rod
1 Put the piston rod on a V block support
2 Ensure direction of cushioning bush during assembly

as shown in K Fig 48. ( T E-145)
D065420
Fig 48.
D065400
Fig 46. 3 Remove grub screw and locking ball. See
K Fig 49. ( T E-146)
E-145 9813/0400-2 E-145

Hydraulic Rams
D065430
D065450
Fig 49. Fig 51.
D065440
Fig 50. D065460
Fig 52.
E-146 9813/0400-2 E-146

Hydraulic Rams
D065470 D065490
Fig 53. Fig 55.
D065480 D065500
Fig 54. Fig 56.
E-147 9813/0400-2 E-147

Hydraulic Rams
D065510 D065530
Fig 57. Fig 59.
D065520 D065540
Fig 58. Fig 60.
E-148 9813/0400-2 E-148

Hydraulic Rams
D065550 D065570
Fig 61. Fig 63.
A Snap ring
B Wiper
C Secondary rod seal
D Primary rod seal
E Bimetal bush
D065560
Fig 62.
D065580
Fig 64.
F Soft bearing strips
G Piston seal
H Hard bearing strips
E-149 9813/0400-2 E-149

Hydraulic Rams
D065610
Fig 67.
D065590 3 Remove secondary rod seal back up ring as shown in

Fig 65. K Fig 68. ( T E-150)
I Primary seal
J Backup ring
K Wiper
L Secondary seal
Disassembly of Seals in Head End Cover
1 Remove wiper locking snap ring as shown in

K Fig 66. ( T E-150)
D065620
Fig 68.
4 Remove primary seal using bend screw driver as

D065600
Fig 66.
2 Remove secondary seal using bend screw driver as

E-150 9813/0400-2 E-150

Hydraulic Rams
Disassembly of Seals in Piston
1 Remove hard and soft bearing strips
2 Then remove the piston seal. See

K Fig 64. ( T E-149)
Cylinder Assembly
1 Clean the component with clean solvent
Note: Do not clean the component with kerosene.
Note: Do not file any of the components.
2 Dry with clean cloth
D065630
3 Polish all sharp edge with scorch bright
Fig 69.
4 Apply clean hydraulic oil onto the seal
5 Remove wiper as shown in K Fig 70. ( T E-151)
Assembly of Seals in Head End Cover
1 Assemble primary rod seal and then put backup ring.

See K Fig 71. ( T E-151) and K Fig 72. ( T E-152)
D065650
Fig 71.
D065640
Note: Make sure that, the lip direction as per
Fig 70.
K Fig 73. ( T E-152)
E-151 9813/0400-2 E-151

Hydraulic Rams
D065660 D065680
Fig 72. Fig 74.
D065690
Fig 75.
Note: Make sure that, the lip direction as per

K Fig 76. ( T E-153)
D065670
Fig 73.
2 Assemble secondary rod backup ring first then put

secondary rod seal. See K Fig 74. ( T E-152) and
K Fig 75. ( T E-152)
E-152 9813/0400-2 E-152

Hydraulic Rams
D065750
Fig 78.
D065730
Fig 76.
3 Assemble wiper K Fig 77. ( T E-153) and then put

the snap ring K Fig 79. ( T E-153).
D065760
Fig 79.
D065740
Fig 77.
E-153 9813/0400-2 E-153

Hydraulic Rams
D065780
Fig 80.
A Snap ring D065800
Fig 82.
B Secondary rod seal with backup ring
C Primary rod seal with backup ring
D Bimetal bush
Assembly of Seals in Piston
1 Assemble the piston seal first and then the bearing

strips. See K Fig 81. ( T E-154),
K Fig 82. ( T E-154) and K Fig 83. ( T E-154)
D065810
Fig 83.
D065790
Fig 81.
E-154 9813/0400-2 E-154

Hydraulic Rams
4 Assemble the head end cushioning bush
K Fig 86. ( T E-155)
D065840
Fig 86.
D065820
Fig 84. Note: Make sure that, the correct direction of the
cushioning bush. The wider part of the slot should be
Assembly of Head End Cover facing the head end cover. See K Fig 87. ( T E-155)
1 Apply clean hydraulic oil inside the head end cover (at
seals and wiper area)
2 Insert gently the head end cover onto the piston rod
sub assembly.
Note: Make sure that, the seal lip does not touch the piston
rod threads or the same is not reversed or twisted during
assembly.
3 Check for smooth movement of head end cover on

piston rod. See K Fig 85. ( T E-155) D065850
Fig 87.
Assembly of Piston and Piston Nut
1 Assemble the piston onto piston rod sub-assembly

threads using special fixture and torque wrench/pins
as shown in K Fig 88. ( T E-156)
2 Torque it to the specified value mentioned as

mentioned in the drawings
D065830
Fig 85.
E-155 9813/0400-2 E-155

Hydraulic Rams
D065860
Fig 88.
3 Assemble the piston rod nut and torque it to the

specified value as mentioned in the drawings
Note: Piston rod nut is left hand threaded/where ever

applicable
4 Assemble the alloy steel ball
5 Apply loctite 242 or Anabond 118 on hex socket set

screw and assemble the same
6 Torque it to value specified in the drawings and then

caulk at two places
D065870
Fig 89.
E-156 9813/0400-2 E-156

Hydraulic Rams
Assembly of Piston Rod Sub-assembly Do’s in a Hydraulic Cylinder
1 Support the tube sub-assembly on the ground – Use soft lint-free cloth, never use cotton waste it may
contain metal chips which will damage working
2 Apply little hydraulic oil inside the tube sub assembly surface of the components
and piston seal outer portion to ensure smooth entry
– Periodically clean the dust/mud accumulated on
on the piston rod sub assembly
Wiper seals
Note: Make sure that, piston rod sub-assembly and tube – Ensure that the oil is in cold condition before opening
sub-assembly are in line to ensure smooth assembly. the cylinder
– Ensure that the cylinder is assembled and dis-
3 Assemble the hex socket head cap screw and torque assembled in clean dust free atmosphere
it to the specified value – Ensure usage proper lifting tackles (Rope, Belts, etc.)
while handling the cylinder
4 Push the piston rod sub-assembly completely inside
– Apply grease on extended piston rod, if any welding
the assemble the protection cover
is being carried out near the cylinder. This is to avoid
welding spatters from getting stuck on the piston rod
Note: Make sure that, the cylinder is filled with hydraulic oil
surface. Wipe off the grease after welding is
for protection.
completed
– Use only the specified grade of hydraulic oil
– Use Grease gun to ensure proper greasing and apply
grease at all the greasing points periodically
– Ensure that there are no obstructions at the working
area like electrical line, inflammable material, etc.
– Check the hydraulic oil contamination and change if
required
– Apply rust preventive oil on the exposed surface of
D065880
the piston rod during prolonged storage
Fig 90.
Dont’s in a Hydraulic Cylinder

– Don’t operate the machine beyond the specified load/
pressure limit
– Don’t use the bucket to push rocks, boulders, etc.
– Don’t load the bucket unevenly
– Don’t use the hydraulic cylinder as a conductor for
welding purpose
– If you have to weld on structure connect earth wire to
the structure only not on the cylinder
– Earth must be given close to the point of welding
– Don’t paint on the working surface of the piston rods
and wiper seal
– Don’t heat hydraulic cylinder while dismantling
– Don’t open hydraulic connections without releasing
the system pressure
– Don’t carry out welding without removing the battery
terminals
E-157 9813/0400-2 E-157

Service Procedure
Make the Machine Safe
TE-009
Note: You can complete most of the maintenance

procedures with the boom lowered. Unless a maintenance
procedure instructs you differently, you must lower the
boom.
You must make the machine safe before you complete any
service procedures.
1 Park the machine on firm level ground.
2 Apply the parking brake (if fitted).
3 Lower the equipment or, raise and fit the applicable

safety strut.
4 Stop the engine.
5 Turn the ignition to the ÒN' position.
6 Operate the hand controllers to release pressure in

the hydraulic system.
7 Turn the ignition to the ÒFF' position.
8 Remove the starter key
9 Disconnect the battery (if necessary).
10 Release the hydraulic oil tank pressure.
11 Chock the wheels/tracks as applicable.
12 If the machine is raised from the ground make sure it

is securely chocked. NEVER WORK UNDER A
MACHINE RAISED ON STABILISERS OR JACKS.
13 If you wish to arc weld the machine disconnect the

alternator and electronic control units (if fitted).
E-158 9813/0400-2 E-158

Service Procedure
Pressure Testing - General
Confirmation of the Oil Temperature

Confirm the oil temperature is between 45°C - 55°C using
the self check function. If the temperature is low use the
following warm-up procedure.
Warming-up Procedure
1 Turn the throttle control to mid-range and make sure
the work mode is set to E.
2 Run the engine until the coolant temperature gauge

reads within the normal (green) range.
3 Set the servo isolator switch to ON to enable the

hydraulic servo controls to be operated.
4 Operate the bucket control slowly until it reaches one

end of its travel and leave it there for 10 seconds.
5 Operate the bucket control slowly to the other end of

its travel and leave it there for 10 seconds.
6 Repeat steps 4 and 5 for 10 minutes to warm up the

hydraulic circuit.
7 Operate the excavating controls three to five times in

each direction to distribute warm hydraulic oil around
the system.
Note: All pressure testing to be carried out with the engine

set at minimum engine revs unless otherwise stated.
E-159 9813/0400-2 E-159

Service Procedure
Pressure Testing Points
TP3
TP1
TP2
C068440-C1
Fig 1.
TP1 Main Pump P1
TP2 Main Pump P2
TP3 Servo Pressure
K Table 1. ( T E-161)
E-160 9813/0400-2 E-160

Service Procedure
Table 1.
Part Name Pressure bar (lb/in2) Measurement Method Measurement Port
K Fig 1. ( T E-160)
Main Relief Standard: 343 bar (4975 lb/in2) Dipper Relief K Main TP1 or TP2
Power Boost: 373 bar (5395 lb/in2) Relief Valve (MRV)
Pressure ( T E-164)
Pilot Relief 37 - 43 bar (537 - 624 lb/in2) Lever Neutral K Servo TP3
Relief
Pressure ( T E-166)
Slew Port Relief Left/Right 289 bar (4192 lb/in2) Slew Relief K Slew TP2
Motor Pressure
Relief ( T E-173)
Boom Port Relief Raise 392 bar (5685 lb/in2) Boom Up Relief TP1(1)
K Auxiliary Relief
Valves ( T E-167)
Lower 264 bar (3829 lb/in2) Boom down Relief TP1
K Auxiliary Relief
Valves ( T E-167)
Bucket Port Relief Open/Close 392 bar (5685 lb/in2) Bucket Relief TP1(1)
K Auxiliary Relief
Valves ( T E-167)
Dipper Port Relief Out/In 392 bar (5685 lb/in2) Dipper Relief TP2(1)
K Auxiliary Relief
Valves ( T E-167)
Track Motor Relief 353bar (5112 lb/in2) Track Relief K Travel TP1 or TP2(1)
Motor Relief
Pressure ( T E-175)
(1) The main relief setting must be increased during testing.
E-161 9813/0400-2 E-161

Service Procedure
Pressure Relief Valve Location

TE-011
1 4
9
8
10
11
C047240-C1>
Fig 2.
K Table 2. ( T E-163)
E-162 9813/0400-2 E-162

Service Procedure
Table 2.
1 Main Relief Valve (MRV)
2 Tab/Dozer Relief Valve
3 Arm Out Relief Valve
4 Option Relief Valve
5 Boom Up Relief Valve
6 Bucket Close Relief Valve
7 Option Relief Valve
8 Arm In Relief Valve
9 T.A.B./Dozer Relief Valve
10 Boom Down Relief Valve
11 Bucket Open Relief Valve
K Fig 2. ( T E-162).
E-163 9813/0400-2 E-163

Service Procedure
Main Relief Valve (MRV) Pressure

TE-012
1 Prepare the Machine
a Operate the dipper out and lower the boom to set

the bucket on the ground.
C030150-1
Fig 3. C
b Make the machine safe, refer to Section E, A
Service Procedures.
c Install a 0 - 400 bar (0 - 6000 lb/in2) pressure

gauge in TP1 or TP2.
D
d Start the engine, and confirm that the engine is at B
its maximum no-load speed and it is in the E mode E
to test standard pressure and L mode to test
power boost pressure.
A406580-C1
e Raise the boom and then operate the dipper out Fig 4.
control. Read the pressure gauge with the dipper
ram stalled at the end of its stroke. a Make the machine safe, refer to Section E,
Service Procedures.
f If it is outside the limits, stop the engine and adjust
the MRV as below. b Remove servo hose E and plug hose.
Note: For accurate setting, the pressure should be c Start the engine, and confirm that the engine is at
adjusted up to the required level. its maximum no-load speed and it is in the E
mode.
2 High Pressure Setting (Power Boost)
d Stall the dipper.
e Hold nut C and release lock nut B and screw the

low pressure setting nut A clockwise all the way
in.
f Hold nut C and slacken nut D. Screw nut C in, to

increase pressure or out to decrease pressure.
g Once required pressure is achieved on the

pressure gauge, hold nut C and lock nut D back
up.
3 Low Pressure Setting (Standard)
E-164 9813/0400-2 E-164

Service Procedure
a confirm that the engine is at its maximum no-load
speed and it is in the L mode.
b Stall the dipper.
c Hold nut C and slacken locknut B. Screw nut A out

to reduce pressure or in to increase pressure.
d Once required pressure is achieved on the

pressure gauge, lock nut B against nut C.
e Make the machine safe, refer to Section E,

Service Procedures.
f Re-attach the servo hose to MRV.
4 Check the pressures.
E-165 9813/0400-2 E-165

Service Procedure
Servo Relief Pressure
Servo Relief Pressure

TE-013
1 Prepare the Machine 3 Start the engine and confirm that the engine is at its
minimum no-load speed and it is in the E mode. The
a Operate the dipper out and lower the boom to set pressure gauge reading should be compared to the
the bucket on the ground. technical data at the start of this section. If it is outside
the limits adjust the pilot relief valve as below.
4 Loosen the lock nut B of the pilot Relief Valve.
5 The valve is adjusted by turning relief valve adjusting

screw A (one turn of the adjustment screw equals
39.2 bar, (568.5 lb in2).
C030150-1
Fig 5. 6 Tighten lock nut B to 17 Nm (12. Ibf ft), check the
relief pressure again.
b Make the machine safe, refer to Section E,
Service Procedures.
2 Before testing the Pilot Relief valve C

K Fig 6. ( T E-166), connect a 0-100 bar (0-1500 lb/
in2) pressure gauge to test point TP3.
TP3
C
B
A405800-C3
Fig 6.
Note: For accurate setting, the pressure should be

adjusted up to the required level.
E-166 9813/0400-2 E-166

Service Procedure
Auxiliary Relief Valves

TE-014_2
General
1 Prepare the machine

C030150-1
Fig 7.

Service Procedures.
2 Increase MRV Pressure, refer to Section E, Service

Procedures.
3 Test the ARVs with the engine at idle using the

appropriate test points.
4 Restore Original MRV Pressure, refer to Section E,

Service Procedures.
E-167 9813/0400-2 E-167

Service Procedure
Boom Ram
Boom Up
1 Prepare the machine

C030150-1
Fig 8.

C002690-C1
Service Procedures. Fig 9.
c Connect a 0 - 400 bar (0 - 6000 lb/in2) pressure b The pressure gauge reading should be compared
gauge and adaptor to port TP1 on the hydraulic to the technical data at the start of the section. If it
pump. is outside the limits, adjust the ARV.
2 Increase MRV Pressure, refer to Section E, Service Note: For accurate pressure setting, the pressure should
Procedures. be adjusted up to the required level. Release lock nut X.
Adjust setting screw Y to a pressure below the required
3 Start the engine, lower the gate lock lever and run the level and then bring the pressure back up for final setting.
engine at minimum no-load speed in the E mode. Tighten lock nut X.
a Fully raise the boom and then continue to operate

the right control lever as at A.
312460-C1
Fig 10.

Service Procedures.
E-168 9813/0400-2 E-168

Service Procedure
Boom Down b The pressure gauge reading (Boom down) should
be compared to the technical data at the start of
1 Prepare the machine the section. If it is outside the limits, adjust the
ARV.
the bucket on the ground. Note: For accurate pressure setting, the pressure should
be adjusted up to the required level. Release lock nut X.
Adjust setting screw Y to a pressure below the required
level and then bring the pressure back up for final setting.
Tighten lock nut X.
C030150-1
Fig 11.

Service Procedures.
c Connect a 0 - 400 bar (0 - 6000 lb/in2) pressure

312460-C1
gauge and adaptor to port TP1 on the hydraulic
Fig 13.
pump.
3 The relief valves for boom up and boom down must
2 It is not physically possible to fully close the boom
be swapped and returned to the correct ports.
ram, without lifting the undercarriage of the ground.
Therefore the ARV's must be swapped over.
Service Procedures.
a Fully raise the boom and then continue to operate
the right control lever as at A at minimum no-load
speed in the E mode.
C002690-C1
Fig 12.
E-169 9813/0400-2 E-169

Service Procedure
Dipper Ram
a Operate the dipper out and lower the boom to set A

B
C030150-1
Fig 14.

Service Procedures.
C002700-C1
c Connect a 0 - 400 bar (0 - 6000 lb/in2) pressure Fig 15.

pump. c The pressure gauge reading (Dipper Out) should
be compared to the technical data at the start of
2 Increase MRV Pressure, refer to Section E, Service the section. If it is outside the limits, adjust the
Procedures. ARV.
3 Start the engine, lower the gate lock lever and run the d Move the dipper fully in and then continue to
engine at minimum no-load speed in the E mode. operate the control lever, as at B.
4 Pressure Adjustment e Compare the pressure gauge reading (Dipper In)

to that stated in the technical data section at the
a Raise the boom enough to allow the Dipper to start of the section. If it is outside the limits, adjust
move freely. ARV.
b Move the dipper fully out and then continue to Note: For accurate setting, the pressure should be
operate the control lever, as at A. adjusted up to the required level. Release lock nut X.
Adjust setting screw Y to indicate a pressure below the
required level and then bring the pressure back up for final
setting. Tighten lock nut X.
312460-C1
Fig 16.

Service Procedures.
E-170 9813/0400-2 E-170

Service Procedure
Bucket Ram

B A
C030150-1
Fig 17.

Service Procedures.
C002690-C2
c Connect a 0 - 400 bar (0 - 6000 lb/in2) pressure Fig 18.
pump. c The pressure gauge reading (Bucket Open)
should be compared to the technical data at the
2 Increase MRV Pressure, refer to Section E, Service start of the section. If it is outside the limits, adjust
Procedures. the ARV.
3 Start the engine, lower the gate lock lever and run the d Close the bucket fully and then continue to
engine at minimum no-load speed in the E mode. operate the control lever, as at B.
4 Pressure Adjustment e The pressure gauge reading (Bucket Closed)

should be compared to the technical data at the
a Raise the boom. start of the section. If it is outside the limits, adjust
ARV.
b Open the bucket fully and then continue to
operate the control lever at A. Note: For accurate setting, the pressure should be
adjusted up to the required level. Release lock nut X.
Adjust setting screw Y to indicate a pressure below the
312460-C1
Fig 19.

Service Procedures.
E-171 9813/0400-2 E-171

Service Procedure
Option ARV (Monoboom) 4 Operate the option by pressing the foot pedal. Check
the pressure on the gauge, adjust the ARV.
1 Prepare the Machine.
Note: For accurate setting, the pressure should be
a Operate the dipper out and lower the boom to set adjusted up to the required level. Release lock nut X.
the bucket on the ground. Adjust setting screw Y to indicate a pressure below the

Service Procedures.
C030150-1
Fig 20.

Service Procedures.
c Fit two caps B to the option pipes on the dipper.

312460-C1
Fig 22.
JS06720-C1
JS06720-C1
Fig 21.
d Connect a 0 - 400 bar (0-6000 lbf/in2) pressure

gauge to TP1.

Procedures.
3 Start the engine, lower the gate lock lever and run the
engine at minimum no-load speed in the E mode.
E-172 9813/0400-2 E-172

Service Procedure
Slew Motor Pressure Relief

TE-015
1 Prepare the machine Note: If the water-proof slew lock solenoid valve is not
removed. Full slew pressure can not be read.
the bucket on the ground. Note: Pressure measurement is also possible on the slew
motor, upper section.
5 If the readings are outside the limits, continue as

below.
6 Pressure Adjustment
C030150-1 a Make the machine safe, refer to Section E,

Fig 23. Service Procedures.
b Make the machine safe, refer to Section E, b Remove relief valve to be adjusted.
Service Procedures.
c The difference between the set pressure and the
2 Connect a 0-400 bar (0 - 6000 lb/in2) pressure gauge present pressure determines the number of shims
and adaptor to test point TP2. E required for adjustment.
3 Initiate slew lock procedures. 7 Remove the relief valve assembly from the slew
motor.
a Remove the water-proof connector on the slew
lock solenoid valve. Note: If both relief valves are removed at the same time,
mark them left and right to facilitate re-assembly in the
b Press the slew lock switch which is on the right correct position.
hand console inside the cab, and confirm that the
slew lock symbol appears on the monitor. 8 Disassembly
a Place the relief valve in a vice and remove the cap

A with a 14 mm hexagonal socket, take out the
piston C, liner B poppet E, spacer D, shims E and
graphicA335121I
spring F.
c Start the engine, (error codes may appear for
disconnected solenoid) and operate the engine at
around 1000 rpm, then operate the slew lever
slowly. Listen to confirm that the relief sound is
heard and that the machine does not slew.
E
d Run the engine at minimum no-load speed and in C
the E mode. F
D
e Operate the slew lever. B
4 The pressure gauge reading should be compared to
A
A405850-C1
the technical data at the start of this section. If it is
Fig 24.
outside the limits adjust the slew motor relief valve as
below.
b Add shim to increase pressure. Remove shim to
decrease pressure.
E-173 9813/0400-2 E-173

Service Procedure
c Re-assemble relief valve assembly
d Fix the sleeve into a vice and install the cap A with
a torque of 156.9 Nm (115.17 lb ft).
e Install the relief assembly in the slew motor unit,

and confirm the pressure.
E-174 9813/0400-2 E-174

Service Procedure
Travel Motor Relief Pressure
Travel Motor Relief Pressure

TE-016
1 Prepare the Machine 4 Start the engine, select MID speed travel, lower the
gate lock lever and run the engine at minimum no-
a Operate the dipper out and lower the boom to set load speed in the E mode.
5 Slowly engage the locked travel motor and measure
the pressure in forward and reverse.
6 The pressure gauge reading (travel motor) should be

compared to the technical data at the start of the
section. If it is outside the limits, adjust relief valve
pressure.
C030150-1
Fig 25. Note: For accurate setting, the pressure should be
adjusted up to the required level. Release lock nut A.
b Make the machine safe, refer to Section E, Adjust setting screw B to indicate a pressure below the
Service Procedures. required level and then bring the pressure back up for final
setting. Tighten lock nut A.
c Connect a 0 - 400 bar (0 - 6000 lb/in2) pressure
gauge to test point TP1 or TP2.

B
Procedures.
3 Insert a lock pin P between the drive sprocket to be

measured and the side frame. A
∅80
∅35
P
A
B
300 150
TOOL-C1
Fig 26. 716370-C8
Fig 28.

Service Procedures.
C002730-C1
Fig 27.
E-175 9813/0400-2 E-175

Fault Finding
Hydraulic Contamination
TE-002_3
Hydraulic Fluid Quality cleaning unit. K Fig 1. ( T E-176). 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-176). 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-176 9813/0400-2 E-176

Fault Finding
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-177 9813/0400-2 E-177

Fault Finding
Main Control Valve
Main Control Valve
Table 1.
Symptoms Possible Causes Countermeasures
Spool sticking 1. Oil temperature is abnormally high. Remove the obstruction.
2. Hydraulic oil is dirty Replace the hydraulic oil and clean the
circuit at the same time.
3. Port connector is tightened too much Check the torque.
4. Valve housing is deformed due to Loosen the installation bolt and check.
Installation
5. Pressure is too high Attach pressure gauge to pump port and
ram port and check the pressure.
6. Spool is bent Replace the valve assembly.
7. Return spring is damaged Replace the damaged parts.
8. Spring or cap is not on straight Loosen the cap and after aligning, tighten.
9. Temperature inside valve is not even. Warm up the circuit.
Spool does not stroke 1. Valve is clogged inside with dirt Remove the dirt (flushing).
Load cannot be maintained 1. Oil leakage from the ram Check the ram.
2. Oil is by-passing from the valve spool Replace the valve assembly.
3. Oil leakage from the port relief valve Remove the port relief from the housing
and clean the housing seat and relief valve
seat.
4. Oil leakage from the lock valve Disassemble the lock valve and clean the
poppet seat and sleeve, plug seat. If the
seat is damaged, replace the poppet, or lap
the poppet and seat.
When the spool is selected 1. Foreign matter in load check valve Disassemble the check valve and clean.
from neutral to raise position, 2. Check valve poppet or seat damaged Replace the poppet or lap the poppet and
the load falls. seat part.
E-178 9813/0400-2 E-178

Fault Finding
Relief Valve
Relief Valve
Table 2.
Pressure does not rise at all 1. The main poppet, sleeve or pilot poppets 1 Check whether foreign matter is in
are sticking open or foreign matter is in the each poppet.
valve seat.
2 Check whether each part is sliding
smoothly.
3 Clean all the parts.
Relief pressure is unstable 1. The pilot poppet seat is damaged. Replace the damaged parts.
2. The piston is sticking to the main poppet. Remove the surface scratches. Clean all
the parts.
Relief pressure is out of control 1. Wear due to foreign matter. Replace the worn parts
2. Lock nut and adjuster are loose. Reset the pressure and tighten the lock nut
to the rated torque.
Oil leakage 1. Damaged seat or worn O-ring. Replace damaged or worn parts. Check
whether each part is sliding smoothly.
2. Parts are sticking due to foreign matter. Check for scratches, cuts or foreign matter.
Clean all the parts.
E-179 9813/0400-2 E-179

Fault Finding
Hydraulic System
Hydraulic System
Table 3.
The hydraulic system is not 1. Pump problem. Check the pressure or replace the pump.
working well or not at all 2.Foreign matter clogging inside the relief Disassemble the relief valve and clean.
valve.
3. Relief valve trouble. Check according to the maintenance
procedures.
4. Ram trouble. Repair or replace.
5. Load is too heavy. Check the circuit pressure.
6. Crack in the valve. Replace the valve assembly.
7. Spool does not stroke fully. Check the spool movement and operation
link.
8. Oil level too low. Replenish hydraulic oil.
9. Filters inside circuit are clogged. Clean filter or replace.
10. Hose runs are kinked. Check the hoses.
E-180 9813/0400-2 E-180

Fault Finding
Slew Motor
Slew Motor
Table 4.
Symptom Cause External Inspection Countermeasure Repair
Motor does Internal damage to the Measure the oil drain High possibility of K Table 5. ( T E-182).
not run motor. volume. damage to the sliding
surfaces if the supply
volume is approximately
equal to the drain volume.
Dismantle and inspect.
Internal damage to the Open the motor inlet and High possibility of internal Renew damaged parts or
motor. outlet ports and apply 20 damage to the motor if renew the motor
kgf/cm2 (284 lbf/in2) pilot the supply shaft does not assembly.
pressure to the brake rotate smoothly when this
release port. Try to rotate torque is applied.
the shaft with a torque of Dismantle and inspect.
approx. 39 Nm (29 lbf ft).
Relief valve in circuit not Measure pressure. Reset to the prescribed
set correctly. setting.
Excessive Wear or damage to the Measure the oil drain Leakage is too high if the K Table 5. ( T E-182).
slip motor sliding surfaces or volume. oil drain volume exceeds
to the high-pressure seal. 5 l/min (1.1 gal/min).
Dismantle and inspect.
Oil hot and excessive Measure the oil Reduce the oil K Table 5. ( T E-182).
parts or circuit. temperature. temperature.
Abnormal Seizure of motor sliding Check for any metallic If metallic matter is Repair or renew the
heating parts or circuit. matter deposited in motor discovered or the supply damaged parts. Renew
drain oil or drain filter. shaft does not rotate the motor assembly.
Apply a 30 kgf/cm2 (427 smoothly when torque is
lbf/in2) pilot pressure to applied, there is a high
the brake release port possibility of internal
and try to rotate the shaft damage to the motor.
with a torque of Dismantle and inspect.
approx.39 Nm (29 lbf ft).
Leakage Damage or wear to oil Renew the oil seals.
from oil seal lip.
seals Damage or wear of the Repair the problem or
shaft seal. renew the motor
assembly.
Abnormal pressure in the Check the pressure in the Set the pressure in the Renew the oil seal.
casing. casing and measure the casing below 3 kg/cm2. Repair or renew the
drain volume. (43 lbf/in2) Dismantle and damaged parts. Renew
inspect if drain volume is the motor assembly.
excessive.
E-181 9813/0400-2 E-181

Fault Finding
Slew Motor
Symptom Cause External Inspection Countermeasure Repair

Insufficient Wear or seizure of the Open motor inlet and High possibility of internal Inspect the parts and
torque motor sliding surfaces. outlet ports and apply 20 damage to the motor if bearing according to a-e
kgf/cm2 (284 lbf/in2) pilot the supply shaft does not and renew any defective
pressure to the brake rotate smoothly when this parts.K Table 5.
release port.Try to rotate torque is applied. ( T E-182)
the shaft with a torque of Dismantle and inspect.
approx. 39 Nm (29 lbf ft).
Relief valve in the circuit Measure relief pressure. Reset to the prescribed
is not set correctly. setting.
Internal damage to the Check if any metallic High possibility of internal Repair or renew
motor. matter is deposited in the damage to the motor if damaged parts. Renew
motor drain oil or drain metallic matter is the motor assembly.
filter. discovered. Dismantle
and inspect.
Abnormal Large amount of air Check the oil in the tank Thoroughly bleed the air.
noise mixed in the oil. and motor casing.
Loosening of bolts or Check if the piping Tighten to the specified
pipes connections, attachment torque.
mounting bolts, motor
attachment bolts or other
bolts are loose.
Oil leakage O-ring is damaged Renew O-rings.
from mating Seal face is damaged. Repair seal face or
surfaces renew.
Bolts are loose. Check the bolt tightness. Tighten the bolts to the
correct torque.
Table 5.
No. Part Inspected Repair
a Wear of the sliding surface of balance plate Repair or renew the part
b Damage to sliding surface of cam plate Repair the part or renew the motor.
c Damage to sliding surface of the piston assemblies Repair the part or renew the motor.
d External wear to the piston assemblies Repair the part or renew the motor.
e Wear to piston bores in cylinder assembly Renew the motor.
f Damage to Teflon ring 19 or Ò'-rings Renew the part.
E-182 9813/0400-2 E-182

Fault Finding
Hydraulic Pump
Hydraulic Pump
Often the regulator and attendant valves or pump are 2 Abnormal Vibration and Sound. Check to see if
combined which makes it very difficult to discover the there is any abnormal vibration or sound in the pump
reason for the trouble. Inspect the following categories main body. Check to see if it is like the regular
which will assist in discovering the abnormal point. frequency sound of the regulator's working or
attendant valve relief working. If it is an abnormal
1 Filter and Drain Oil Inspection. Inspect the filter vibration or sound, it is possible that there is damage
element. Check to see whether there is an or cavitation inside the pump.
abnormally large amount of foreign matter. There will
be a small amount of metallic powder due to wear of 3 Measure Pressure of Each Part. When it is a control
the shoe or cylinder, but if there is a large amount of problem, do not unnecessarily open ports for
metallic powder in the filter, it may be due to trouble inspection purposes, measure the pressure for each
with the shoe. Also check the drain oil in the pump section and find the abnormal item.
casing.
Table 6. Prime Mover Overload

Cause Treatment Note
Are the revolutions - pressure higher Set to pre-determined value.
than pre-determined values?
Is the regulator torque setting too high? Re-inspect regulator. Refer to regulator instructions.
Seizure or damage of pumps internal Replace damaged parts. Check the filter or drain oil for signs of
parts abnormal wear.
Wrong regulator hose connection. Correct hose lines.
Table 7. When pump flow is extremely low, delivery pressures does not increase
Regulator breakdown Repair the regulator Refer to regulator instructions
Seizure or damage of pump internal Replace damaged parts. Check filter, drain oil.
parts.
Pump breakdown. Replace damaged parts. Remove pump and inspect shaft
coupling.
Attendant valve breakdown. Inspect attendant valve.
Incorrect regulator hose connection. Correct hose lines.
Table 8. Abnormal Sound and Vibration

Cavitation. Prevent cavitation. Check to see if Boost pressure is low. Pump is broken.
hydraulic oil is white and cloudy. Air is sucked by suction pipe. Suction
resistance is high.
Damage of shoe caulking part. Replace piston, shoe, shoe plate.
Crack in cylinder. Replace cylinder
Bad installation of pump. Correct installation.
Relief valve bouncing. Repair relief valve. Refer to relief valve instructions.
E-183 9813/0400-2 E-183

Fault Finding
Hydraulic Rams
Hydraulic Rams
Hydraulic Ram Faults and Remedies ( T E-185). However, machine trouble is most often
caused, not by just one faulty part, but its relationship with
It is often not easy to find the part causing the fault. In the other parts. Not all of the possible causes and treatments
table possible problems are listed. K Table 9. ( T E-184). are listed in the tables therefore, it may be necessary for
Repair is difficult, refer to the estimated cause and the person responsible for repairs to make further
treatment listed in the table. The general phenomenon, investigations to find the cause of the trouble.
estimated causes and treatment are shown. K Table 10.
Table 9.
Item Symptoms
1 Oil leakage from piston rod sliding part
2 Oil leakage from cylinder head meeting part
3 Oil leakage from cylinder head meeting part
4 Faulty operation
E-184 9813/0400-2 E-184

Fault Finding
Hydraulic Rams
Table 10.
Item Symptoms Related Parts Trouble Treatment
On the sliding surface, there are 1 Use an oil stone and remove the scratch
scratches and rust that can be and make the sliding surface smooth.
felt by the fingernail. (Less than 1.5 S). If oil leakage continues
even though the rod surface is made
smooth, the scratch may cause damage
to the U-ring and other seals, so
disassemble and inspect.
Piston rod 2 If the scratches and rust cover such a
wide area that they cannot be repaired by
an oil stone, replace the piston rod and U-
ring, wiper ring and seals and the piston
rod bearing member.
The plating is peeling. Re-plate or replace the piston rod. Also inspect
the seal and piston rod bearing member and
replace if damaged.
Foreign matter is biting into the Remove foreign matter. If there is damage to
inner and outer surfaces of the packing, replace it.
packing.
There is a scratch on the inner Replace.
Piston rod and outer surface of the packing.
1 sliding part oil The lip and groove parts are Possibly due to burning caused by adiabatic
leakage locally carbonized (burned). compression from air remaining inside the
ram. After replacing the packing, first operating
the ram at low-pressure, low speed to
sufficiently bleed the air.
Packaging rubber elasticity is The packing life or hydraulic oil deterioration
gone and breaks into pieces. and high temperature are possible reasons.
Rod packing
(Buffer ring, U- 1 Renew hydraulic oil.
ring)
2 Check the hydraulic oil temperature
(Below 80 C is advisable).
3 Check if high temperature locally.
Lip is deficient all around. Replace.
It is possible that abnormal high pressure is
working on the packing.
1 Check the operation pressure, cushion

pressure.
2 Part which is attached to the buffer ring
may be abnormal. Inspect the buffer ring.
E-185 9813/0400-2 E-185

Fault Finding
Hydraulic Rams

Back up ring The protrusion of the heel of the As a rule, replace the rod packing at the same
packing is excessive. time. (It is desirable to replace parts which are
attached to the buffer ring at the same time). It
is possible that abnormal high pressure is the
cause. Check the same as above (heel of
packing protruding).
Foreign matter is biting into the Remove the foreign matter.
lip. The lip is damaged.
Wiper ring
Piston rod There are also other abnormal Replace.
1 sliding part oil damage.
leakage Wear is large and the clearance Replace.
with piston rod exceeds the
*maximum permissible value.
Bushing (*Refer to maintenance
standards for maximum
permissible value.)
Large scratch on the sliding part. Replace. Also inspect the piston rod.
Cylinder head Scratches, rust on the seal Remove scratch, rust with oil stone. If it cannot
attachment parts. be repaired, replace the cylinder head.
Foreign matter biting on inner Remove foreign matter
and outer diameter. Replace 'O'-ring if damaged.
O-ring damaged. Inspect inside tube: if any scratches or
rust, make surface smooth with oil stone
Inspect cylinder head 'O'-ring groove: if
O-ring any scratches or rust, make surface
smooth with oil stone.
Inspect back up ring: if any deformation or
protrusion, replace.
Confirm the above and replace 'O'-ring.

Oil leakage Back up ring Deformation, protrusion Replace with 'O'-ring.
2 from cylinder Looseness Disassemble cylinder head and inspect
head joint 'O'-ring and back up ring.
Check tube and cylinder head thread for
Cylinder head
damage. If any damage, replace.
After inspection, tighten to specified
torque.
Bolt Looseness, stretching, broken Replace all bolts and tighten to specified
torque.
Cylinder tube Abnormal bulge Replace with new parts. Oil leakage from
connecting parts may be caused by abnormal
pressure (including cushion pressure). Inspect
the tube for bulges, deformation and check the
circuit pressure.
E-186 9813/0400-2 E-186

Fault Finding
Hydraulic Rams

Oil leakage Crack in welding Replace with new parts.
from pipe and
cylinder tube Cracks will develop into fractures.
welded seam Cylinder tube Fractures are very dangerous, so if any
3 pipe (hollow cracks are found, stop work immediately
piston rod) and replace with new parts.
Welding on top of cracks will have no
effect.
Poor Piston rod Bending is more than the Replace with new part. The seal and sliding
operation cylinder tube specified limit. (Bending part material may be damaged too, so inspect.
distortion: Refer to maintenance If abnormal, replace.
standards)
Cylinder tube There is a recess Replace with new part. As above, inspect the
seal and sliding part material.
4
Abnormal wear, damage of Replace with new part
sliding parts. As above, inspect the seal and sliding
4-1 Piston rod part material.
Movement cylinder rod
not smooth sliding part Foreign matter intruding on Remove foreign material.
piston and cylinder head sliding As above, inspect the seal and sliding
area part material.
E-187 9813/0400-2 E-187

Fault Finding
Hydraulic Rams

4-2 Inner oil Piston seal Scratches, wear are present Replace with new part. Inspect the cylinder
leakage. tube inner surface.
Piston rod Cylinder tube Scratches, rust on the inside Remove the scratches/rust by honing or
extends with an oil stone and make the surfaces
when work smooth.
stops or
lowers If the scratch is deep and cannot be
abnormally repaired, replace the cylinder
during work. Replace piston seal.
Also, Piston Nut Loose nut Tighten to specified torque
specified
operating Valves Leak from valve Inspect the valve leakage amount and service.
speed is not
achieved.
Note: Note: Hydraulic oil expands and contracts due to changes in temperature and pressure. Accordingly, the ram
also expands and this can be mistaken for internal leakage. When inspecting for internal leakage, do so at set
conditions
4-3 Air Air remaining inside ram Bleed the air. For rams that do not have an
Operation is unsteady airbleeder, operate back and forth several
times at low pressure and low speed to bleed
4 the air. For rams with an air bleeder, remove
the load to reduce the pressure then loosen the
air bleeder and completely bleed the air.
Note: The ram may expand if it is stopped

suddenly. This is due to the compression of the
hydraulic oil. This occurs especially with long
stroke rams.
4-4 Heavy Pin bushing, Pin Gap between installation part Measure the pin and pin bushing and replace
shock and pin bushing is too large parts if measurements exceed the
loading when specifications.
changing
from
extension to
retraction
and back
4-5 Noisy Oil supply Insufficient oil Add oil.
operation Pin bushing, Pin Scuffing at connecting part Replace with new part and add oil.
Note: If left in the state where operation is poor, the ram will no longer move and other parts will be affected
adversely. Inspect early and carry out appropriate measures.
E-188 9813/0400-2 E-188

Fault Finding
Hydraulic Rams
E-189 9813/0400-2 E-189

Section E: Service Manual - JS200, JS140 & JS205

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Section E: Service Manual - JS200, JS140 & JS205

Uploaded by

Copyright:

Available Formats

Section E

E-0 9813/0400-2 E-0

Contents Page No.

Basic System Operation

Main Control Valve

Contents Page No.

Remote Control Valve (Hand Control)

Travel Pedal Valve

Contents Page No.

Contents Page No.

Slew Motor Main Control Valve

Table 3. JS140 A separate restriction valve in the system provides smooth

E-1 9813/0400-2 E-1

ECU4 allows the fool proofing of the hour meter recording,

E-2 9813/0400-2 E-2

Basic System Operation

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

E-3 9813/0400-2 E-3

Used to enclose several Throttling orifice - normally

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

3-position, 6-port spring

3-Position, 4-port spring

Non-return valve with back

Pilot operated non-return

One way restrictor

High pressure selector

E-4 9813/0400-2 E-4

Pressure sealed tank

Crossing lines Filter or strainer

Line plugged with take off line Cooler - indicating direction

Quick release couplings -

Reservoir - return line above

E-5 9813/0400-2 E-5

Rotating shaft - two directions Solenoid two windings

Detent Electric motor operated

Locking device Internal pressure pilot

Over centre device

Push button operated

Roller trip operated (one

E-6 9813/0400-2 E-6

K Fig 1. ( T E-7) shows a control valve represented by

K Fig 5. ( T E-7) - 'F' spools are often shown as four

K Fig 6. ( T E-7) - 'N' spools are sometimes used to

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

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

E-7 9813/0400-2 E-7

Example of Schematic Circuit

Fig 7. Simple Schematic Circuit

If the lever operated spool is moved away from neutral

E-8 9813/0400-2 E-8

JS200, JS205 Item Description

E-9 9813/0400-2 E-9

JS140 Item Description

Table 2. Component identification * Option

E-11 9813/0400-2 E-11

Fig 2. 229/02700 issue 4

7 Main Control Valve

E-13 9813/0400-2 E-13