Binder6 PDF
Binder6 PDF
Binder6 PDF
Hydraulics
Service Manual - Side Engine Loadalls
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering
Section K - Engine
Section M - Electronic Data Systems
Publication No.
9803/3760-07
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
Section E - Hydaulics
Notes:
E-i E-i
Section E - Hydraulics
E - ii E - ii
Section E - Hydraulics
E - iii E - iii
Section E - Hydraulics
Inloader Valve
Introduction .......................................................................................... E18 - 1
Related Topics ..................................................................................... E18 - 2
Operation Overview ............................................................................. E18 - 3
Hydraulic Operation and Schematics .................................................. E18 - 4
Electrical Operation and Schematics ................................................... E18 - 8
Removal and Replacement ................................................................. E18 - 9
E - iv E - iv
Section E - Hydraulics
Extension Ram
Introduction .......................................................................................... E29 - 1
Related Topics ..................................................................................... E29 - 2
Removal and Replacement - 2 Stage Boom ....................................... E29 - 3
Removal and Replacement - 3 Stage Boom ....................................... E29 - 5
Lift Rams
Introduction .......................................................................................... E30 - 1
Related Topics ..................................................................................... E30 - 2
Removal and Replacement ................................................................. E30 - 3
Tilt Ram
Introduction .......................................................................................... E31 - 1
Related Topics ..................................................................................... E31 - 2
Removal and Replacement - 2 Stage Boom (P1) ................................ E31 - 3
Removal and Replacement - 2 Stage Boom (P2) ................................ E31 - 5
Removal and Replacement - 3 Stage Boom ....................................... E31 - 7
Displacement Ram
Introduction .......................................................................................... E32 - 1
Related Topics ..................................................................................... E32 - 2
Removal and Replacement - Single Ram (P1) .................................... E32 - 3
Removal and Replacement - Single Ram (P2) .................................... E32 - 5
Removal and Replacement - Twin Rams, 2 Stage Boom .................... E32 - 7
Removal and Replacement - Twin Rams, 3 Stage Boom .................... E32 - 8
Sway Ram
Introduction .......................................................................................... E33 - 1
Related Topics ..................................................................................... E33 - 2
Removal and Replacement ................................................................. E33 - 3
Stabiliser Rams
Introduction .......................................................................................... E34 - 1
Related Topics ..................................................................................... E34 - 2
Removal and Replacement ................................................................. E34 - 3
E-v E-v
Section E - Hydraulics
E - vi E - vi
Applications
E0-1
Table
Important: The machine model names are NOT Table entries shaded grey indicate a topic not included
referred to in the topics. You must refer to the in this issue of the manual.
applications table for the applicable machine models.
Machine models
Topic Ref Title Variant 531-70, 535-95, 536-60, 541-70, 533-105 536-70, 526-56
531-T70 535-T95 536-T60 541-T70 536-T70
E1 Systems and Schematics z z z z z z z
E2 Parallel Hydraulic SYSTEM Non LLMC Machines, LLMC z z z z z z
Machines up to October
2010(1)
E3 LSP Gearpump Hydraulic SYSTEM Up to November 2009 z z z z z
E4 LSP Variflow Hydraulic SYSTEM Up to November 2009 z z z z z
E5 LSP Electro Servo SYSTEM (S1) Agri Xtra z z z
9803/3760-07 (AE-00-00)
E6 LSP Electro Servo SYSTEM (S2) Agri, Agri Plus, Agri Super z z z z z
November 2009 to October
2010(1)
E7 Servo Parallel Hydraulic SYSTEM SLC machines up to October z
2010(1)
E8 Smooth Ride SYSTEM (SRS) - Parallel z z z z z z
E9 Smooth Ride SYSTEM (SRS) LSP Up to November 2009 z z z z z
E10 Smooth Ride SYSTEM (SRS) Electro Servo (S1) Agri Xtra z z z z
E11 Smooth Ride SYSTEM (SRS) Electro Servo (S2) Agri, Agri Plus, Agri Super z z z z z
November 2009 to October
2010(1)
E12 Smooth Ride SYSTEM (SRS)Servo Parallel SLC z
Table
Section E0 - Hydraulics
Applications
E0-1
Machine models
E0-2
Topic Ref Title Variant 531-70, 535-95, 536-60, 541-70, 533-105 536-70, 526-56
531-T70 535-T95 536-T60 541-T70 536-T70
E13 Parallel Control Valve 4 Section Non LLMC Machines, LLMC z z z z z
machines up to October
2010(1)
E14 Parallel Control Valve 6 Section Non LLMC Machines, LLMC z
machines up to October
2010(1)
E15 Flowshare (LSP) Control Valve z z z z z
E16 LSP Electro Servo Control Valve (S1) Agri Xtra z z z z
LSP Electro Servo Control Valve (S2) Agri, Agri Plus, Agri Super z z z z z
November 2009 to October
2010(1)
E17 Servo Parallel Control Valve SLC Machines without z
LLMC, LLMC machines up to
October 2010(1)
E18 Inloader Valve Gearpump Systems z z z z z
E19 Servo Pilot Valve LSP Hydraulic Systems - Up z z z z z
to November 2009
E20 Servo Pilot Pressure Supply Valve (S1) Agri Xtra up to October z z z z
9803/3760-07 (AE-00-00)
2010(1)
E21 Servo Pilot Pressure Supply Valve (S2) Agri, Agri Plus, Agri Super z z z z z
November 2009 to October
2010(1)
E22 Pilot Manifold Block SLC machines up to October z
2010(1)
E23 Main Pump - Variflow z z z z z
E24 Main Pump - Gearpump 80 l/min Double Pump z z z z z z
80 l/min Triple Pump z z z z z
110 l/min z z z z
125 l/min z
E25 Cooling Fan Motor z z z z z z z
Table
Section E0 - Hydraulics
Applications
E0-2
Machine models
E0-3
Topic Ref Title Variant 531-70, 535-95, 536-60, 541-70, 533-105 536-70, 526-56
531-T70 535-T95 536-T60 541-T70 536-T70
E26 Control Lever - Electro Servo (S1) Agri Xtra z z z z
E27 Control Lever - Electro Servo (S2) Agri, Agri Plus, Agri Super z z z z z
November 2009 to October
2010(1)
E28 Control Lever - Servo Parallel SLC z
E29 Extension Ram z z z z z z z
E30 Lift Rams z z z z z z z
E31 Tilt Ram z z z z z z z
E32 Displacement Ram z z z z z z z
E33 Sway Ram z z z z
E34 Stabiliser Rams z
E35 Ram Maintenance z z z z z z z
E36 Sway/Fan Changeover Valve z z z z
(1) For details of LLMC machines from October 2010 refer to the service manual 9813/0900.
9803/3760-07 (AE-00-00)
Table
Section E0 - Hydraulics
Applications
E0-3
Section E0 - Hydraulics
Applications
Table
This topic contains hydraulic schematics for the complete system. Detailed schematics for individual systems are given
throughout the manual.
K Systems ( T E1-2)
K Applications ( T E1-6)
K Schematics - Parallel System with Dual Lever Controls ( T E1-8)
K Schematics - Parallel System with Single Lever Controls ( T E1-15)
K Schematics - LSP Gearpump System ( T E1-22)
K Schematics - LSP Variflow System ( T E1-28)
K Schematics - LSP Electro Servo System (S1) ( T E1-38)
K Schematics - LSP Electro Servo System (S2) ( T E1-41)
Systems
K Table 1. System Variants - Identification References K Table 2. System Variants - Identification References
- Hydraulics ( T E1-2) - LLMC ( T E1-5)
Parallel System K Parallel Fixed flow double or triple gear pump. Parallel control valve (black) with two
with Single Lever Hydraulic electro servo and two manual spools.
Controls SYSTEM ( T E2-1) Cab mounted control lever with push
button controls.
K Schematics -
Parallel System
with Single Lever
Controls ( T E1-15)
LSP Gearpump K LSP Gearpump Fixed flow triple gear pump. Flowshare control valve (blue) with two
System Hydraulic proportional electro servo and two
SYSTEM ( T E3-1) manual spools. Cab mounted control
lever with thumb wheel controls.
K Schematics -
LSP Gearpump
System ( T E1-22)
SYSTEM Type SYSTEM Topic Main Pump Type Control Lever Type
LSP Variflow K LSP Variflow Variable flow pump with one fixed flow Flowshare control valve (blue) with two
System Hydraulic gearpump for cooling fan, sway and electro servo and two manual spools.
SYSTEM ( T E4-1) servo oil supply. Cab mounted control lever with
thumbwheel controls.
K Schematics -
LSP Variflow
System ( T E1-28)
LSP Electro K LSP Electro Variable flow pump with one fixed flow Flowshare control valve (blue) with four
Servo System Servo Hydraulic gearpump for cooling fan, sway and integrated electro servo spools. Seat
SYSTEM servo oil supply. pod mounted control lever with
(S1) ( T E5-1) thumbwheel controls
K Schematics -
LSP Electro Servo
System
(S1) ( T E1-38)
LSP Electro K LSP Electro Variable flow pump with one fixed flow Flowshare control valve (blue) with four
Servo System Servo Hydraulic gearpump for cooling fan, sway and integrated electro servo spools. Valve
SYSTEM servo oil supply. block controlled by hydraulic control
(S1) ( T E5-1) ECU. Cab pod mounted control lever
with thumbwheel controls
K Schematics -
LSP Electro Servo
System
(S2) ( T E1-41)
SYSTEM Type SYSTEM Topic Main Pump Type Control Lever Type
Parallel System K Servo Parallel Fixed flow double gear pump. Parallel control valve (black) with two
with Servo Hydraulic integrated electro servo spools and two
Controls SYSTEM ( T E7-1) manual spools. Cab mounted control
lever with thumbwheel controls.
Hydraulic services are controlled by a
machine control ECU with electronic
flowshare feature.
K Schematics -
Parallel System
with Single Lever
Controls ( T E1-15)
C094300-C14
Fig 1.
LLMC
X
C094300-C13
Fig 2.
E1-6
K Systems ( T E1-2)
9803/3760-07 (E-00-01)
z
56) ( T E1-14)
K Parallel Single Lever control 160/02046-13 (536-70, All non LLMC machines z z
541-70) ( T E1-17) LLMC machines up to October
2010(2)
K Parallel Single Lever control 160/01792-14 (531- All non LLMC machines z
70) ( T E1-18) LLMC machines up to October
2010(2)
K Parallel Single Lever control 333/C1454-4 (535- Non LLMC machines from z
95) ( T E1-19) December 2010
K Parallel Single Lever Control 332/E9601-3 (526- All non LLMC machines z
56) ( T E1-20) LLMC machines up to October
2010(2)
K LSP Gearpump 160/15656-4 (531-70) ( T E1-24) Machines up to November 2009 z
Systems and Schematics
Section E1 - Hydraulics
Applications
E1-6
Machine models
(1)
E1-7
Schematic Applications 531-70, 535-95, 536-60, 541-70, 533-105 536-70, 526-56
531-T70 535-T95 536-T60 541-T70 536-T70
K LSP Gearpump 160/15658-4 (536-60) ( T E1-25) Machines up to November 2009 z
K LSP Gearpump 160/15659-4 (535-95) ( T E1-26) Machines up to November 2009 z
K LSP Gearpump 160/15657-4 (541-70) ( T E1-27) Machines up to November 2009 z
K LSP Variflow 160/16083-3 (531-70) ( T E1-30) Machines up to June 2009 z
K LSP Variflow 332/D7245-1 (531-70) ( T E1-31) Machines from June 2009 to z
November 2009
K LSP Variflow 332/C2606-1 (535-95) ( T E1-32) Machines up to June 2009 z
K LSP Variflow 332/F5370-1 (535-95) ( T E1-33) Machines from June 2009 to z
November 2009
K LSP Variflow 160/16347-1 (536-60) ( T E1-34) Machines up to June 2009 z
K LSP Variflow 332/F5377-1 (536-60) ( T E1-35) Machines from June 2009 to z
November 2009
K LSP Variflow 160/16082-3 (541-70) ( T E1-36) Machines up to June 2009 z
K LSP Variflow 332/F5356-1 (541-70) ( T E1-37) Machines from June 2009 to z
November 2009
K LSP Electro Servo (S1) (536-60, 531-70, 536-70, 541- Non LLMC Agri Xtra machines
9803/3760-07 (E-00-01)
z z z z
70) ( T E1-40) Agri Xtra LLMC machines up to
October 2010(2)
K LSP Electro Servo (S2) 332/F6315-9 (531-70) ( T E1-43) Agri Machines from November z
2009
K LSP Electro Servo (S2) 332/F6317-8 (535-95) ( T E1-44) Agri Machines from November z
2009
K LSP Electro Servo (S2) 332/F6313-8 (536-60) ( T E1-45) Agri Machines from November z
2009
K LSP Electro Servo (S2) 332/F6316-9 (536-70, 541- Agri Machines from November z z
70) ( T E1-46) 2009
(1) The table lists specification variants and the applicable machine models. Use the table to make sure you refer to the correct information.
(2) For details of LLMC machines from October 2010 refer to the service manual 9813/0900.
Systems and Schematics
Section E1 - Hydraulics
Applications
E1-7
Schematics - Parallel System with Dual Lever Controls
E1-8
The schematics show a number of options, check the 2D Lift spool 11B Regenerative valve - if fitted
machine to see which options apply.
2E Extension spool 12 Auxiliary 1 Boom Quick Release
For identification of the machine hydraulic and LLMC 2F Tilt spool Couplings
system refer to the tables. K Systems ( T E1-2) 2G Auxiliary spool (standard build)
2K Auxiliary relief valve (ARV) 13B Auxiliary 1 boom quick release couplings
Table 4. Component Key:
2L Auxiliary relief valve (ARV) 13C Auxiliary 2 boom quick release couplings
K Fig 3. Parallel Dual Lever Control 160/02300-7
(531-70) ( T E1-10) 2M Load hold check valves (LHCVs) 14 Hydraulic Pin Locking (option) - if fitted
K Fig 4. Parallel Dual Lever Control 160/12719-8 2P Unloader valve (stabiliser services) - if fitted 14A Diverter valve (boom)
(535-95) ( T E1-11) 14B Auxiliary 1 boom quick release couplings
2R Stabiliser RH - if fitted
K Fig 5. Parallel Dual Lever Control 160/13379-5 14C Auxiliary 2 boom quick release couplings
2S Stabiliser LH - if fitted
(533-105) ( T E1-12)
3 Steer Unit Assembly 14D Manual change-over valve
K Fig 6. Parallel Dual Lever Control 160/02301-8
3A Steer valve 14E Flow restrictor
(536-70, 541-70) ( T E1-13)
3B Shock valves (option) - if fitted 14F Hydraulic pin locking cylinder
K Fig 7. Parallel Dual Lever Control 332/C6641-3
(526-56) ( T E1-14) 3C Main relief valve 15 Sway Control Valve (option) - if fitted
B Pressure cap breather 15A One way restrictors
9803/3760-07 (E-00-01)
3D Non-return valve
F Return line filter 4 Cooling Fan Motor (non-reversible) 15B Pilot operated check-valve
F1 Filter by-pass 4A Relief valve 15C Sway hydraulic cylinder
S Pump suction strainer 5 Reversible Cooling Fan Motor (option) - if 16 Steer Mode Valve(1)(2)
T Tank fitted 16A Two Wheel steer solenoid
1 Pump Assembly 5A Relief valves 16B Four Wheel and crab steer solenoid
1A Main pump 5B Fan change-over solenoid 16C Four Wheel steer solenoid
1B Fan pump 8 Lift ram 16D Crab steer solenoid
1C Steer pump - if fitted 8A Counter-balance valve 17 Front Power Track-Rod
1D Priority valve 9 Displacement Ram(s) 17A Front steer rams - if fitted
1E Test point(s) 10 Tilt Ram 18 Rear power track-rod
2 Valve Block 10A Counter-balance valve 18A Rear steer rams - if fitted
2A Main relief valve (MRV) 11 Extension Ram(s) 19 Restricted non return valve
11A Counter-balance valve
Schematics - Parallel System with Dual Lever Controls
Systems and Schematics
Section E1 - Hydraulics
E1-8
20 Lift Circuit with optional Smooth Ride 30 Proportional valve(3)
System (SRS) - if fitted
E1-9
31 Variable orifice valve(3)
20A Solenoid valve
32 Compensator valve(3)
20B Solenoid valve
20C Accumulators (1) Electrically operated steer mode valve shown.
20D Pressure switch Manual version also available.
(2) Schematic shows latest type steer mode valve.
21 Trailer BrakeValve Assembly (option) - if For schematics of all steer mode valves refer to
fitted Section H - Steering.
21A Pilot valve (3) For machines with LLMC built from October 2010
21B Brake valve
21C Trailer brake coupling
21D Brake circuit connection
22 Auxiliary 1 with Trailer Hitch (option) - if
fitted
22A Solenoid diverter valve (chassis mounted)
22B Trailer hitch ram
22C Auxiliary 1 boom quick release couplings
22D Trailer/Auxiliary quick release coupling
22E Restrictor adaptor
9803/3760-07 (E-00-01)
23 Stabiliser Hydraulic Cylinder RH - if fitted
23A Lock-out valve - if fitted
23B Pressure switch (option) - if fitted
24 Stabiliser Hydraulic Cylinder LH - if fitted
24A Lock-out valve - if fitted
24B Pressure switch (option) - if fitted
25 Load Control Valve (option) - if fitted
26 Auxiliary 1 High Flow (option) boom quick
release couplings
27 Rear Auxiliary (option) - if fitted
27A Diverter valve
27B Rear Auxiliary quick release couplings
28 Pressure reducing valve(3)
29 Accumulator(3)
Schematics - Parallel System with Dual Lever Controls
Systems and Schematics
Section E1 - Hydraulics
E1-9
E1-10
3C 3D
9803/3760-07 (E-00-01)
160-02300-7-sheet1
Fig 3. Parallel Dual Lever Control 160/02300-7 (531-70)
E1-10
E1-11
9803/3760-07 (E-00-01)
20A
20
20D
20B
20C
160-12719-8-sheet1
Fig 4. Parallel Dual Lever Control 160/12719-8 (535-95)
E1-11
E1-12
9803/3760-07 (E-00-01)
160-13379-5-sheet1
Fig 5. Parallel Dual Lever Control 160/13379-5 (533-105)
E1-12
E1-13
9803/3760-07 (E-00-01)
160-02301-8-sheet1
Fig 6. Parallel Dual Lever Control 160/02301-8 (536-70, 541-70)
E1-13
Section E1 - Hydraulics
Systems and Schematics
Schematics - Parallel System with Dual Lever Controls
332-C6641-3
Fig 7. Parallel Dual Lever Control 332/C6641-3 (526-56)
K Applications ( T E1-6)
K Table 4. Component Key: ( T E1-8)
E1-15
The schematics show a number of options, check the 2A Main relief valve (MRV) 11B Auxiliary relief valve (ARV) - if fitted
machine to see which options apply.
2B Pressure reducing valve (20 bar) 11C Auxiliary relief valve (ARV) - if fitted
For identification of the machine hydraulic and LLMC 2C Pressure maintaining valve (10 bar) 12 Auxiliary 1 Boom Quick Release
system refer to the tables. K Systems ( T E1-2) 2D Lift spool Couplings
9803/3760-07 (E-00-01)
3C Main relief valve
B Pressure cap breather 15A Diverter valve
3D Non-return valve
F Filter 15B Auxiliary 1 boom quick release couplings
4 Cooling Fan Motor
F1 Filter by-pass 15C Auxiliary 2 boom quick release couplings
5 Reversible Cooling Fan Motor (option) - if
S Pump suction strainer fitted 15D Hydraulic pin lock ram
T Tank 5A Relief valves 15E Manual change over valve
1 Pump Assembly (1) 5B Fan change-over solenoid 16 Auxiliary 1 with Trailer Hitch (option) - if
fitted
1A Main pump 8 Lift Ram
16A Diverter valve (chassis mounted)
1B Fan pump 8A Lift ram check valve
16B Trailer hitch ram
1C Steer pump 9 Displacement Ram
16C Auxiliary 1 boom quick release couplings
1D Priority valve 10 Tilt Ram
16D Trailer/Auxiliary quick release coupling
1E Test points 10A Tilt ram check valve
16E Restrictor adaptor
1F Test point - if fitted 11 Extension Ram
17 Steer Mode Valve
2 Valve Block 11A Extension ram check valve
Systems and Schematics
Schematics - Parallel System with Single Lever Controls
Section E1 - Hydraulics
E1-15
17A 2 Wheel steer solenoid 33 Compensator valve(2)
17B 4 Wheel and crab steer solenoid 34 Bi-Directional check valve (if fitted)
E1-16
17C 4 Wheel steer solenoid
17D Crab steer solenoid (1) From machine SN 771430 the positions of fan
pump 1B and steer pump 1C of pump assembly
17E 2WS/AWS solenoid valve 1 are reversed.
18 Front Power Track Rod (2) For machines with LLMC built from October 2010
19 Trailer Brake Valve Assembly (option) - if
fitted
19A Pilot valve
19B Brake valve
19C Trailer brake coupling
19D Brake circuit connection
20 Restricted Non Return Valve
21 Rear Power Track Rod
22 Lift Circuit with optional Smooth Ride
System (SRS) - if fitted
22A Solenoid valve
22B Solenoid valve
22C Accumulators
9803/3760-07 (E-00-01)
22D Pressure switch
23 Rear Auxiliary (option) - if fitted
23A Diverter valve
23B Rear Auxiliary quick release couplings
27 Pilot Manifold
27A Accumulator
27B Full lock solenoid
27C Tilt lock solenoid (if fitted)
28 Two axis servo control lever
29 Pressure reducing valve(2)
30 Accumulator(2)
31 Proportional valve(2)
32 Variable orifice valve(2)
Systems and Schematics
Schematics - Parallel System with Single Lever Controls
Section E1 - Hydraulics
E1-16
E1-17
34
9803/3760-07 (E-00-01)
160-02046-13-sheet1
Fig 8. Parallel Single Lever control 160/02046-13 (536-70, 541-70)
E1-17
E1-18
34
9803/3760-07 (E-00-01)
2N
160-01792-14-sheet1
Fig 9. Parallel Single Lever control 160/01792-14 (531-70)
E1-18
E1-19
34
9803/3760-07 (E-00-01)
2N
333-c1454-4-sheet1
Fig 10. Parallel Single Lever control 333/C1454-4 (535-95)
E1-19
E1-20
9803/3760-07 (E-00-01)
332-e9601-3-sheet1
Fig 11. Parallel Single Lever Control 332/E9601-3 (526-56)
E1-20
E1-21
34
9803/3760-07 (E-00-01)
2N
333-c9759-1-sheet1
Fig 12. Parallel Single Lever Control 333/C9759-1 (531-70 Russia Build Specification)
E1-21
Schematics - LSP Gearpump System
E1-22
The schematics show a number of options, check the 7C Load sense relief valve 13 Lift Cylinder
machine to see which options apply.
7D Raise/lower spool 13A Counterbalance valve
For identification of the machine hydraulic and LLMC 7E Extend/retract spool 13B Counterbalance valve
system refer to the tables. K Systems ( T E1-2) 7F Tilt spool 13C Displacement lift valve
For machine applications refer to the applications 7G Auxiliary spool 14 Displacement Cylinder(s)
table. K Applications ( T E1-6) 7H Auxiliary relief valve (ARV) 15 Tilt Cylinder
7J Auxiliary relief valve (ARV) 15A Counterbalance valve
Table 6. Component Key:
K Fig 13. LSP Gearpump 160/15656-4 (531-70) 7M Auxiliary relief valve (ARV) 16 Extension Cylinder(s)
( T E1-24) 7N Auxiliary relief valve (ARV) 16A Counterbalance valve(s)
K Fig 14. LSP Gearpump 160/15658-4 (536-60) 7P Pressure compensator valve 17 Auxiliary 1 Circuit
( T E1-25)
7Q Load hold check valve 17A High flow auxiliary (option) - if fitted
K Fig 15. LSP Gearpump 160/15659-4 (535-95)
8 Steer Unit Assembly 18 Twin Auxiliary (option) - if fitted
( T E1-26)
8A Steer valve 18A Solenoid diverter valve (boom mounted)
K Fig 16. LSP Gearpump 160/15657-4 (541-70)
( T E1-27) 8B Main relief valve 19 Twin Auxiliary (option) with Hydraulic Pin
8C Shock valves - if fitted Locking (option) - if fitted
1 Pressure cap breather
9 Cooling Fan Motor (non-reversible) 19A Solenoid diverter valve (boom mounted)
2 Return line filter
19B Quick-fit carriage manual isolation valve
9803/3760-07 (E-00-01)
2A Filter by-pass 9A Relief valve
10 Reversible cooling fan motor (option) - if fitted 19C Restrictor
3 Suction strainer
10A Relief valves 19D Locking pin ram
4 Hydraulic tank
10B Fan direction changeover valve 20 Hydraulic Pick-up Hitch (option) - if fitted
5A Pressure test point (Main system pressure)
11 Inloader Valve 20A Solenoid diverter valve (chassis mounted)
5B Pressure test point (Servo pilot pressure)
11A Inloader override solenoid valve 20B Restrictor
6 Pump Assembly
12 Servo Pilot Pressure Supply Valve 20C Quick release coupling
6A Main pump
12A Boom `extend' valve 20D Pick-up hitch cylinder
6B Fan pump
12B Auxiliary service valve 21 Steer Mode Valve
6C Steering pump
12C Auxiliary service valve 21A 4WS/Crab solenoid valve
6D Steer priority valve
12D Boom `retract' valve 21B 2WS/AWS solenoid valve
7 Control valve block
12E Accumulator 21C Front power track rod
7A Flushing valve
12F Relief valve 21D Rear power track rod
7B Flow regulator valve
22 Sway Mode Valve (option) - if fitted
Systems and Schematics
Schematics - LSP Gearpump System
Section E1 - Hydraulics
E1-22
22A Sway control solenoid valve
22B Sway mode/cooling fan changeover valve
E1-23
22C Relief valve
22D Pilot operated check valves
22E Sway cylinder
23 Trailer Brake Valve (option) - if fitted
23A Trailer brake coupling
23B Brake valve
23C Pilot valve
23D Brake circuit connection
24 Lift Circuit with optional Smooth Ride
System (SRS) - if fitted
24A Solenoid valve
24B Solenoid valve
24C Accumulators
24D Pressure switch
25 Servo Pilot Filter
26 Oil Cooler
9803/3760-07 (E-00-01)
Systems and Schematics
Schematics - LSP Gearpump System
Section E1 - Hydraulics
E1-23
E1-24
9803/3760-07 (E-00-01)
160/15656-4
Fig 13. LSP Gearpump 160/15656-4 (531-70)
E1-24
E1-25
9803/3760-07 (E-00-01)
160/15658-4
Fig 14. LSP Gearpump 160/15658-4 (536-60)
E1-25
E1-26
9803/3760-07 (E-00-01)
160/15659-4
Fig 15. LSP Gearpump 160/15659-4 (535-95)
E1-26
E1-27
9803/3760-07 (E-00-01)
160/15657-4
Fig 16. LSP Gearpump 160/15657-4 (541-70)
E1-27
Schematics - LSP Variflow System
E1-28
The schematics show a number of options, check the 7 Pump Assembly(1) 11A Relief valves
machine to see which options apply.
7A Main Variflow pump 11B Fan direction changeover valve
For identification of the machine hydraulic and LLMC 7B Fan pump 13 Servo Pilot Pressure Supply Valve(1)
system refer to the tables. K Systems ( T E1-2) 7C Pump Control Solenoid 13A Boom `extend' valve
For machine applications refer to the applications 7D Pressure regulator spool 13B Auxiliary service valve
table. K Applications ( T E1-6) 7E Flow regulator spool 13C Auxiliary service valve
7F Steer Priority Valve (up to June 2009) 13D Boom `retract' valve
Table 7. Component Key:
8 (1) 13E Accumulator
K Fig 17. LSP Variflow 160/16083-3 (531-70) Control Valve Block
( T E1-30) 8A Flushing valve 13F Relief valve
K Fig 18. LSP Variflow 332/D7245-1 (531-70) 8B Flow regulator valve 14 Lift Cylinder
( T E1-31)
8C Load sense relief valve 14A Counterbalance valve
K Fig 19. LSP Variflow 332/C2606-1 (535-95)
8D Raise/lower spool 14B Counterbalance valve
( T E1-32)
8E Extend/retract spool 14C Displacement lift valve
K Fig 20. LSP Variflow 332/F5370-1 (535-95)
( T E1-33) 8F Tilt spool 15 Displacement cylinder(s)
K Fig 21. LSP Variflow 160/16347-1 (536-60) 8G Auxiliary spool 16 Tilt Cylinder
( T E1-34) 8H Auxiliary relief valve (ARV) 16A Counterbalance valve
K Fig 22. LSP Variflow 332/F5377-1 (536-60)
9803/3760-07 (E-00-01)
8J Auxiliary relief valve (ARV) 17A Extend Circuit (2 stage boom)
( T E1-35)
8M Auxiliary relief valve (ARV) 17B Extend Circuit (3 stage boom)
K Fig 23. LSP Variflow 160/16082-3 (541-70)
8N Auxiliary relief valve (ARV) 17C Extension Cylinder
( T E1-36)
8P Pressure compensator valve 17D Counterbalance valve(s)
K Fig 24. LSP Variflow 332/F5356-1 (541-70)
( T E1-37) 8Q Load hold check valve 18 Auxiliary 1 Circuit
1 Pressure cap breather 8X Steer Priority Valve (from June 2009) 18A Hi Flow Auxiliary (option) - If fitted
9 (1) 19 Twin Auxiliary (option) - if fitted
2 Return line filter Steer Unit Assembly
2A Filter by-pass 9A Steer valve 19A Solenoid diverter valve (boom mounted)
3 Suction strainer 9B Main relief valve 20 Twin Auxiliary (option) with Hydraulic Pin
Locking (option) - if fitted
4 Hydraulic tank 9C Shock valves - if fitted
20A Solenoid diverter valve (boom mounted)
5 Diffuser - if fitted 10 Cooling Fan Motor (non-reversible)(1)
20B Quick-fit carriage manual isolation valve
6A Pressure test point (Main system pressure) 10A Relief valve
20C Restrictor
6B Pressure test point (Servo pilot pressure) 11 Reversible Cooling Fan Motor (option) - if
fitted(1) 20D Locking pin ram
Systems and Schematics
Section E1 - Hydraulics
E1-28
Schematics - LSP Variflow System
21 Hydraulic Pick-up Hitch (option) - if fitted 30 Pilot Pressure Regulator Valve
21A Solenoid diverter valve (chassis mounted) 31 Filters
E1-29
21B Restrictor 32 Bi-Directional Check Valve
21C Quick release coupling
21D Pick-up hitch cylinder (1) For information about this device refer to Related
Topics.
22 Steer Mode Valve(1)
22A 4WS/Crab solenoid valve
22B 2WS/AWS solenoid valve
22C Front power track rod
22D Rear power track rod
23 Sway Mode Valve (option) - if fitted(1)
23A Sway control solenoid valve
23B Sway mode/cooling fan changeover valve
23C Relief valve
23D Pilot operated check valves
23E Sway cylinder
24 Trailer Brake Valve (option) - if fitted
24A Trailer brake coupling
24B Brake valve
9803/3760-07 (E-00-01)
24C Pilot valve
24D Brake circuit connection
25 Lift Circuit with optional Smooth Ride
System (SRS) - if fitted(1)
25A Solenoid valve
25B Solenoid valve
25C Accumulators
25D Pressure switch
26 Servo Pilot Filter
27 Oil Cooler
28 Load Pressure Sense Valve (up to June
2009)
29 Pump Shut-Off Valve
Systems and Schematics
Section E1 - Hydraulics
E1-29
Schematics - LSP Variflow System
E1-30
9803/3760-07 (E-00-01)
160/16083-3
Fig 17. LSP Variflow 160/16083-3 (531-70)
E1-30
Schematics - LSP Variflow System
1.2
1.6
A B
E1-31
c d
P T SA SB
F1
A B
R1 A
a b
P T 48
310 BAR
BAR B
C
F2 R2
23C T P DLS
150 BAR
A M 310 BAR
B T F P 240
BAR P
T P
8X 8 BAR
B A LS
0.8
V2 C2
T P D
X 0.8
L R
LIFT
24
340 BAR
A B
B1 120 L/MIN
R
A1 120 L/MIN
B
LS
N P
P T TILT
275
BAR T
A B
B B2 120 L/MIN
A A2 120 L/MIN
310 BAR
140 T
BAR
EXTEND
a
b B B M
A B A A F
B3 80 L/MIN
A3 120 L/MIN
9803/3760-07 (E-00-01)
AUXILIARY B P2 D
B M
a A P1
F M
X T A F
b
A B
220 B B4 100 L/MIN
BAR
A A4 100 L/MIN
220 T
B1 BAR
B2
AUXILIARY 1
C
P2 D M
B M
25 BAR B
P1 F
F
A A
AUXILIARY 2
7A 63CC 16CC
S1 L2 L1 L S2
A B C D
AUXILIARY 1
C
B P2 D M
30 BAR M
ACC B AUXILIARY 2
P 0-25 BAR 0-25 BAR 0-25 BAR 0-25 BAR
P1 F
F
A A
T
0.5 BAR
TP
332/D7245-1
Fig 18. LSP Variflow 332/D7245-1 (531-70)
E1-31
Schematics - LSP Variflow System
E1-32
9803/3760-07 (E-00-01)
332/C2606-1
Fig 19. LSP Variflow 332/C2606-1 (535-95)
E1-32
Schematics - LSP Variflow System
1.2
1.6
A B
E1-33
c d
P T SA SB
F1
A B
R1 A
a b
P T 48
310 BAR
BAR B
C
F2 R2
23C T P DLS
150 BAR
T P
8X 8 BAR
B A LS
0.8
V2 C2
T P D
X 0.8
L R
LIFT
24
340 BAR
A B
B1 120 L/MIN
R
A1 120 L/MIN
B
LS
N P
P T TILT
240
BAR T
A B
B B2 120 L/MIN
285
A A2 120 L/MIN BAR
250 T 310
BAR BAR
EXTEND
a
b
276
A B BAR
B3 115 L/MIN
A3 115 L/MIN
B B M
AUXILIARY
A A F
a
X
9803/3760-07 (E-00-01)
T b
A B
220
M
B B4 100 L/MIN
BAR
A A4 100 L/MIN F
220 T
B1 BAR
B2
C
B P2 D
B M
25 BAR A P1
F M
A F
7A 63CC 16CC
S1 L2 L1 L S2
AUXILIARY 1
A B C D C
P2 D M
B M
B
30 BAR P1 F
F
ACC A A
AUXILIARY 2
P 0-25 BAR 0-25 BAR 0-25 BAR 0-25 BAR
T
0.5 BAR
TP
AUXILIARY 1
C
B P2 D M
M
B AUXILIARY 2
P1 F
F
A A
332/F5370-1
Fig 20. LSP Variflow 332/F5370-1 (535-95)
E1-33
Schematics - LSP Variflow System
E1-34
9803/3760-07 (E-00-01)
160/16347-1
Fig 21. LSP Variflow 160/16347-1 (536-60)
E1-34
Schematics - LSP Variflow System
A B
E1-35
c d
P T
F1
A B
R1 A
a b
P T 48
310 BAR
BAR B
C
F2 R2
T P DLS
T P
8X 8 BAR
B A LS
0.8
V2 C2
T P D
X 0.8
L R
LIFT
24
340 BAR
A B
B1 120 L/MIN
R
A1 120 L/MIN
B
LS
N P
P T TILT
275
BAR T
A B
B B2 120 L/MIN
A A2 120 L/MIN
140 T 310
BAR BAR
EXTEND
a
b
A B
B3 80 L/MIN
A3 120 L/MIN
B B M
AUXILIARY
9803/3760-07 (E-00-01)
A A F
a
X T b
A B
220 B B4 100 L/MIN
BAR
A A4 100 L/MIN
220 T
B1 BAR
C
B P2 D
B M
B2 A P1
F M
A F
25 BAR
7A 63CC 16CC
AUXILIARY 1
C
P2 D M
B M
S1 L2 L1 L S2 B
P1 F
A B C D F
A A
AUXILIARY 2
30 BAR
ACC
P 0-25 BAR 0-25 BAR 0-25 BAR 0-25 BAR
T
AUXILIARY 1
0.5 BAR
C
TP B P2 D M
M
B AUXILIARY 2
P1 F
F
A A
332/F5377-1
Fig 22. LSP Variflow 332/F5377-1 (536-60)
E1-35
Schematics - LSP Variflow System
E1-36
9803/3760-07 (E-00-01)
160/16082-3
Fig 23. LSP Variflow 160/16082-3 (541-70)
E1-36
Schematics - LSP Variflow System
1.2
1.6
A B
E1-37
c d
P T SA SB
F1
A B
R1 A
a b
P T 48
310 BAR
BAR B
C
F2 R2
T P DLS
23C
150 BAR
T P
8X 8 BAR
B A LS
0.8
V2 C2
T P D
X 0.8
L R
LIFT
24
340 BAR
A B
B1 120 L/MIN
R
A1 120 L/MIN
B
LS
N P
P T TILT
275
BAR T
A B
B B2 120 L/MIN
A A2 120 L/MIN
310 BAR
140 T
BAR
EXTEND
a
b B B M
A B A A F
B3 80 L/MIN
A3 120 L/MIN
9803/3760-07 (E-00-01)
AUXILIARY B P2 D
B M
a A P1
F M
X T A F
b
A B
220 B B4 100 L/MIN
BAR
A A4 100 L/MIN
220 T
B1 BAR
B2
AUXILIARY 1
C
P2 D M
B M
25 BAR B
P1 F
F
A A
AUXILIARY 2
63CC 16CC
7A
S1 L2 L1 L S2
A B C D
AUXILIARY 1
C
B P2 D M
30 BAR M
ACC B AUXILIARY 2
P 0-25 BAR 0-25 BAR 0-25 BAR 0-25 BAR
P1 F
F
A A
T
0.5 BAR
TP
332/F5356-1
Fig 24. LSP Variflow 332/F5356-1 (541-70)
E1-37
Schematics - LSP Variflow System
Schematics - LSP Electro Servo System (S1)
E1-38
The schematics show a number of options, check the 8E Extend/retract spool 17A Counterbalance valve(s)
machine to see which options apply.
8F Tilt spool 18 Auxiliary 1 Circuit
For identification of the machine hydraulic and LLMC 8G Auxiliary spool 18A Single auxiliary with hydraulic pin locking
system refer to the tables. K Systems ( T E1-2) 8H Auxiliary relief valve (ARV) (option) - if fitted
8N Auxiliary relief valve (ARV) 20 Twin Auxiliary (option) with Hydraulic pin
Table 8. Component Key: Locking (option) - if fitted
K Fig 25. LSP Electro Servo (S1) (536-60, 531-70, 8P Pressure compensator valve
20A Solenoid diverter valve (boom mounted)
536-70, 541-70) ( T E1-40) 8Q Load hold check valve
20B Quick-fit carriage manual isolation valve
1 Pressure cap breather 9 Steer Unit Assembly(1)
20C Shut Off Valve
2 Return line filter 9A Steer valve
20D Locking pin ram
2A Filter by-pass 9B Main relief valve
21 Hydraulic Pick-up Hitch (option) - if fitted
3 Suction strainer 9C Shock valves - if fitted
21A Solenoid diverter valve (chassis mounted)
4 Hydraulic tank 10 Cooling Fan Motor (non-reversible)(1)
21B Restrictor
5 Diffuser 10A Relief valve
21C Quick release coupling
6A Pressure test point (Pump pressure) 11 Reversible cooling fan motor (option) - if fitted
21D Pick-up hitch cylinder
9803/3760-07 (E-00-01)
6B Pressure test point (Servo pilot pressure) 11A Relief valves
22 Steer Mode Valve(1)
7 Pump Assembly(1) 11B Fan direction changeover valve
22A 4WS/Crab solenoid valve
7A Main Variflow pump 13 Servo Pilot Pressure Supply Valve(1)
22B 2WS/AWS solenoid valve
7B Fan pump 13A Accumulator
22C Front power track rod
7C Pump Control Solenoid 13B Relief valve
22D Rear power track rod
7D Pressure regulator spool 14 Lift Cylinder
23 Sway Mode Valve (option) - if fitted(1)
7E Flow regulator spool 14A Counterbalance valve
23A Sway control solenoid valve
7F Steer Priority Valve 14B Counterbalance valve
23B Sway mode/cooling fan changeover valve
8 Control Valve Block(1) 14C Lift Assist Valve
23C Relief valve
8A Flushing valve 15 Displacement Cylinder(s)
23D Pilot operated check valves
8B Flow regulator valve 16 Tilt Cylinder
23E Sway cylinder
8C Load sense relief valve 16A Counterbalance valve
24 Trailer Brake Valve (option) - if fitted
8D Raise/lower spool 17 Extension Cylinder(s)
24A Trailer brake coupling
Schematics - LSP Electro Servo System (S1)
Systems and Schematics
Section E1 - Hydraulics
E1-38
24B Brake valve
24C Pilot valve
E1-39
24D Brake circuit connection
25 Lift Circuit with optional Smooth Ride
System (SRS) - if fitted(1)
25A Solenoid valve
25B Solenoid valve
25C Accumulators
25D Pressure switch
26 Servo Pilot Filter
27 Oil Cooler
28 Bi-Directional Check Valve - if fitted
9803/3760-07 (E-00-01)
Schematics - LSP Electro Servo System (S1)
Systems and Schematics
Section E1 - Hydraulics
E1-39
E1-40
9803/3760-07 (E-00-01)
C052830
Fig 25. LSP Electro Servo (S1) (536-60, 531-70, 536-70, 541-70)
K Applications ( T E1-6)
Schematics - LSP Electro Servo System (S1)
Systems and Schematics
Section E1 - Hydraulics
E1-40
Schematics - LSP Electro Servo System (S2)
E1-41
The schematics show a number of options, check the 8 Control Valve Block 13E Accumulator
machine to see which options apply.
8A Flushing valve 13F Relief valve
For identification of the machine hydraulic and LLMC 8B Flow regulator valve 14 Lift Cylinder
system refer to the tables. K Systems ( T E1-2) 8C Load sense relief valve 14A Counterbalance valve
For machine applications refer to the applications 8D Raise/lower spool 14B Counterbalance valve
table. K Applications ( T E1-6) 8E Extend/retract spool 14C Displacement lift valve
8F Tilt spool 15 Displacement cylinder(s)
Table 9. Component Key:
K Fig 26. LSP Electro Servo (S2) 332/F6315-9 8G Auxiliary spool 16 Tilt Cylinder
(531-70) ( T E1-43) 8H Auxiliary relief valve (ARV) 16A Counterbalance valve
K Fig 27. LSP Electro Servo (S2) 332/F6317-8 8J Auxiliary relief valve (ARV) 17A Extend Circuit (2 stage boom)
(535-95) ( T E1-44)
8M Auxiliary relief valve (ARV) 17B Extend Circuit (3 stage boom)
K Fig 28. LSP Electro Servo (S2) 332/F6313-8
8N Auxiliary relief valve (ARV) 17C Extension Cylinder
(536-60) ( T E1-45)
8P Pressure compensator valve 17D Counterbalance valve(s)
K Fig 29. LSP Electro Servo (S2) 332/F6316-9
(536-70, 541-70) ( T E1-46) 8Q Load hold check valve 18 Auxiliary 1 Circuit
1 Pressure cap breather 8X Steer Priority Valve (from June 2009) 18A Hi Flow Auxiliary (option) - If fitted
2 Return line filter 9 Steer Unit Assembly 19 Twin Auxiliary (option) - if fitted
9803/3760-07 (E-00-01)
2A Filter by-pass 9A Steer valve 19A Solenoid diverter valve (boom mounted)
3 Suction strainer 9B Main relief valve 20 Twin Auxiliary (option) with Hydraulic Pin
9C Shock valves - if fitted Locking (option) - if fitted
4 Hydraulic tank
10 Cooling Fan Motor (non-reversible) 20A Solenoid diverter valve (boom mounted)
5 Diffuser - if fitted
10A Relief valve 20B Quick-fit carriage manual isolation valve
6A Pressure test point (Main system pressure)
11 Reversible Cooling Fan Motor (option) - if 20C Restrictor
6B Pressure test point (Servo pilot pressure)
fitted 20D Locking pin ram
7 Pump Assembly
11A Relief valves 21 Hydraulic Pick-up Hitch (option) - if fitted
7A Main Variflow pump
11B Fan direction changeover valve 21A Solenoid diverter valve (chassis mounted)
7B Fan pump
13 Servo Pilot Pressure Supply Valve 21B Restrictor
7C Pump Control Solenoid
13A Boom `extend' valve 21C Quick release coupling
7D Pressure regulator spool
13B Auxiliary service valve 21D Pick-up hitch cylinder
7E Flow regulator spool
13C Auxiliary service valve 22 Steer Mode Valve
7F Steer Priority Valve (up to June 2009)
13D Boom `retract' valve 22A 4WS/Crab solenoid valve
Schematics - LSP Electro Servo System (S2)
Systems and Schematics
Section E1 - Hydraulics
E1-41
22B 2WS/AWS solenoid valve
22C Front power track rod
E1-42
22D Rear power track rod
23 Sway Mode Valve (option) - if fitted
23A Sway control solenoid valve
23B Sway mode/cooling fan changeover valve
23C Relief valve
23D Pilot operated check valves
23E Sway cylinder
24 Trailer Brake Valve (option) - if fitted
24A Trailer brake coupling
24B Brake valve
24C Pilot valve
24D Brake circuit connection
25 Lift Circuit with optional Smooth Ride
System (SRS) - if fitted
25A Solenoid valve
25B Solenoid valve
25C Accumulators
9803/3760-07 (E-00-01)
25D Pressure switch
26 Servo Pilot Filter
27 Oil Cooler
28 Load Pressure Sense Valve (up to June
2009)
29 Pump Shut-Off Valve
30 Pilot Pressure Regulator Valve
31 Filters
32 Bi-Directional Check Valve
33 Make up Valve (if fitted)
Schematics - LSP Electro Servo System (S2)
Systems and Schematics
Section E1 - Hydraulics
E1-42
23D
22A
E1-43
22C 22D 23E
25C
23 23A
25B
22B 25D 14
25
22
23B
11
25A 14A 14
23C 8
6A
11A 11B 8X 14B
24D
8C 14C
24 16A
9 9A
24A 24B 8Q
10
8D
24C 15 16
8P
9B 10A
8H 8Q 17A
8F
32
8P
8J 17D 17C
8Q 18
27
8E
2 8P 21A
2A 21 21B
8M 8Q 21D
21C
9803/3760-07 (E-00-01)
7E 8G
7D 8P 19A
8N
7 19
7C 8A
7B
20A
7A
1 20
31 30 20D
20B 20C
2A 2 3
4
29
332-f6315-9-sheet1
Fig 26. LSP Electro Servo (S2) 332/F6315-9 (531-70)
E1-43
23D
E1-44
22A
22C 22D
23E
25C
23 23A
25B 25D
22B 14
23B 25
22
25A
11
23C 8 14A 14
6A
11A 8X
24D
11B
8C
14B 14C
9 9A 16A
24 8D
10 24A 24B 8Q
16
24C
8P
15
9B 10A
8F
8H 8Q
32 17D
8P 17C
8J
8E 17C
8Q
27 A
17A 17D
17D
2
A
2A 8P 18
8G
8M 8Q
9803/3760-07 (E-00-01)
18A
7E
7D 8P 21A
8N
7
21 21B
7C 8A A
7B 21D
21C
7A
1 19 19A
33
31
30 20A
3
2A 2
20
4
29 20D
20B 20C
332-f6317-8-sheet1
Fig 27. LSP Electro Servo (S2) 332/F6317-8 (535-95)
E1-44
22
E1-45
22C 22D
25C
22A
25B
14
22B
25 25D
25A
11
14A 14
8
6A
8X
11A
11B 24D
8C
14B 14C
8D 16A
9 9A 24
24A 24B 8Q
10 15
24C
16
8P
15
9B 10A
8F
8Q
8H
32
8P
8J 17D 17C
8E 18
8Q
27
17A
2 21A
8P
2A 21 21B
8G
8M 8Q 21D
9803/3760-07 (E-00-01)
21C
7E
7D 8P
8N
7 19A
19
7C 8A
7B
7A
1 20A
20
31
20D
20B 20C
30
2A 2 3
29
4
332-f6313-8-sheet1
Fig 28. LSP Electro Servo (S2) 332/F6313-8 (536-60)
E1-45
22
E1-46
22C 23D
22D 23E
22A 25C
23
25B 25D
22B 23A 14
23B 25
25A
11
23C 14A 14
8
6A
8X
11A
24D
11B
8C
14B 14C
9A 8D 16A
24A 24 8Q
9 24B
10
24C 15 16
8P
9B 10A
8F
8H 8Q
17A
32
8J 8P
17D 17C
8E 18
8Q
27
2 21A
8P
2A 21 21B
8G
8M 8Q 21D
9803/3760-07 (E-00-01)
21C
7E
8P
7D
8N 19A
7 19
8A
7C
7B
7A 20A
1
20
31 30 20D
20C
20B
2A 2 3
29
4
332-f6316-9-sheet1
Fig 29. LSP Electro Servo (S2) 332/F6316-9 (536-70, 541-70)
E1-46
Section E2 - Hydraulics
This topic contains information about a machine SYSTEM. The system has some devices that connect either
mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications
table. K Related Topics ( T E2-3).
Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer
to the relevant topics. K Related Topics ( T E2-3)
This topic is intended to help you understand what the system does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
(1) Specification variant. Make sure you refer to the correct specification.
(1) The table lists procedure and specification variants and the applicable machine models. Use the table to make sure
you refer to the correct information.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
(1) Tool available from JCB Service, refer to Section 1 - Service Tools
Specifications
4 Spool Valve Block (S1) topic for the applicable machine models. K Table 1.
Specification Variants ( T E2-2)
IMPORTANT: These specifications are only applicable to
some machine models. Refer to the table at the front of this
(1) Machines with pick-up hitch. Since this ARV also controls the pressure to the boom auxiliary service, ensure that this
pressure will not cause damage to attachments used with the machine.
(2) Russia build specification machines
(3) If fitted.
Pilot Pressure Range: (machines with single lever controls) bar kgf/cm2 lbf/in2
All Machines 10 - 30 10.2 - 30.6 145 - 435
764190-2
Fig 1. Loading Control Pattern
764190-1
Fig 2. Placing Control Pattern
4 Spool Valve Block (S2) topic for the applicable machine models. K Table 1.
Specification Variants ( T E2-2)
IMPORTANT: These specifications are only applicable to
some machine models. Refer to the table at the front of this
(1) Machines with pick-up hitch. Since this ARV also controls the pressure to the boom auxiliary service, ensure that this
pressure will not cause damage to attachments used with the machine.
(2) If fitted.
Pilot Pressure Range: (machines with single lever controls) bar kgf/cm2 lbf/in2
All Machines 10 - 30 10.2 - 30.6 145 - 435
764190-2 764190-1
Fig 3. Loading Control Pattern Fig 4. Placing Control Pattern
4 Spool Valve Block (S3) topic for the applicable machine models. K Table 1.
Specification Variants ( T E2-2)
IMPORTANT: These specifications are only applicable to
some machine models. Refer to the table at the front of this
C068090
Fig 5.
4 Spool Valve Block (S4) topic for the applicable machine models. K Table 1.
Specification Variants ( T E2-2)
IMPORTANT: These specifications are only applicable to
some machine models. Refer to the table at the front of this
764190-2-C1
Fig 6.
6 Spool Valve Block (S5) topic for the applicable machine models. K Table 1.
Specification Variants ( T E2-2)
IMPORTANT: These specifications are only applicable to
some machine models. Refer to the table at the front of this
A296260-1
Fig 7.
Hydraulic Pump
Table 4. 80 litres/min.
Type: Double gear pump
Mounting: Gearbox
Direction of Rotation: Anti-clockwise
Theoretical displacement: cc/rev cu in/rev
Main services pump (mounting flange end) 36 2.19
Cooling fan pump 16 0.98
Flow at 2200 rev/min and system pressure (90% min. displacement): litres/min UK gal/min US gal/min
Main services pump (mounting flange end) 71.3 15.7 18.8
Cooling fan pump 31.7 7.0 8.4
Maximum Pressure: bar kg/cm2 lb/in2
port EF 265 270 3840
port P 200 204 2900
Maximum Speed: 3000 rev/min
Minimum Speed: 500 rev/min
Weight: 22.7 kg (50 lbs)
Table 5. 80 litres/min.
Type Triple gear pump
Mounting: Gearbox
Direction of Rotation: Anti-clockwise
Theoretical displacement: cc/rev cu in/rev
Main services pump (mounting flange end) 29 1.77
Steering pump 19 1.16
Cooling fan pump 16 0.98
Flow at 2200 rev/min and system pressure (90% min. displacement): litres/min UK gal/min US gal/min
Main services pump (mounting flange end) 57.4 12.6 15.1
Steering pump 37.6 8.3 9.9
Cooling fan pump 31.7 7.0 8.4
Maximum Pressure: bar kg/cm 2 lb/in2
port EF 265 270 3840
port P 200 204 2900
Maximum Speed: 3000 rev/min
Minimum Speed: 500 rev/min
Weight: 33.3 kg (73.4 lbs)
SE engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 10 cc/rev
Fan Speed (at maximum engine rev/min): 2800
Maximum Pressure Setting 198 bar (2871 lbf/in2)
Body Colour Black
Weight: TBA
SD 63 kW engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 15 cc/rev
Fan Speed (at maximum engine rev/min): 1800
Maximum Pressure Setting 56 bar (812 lbf/in2)
Body Colour Red
SD 74 kW and SF engines:
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 12 cc/rev
Fan Speed (at maximum engine rev/min): 2500
Maximum Pressure Setting 120 (1740 lbf/in2)
Body Colour Black
SE engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 10 cc/rev
SD 63 kW engines :
Type: Gear motor
Direction of Rotation: Clockwise
Motor Displacement 19 cc/rev
Fan Speed (at maximum engine rev/min): TBA
Maximum Pressure Setting 56 bar (812 lbf/in2)
Body Colour Red
SE 97kW engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 11 cc/rev
Fan Speed (at maximum engine rev/min): TBA
Maximum Pressure Setting 115 bar (1668 lbf/in2)
Colour Code (See sticker) None
SD 63 kW engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
SD 74 kW and SF engines:
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 15 cc/rev
Fan Speed (at maximum engine rev/min): TBA
Maximum Pressure Setting 80 bar (1160 lbf/in2)
Body Colour Black
Operation Overview
C026640-C2
Oil is drawn from the hydraulic tank 8-T by the hydraulic Machines with dual lever control use two control levers 8-
pump assembly 8-1. The pump assembly is mounted on 2A and 8-2B for operation of the three loader service
the rear of the bevel gearbox and is driven by the engine. spools. A third lever 8-2C operates the auxiliary service
spool. The levers operate the spools via mechanical
The pump has three sections, 8-1A, 8-1B and 8-1C. Oil linkages. For machines with stabilisers two more levers
from the larger pump section 8-1A flows direct to the are fitted to operate the stabiliser service spools (6 spool
control valve block 8 -2. Pump section 8-1C has an integral control valve).
priority valve which always gives priority demand to the
steer circuit. With the steering in the straight ahead Single Lever Control
position (i.e. with no steering demand), oil from pump
section 8-1C flows through the priority valve and joins with Machines with single lever control use a lever 8-2D which
the flow from 8-1A to feed the control valve block 8-2. moves in two axis and operates two service spools via
Pump section 8-1B is dedicated to driving the cooling fan. mechanical linkages. Buttons on the control lever operate
Oil from pump section 8-1B flows directly to the cooling fan solenoid valves on the remaining two spools.
hydraulic motor 8-4. On sway machines a changeover
valve switches oil supply between the sway ram service
and the fan motor.
When the control valve spools are actuated, oil from the
pump passes into the service ports, operating the relevant
hydraulic ram.
To make the description as clear as possible the diagram When a service is operated, boom extend for example, the
shows only part of the complete hydraulic system. For the movement of the control lever and its mechanical linkages
complete hydraulic schematics, refer to the schematics operate the valve spool 2B. The hydraulic oil flows through
topic. K Related Topics ( T E2-3) the valve spool 2B to the extend ram 3.
Note: Note: The pressure values given are examples for Oil from the other side of the ram 3 flows across the service
the purpose of explanation only. spool and back to tank T.
K Specifications ( T E2-4)
Main System Pressure Relief
No Services Operated
K Fig 11. ( T E2-21)
K Fig 9. ( T E2-19)
When a service ram reaches the end of its stroke, or the
Oil from the primary pump 1A flows to the inlet-outlet service meets resistance and generates pressure above a
section of the control valve 2 through the valve spool 2B specified pressure, the main relief valve 2A opens and oil
and returns to tank T. is dumped to tank, preventing further pressure rise.
Note that oil from secondary pump 1C supplies the steer Table 10. Colour Key to Oil Flow and Pressure
circuit via steer priority valve 1D. As there is no steering
Full Pressure
load this supply joins with pump supply 1A and flows
through the valve spool 2B.
Neutral
Oil from pump 1B supplies the hydraulic fan circuit.
Exhaust
Service Operation
K Fig 10. ( T E2-20)
C080460-C3
Fig 9. No Services Operated
C080460-C4
Fig 10. One Service Operated
C080460-C5
Fig 11. Main System Pressure Relief
711360-1
710510
Fig 12. Typical 4 Spool Control Valve
Fig 13. 4 Spool Control Valve Schematic
Oil from the pump enters the control valve at P, passing the
adjustable main relief valve (MRV) 2A. As the spools 2D,
2E, 2F and 2G, are in neutral, the oil passes round their
central waists, the spool lands preventing the oil from
entering the service ports. On reaching the end housing
the oil enters the exhaust gallery and is discharged back to
tank T. The control valve also incorporates adjustable
auxiliary relief valves (ARV's) 2H, 2J, 2K and 2L.
4 Spool Control Valve (Single Lever enables operation of the service spools a limited number
of times with the engine stopped.
Control)
When the spools are actuated, oil from the pump passes
into the service ports A or B, operating the relevant
hydraulic ram. See the applicable hydraulic schematic for
service port connections.
C085160
C085250-C1 Fig 15. 4 Spool Control Valve (Single Lever Control)
Fig 14. Typical 4 Spool Control Valve Schematic
Oil from the pump enters the control valve at P, passing the
adjustable main relief valve (MRV) 2A, the pressure
reduction valve 2B and pressure maintaining valve 2C.
Valves 2B and 2C are not adjustable.
As the spools 2D, 2E, 2F and 2G, are in neutral, the oil
passes round their central waists, the spool lands
preventing the oil from entering the service ports. On
reaching the end housing the oil enters the exhaust gallery
and is discharged back to tank T. The control valve also
incorporates adjustable auxiliary relief valves (ARV's) 2H,
2J, 2K and 2L.
S296330-2
Fig 16. Typical 6 Spool Control Valve
When the spools are actuated, oil from the pump passes
into the service ports A or B, operating the relevant
hydraulic ram. See the applicable hydraulic schematic for
C085140
service port connections. Fig 17. 6 Spool Control Valve Schematic
Oil from the pump enters the control valve at P, passing the
adjustable main relief valve (M.R.V.) 2A. As the spools 2D,
2E, 2F, 2G, 2R and 2S are in neutral, the oil passes round
their central waists, the spool lands preventing the oil from
entering the service ports. On reaching the end housing
the oil enters the exhaust gallery and is discharged back to
tank T. The control valve also incorporates adjustable
auxiliary relief valves (A.R.V.'s) 2N, 2P, 2L and 2M.
C021880-C2
Fig 18.
1 Valve at Rest:
2 Poppet Opens:
C021910-C2
Fig 19.
1 Valve at Rest:
2 Poppet Opens:
3 Anti-cavitation Mode:
C094840
Fig 20. Single displacement ram at the rear of the
boom pivot.
416480-1
Fig 21. Boom Raise Cycle (Single displacement ram at the rear of the boom pivot)
416490-1
Fig 22. Boom Lower Cycle (Single displacement ram at the rear of the boom pivot)
C083280-C3
Fig 23. Single displacement ram forward of ram pivot.
416480-C1
Fig 24. Boom Raise Cycle (Single displacement ram forward of ram pivot)
416480-C2
Fig 25. Boom Lower Cycle (Single displacement ram forward of ram pivot)
334120
Fig 27.
As the boom extends with the forks lightly loaded, oil from
the valve block flows through the outer extension ram
hose-burst check-valve (HBCV) 13A to the head side of
outer extension ram 12.
334130
Fig 28.
Oil displaced from the rod side of the inner extension ram
11 now passes through the extension spool and back to
tank. This oil is prevented from supplementing the main
pump flow by check-valve 13C.
The boom will extend slower, but with more force than the
regenerative cycle.
334140
Fig 29.
Fault Finding
Tables
Fault:
K Table 11. Lack of power at all hydraulic functions ( T E2-38)
K Table 12. All mechanically operated hydraulic services slow to operate ( T E2-38)
K Table 13. All solenoid/servo operated hydraulic services slow to operate ( T E2-39)
K Table 14. One mechanically operated hydraulic service fails to operate or is slow to operate ( T E2-39)
K Table 15. One solenoid/servo operated hydraulic services fails to operate (if fitted) ( T E2-39)
K Table 16. The engine tends to stall when hydraulics are under load ( T E2-39)
K Table 17. Ram creep ( T E2-39)
K Table 18. 3 stage boom extend retract system ( T E2-40)
K Table 19. Forks creep down ( T E2-40)
K Table 20. Parallel lift faulty ( T E2-41)
Table 14. One mechanically operated hydraulic service fails to operate or is slow to operate
Possible Cause Action
Associated service pipe lines leaking, damaged, trapped or Check hoses, renew as required.
kinked.
Associated ram leaking. Renew seals.
ARV setting incorrect. Check and adjust as required.
Associated valve block section leaking or not operating. – Check for leaks, rectify as required.
– Check that the control lever is operating the spool,
rectify as required.
Associated check valve not opening to allow return of oil to Check and rectify as required.
tank.
Diverter not opening. Check electrical power supply and valve operation, rectify
as required.
Table 15. One solenoid/servo operated hydraulic services fails to operate (if fitted)
Possible Cause Action
K Table 14. One mechanically operated hydraulic
service fails to operate or is slow to operate ( T E2-39).
Solenoid not energised. – Check for faulty solenoid. Renew if necessary.
– Check relevant electrical circuit i.e. switches, relays,
wiring, etc. and rectify as required.
Blockage in solenoid operated valve. – Inspect and clean or renew as necessary.
– Clean or renew the valve internal filter as necessary.
Table 16. The engine tends to stall when hydraulics are under load
Possible Cause Action
MRV valve setting incorrect Check and adjust as required.
Engine performance. Check engine performance.
Test Procedures
Checking Pump Flow discharge line from each pump section in turn as
described below:
Double Pump
Main Services Pump (Section 1): Disconnect hose
The separate sections of the gear pump assembly supply 31-A from the pump. Fit the flow meter and load valve
hydraulic oil to the main services circuits, to the steering between hose 31-A and the pump.
circuit and to the hydraulic cooling fan circuit. To determine
the source of a problem i.e pump, steer circuit or services Cooling Fan Pump (Section 2): Disconnect hose 31-
circuit, measure the output flow at system pressure from B from the pump. Fit the flow meter and load valve
each pump outlet port in turn. between hose 31-B and the pump.
!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.
!MWARNING
Hydraulic Pressure 416111-C9
Hydraulic fluid at system pressure can injure you. Fig 31. Typical Double Pump
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service Note: Make sure the load valve and flow meter is installed
hose line must be vented. Make sure the hose service the correct way round i.e. with the direction arrow pointing
line has been vented before connecting or removing away from the pump.
hoses. Make sure the engine cannot be started while
the hoses are open. !MCAUTION
INT-3-1-11_2
Make sure the load valve is in the OPEN position, (the
2 Vent the hydraulic pressure, see Section 2 - General adjusting knob screwed fully OUT), before starting the
Procedures. K Related Topics ( T E2-3) following pressure test. Failure to do this could
damage the pump.
HYD-4-4_1
A326060-1
Fig 30. Test Equipment
!MWARNING
Take care when disconnecting hydraulic hoses and
fittings as the oil will be HOT.
TRANS-1-2
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
A335530-C3
Fig 33. Typical Triple Pump
Note: Make sure the load valve and flow meter is installed
the correct way round i.e. with the direction arrow pointing
away from the pump.
!MCAUTION
A326060-1 Make sure the load valve is in the OPEN position, (the
Fig 32. Test Equipment adjusting knob screwed fully OUT), before starting the
following pressure test. Failure to do this could
3 Connect a flow meter 32-A, 0-400 bar (0-6000 lbf/in2) damage the pump.
pressure gauge 32-B and load valve 32-C into the
HYD-4-4_1
!MWARNING
Take care when disconnecting hydraulic hoses and
fittings as the oil will be HOT.
TRANS-1-2
A326080-C2
Fig 34.
416111-C10
Fig 35. Test Point (Typical Double Pump)
Auxiliary Relief Valve Pressure (ARV) - K Fig 39. Tilt ram hose at the rear boom bulkhead
ARV’s set higher than the MRV bracket ( T E2-48)
K Fig 40. Tilt ram hose forward of the boom pivot
Some ARVs are set at a higher pressure than the MRV. ( T E2-49)
This is usually one of the tilt ram ARVs. Because the tilt
ram is smaller than the lift ram, higher hydraulic pressure K Fig 41. Tilt ram hose on the displacement ram
is required on one side of the tilt ram to prevent the load hose, boom underside ( T E2-49)
tilting the forks forward.
4 Start the engine and tilt the forks fully back. Remove
Check the pressure setting and ARV location for the the safety strut and slowly lower the boom. As the
applicable machine. K Specifications ( T E2-4) boom is lowered the pressure gauge will show the
A.R.V. pressure, which should be as stated.
1 Park the machine and make it safe. Raise the boom K Specifications ( T E2-4)
and fit the safety strut. Tilt the forks fully forward.
Obey the care and safety procedures. K Related 5 If the pressure is incorrect, adjust the A.R.V. K Relief
Topics ( T E2-3) Valve Adjustment ( T E2-50).
331440-1
Fig 39. Tilt ram hose at the rear boom bulkhead bracket
A326200-1
Fig 40. Tilt ram hose forward of the boom pivot
346500-1
Fig 41. Tilt ram hose on the displacement ram hose, boom underside
A296360-1
Fig 42. Relief Valve Adjuster Screw and Locknut
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
1 Turn the ignition key switch to ON, but do not start the
engine.
!MWARNING
Communications
Bad communications can cause accidents. Keep
people around you informed of what you will be doing.
If you will be working with other people, make sure any
hand signals that may be used are understood by
everybody. Work sites can be noisy, do not rely on
spoken commands.
INT-2-2-3
1 Raise the boom and fit the safety strut, see Section 2
- General Procedures. K Related Topics ( T E2-3)
764810-1
2 Carry out General Safety procedures, see Section 2 Fig 44. Manual Spool Displacement
- General Procedures. K Related Topics ( T E2-3)
6 Repeat the procedure for each manual spool as
3 Vent the hydraulic pressure, see Section 2 - General necessary.
Procedures. K Related Topics ( T E2-3)
Table 21. Spool Displacement
4 Check spool displacement 44-A.
Displacement: Measurement:
a Person 2 - Using the control lever, move and hold 44-A 8mm +/- 1mm (0.32in +/- 0.04in)
the spool in position 44-1. 44-B 8mm +/- 1mm (0.32in +/- 0.04in)
Bleed Procedures
3 Stop the engine and remove the starter key. 6 Connect the other end of the bleed hose assembly to
the female quick release coupling 47-E on the boom
4 Assemble a suitable bleed hose 45-A, fitted with a nose.
male quick release coupling (QRC) 45-B and female
quick release coupling 45-C. Important: Route the hose beneath the boom so that it
does not become entangled when the boom is extended/
Note: Ensure the male quick release coupling 45-B is retracted.
connected to the straight swivel end of the hose.
802870-C2
Fig 45.
802860-C2
Length (Approx.) 6300 mm (20 ft 6 in.) 7 Start the engine and operate the boom service to fully
Bore 3/8" retract the inner and outer boom sections.
Pressure Rating High (Suitable for 240 bar operating
8 SLOWLY operate the boom extend and auxiliary
pressure)
service together, until the outer ram 48-F is fully
extended. Make sure that the auxiliary service
5 Attach the bleed hose assembly to the male quick selected provides a return to tank for the outer ram so
release coupling 46-D on the top extension hose. that the inner ram does not extend.
!MCAUTION
Allow the hydraulic fluid temperature to cool before
removing the hydraulic tank filler cap. Open the cap
slowly to prevent oil being forced out of the filler neck.
5-3-4-8
802860-C3
12 Detach the bleed hose assembly from the quick
Fig 48. release couplings on the machine.
Should the inner ram extend during this sequence, 13 On completion, extend and retract the boom fully five
deselect the auxiliary service and operate the retract times while checking that the boom sections open
service to fully retract the inner ram before continuing and close fully together. Inspect the hydraulic
to extend the outer ram with the correct tank line connections and check for leaks.
auxiliary service.
14 If the boom sections do not open and close fully
9 With the outer ram 48-F fully extended and the inner together repeat bleeding procedure.
ram fully retracted, fully retract the outer ram using
the boom retract and auxiliary service together. Use If the boom sections do not open and close fully
the auxiliary service in the opposite direction to that together after repeating the bleeding procedure.
used in step 8 to provide an additional pressure feed K Fault Finding ( T E2-37)
during the retract function.
732380-C3
Fig 49.
Important: Make sure that the boom is in the lowered 4 Start the engine and operate the sway lever to sway
position when bleeding the sway ram circuit. the machine fully to the operator’s left side. Hold the
lever in this position until no more air is expelled
Note: This procedure requires two people. One person to through the bleed valve 1. Return the control lever to
operate the sway controls and another to tighten the bleed its neutral position. Immediately tighten the bleed
screw when all air has been expelled. If this procedure is valve 1 to prevent air entering the circuit.
done by one person air may enter the cylinder due to the
delay in dismounting from the cab to attend to the sway
cylinder.
!MWARNING
Communications
Bad communications can cause accidents. If two or
more people are working on the machine, make sure
each is aware of what the others are doing. Before
starting the engine make sure the others are clear of
the danger areas; examples of danger areas are: the
rotating blades and belt on the engine, the
attachments and linkages, and anywhere beneath or
behind the machine. People can be killed or injured if
these precautions are not taken.
INT-3-1-5
Important: DO NOT stand between the chassis and the 8 Check the hydraulic fluid level. K Related
wheel. You can be trapped or crushed when sway is Topics ( T E2-3)
operated.
This topic contains information about a machine SYSTEM. The system has some devices that connect either
mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications
table. K Related Topics ( T E3-3).
Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer
to the relevant topics. K Related Topics ( T E3-3)
This topic is intended to help you understand what the system does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
(1) Specification variant. Make sure you refer to the correct specification.
(1) The table lists procedure and specification variants and the applicable machine models. Use the table to make sure
you refer to the correct information.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
(1) Tool available from JCB Service, refer to Section 1 - Service Tools
Specifications
(1) Before testing the Load Sense Relief Valve pressure, allow the hydraulic system to warm up to 50 °C (122 °F) to ensure
an accurate reading. Be sure to identify the machine variant correctly.
C093420
Fig 1.
Hydraulic Pump
Table 4. 110 litres/min.
Type Triple gear pump
Mounting: Gearbox
Direction of Rotation: Anti-clockwise
Theoretical displacement: cc/rev cu in/rev
Main services pump (mounting flange end) 36 2.19
Steering pump 19 1.16
Cooling fan pump 16 0.98
Flow at 2200 rev/min and system pressure (90% min. displacement): litres/min UK gal/min US gal/min
Main services pump (mounting flange end) 71.3 15.7 18.8
Steering pump 37.6 8.3 9.9
Cooling fan pump 31.7 7.0 8.4
Maximum Pressure: bar kg/cm 2 lb/in2
port EF 265 270 3840
port P 200 204 2900
Maximum Speed: 2500 rev/min
Minimum Speed: 500 rev/min
Weight: 34.1 kg (75.2 lbs)
SE engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 10 cc/rev
Fan Speed (at maximum engine rev/min): 2800
Maximum Pressure Setting 198 bar (2871 lbf/in2)
Body Colour Black
Weight: TBA
SD 63 kW engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 15 cc/rev
Fan Speed (at maximum engine rev/min): 1800
Maximum Pressure Setting 56 bar (812 lbf/in2)
Body Colour Red
SD 74 kW and SF engines:
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 12 cc/rev
Fan Speed (at maximum engine rev/min): 2500
Maximum Pressure Setting 120 (1740 lbf/in2)
Body Colour Black
SE engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 10 cc/rev
SD 63 kW engines :
Type: Gear motor
Direction of Rotation: Clockwise
Motor Displacement 19 cc/rev
Fan Speed (at maximum engine rev/min): TBA
Maximum Pressure Setting 56 bar (812 lbf/in2)
Body Colour Red
Operation Overview
The following explains the basic operation of Flowshare Before attempting to service or fault find the system ensure
machines with a gearpump driven hydraulic system. There that you read and understand all the descriptions in this
are other types of hydraulic systems. Make sure you are section. The following descriptions make some
referring to the correct system. K Related comparisons to the normal hydraulic system. `Normal
Topics ( T E3-3) system' refers to standard parallel valve block
machines as described in K Parallel Hydraulic
The JCB Flowshare hydraulic system differs in many SYSTEM ( T E2-1)
important aspects to that of the normal hydraulic system.
Oil at servo pressure Oil suction line from the tank Return to tank
to the pump sections
C048040-C2
Fig 2. Component Location
Hydraulic Pump Central to the control of the proportional solenoids are the
PWM controller electronic control unit (ECU’s) 2-6
Oil is drawn from the hydraulic tank 2-10 by the hydraulic mounted to the control lever assembly.
pump assembly 2-3. The pump assembly is mounted on
the rear of the bevel gearbox and is driven by the engine. There is one ECU for each thumbwheel switch. The ECU
receives analogue electrical inputs from the thumbwheel
The pump has three sections, 2-3A, 2-3B and 2-3C. Oil switches and supplies a modulated output signal (PWM) to
from the larger pump section 3A flows direct to the control the relevant proportional solenoid valve.
valve block 2-7. Pump section 2-3C has an integral priority
valve which always gives priority demand to the steer The proportional solenoid valves work as separate
circuit. With the steering in the straight ahead position (i.e. pressure reducing valves. They direct servo pilot oil to
with no steering demand), oil from pump section 2-3C move the auxiliary, or extend retract service spool, at a
flows through the priority valve and joins with the flow from pressure proportional to the amount the operator moves
2-3A to feed the control valve block 2-7. Pump section 2- the thumbwheel switch. K Thumbwheel
3B is dedicated to driving the cooling fan. Oil from pump Controls ( T E3-33)
section 2-3B flows directly to the cooling fan hydraulic
motor 2-2. On sway machines a changeover valve Load Sensing
switches oil supply between the sway ram service and the
fan motor. The hydraulic system incorporates a hydraulic load sense
circuit. When no services are operated, there is no
The hydraulic oil cooler 2-1 in the return line from the fan demand for flow from the hydraulic system, the oil from the
hydraulic motor 2-2, cools the system hydraulic oil as it is gearpump flows to the inlet-outlet section of the control
continually circulated around the cooling fan circuit. valve 2-7 and directly back to tank. There is no `neutral
K Main Pump - Gearpump ( T E24-1) circuit' as defined in the normal system.
Servo Pilot Valve When a service is operated, the system senses the
demand and responds by increasing the pump operating
The servo pilot valve 2-8 supplies variable hydraulic pilot pressure to a value slightly above that required to move the
pressure to operate the valve spools in the main control load. The load sense feature also incorporates the main
valve 2-7. The valve incorporates proportional control pressure relief function, which is controlled by the load
solenoids to control the pilot pressure. The solenoids are sense relief valve 2-7A. This replaces the Main Relief
controlled via the control lever thumbwheels 2-11. Valve (MRV) used in the normal system.
K Servo Pilot Valve ( T E19-1)
Inloader Operation
Manual Control
The output flow from the secondary hydraulic pump 2-3C
The control lever 2-5 moves in two axis and it operates the is automatically controlled by an inloader valve 2-4. The
boom lift and carriage tilt service spools via mechanical valve responds to the hydraulic load sense pressure and
linkages. main system pressure connecting the flow from pump 2-
3C into the main hydraulic system only when it is required.
The hydraulic operation of the inloader valve is overridden
Electronic Proportional Control
electrically by energising inloader valve solenoid. The
solenoid is energised by a signal from the IFT ECU 2-12.
The control lever 2-5 incorporates proportional control
thumbwheel switches. The thumbwheels 2-11 operate the
The IFT ECU is programmed to energise the inloader
extend retract service and the auxiliary service.
valve solenoid dependant on engine speed (rpm). When
the solenoid is energised the flow from pump section is
The thumbwheels control four electro-hydraulic
diverted to tank. K Inloader Valve ( T E18-1)
proportional solenoid valves housed in the servo pilot
valve block 2-8.
Oil from the main hydraulic pump arrives at the inlet gallery
P. When the relevant service spool D is selected, the spool
moves against the force of the centring spring E, allowing
the oil to flow to move the required service. When the
service spool D is de-selected the centring spring returns
the spool to the neutral position.
A405000-C1
Fig 3. Servo Pilot Operated Spool
Control Lever
The control lever operates in two axis. It also incorporates
two thumbwheel switches. The control is configured as
follows:
Control Lever - AXIS Two Mechanical linkage Control valve - SPOOL Two
No Services Operated
K Fig 4. ( T E3-15)
C047530-C1
Fig 4. No Services Operated
Service Operation
K Fig 5. ( T E3-17)
Oil from the other side of the ram 5 flows across the service
spool and back to tank in the normal way.
Inloader Operation
K Fig 5. ( T E3-17)
C047530-C2
Fig 5. One service Operated
A405030-1
Fig 6.
With the spools in the neutral position oil from the pump P
flows to each service spool S and is dead ended. This
generates sufficient pressure (about 15 bar) to overcome
the spring E1 and oil flows across the flushing valve spool
assembly E to tank T. Any load acting on the service ram
R is held by the service spool S.
A405041-1
Fig 7.
Pump pressure = Pressure in load sense gallery LS + pressure from spring E1.
When the service spool S is moved the oil from the pump
P is connected to the gallery P1. The pressure in this
chamber opens the pressure compensator valve PC
allowing oil into the load sense gallery LS. Oil pressure
builds in the gallery LS and the flushing valve spool E
begins to close under the combined action of the oil
pressure and spring force, causing the pump pressure to
rise as follows:
714761-1
Fig 8.
714771-1
Fig 9.
When another service with a higher load is operated Should the oil flow demanded by the sum of the combined
simultaneously, a typical example is the lifting of the boom services operating ever exceed that of the pump, all the
X and simultaneous operation of the tilt Y as shown. pressure compensator valves will partially close
K Fig 9. ( T E3-21) accordingly, effectively dividing the available flow between
all the services proportionally.
The higher load pressure in the tilt service causes the
pressure compensator valve PC in the boom service to In this condition the service ram with the highest load will
partially close, reducing the size of the opening through not stop, because the speed of the other service rams
which the oil must flow, and in this way maintains a operating will have been reduced proportionally by the
pressure drop across the pressure compensator equal to action of the pressure compensator valves to compensate.
the pressure drop across the boom service spool.
When one of the service spools is returned to neutral, the
In this example, because of the action of the pressure speed of the other service rams still operating will all
compensator valve the boom service is always kept increase proportionally.
independent of the other services, the boom ram speed
remains constant (as controlled by the boom service
spool) and is not affected by the greater operating
pressure in the tilt service.
E3-22
K Fig 10. ( T E3-23)
9803/3760-07 (E-01-01)
Table 8. Colour Key to Oil Flow and Pressure
Full Pressure
Servo
Neutral
Exhaust
LSP Gearpump Hydraulic SYSTEM
Section E3 - Hydraulics
E3-22
Hydraulic Operation and Schematics
Section E3 - Hydraulics
LSP Gearpump Hydraulic SYSTEM
Hydraulic Operation and Schematics
C047530-C3
Fig 10. Main System Pressure Relief
C094840
Fig 11. Single displacement ram at the rear of the
boom pivot.
C094820
Fig 12. Boom Raise Cycle (Single displacement ram at the rear of the boom pivot)
C094820-C1
Fig 13. Boom Lower Cycle (Single displacement ram at the rear of the boom pivot)
C094810
Fig 14. Twin displacement rams forward of the boom
pivot.
Oil is forced out of the rod side of displacement rams 9 and Auxiliary relief valve (ARV) 2J opens to protect the tilt ram
9A as the boom rises. The oil cannot flow past the tilt spool from over pressurisation. The anti-cavitation feature of
2F, as the spool is not selected. Instead, it flows to the valve 2H ensures that, in these circumstances, the tilt and
head side of tilt ram 10. Oil displaced from the rod side of displacement rams will not cavitate.
C094800-C1
Fig 15. Boom Raise Cycle (Twin displacement rams forward of the boom pivot)
C094800
Fig 16. Boom Lower Cycle (Twin displacement rams forward of the boom pivot)
C083280
Fig 17. Single displacement ram forward of the boom
pivot.
C094880
Fig 18. Boom Raise Cycle (Single displacement forward of the boom pivot)
C094880-C1
Fig 19. Boom Lower Cycle (Single displacement ram forward of the boom pivot)
Component Key:
A Thumbwheel Switch - Boom Extend/Retract
A1 Thumbwheel Input (degrees)
A2 Thumbwheel Output (volts)
B PWM Controller (ECU)
B1 ECU Input (volts)
B2 ECU Output (mA)
C Proportional Solenoid Valves - Boom Extend/
Retract
C1 Valve Output (bar)
C2 Valve Input (mA)
D Proportional Solenoid Valves - Auxiliary Service
E Boom Service Spool
F Boom Extension Ram
C044280
Fig 20. Boom Extend and Retract - Example
C044340-C2
Fig 22.
Fault Finding
Tables
Table 13. The engine tends to stall when hydraulics are under load.
– Due to blocked servo pilot filter element. – Renew the servo pilot filter element.
– Due to proportional solenoid valve cartridge damaged, – Renew the pilot pressure supply valve.
or sticking due to contamination.
– Due to faulty servo regulating valve.
Action Yes No
13 Strip inner extension cylinder and ensure make-up valve in Done Go to 2
piston head is intact and free from contamination. If the
valve is damaged, replace with improved type. Adjust
make-up valve and bleed cylinders. OK now?
14 Does the outer boom fully retract leaving intermediate Go to 15 Go to 2
boom slightly extended?
15 Strip outer extension cylinder and ensure make-up valve in Done Go to 2
piston head is intact and free from contamination. If the
valve is damaged, replace with improved type. Adjust
make-up valve and bleed cylinders. OK now?
Note: The maximum auxiliary service flow available operation, and upto 65 litre min. with `constant' operation
should be upto 95 litre min. with `manual' thumbwheel selected.
Test Procedures
Checking Pump Flow discharge line from each pump section in turn as
described below:
The separate sections of the gear pump assembly supply
hydraulic oil to the main services circuits, to the steering Main Services Pump (Section 1): Disconnect hose
circuit and to the hydraulic cooling fan circuit. To determine 24-A from the pipe 24-B. Fit the flow meter and load
the source of a problem i.e pump, steer circuit or services valve between hose 24-A and the pipe 24-B.
circuit, measure the output flow at system pressure from
each pump outlet port in turn. For machines (over 10.5 metre lift height) only, also
disconnect hose 24-C from the pipe 24-B. Cap the
open port in the pipe, then connect a suitable slave
!MWARNING hose 25- D to hose 24-C and route the hose to the
Make the machine safe before working underneath it. hydraulic tank. Slowly remove the hydraulic tank filler
Park the machine on level ground, lower the cap and place the end of the slave hose 25-D inside
attachments to the ground. Apply the park brake, put the filler tube as shown. K Fig 25. ( T E3-44).
the transmission in neutral and stop the engine. Block
both sides of all four wheels. Steering Pump (Section 2): Disconnect hose 24-C
from the priority valve 24-E (port EF). Fit the flow
Disconnect the battery, to prevent the engine being meter and load valve between hose 24-C and the
started while you are beneath the machine. priority valve 24-E.
GEN-4-1_1
Cooling Fan Pump (Section 3): Disconnect hose 24-
1 Carry out General Safety procedures, see Section 2 F from the pump. Fit the flow meter and load valve
- General Procedures. K Related Topics ( T E3-3) between hose 24-F and the pump.
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
A335530-C3
Fig 24. Typical Triple Pump
Note: Make sure the load valve and flow meter is installed
the correct way round i.e. with the direction arrow pointing
away from the pump.
!MCAUTION
A326060-1 Make sure the load valve is in the OPEN position, (the
Fig 23. Test Equipment adjusting knob screwed fully OUT), before starting the
following pressure test. Failure to do this could
3 Connect a flow meter 23-A, 0-400 bar (0-6000 lbf/in2) damage the pump.
pressure gauge 23-B and load valve 23-C into the HYD-4-4_1
!MWARNING
Take care when disconnecting hydraulic hoses and
fittings as the oil will be HOT.
TRANS-1-2
A326080-C2
Fig 25.
!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.
!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.
2 With the engine running at 1500 rpm, check the load Fig 27.
sense relief valve setting by operating the boom lower
service and hold the boom ram fully closed. Note the
maximum reading on the pressure gauge. The
maximum pressure should be as stated in
Specifications. K Specifications ( T E3-4)
Auxiliary Relief Valve Pressure (ARV) - 5 If the pressure is incorrect, adjust the ARV. K Relief
Valve Adjustment ( T E3-49)
ARV’s set higher than the LSRV
Some ARVs are set at a higher pressure than the LSRV. !MWARNING
This is usually one of the tilt ram ARVs. Because the tilt
Take care when disconnecting hydraulic hoses and
ram is smaller than the lift ram, higher hydraulic pressure
fittings as the oil will be HOT.
is required on one side of the tilt ram to prevent the load
TRANS-1-2
tilting the forks forward.
6 After completing the test, raise the boom and fit the
Check the pressure setting and ARV location for the
safety strut. switch OFF the engine and vent residual
applicable machine. K Specifications ( T E3-4)
hydraulic pressure. Disconnect the pressure gauge
and remove tee piece 28-B. Reconnect the tilt ram
1 Park the machine and make it safe. Raise the boom
rod side hose 28-A.
and fit the safety strut. Tilt the forks fully forward.
Obey the care and safety procedures. K Related
Topics ( T E3-3)
Smooth Ride System (SRS)
2 Vent residual hydraulic pressure. Obey the care and Machines fitted with SRS feature spool position
safety procedures. K Related Topics ( T E3-3) microswitches. K LSP Variflow Hydraulic
SYSTEM ( T E4-1) To gain access to the tilt ram head side
3 Locate the hydraulic line for the high pressure side of ARV it is necessary to remove the adjacent microswitch
the tilt ram. Fit a tee piece in the hydraulic line. 29-A. Before removing measure how far the switch body
protrudes from the spool housing. When replacing be sure
Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure
screw in the switch to its original position. Test its operation
gauge to the tee piece.
using a multimeter.
717071-1
Fig 28.
4 Start the engine and tilt the forks fully back. Remove
the safety strut and slowly lower the boom. As the
boom is lowered the pressure gauge will show the
C029990
ARV pressure, which should be as stated.
Fig 29.
K Specifications ( T E3-4)
A296360-1
Fig 30. Relief Valve Adjuster Screw and Locknut
Bleed Procedures
3 Stop the engine and remove the starter key. 6 Connect the other end of the bleed hose assembly to
the female quick release coupling 33-E on the boom
4 Assemble a suitable bleed hose 31-A, fitted with a nose.
male quick release coupling (QRC) 31-B and female
quick release coupling 31-C. Important: Route the hose beneath the boom so that it
does not become entangled when the boom is extended/
Note: Ensure the male quick release coupling 31-B is retracted.
connected to the straight swivel end of the hose.
802870-C2
Fig 31.
802860-C2
Length (Approx.) 6300 mm (20 ft 6 in.) 7 Start the engine and operate the boom service to fully
Bore 3/8" retract the inner and outer boom sections.
Pressure Rating High (Suitable for 240 bar operating
8 SLOWLY operate the boom extend and auxiliary
pressure)
service together, until the outer ram 34-F is fully
extended. Make sure that the auxiliary service
5 Attach the bleed hose assembly to the male quick selected provides a return to tank for the outer ram so
release coupling 32-D on the top extension hose. that the inner ram does not extend.
!MCAUTION
Allow the hydraulic fluid temperature to cool before
removing the hydraulic tank filler cap. Open the cap
slowly to prevent oil being forced out of the filler neck.
5-3-4-8
802860-C3
12 Detach the bleed hose assembly from the quick
Fig 34. release couplings on the machine.
Should the inner ram extend during this sequence, 13 On completion, extend and retract the boom fully five
deselect the auxiliary service and operate the retract times while checking that the boom sections open
service to fully retract the inner ram before continuing and close fully together. Inspect the hydraulic
to extend the outer ram with the correct tank line connections and check for leaks.
auxiliary service.
14 If the boom sections do not open and close fully
9 With the outer ram 34-F fully extended and the inner together repeat bleeding procedure.
ram fully retracted, fully retract the outer ram using
the boom retract and auxiliary service together. Use If the boom sections do not open and close fully
the auxiliary service in the opposite direction to that together after repeating the bleeding procedure, see
used in step 8 to provide an additional pressure feed Fault Finding. K Fault Finding ( T E3-38)
during the retract function.
732380-C3
Fig 35.
Important: Make sure that the boom is in the lowered 4 Start the engine and operate the sway lever to sway
position when bleeding the sway ram circuit. the machine fully to the operator’s left side. Hold the
lever in this position until no more air is expelled
Note: This procedure requires two people. One person to through the bleed valve 1. Return the control lever to
operate the sway controls and another to tighten the bleed its neutral position. Immediately tighten the bleed
screw when all air has been expelled. If this procedure is valve 1 to prevent air entering the circuit.
done by one person air may enter the cylinder due to the
delay in dismounting from the cab to attend to the sway
cylinder.
!MWARNING
Communications
Bad communications can cause accidents. If two or
more people are working on the machine, make sure
each is aware of what the others are doing. Before
starting the engine make sure the others are clear of
the danger areas; examples of danger areas are: the
rotating blades and belt on the engine, the
attachments and linkages, and anywhere beneath or
behind the machine. People can be killed or injured if
these precautions are not taken.
INT-3-1-5
Important: DO NOT stand between the chassis and the 8 Check the hydraulic fluid level. K Related
wheel. You can be trapped or crushed when sway is Topics ( T E3-3)
operated.
This topic contains information about a machine SYSTEM. The system has some devices that connect either
mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications
table. K Related Topics ( T E4-3).
Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer
to the relevant topics. K Related Topics ( T E4-3)
This topic is intended to help you understand what the system does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
(1) Specification variant. Make sure you refer to the correct specification.
(1) The table lists procedure and specification variants and the applicable machine models. Use the table to make sure
you refer to the correct information.
Specifications
(1) Before testing the Load Sense Relief Valve pressure, allow the hydraulic system to warm up to 50 °C (122 °F) to
ensure an accurate reading. Be sure to identify the machine variant correctly.
C093420
Fig 1.
Variflow Pump
SE engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 10 cc/rev
Fan Speed (at maximum engine rev/min): 2800
SD 63 kW engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 15 cc/rev
Fan Speed (at maximum engine rev/min): 1800
Maximum Pressure Setting 56 bar (812 lbf/in2)
Body Colour Red
SD 74 kW and SF engines:
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 12 cc/rev
Fan Speed (at maximum engine rev/min): 2500
Maximum Pressure Setting 120 (1740 lbf/in2)
Body Colour Black
SE engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 10 cc/rev
Fan Speed (at maximum engine rev/min): 2800
Maximum Pressure Setting 198 bar (2871 lbf/in2)
Body Colour Black
Weight: TBA
SD 63 kW engines :
Type: Gear motor
Direction of Rotation: Clockwise
Motor Displacement 19 cc/rev
Operation Overview
The following explains the basic operation of Flowshare system. Before attempting to service or fault find the
machines with a variflow pump driven hydraulic system. system ensure that you read and understand all the
There are other types of hydraulic systems. Make sure you descriptions in this section. The following descriptions
are referring to the correct system. K Related make some comparisons to the normal hydraulic
Topics ( T E4-3) system. `Normal system' refers to standard parallel
valve block machines as described in K Parallel
The JCB Flowshare variflow hydraulic system differs in Hydraulic SYSTEM ( T E2-1)
many important aspects to that of the normal hydraulic
Component Location
Table 5. Component Location and Identification
Item Description
K Fig 2. ( T E4-10)
1 Oil Cooler Oil from pump section 3B flows through the oil
cooler
2 Fan motor Driven by pump section 3B
2A Hydraulic Oil Filter Positioned in the fan return line to tank
3 Pump assembly A variflow pump A with an additional K Hydraulic Pump ( T E4-11)
gearpump section B for the fan drive
4 Control Lever Two axis control lever K Control Lever ( T E4-13)
5 PWM ECU's Electronic control for servo pilot valve K Thumbwheel
5A 5v voltage regulator Power supply for thumbwheel controls Controls ( T E4-37)
8A
12
C048480-C4
Oil from the main hydraulic pump arrives at the inlet gallery
P. When the relevant service spool D is selected, the spool
moves against the force of the centring spring E, allowing
the oil to flow to move the required service. When the
service spool D is de-selected the centring spring returns
the spool to the neutral position.
A405000-C1
Fig 3. Servo Pilot Operated Spool
Control Lever
The control lever operates in two axis. It also incorporates
two thumbwheel switches. The control is configured as
follows:
Control Lever - AXIS Two Mechanical linkage Control valve - SPOOL Two
Variflow Pump
C051000-C1
Fig 4.
No Services Operated
K Fig 5. ( T E4-17)
C047550-C1
Fig 5. No Services Operated
Service Operation
K Fig 6. ( T E4-19)
Oil from the other side of the ram 5 flows across the service
spool and back to tank in the normal way.
C047550-C2
Fig 6. One Service Operated
Servo
Neutral
Exhaust
C047550-C3
Fig 7. Main System Pressure Relief
A405030-1
Fig 8.
With the spools in the neutral position oil from the pump P
flows to each service spool S and is dead ended. This
generates sufficient pressure (about 15 bar) to overcome
the spring E1 and oil flows across the flushing valve spool
assembly E to tank T. Any load acting on the service ram
R is held by the service spool S.
A405041-1
Fig 9.
Pump pressure = Pressure in load sense gallery LS + pressure from spring E1.
When the service spool S is moved the oil from the pump
P is connected to the gallery P1. The pressure in this
chamber opens the pressure compensator valve PC
allowing oil into the load sense gallery LS. Oil pressure
builds in the gallery LS and the flushing valve spool E
begins to close under the combined action of the oil
pressure and spring force, causing the pump pressure to
rise as follows:
714761-1
Fig 10.
714771-1
Fig 11.
When another service with a higher load is operated Should the oil flow demanded by the sum of the combined
simultaneously, a typical example is the lifting of the boom services operating ever exceed that of the pump, all the
X and simultaneous operation of the tilt Y as shown. pressure compensator valves will partially close
K Fig 11. ( T E4-25) accordingly, effectively dividing the available flow between
all the services proportionally.
The higher load pressure in the tilt service causes the
pressure compensator valve PC in the boom service to In this condition the service ram with the highest load will
partially close, reducing the size of the opening through not stop, because the speed of the other service rams
which the oil must flow, and in this way maintains a operating will have been reduced proportionally by the
pressure drop across the pressure compensator equal to action of the pressure compensator valves to compensate.
the pressure drop across the boom service spool.
When one of the service spools is returned to neutral, the
In this example, because of the action of the pressure speed of the other service rams still operating will all
compensator valve the boom service is always kept increase proportionally.
independent of the other services, the boom ram speed
remains constant (as controlled by the boom service
spool) and is not affected by the greater operating
pressure in the tilt service.
C051000
Fig 12. Sectioned View
The pump output flow and operating pressure are When the output flow is enough to satisfy the flow
controlled by varying the angle of the tilting swashplate A. demanded by the service, the pump operating pressure P
The swashplate is moved in one direction by the force of (red) increases sufficiently to start to move the service ram.
the spring B, and in the opposite direction by control The increase in the pump operating pressure pushes the
pressure (orange) acting behind the swash control piston flow compensator spool D back to the left, against the force
C. The control pressure is derived from the pump of the spring E and hydraulic load sense pressure; this in
operating pressure (red) by the action of the flow turn increases the control pressure acting on the swash
compensator spool D. The flow compensator spool control piston C, which decreases the angle of the
regulates the angle of the swashplate automatically in swashplate A against the force of spring B. As the
response to changes in the hydraulic load sense pressure swashplate angle decreases, the output flow from the
(yellow) from the hydraulic service. pump decreases. In this way, the pump delivers only the
minimum flow needed to maintain the system pressure
Flow Compensator Valve: When a hydraulic service is required to operate the service.
operated, boom lift for example, a pressure signal
(demand) is generated in the load sense line LS from the Note: The flow compensator spool D is moving constantly,
control valve block. The increase in the load sense thereby regulating the pump swashplate to balance the
pressure, combined with the force of the spring E pushes pressures acting on each end of the spool. The additional
the flow compensator spool D to the right, this in turn, force of spring E is factory set to be equivalent to 25 bar
allows some control pressure (orange) acting on the (360 lbf/in2), therefore the pump operating pressure (i.e.
swash control piston C to vent back to tank via the case main system pressure) will always be maintained at 25 bar
drain (green). The force of the spring B increases the angle above the load sense pressure. This is sometimes
of the swashplate A and the pump output flow increases referred to as the `Delta-P' pressure setting.
proportionally.
C094840
Fig 13. Single displacement ram at the rear of the
boom pivot.
C094820
Fig 14. Boom Raise Cycle (Single displacement ram at the rear of the boom pivot)
C094820-C1
Fig 15. Boom Lower Cycle (Single displacement ram at the rear of the boom pivot)
C094810
Fig 16. Twin displacement rams forward of the boom
pivot.
Oil is forced out of the rod side of displacement rams 9 and Auxiliary relief valve (ARV) 2J opens to protect the tilt ram
9A as the boom rises. The oil cannot flow past the tilt spool from over pressurisation. The anti-cavitation feature of
2F, as the spool is not selected. Instead, it flows to the valve 2H ensures that, in these circumstances, the tilt and
head side of tilt ram 10. Oil displaced from the rod side of displacement rams will not cavitate.
C094800-C1
Fig 17. Boom Raise Cycle (Twin displacement rams forward of the boom pivot)
C094800
Fig 18. Boom Lower Cycle (Twin displacement rams forward of the boom pivot)
C083280
Fig 19. Single displacement ram forward of the boom
pivot.
C094880
Fig 20. Boom Raise Cycle (Single displacement forward of the boom pivot)
C094880-C1
Fig 21. Boom Lower Cycle (Single displacement ram forward of the boom pivot)
Component Key:
A Thumbwheel Switch - Boom Extend/Retract
A1 Thumbwheel Input (degrees)
A2 Thumbwheel Output (volts)
B PWM Controller (ECU)
B1 ECU Input (volts)
B2 ECU Output (mA)
C Proportional Solenoid Valves - Boom Extend/
Retract
C1 Valve Output (bar)
C2 Valve Input (mA)
D Proportional Solenoid Valves - Auxiliary Service
E Boom Service Spool
F Boom Extension Ram
C044280
Fig 22. Boom Extend and Retract - Example
C044340-C2
Fig 24.
Hydraulic Variable Control System The instrument panel HVCS warning light illuminates as
follows:
(HVCS)
This section explains how the HVCS electrical system Condition Light Status HVCS Status
works. Ignition On Light On Indicates HVCS system is
present
K Fig 26. Electrical Schematic - HVCS ( T E4-43)
Engine Light Off Normal HVCS Operation
K Fig 27. Wires and Connectors - HVCS ( T E4-44) Running
Engine Light On Hydraulic Oil Overheated
K Device and Connector Key ( T E4-45) Running (hydraulic pump output is
automatically reduced
Central to the system is the pump controller electronic until oil temperature falls).
control unit (ECU) 4008 mounted in the engine Engine Light Flashes HVCS Fault
compartment. The ECU receives an engine load signal Running
(actual engine torque) from the engine ECU (not shown)
via the instrument panel (centre cluster) 4002/6017, and
Note: The instrument panel (centre cluster) 4002/6017
also a hydraulic fluid temperature signal from the variflow
converts the existing engine load CANbus protocol signal
pump temperature sensor 5014.
from the engine ECU, into a corresponding LINbus
protocol signal to the pump controller ECU 4008.
When the pump controller ECU senses that the engine is
being overloaded, or when the hydraulic fluid temperature
increases, it sends a corresponding pulse width modulated
(PWM) current signal output to the variflow pump
proportional solenoid valve 3047. The solenoid valve
operates to adjust the pump performance (power curve
characteristic) and thereby limits the hydraulic power
available to the hydraulic services.
C053110
Fig 25. HVCS Warning Light
C051010-C1
Fig 26. Electrical Schematic - HVCS
Component Key:
4008 Pump Controller ECU
6017/4002 Instrument panel (Centre cluster)
4012/4013 Instrument panel (J1/J2 cluster) - HVCS
`Active' warning light
3047 HVCS Proportional solenoid valve (Variflow
pump)
5014 Hydraulic fluid temperature sensor (Variflow
pump - suction port)
C050940-C1
The table shows the harness connectors that connect to the electrical devices. The connectors are shown looking at the
mating face when disconnected. Remember that the drawings show the harness connectors NOT the device connectors.
Use the table and the relevant electrical schematic to identify the pins in the harness connectors. Continuity checks on
the harness wires can be carried out using a multi-meter. Do not touch ECU connector pins. Do not use a multi-meter on
ECU connector pins.
Device Description Location Harness Connector
-001 Chassis Harness Ground Refer to Section C - Electrical Harness
System. K Related Topics ( T E4-3)
M10
3047 Variflow Pump Control Located on the Variflow Pump
Solenoid
4002 Centre Cluster (With LCD) The ECU connector is located behind the centre
Display Connector cluster unit.
4012 LMS Display ECU The ECU connectors are located behind the LMS
Connector J1 (Grey) display unit. Be sure to identify the correct 11 20
connector. Connector J1 is coloured Grey.
1 10
4013 LMS Display ECU The ECU connectors are located behind the LMS
Connector J2 (Black) display unit. Be sure to identify the correct 10 1
connector. Connector J2 is coloured black.
20 11
5014 Hydraulic Oil Temperature Located on the Variflow pump suction hose.
Sensor
6017 Centre Cluster Display The display panel connectors are located behind
(Without LCD) Connector the panel.
Fault Finding
Tables
– Due to blocked servo pilot filter element. – Renew the servo pilot filter element.
– Due to faulty servo regulating valve. – Renew the pilot pressure supply valve.
Insufficient output flow from variflow pump because the – Check and adjust, or renew the LSRV as required.
pump is not receiving the correct load sense pressure: – Measure the load sense pressure.
Table 12. The engine tends to stall when hydraulics are under load
– Due to blocked servo pilot filter element. – Renew the servo pilot filter element.
– Due to proportional solenoid valve cartridge damaged, – Renew the pilot pressure supply valve.
or sticking due to contamination.
– Due to faulty servo regulating valve.
(1) For a detailed description of the PWM controller (ECU) and thumbwheel operation, and expected output current and
input voltages, see Circuit Descriptions.
Note: The maximum auxiliary service flow available operation, and upto 65 litre min. with `constant' operation
should be upto 95 litre min. with `manual' thumbwheel selected.
Test Procedures
Main System Pressures 2 Working under the RH side of the machine, connect a
0 - 400 bar (5801 lbf/in2) pressure transducer to the
To investigate any hydraulic performance issues you must pump output test point 28-B and connect to ‘Channel
complete the pressure tests. 1’ on the test set.
– Stand-by Pressure - This is the pressure measured at 3 Connect another 0 - 400 bar (5801 lbf/in2) pressure
the pump when the hydraulic services are not transducer to the pump load sense pressure test
operated. point 28-A and connect to ‘Channel 2’ on the test set.
– Delta P Pressure - This is the pressure setting of the
pump controller. The controller makes sure that the
pump delivers a pressure above what is required by
the hydraulic services. This extra pressure is the delta
P pressure.
– Load Sense Relief Valve Pressure - This is the
maximum pressure that can be achieved within the
hydraulic system.
!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2 C075860
Fig 28.
1 Park the machine and make it safe. Vent the hydraulic
system. Obey the care and safety procedures. 4 Press button 29-D to switch the test set ON, then
K Related Topics ( T E4-3) press button 29-E to set the screen to display delta-P
between channels 1 and 2.
!MCAUTION
Make sure the load valve is in the OPEN position, (the
adjusting knob screwed fully OUT), before starting the
following pressure test. Failure to do this could
damage the pump.
HYD-4-4_1
5 Connect a flow meter 30-F and load valve 30-G to the c Note the pressure shown on channel 1. This is the
auxiliary quick release couplings 30-H on the boom. pump standby pressure.
See Section 1 - Service Tools. K Related
Topics ( T E4-3) 8 Measure the Delta P Pressure:
Table 18.
Standby Load Sense Delta-P Steering
Relief
C075860-C1
Fig 31.
C050620-C1
After adjustment also check the load sense pressure Fig 32.
and main system pressure which may have changed
slightly after adjusting the delta-P.
!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.
Auxiliary Relief Valve Pressure (ARV) - Note: Locate a connection in the tilt ram circuit at the rear
of the boom. The illustrations show typical locations.
ARV’s set higher than the MRV
Some ARVs are set at a higher pressure than the MRV. K Fig 34. Tilt ram hose at the rear boom bulkhead
This is usually one of the tilt ram ARVs. Because the tilt bracket ( T E4-56)
ram is smaller than the lift ram, higher hydraulic pressure
is required on one side of the tilt ram to prevent the load 4 Start the engine and tilt the forks fully back. Remove
tilting the forks forward. the safety strut and slowly lower the boom. As the
boom is lowered the pressure gauge will show the
Check the pressure setting and ARV location for the A.R.V. pressure, which should be as stated.
applicable machine. K Specifications ( T E4-4) K Specifications ( T E4-4)
1 Park the machine and make it safe. Raise the boom 5 If the pressure is incorrect, adjust the A.R.V. K Relief
and fit the safety strut. Tilt the forks fully forward. Valve Adjustment ( T E2-50).
Obey the care and safety procedures. K Related
Topics ( T E4-3)
!MWARNING
2 Vent residual hydraulic pressure. Obey the care and Take care when disconnecting hydraulic hoses and
safety procedures. K Related Topics ( T E4-3) fittings as the oil will be HOT.
TRANS-1-2
3 Locate the hydraulic line for the high pressure side of
the tilt ram. Fit a tee piece in the hydraulic line. 6 After completing the test, fully lower the boom, switch
Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure OFF the engine and vent residual hydraulic pressure.
gauge to the tee piece. Disconnect the pressure gauge and reconnect the tilt
ram hose.
331440-1
Fig 34. Tilt ram hose at the rear boom bulkhead bracket
Testing the HVCS System Operation 7 Connect the black connector 4 of the test lead to the
negative lead of the electrical multimeter connected
The Variable Pump Control System (HVCS) automatically to the negative or COM terminal.
reduces the swashplate angle if the engine is overloaded,
or if the hydraulic oil temperature is high. Use the following
test procedure to check the HVCS is operating correctly.
C082990
Fig 35. Test Lead (A) - JCB Part No. 332/E0800
Preparation
T040560-2
1 Make the machine safe with the boom lowered to the Fig 36.
ground.
6 Connect the red connector 3 of the test lead to the Fig 37.
positive lead of the electrical multimeter connected to
the A (Amp) terminal. Test Procedure
Note: Do not connect the positive lead to the mA terminal 1 Operate the machine to increase the temperature of
as this can affect the recorded values. the hydraulic oil to the working temperature of 50°C
(122°F).
Important: Do not set the multimeter to mA as this can For each test, measure then record the engine speed
affect the recorded values. and current values at the pump solenoid.
Table 19.
Test Required Values Recorded Values
Engine Speed Pump Signal Engine Speed Pump Signal
(rpm) (Amp) (rpm) (Amp)
Ignition ON 0 0.6 - 0.7
Engine Idle (No hydraulic functions operated) 850 1.7 - 1.83
Maximum Engine Speed (No hydraulic functions 2370 1.7 - 1.83
operated)
Transmission Stall (Maximum throttle applied) 1900 - 2100 1.25 - 1.35
Combined Transmission Stall (1)
1500 - 1700 0.95 - 1.05
(1) Combined Transmission stall refers to stalling the transmission with the dump and retract services fully selected.
The pump signals are dependant on the output from the Task: Complete a continuity test between pin #10 of Pump
ECU and the resistance of the wiring and other ECU connector 5 and pin #1 of Pump Solenoid connector
components in the circuit. 2.
K Table 19. ( T E4-58). If the recorded values are outside Result: Continuity OK?
of the required values, then the HVCS cannot operate
correctly. You must test the electrical circuit to identify – Yes. Continue to Test 3.
which component is at fault. Complete the Tests 1 to 5 (as – No. Examine the items shown:
necessary) to find the cause of the fault.
Examine the Engine Harness to Chassis Harness
Note: A schematic drawing and photographs to show Connection 6.
component locations are provided. K HVCS Schematic
and Component Locations ( T E4-62). Examine the Chassis Harness to Transmission
Harness Connection 7.
Before you Start the Fault Diagnosis Procedure
Examine the engine, chassis and transmission
1 Disconnect the test lead A. harness wiring for damage.
Task: Measure the resistance of the pump solenoid coil 1. Result: Continuity OK?
T040570-1
Fig 38.
T040620-1
Fig 40.
Test 4b
Expected Values:
T040920-1
Fig 41. Schematic Drawing
T040950-1 T040580-1
Fig 42. Fig 44.
T040600-4 T040590-1
Fig 43. Fig 45.
T040940-1
Fig 46.
Bleed Procedures
Important: Make sure that the boom is in the lowered 4 Start the engine and operate the sway lever to sway
position when bleeding the sway ram circuit. the machine fully to the operator’s left side. Hold the
lever in this position until no more air is expelled
Note: This procedure requires two people. One person to through the bleed valve 1. Return the control lever to
operate the sway controls and another to tighten the bleed its neutral position. Immediately tighten the bleed
screw when all air has been expelled. If this procedure is valve 1 to prevent air entering the circuit.
done by one person air may enter the cylinder due to the
delay in dismounting from the cab to attend to the sway
cylinder.
!MWARNING
Communications
Bad communications can cause accidents. If two or
more people are working on the machine, make sure
each is aware of what the others are doing. Before
starting the engine make sure the others are clear of
the danger areas; examples of danger areas are: the
rotating blades and belt on the engine, the
attachments and linkages, and anywhere beneath or
behind the machine. People can be killed or injured if
these precautions are not taken.
INT-3-1-5
Important: DO NOT stand between the chassis and the 8 Check the hydraulic fluid level. K Related
wheel. You can be trapped or crushed when sway is Topics ( T E4-3)
operated.
This topic contains information about a machine SYSTEM. The system has some devices that connect either
mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications
table. K Related Topics ( T E5-3).
Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer
to the relevant topics. K Related Topics ( T E5-3)
This topic is intended to help you understand what the system does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
(1) Specification variant. Make sure you refer to the correct specification.
(1) The table lists procedure and specification variants and the applicable machine models. Use the table to make sure
you refer to the correct information.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
(1) Tool available from JCB Service, refer to Section 1 - Service Tools
Specifications
4 Spool Control Valve Block (S1) topic for the applicable machine models. K Table 1.
Specification Variants ( T E5-2)
IMPORTANT: These specifications are only applicable to
some machine models. Refer to the table at the front of this
(1) Before testing the Load Sense Relief Valve pressure, allow the hydraulic system to warm up to 50 °C (122 °F) to ensure
an accurate reading. Be sure to identify the machine variant correctly.
C047990
Fig 1.
(1) Before testing the Load Sense Relief Valve pressure, allow the hydraulic system to warm up to 50 °C (122 °F) to ensure
an accurate reading. Be sure to identify the machine variant correctly.
C047990
Fig 2.
Variflow Pump
Type: EK.DS Variable displacement pump with integral gear pump for
cooling fan motor operation
Mounting: Bevel Gearbox
Direction of Rotation: Anti-clockwise
Theoretical displacement: cc/rev cu in/rev
Maximum 63 3.8
Minimum 11.2 (0 )(1) 0.68 (0(1))
Cooling fan pump 16 0.98
Flow at 2200 rev/min (90% min. displacement): litres/min UK gal/min US gal/min
Main services pump variable
Cooling fan pump 31.7 7.0 8.4
Maximum Pressure: bar kg/cm 2
lb/in2
Continuous 250 254 3625
Peak 315 321 4568
Cooling fan pump 250 254 3625
Maximum Speed: 3000 (2600 (1) )
rev/min
Minimum Speed: 500 rev/min
Swivel Angle Control Modes: Description
Electric EK1 Proportional computer controlled 12V solenoid valve
(PWM)
Hydraulic DS Pressure control and flow control (load sense)
Weight: 43.2 kg (95.2 lbs)
Pressure Settings: bar kg/cm2 lb/in2
Maximum Pressure (Main pump relief valve) 295 (290(1)) 301 (295.7(1)) 4277 (4278.6(1))
Standby Pressure 26 - 29 26.5 - 29.6 377 - 420
Delta P Pressure 19.5 - 20.5 (20 - 19.9 - 20.9 (20.3 - 282 - 297 (290 -
21(1)) 21-4(1)) 304.5 (1))
Maximum Steering Pressure 200 204 2900
SE engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 10 cc/rev
Fan Speed (at maximum engine rev/min): 2800
Maximum Pressure Setting 198 bar (2871 lbf/in2)
Body Colour Black
Weight: TBA
SD 63 kW engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 15 cc/rev
Fan Speed (at maximum engine rev/min): 1800
Maximum Pressure Setting 56 bar (812 lbf/in2)
Body Colour Red
SD 74 kW and SF engines:
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 12 cc/rev
Fan Speed (at maximum engine rev/min): 2500
Maximum Pressure Setting 120 (1740 lbf/in2)
Body Colour Black
SE engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 10 cc/rev
SD 63 kW engines :
Type: Gear motor
Direction of Rotation: Clockwise
Motor Displacement 19 cc/rev
Fan Speed (at maximum engine rev/min): TBA
Maximum Pressure Setting 56 bar (812 lbf/in2)
Body Colour Red
SE 97kW engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 11 cc/rev
Fan Speed (at maximum engine rev/min): TBA
Maximum Pressure Setting 115 bar (1668 lbf/in2)
Colour Code (See sticker) None
SD 63 kW engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
SD 74 kW and SF engines:
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 15 cc/rev
Fan Speed (at maximum engine rev/min): TBA
Maximum Pressure Setting 80 bar (1160 lbf/in2)
Body Colour Black
Operation Overview
8A
C048490-C5
Fig 3. Component Location
The pump only supplies the necessary quantity of oil to Load Sensing
satisfy the hydraulic system.The tilting swashplate angle is
controlled by the hydraulic load sense pressure K Load When a service is operated, the system senses the flow
Sensing ( T E5-13) and the pump control solenoid. and adjusts the pump operating pressure to move the load.
The load sense system also includes the main pressure
The pump controller ECU (HVCS) 3-11 operates the pump relief system, which is controlled by the load sense relief
control solenoid. The ECU monitors the load on the engine valve (LSRV) 3-6A. This replaces the Main Relief Valve
by comparing the throttle pedal position with the engine (MRV) used in the normal system.
speed. The ECU also monitors the hydraulic oil
temperature. If the engine is overloaded or the oil
temperature is more than the specified limit, the ECU
sends a signal to the solenoid. The solenoid decreases the
swashplate angle which decreases the pump output flow.
If the oil has overheated the decrease in oil flow lets the oil
cool.
Oil from the pump flows to the priority valve in the inlet
section of the valve block 3-6. The priority valve supplies
the steering circuit first. With no demand from the steering
system, oil from the pump 3-3 flows through the priority
valve to the control valve sections 3-6.
The hydraulic oil cooler 3-1 in the return line from the fan
hydraulic motor 3-2 keeps the system hydraulic oil cool as
it is flows around the cooling fan circuit. K Variflow Pump
Operation ( T E5-29)
Oil from the main hydraulic pump arrives at the inlet gallery
P. When the relevant service spool D is selected, the spool
moves against the force of the centring spring E, allowing
the oil to flow to move the required service. When the
service spool D is de-selected the centring spring returns
the spool to the neutral position.
A405000-C1
Fig 4. Servo Pilot Operated Spool
The control lever moves in two axis and also includes two
thumbwheel switches. The control lever and thumbwheel
switches control eight electro proportional solenoid valves
which operate the four service spools in the valve block.
Control lever - AXIS Two Proportional analogue Power base PWM ECU
electrical signal
Variflow Pump
C051000-C1
Fig 6.
No Services Operated
K Fig 7. ( T E5-20)
Oil from the gear pump 1B also flows through the chassis
mounted filter assembly 2 to the pilot pressure control
valve 4. Oil at pilot pressure flows to the inlet section of the
control valve 3 and flows to the proportional solenoid
valves at each service spool.
C050980-C1
Fig 7. No Services Operated
Service Operation
K Fig 8. ( T E5-22)
Oil from the other side of the ram 5 flows across the service
spool and back to the tank in the normal way.
C050980-C2
Fig 8. One Service Operated
Servo
Neutral
Exhaust
C050980-C3
Fig 9. Main System Pressure Relief
A405030-1
Fig 10.
With the spools in the neutral position oil from the pump P
flows to each service spool S and is dead ended. This
generates sufficient pressure (about 15 bar) to overcome
the spring E1 and oil flows across the flushing valve spool
assembly E to tank T. Any load acting on the service ram
R is held by the service spool S.
A405041-1
Fig 11.
Pump pressure = Pressure in load sense gallery LS + pressure from spring E1.
When the service spool S is moved the oil from the pump
P is connected to the gallery P1. The pressure in this
chamber opens the pressure compensator valve PC
allowing oil into the load sense gallery LS. Oil pressure
builds in the gallery LS and the flushing valve spool E
begins to close under the combined action of the oil
pressure and spring force, causing the pump pressure to
rise as follows:
714761-1
Fig 12.
714771-1
Fig 13.
When another service with a higher load is operated Should the oil flow demanded by the sum of the combined
simultaneously, a typical example is the lifting of the boom services operating ever exceed that of the pump, all the
X and simultaneous operation of the tilt Y as shown. pressure compensator valves will partially close
K Fig 13. ( T E5-28) accordingly, effectively dividing the available flow between
all the services proportionally.
The higher load pressure in the tilt service causes the
pressure compensator valve PC in the boom service to In this condition the service ram with the highest load will
partially close, reducing the size of the opening through not stop, because the speed of the other service rams
which the oil must flow, and in this way maintains a operating will have been reduced proportionally by the
pressure drop across the pressure compensator equal to action of the pressure compensator valves to compensate.
the pressure drop across the boom service spool.
When one of the service spools is returned to neutral, the
In this example, because of the action of the pressure speed of the other service rams still operating will all
compensator valve the boom service is always kept increase proportionally.
independent of the other services, the boom ram speed
remains constant (as controlled by the boom service
spool) and is not affected by the greater operating
pressure in the tilt service.
C051000
Fig 14. Sectioned View
Note: Pressures quoted are for illustration purposes only. response to changes in the hydraulic load sense pressure
Refer to the pump specifications for the correct pressures (yellow) from the hydraulic service.
for machine variant. K Specifications ( T E5-4)
Flow Compensator Valve: When a hydraulic service is
The pump output flow and operating pressure are operated, boom lift for example, a pressure signal
controlled by varying the angle of the tilting swashplate A. (demand) is generated in the load sense line LS from the
The swashplate is moved in one direction by the force of control valve block. The increase in the load sense
the spring B, and in the opposite direction by control pressure, combined with the force of the spring E pushes
pressure (orange) acting behind the swash control piston the flow compensator spool D to the right, this in turn,
C. The control pressure is derived from the pump allows some control pressure (orange) acting on the
operating pressure (red) by the action of the flow swash control piston C to vent back to tank via the case
compensator spool D. The flow compensator spool drain (green). The force of the spring B increases the angle
regulates the angle of the swashplate automatically in of the swashplate A and the pump output flow increases
proportionally.
Parallel Lift
Ram Operation
C094840
Fig 15. Single displacement ram at the rear of the
boom pivot.
C094820
Fig 16. Boom Raise Cycle (Single displacement ram at the rear of the boom pivot)
C094820-C1
Fig 17. Boom Lower Cycle (Single displacement ram at the rear of the boom pivot)
Hydraulic Variable Control System The instrument panel HVCS warning light illuminates as
follows:
(HVCS)
This section explains how the HVCS electrical system Condition Light Status HVCS Status
works. Ignition On Light On Indicates HVCS system is
present
K Fig 19. Electrical Schematic - HVCS ( T E5-35)
Engine Light Off Normal HVCS Operation
K Fig 20. Wires and Connectors - HVCS ( T E5-36) Running
Engine Light On Hydraulic Oil Overheated
K Connector and Device Key ( T E5-48) Running (hydraulic pump output is
automatically reduced
Central to the system is the pump controller electronic until oil temperature falls).
control unit (ECU) 4008 mounted in the engine Engine Light Flashes HVCS Fault
compartment. The ECU receives an engine load signal Running
(actual engine torque) from the engine ECU (not shown)
via the instrument panel (centre cluster) 4002/6017, and
Note: The instrument panel (centre cluster) 4002/6017
also a hydraulic fluid temperature signal from the variflow
converts the existing engine load CANbus protocol signal
pump temperature sensor 5014.
from the engine ECU, into a corresponding LINbus
protocol signal to the pump controller ECU 4008.
When the pump controller ECU senses that the engine is
being overloaded, or when the hydraulic fluid temperature
increases, it sends a corresponding pulse width modulated
(PWM) current signal output to the variflow pump
proportional solenoid valve 3047. The solenoid valve
operates to adjust the pump performance (power curve
characteristic) and thereby limits the hydraulic power
available to the hydraulic services.
C053110
Fig 18. HVCS Warning Light
C050942-C1
Fig 20. Wires and Connectors - HVCS
Fig 21.
A Main control lever handle J Axis 4 - Thumbwheel
B Powerbase PWM ECU K Axis 1 - Raise Lower
C Electrical connector - Thumbwheels and auxiliary II L Axis 2 - Carriage tilt
button
Movement of the control lever 22-A causes an electrical
D Electrical connector - Constant auxiliary button
signal proportional to the lever movement. The Powerbase
E Electrical connector - Powerbase PWM ECU ECU 22-E monitors these signals (inputs) and converts the
F Constant flow button voltage into a corresponding valve current signal (output)
to the relevant solenoid valve coil.
G Auxiliary II button
H Axis 3 - Thumbwheel
Fig 22.
Key
A Alternator
1032B Hydraulic lock switch
1047 System enable switch
2012 Engine running relay
2047 System enable relay
3042 Servo isolation valve solenoid
4007 Servo control ECU
4011 Joystick powerbase ECU
7036 Diode pack (2)
C061590-C1
Fig 23. System Enable and Isolation. Status = system enabled
Key
4013 LMS display connector J2
4007 Servo control ECU
2035 Second auxiliary relay
1022 Joystick auxiliary changeover switch
3010 Auxiliary changeover valve solenoid
Input at pin 17 of the LMS display ECU 4013 goes high and
the AUX II indicator LED comes ON.
C063410-C1
Fig 24. Auxiliary Changeover. Status = auxiliary II enabled
Key
4011 Joystick powerbase ECU
4013 LMS display connector J2
4007 Servo control ECU
1015 Constant auxiliary enable switch
1032B Hydraulic lock switch
B Joystick constant auxiliary switch
Input at pin 3 of the LMS display ECU 4013 goes high and
the constant flow indicator LED comes ON.
Input at pin 3 of the LMS display ECU 4013 goes low and
the constant flow indicator LED goes OFF.
C063430-C1
Fig 25. Constant Auxiliary. Status = constant auxiliary enabled.
A Thumbwheel switch - auxiliary service ECU 4011 provides thumbwheel switches A and B with a
B Thumbwheel switch - extend/retract 5V power supply via pin 17.
service
3007 Proportional control valve solenoid - The thumbwheels send a voltage between 0.7V and 4.3V
auxiliary A service to the ECU 4011 on pin 20 (switch A) and pin 18 (switch
B). The voltage is determined by the position of the
3008 Proportional control valve solenoid - thumbwheel switch.
auxiliary B service
3019 Proportional control valve solenoid - ECU 4011 produces a PWM signal in proportion to the
extend service input voltage to the proportional solenoid coils 3007, 3008,
3019 and 3038 for operation of the service spools.
C063460-C1
Fig 26. Extend/Retract and Auxiliary Services (Thumbwheel Switches)
3030 Proportional control valve solenoid - lift When tilt lock switch 1049 is set to position A the PWM
service outputs to the crowd and dump control valve solenoids are
switched OFF.
C063450-C1
The table shows the harness connectors that connect to the electrical devices. The connectors are shown looking at the
mating face when disconnected. Remember that the drawings show the harness connectors NOT the device connectors.
Use the table and the relevant electrical schematic to identify the pins in the harness connectors. Continuity checks on
the harness wires can be carried out using a multi-meter. Do not touch ECU connector pins. Do not use a multi-meter on
ECU connector pins.
Device Description Location Harness Connector
A Alternator On the right side of the engine
9
D+
B+
M10
1015 Constant Auxiliary Enable TBA
Switch
1047 System Enable Switch Located on the servo control pod. Remove the
switch to get access to the connector.
3030 Lift Proportional Solenoid Located on the electro servo valve block.
4002 Centre Cluster (With LCD) The ECU connector is located behind the centre
Display Connector cluster unit.
4012 LMS Display ECU The ECU connectors are located behind the LMS
Connector J1 (Grey) display unit. Be sure to identify the correct 11 20
connector. Connector J1 is coloured Grey.
1 10
4013 LMS Display ECU The ECU connectors are located behind the LMS
Connector J2 (Black) display unit. Be sure to identify the correct 10 1
connector. Connector J2 is coloured black.
20 11
5014 Hydraulic Oil Temperature Located on the Variflow pump suction hose.
Sensor
6017 Centre Cluster Display The display panel connectors are located behind
(Without LCD) Connector the panel.
Fault Finding
Tables
Fault Descriptions:
K Table 8. ALL services lack power. ( T E5-52)
K Table 9. ALL services slow to operate. ( T E5-53)
K Table 10. ONE service fails, or is slow to operate. ( T E5-53)
K Table 11. The engine tends to stall when hydraulics are under load. ( T E5-54)
K Table 12. Low flow from auxiliary service ( T E5-54)
K Table 13. Boom operation is “Fierce” ( T E5-54)
K Table 14. Boom Ext/Ret slow, or low flow from auxiliary service (Servo operated spools). ( T E5-54)
K Table 15. Forks creep down ( T E5-54)
K Table 16. Parallel lift faulty ( T E5-55)
Table 14. Boom Ext/Ret slow, or low flow from auxiliary service (Servo operated spools).
– Due to blocked servo pilot filter element. – Renew the servo pilot filter element.
– Due to proportional solenoid valve cartridge damaged, – Renew the pilot pressure supply valve.
or sticking due to contamination.
– Due to faulty servo regulating valve.
Note: The maximum auxiliary service flow available operation, and upto 65 litre min. with `constant' operation
should be upto 95 litre min. with `manual' thumbwheel selected.
Test Procedures
Main System Pressures 2 Working under the RH side of the machine, connect a
0 - 400 bar (5801 lbf/in2) pressure transducer to the
To investigate any hydraulic performance issues you must pump output test point 28-B and connect to ‘Channel
complete the pressure tests. 1’ on the test set.
– Stand-by Pressure - This is the pressure measured at 3 Connect another 0 - 400 bar (5801 lbf/in2) pressure
the pump when the hydraulic services are not transducer to the pump load sense pressure test
operated. point 28-A and connect to ‘Channel 2’ on the test set.
– Delta P Pressure - This is the pressure setting of the
pump controller. The controller makes sure that the
pump delivers a pressure above what is required by
the hydraulic services. This extra pressure is the delta
P pressure.
– Load Sense Relief Valve Pressure - This is the
maximum pressure that can be achieved within the
hydraulic system.
!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2 C075860
Fig 28.
1 Park the machine and make it safe. Vent the hydraulic
system. Obey the care and safety procedures. 4 Press button 29-D to switch the test set ON, then
K Related Topics ( T E5-3) press button 29-E to set the screen to display delta-P
between channels 1 and 2.
!MCAUTION
Make sure the load valve is in the OPEN position, (the
adjusting knob screwed fully OUT), before starting the
following pressure test. Failure to do this could
damage the pump.
HYD-4-4_1
Table 17.
Standby Load Sense Delta-P Steering
Relief
C047990-C2
Fig 32.
C075860-C1
Fig 31.
!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.
C050610
2 With the engine running at 1500 rpm, check the
Fig 33.
reading on the pressure gauge. The servo pressure
should be as stated below:
Auxiliary Relief Valve Pressure (ARV) - Note: Locate a connection in the tilt ram circuit at the rear
of the boom. The illustrations show typical locations.
ARV’s set higher than the MRV
Some ARVs are set at a higher pressure than the MRV. K Fig 34. Tilt ram hose at the rear boom bulkhead
This is usually one of the tilt ram ARVs. Because the tilt bracket ( T E5-62)
ram is smaller than the lift ram, higher hydraulic pressure
is required on one side of the tilt ram to prevent the load 4 Start the engine and tilt the forks fully back. Remove
tilting the forks forward. the safety strut and slowly lower the boom. As the
boom is lowered the pressure gauge will show the
Check the pressure setting and ARV location for the A.R.V. pressure, which should be as stated.
applicable machine. K Specifications ( T E5-4) K Specifications ( T E5-4)
1 Park the machine and make it safe. Raise the boom 5 If the pressure is incorrect, adjust the A.R.V. K Relief
and fit the safety strut. Tilt the forks fully forward. Valve Adjustment ( T E2-50).
Obey the care and safety procedures. K Related
Topics ( T E5-3)
!MWARNING
2 Vent residual hydraulic pressure. Obey the care and Take care when disconnecting hydraulic hoses and
safety procedures. K Related Topics ( T E5-3) fittings as the oil will be HOT.
TRANS-1-2
3 Locate the hydraulic line for the high pressure side of
the tilt ram. Fit a tee piece in the hydraulic line. 6 After completing the test, fully lower the boom, switch
Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure OFF the engine and vent residual hydraulic pressure.
gauge to the tee piece. Disconnect the pressure gauge and reconnect the tilt
ram hose.
331440-1
Fig 34. Tilt ram hose at the rear boom bulkhead bracket
Testing the HVCS System Operation 7 Connect the black connector 4 of the test lead to the
negative lead of the electrical multimeter connected
The Variable Pump Control System (HVCS) automatically to the negative or COM terminal.
reduces the swashplate angle if the engine is overloaded,
or if the hydraulic oil temperature is high. Use the following
test procedure to check the HVCS is operating correctly.
C082990
Fig 35. Test Lead (A) - JCB Part No. 332/E0800
Preparation
T040560-2
1 Make the machine safe with the boom lowered to the Fig 36.
ground.
6 Connect the red connector 3 of the test lead to the Fig 37.
positive lead of the electrical multimeter connected to
the A (Amp) terminal. Test Procedure
Note: Do not connect the positive lead to the mA terminal 1 Operate the machine to increase the temperature of
as this can affect the recorded values. the hydraulic oil to the working temperature of 50°C
(122°F).
Important: Do not set the multimeter to mA as this can For each test, measure then record the engine speed
affect the recorded values. and current values at the pump solenoid.
Table 18.
Test Required Values Recorded Values
Engine Speed Pump Signal Engine Speed Pump Signal
(rpm) (Amp) (rpm) (Amp)
Ignition ON 0 0.6 - 0.7
Engine Idle (No hydraulic functions operated) 850 1.7 - 1.83
Maximum Engine Speed (No hydraulic functions 2370 1.7 - 1.83
operated)
Transmission Stall (Maximum throttle applied) 1900 - 2100 1.25 - 1.35
Combined Transmission Stall (1)
1500 - 1700 0.95 - 1.05
(1) Combined Transmission stall refers to stalling the transmission with the dump and retract services fully selected.
The pump signals are dependant on the output from the Task: Complete a continuity test between pin #10 of Pump
ECU and the resistance of the wiring and other ECU connector 5 and pin #1 of Pump Solenoid connector
components in the circuit. 2.
K Table 18. ( T E5-64). If the recorded values are outside Result: Continuity OK?
of the required values, then the HVCS cannot operate
correctly. You must test the electrical circuit to identify – Yes. Continue to Test 3.
which component is at fault. Complete the Tests 1 to 5 (as – No. Examine the items shown:
necessary) to find the cause of the fault.
Examine the Engine Harness to Chassis Harness
Note: A schematic drawing and photographs to show Connection 6.
component locations are provided. K HVCS Schematic
and Component Locations ( T E5-68). Examine the Chassis Harness to Transmission
Harness Connection 7.
Before you Start the Fault Diagnosis Procedure
Examine the engine, chassis and transmission
1 Disconnect the test lead A. harness wiring for damage.
Task: Measure the resistance of the pump solenoid coil 1. Result: Continuity OK?
T040570-1
Fig 38.
T040620-1
Fig 40.
Test 4b
Expected Values:
T040920-1
Fig 41. Schematic Drawing
T040950-1 T040580-1
Fig 42. Fig 44.
T040600-4 T040590-1
Fig 43. Fig 45.
T040940-1
Fig 46.
Bleed Procedures
Important: Make sure that the boom is in the lowered 4 Start the engine and operate the sway lever to sway
position when bleeding the sway ram circuit. the machine fully to the operator’s left side. Hold the
lever in this position until no more air is expelled
Note: This procedure requires two people. One person to through the bleed valve 1. Return the control lever to
operate the sway controls and another to tighten the bleed its neutral position. Immediately tighten the bleed
screw when all air has been expelled. If this procedure is valve 1 to prevent air entering the circuit.
done by one person air may enter the cylinder due to the
delay in dismounting from the cab to attend to the sway
cylinder.
!MWARNING
Communications
Bad communications can cause accidents. If two or
more people are working on the machine, make sure
each is aware of what the others are doing. Before
starting the engine make sure the others are clear of
the danger areas; examples of danger areas are: the
rotating blades and belt on the engine, the
attachments and linkages, and anywhere beneath or
behind the machine. People can be killed or injured if
these precautions are not taken.
INT-3-1-5
Important: DO NOT stand between the chassis and the 8 Check the hydraulic fluid level. K Related
wheel. You can be trapped or crushed when sway is Topics ( T E5-3)
operated.
This topic contains information about a machine SYSTEM. The system has some devices that connect either
mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications
table. K Related Topics ( T E6-3).
Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer
to the relevant topics. K Related Topics ( T E6-3)
This topic is intended to help you understand what the system does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
(1) Specification variant. Make sure your refer to the correct specification
(1) The table lists procedure and specification variants and the applicable machine models. Use the table to make sure
you refer to the correct information.
(1) The table lists procedure and specification variants and the applicable machine models. Use the table to make sure
you refer to the correct information.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
(1) Tool available from JCB Service, refer to Section 1 - Service Tools
Specifications
(1) Before testing the Load Sense Relief Valve pressure, allow the hydraulic system to warm up to 50 °C (122 °F) to ensure
an accurate reading. Be sure to identify the machine variant correctly.
2A
2N 2M
B4 A4
B3 A3
B2 A2
B1 A1
LS
2H P
2J
T
2C
2R
C094030-C1
Fig 1.
SE engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 10 cc/rev
Fan Speed (at maximum engine rev/min): 2800
Maximum Pressure Setting 198 bar (2871 lbf/in2)
Body Colour Black
Weight: TBA
SD 63 kW engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 15 cc/rev
Fan Speed (at maximum engine rev/min): 1800
Maximum Pressure Setting 56 bar (812 lbf/in2)
Body Colour Red
SD 74 kW and SF engines:
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 12 cc/rev
Fan Speed (at maximum engine rev/min): 2500
Maximum Pressure Setting 120 (1740 lbf/in2)
Body Colour Black
SE engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 10 cc/rev
SD 63 kW engines :
Type: Gear motor
Direction of Rotation: Clockwise
Motor Displacement 19 cc/rev
Fan Speed (at maximum engine rev/min): TBA
Maximum Pressure Setting 56 bar (812 lbf/in2)
Body Colour Red
SE 97kW engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 11 cc/rev
Fan Speed (at maximum engine rev/min): TBA
Maximum Pressure Setting 115 bar (1668 lbf/in2)
Colour Code (See sticker) None
SD 63 kW engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Operation Overview
6 12
16
7
6A 9
12
11 8
13
10
14
15
C094040
Fig 2. Component Location
Variflow Hydraulic Pump - Power Control The hydraulic pump 3A is a variable displacement axial
piston type. The angle of the variable tilting swashplate
K Fig 2. Component Location ( T E6-12) mechanism in the pump controls the pump output.
The hydraulic pump 3 pulls oil from the hydraulic tank 9. The pump only supplies the necessary quantity of oil to
The engine operates the pump which is connected to the satisfy the hydraulic system.The tilting swashplate angle is
rear of the bevel gearbox. controlled by the hydraulic load sense pressure K Load
Sensing ( T E6-14) and the pump control solenoid.
The hydraulic pump 3A is a variable displacement axial
piston type. The angle of the variable tilting swashplate The pump controller ECU (HVCS) 11 operates the pump
mechanism in the pump controls the pump output. control solenoid. The ECU monitors the load on the engine
by comparing the throttle pedal position with the engine
The pump only supplies the necessary quantity of oil to speed. The ECU also monitors the hydraulic oil
satisfy the hydraulic system.The tilting swashplate angle is temperature. If the engine is overloaded or the oil
controlled by the hydraulic load sense pressure K Load temperature is more than the specified limit, the ECU
Sensing ( T E6-14) and the pump power controller. sends a signal to the solenoid. The solenoid decreases the
swashplate angle which decreases the pump output flow.
The hydraulic pump power controller cartridge uses a If the oil has overheated the decrease in oil flow lets the oil
system of springs to limit the torque required to drive the cool.
pump. Above preset pressure and flow values the
cartridge overrides the load sense control valves and Oil from the pump flows to the priority valve in the inlet
prevents further tilting of the swashplate. The system is section of the valve block 6. The priority valve supplies the
designed to prevent the engine stalling. steering circuit first. With no demand from the steering
system, oil from the pump 3 flows through the priority valve
Oil from the pump flows to the priority valve in the inlet to the control valve sections 6.
section of the valve block 6. The priority valve supplies the
steering circuit first. With no demand from the steering On the rear of the variflow pump assembly is a gear type
system, oil from the pump 3 flows through the priority valve pump which operates the cooling fan and supplies oil to the
to the control valve sections 6. servo pilot valve. Oil from the pump section 3B flows
directly to the cooling fan hydraulic motor 2 and the servo
On the rear of the variflow pump assembly is a gear type pilot valve 7. On sway machines a changeover valve
pump which operates the cooling fan and supplies oil to the switches oil supply between the sway ram service and the
servo pilot valve. Oil from the pump section 3B flows fan motor.
directly to the cooling fan hydraulic motor 2 and the servo
pilot valve 7. On sway machines a changeover valve The hydraulic oil cooler 1 in the return line from the fan
switches oil supply between the sway ram service and the hydraulic motor 2 keeps the system hydraulic oil cool as it
fan motor. is flows around the cooling fan circuit. K Variflow
Hydraulic Pump - HVCS ( T E6-33)
The hydraulic oil cooler 1 in the return line from the fan
hydraulic motor 2 keeps the system hydraulic oil cool as it Servo Pilot Pressure Supply Valve
is flows around the cooling fan circuit. K Variflow
Hydraulic Pump - Power Control ( T E6-30) K Fig 2. Component Location ( T E6-12)
Variflow Hydraulic Pump - HVCS The system supplies a low pressure hydraulic flow to move
the valve spools. The oil flows through the pilot pressure
K Fig 2. Component Location ( T E6-12) supply valve 7. This valve decreases the pressure and the
oil flows to the proportional control solenoids in the control
The hydraulic pump 3 pulls oil from the hydraulic tank 9. valve block. The proportional control solenoids control the
The engine operates the pump which is connected to the flow to move the selected valve spool.
rear of the bevel gearbox.
Load Sensing
K Fig 2. Component Location ( T E6-12)
Oil from the main hydraulic pump arrives at the inlet gallery
P. When the relevant service spool D is selected, the spool
moves against the force of the centring spring E, allowing
the oil to flow to move the required service. When the
service spool D is de-selected the centring spring returns
the spool to the neutral position.
A405000-C1
Fig 3. Servo Pilot Operated Spool
Electronic Servo Proportional Control to the movement of the lever or thumbwheel switches. The
ECU changes the analogue signals and broadcasts
The control lever 1 and attached thumbwheels operate the messages on the machine CAN bus.
hydraulic services using electrical signals.
The hydraulic control ECU 3 recognises the CAN
This type of lever has two functions, Proportional messages and generates the correct PWM signal for
thumbwheel control and electro servo lever control. operation of the control valve proportional solenoids 4.
The control lever moves in two axis and also includes two The proportional solenoid valves operate as pressure
thumbwheel switches. The control lever and thumbwheel reducing valves. These supply servo pilot oil to move the
switches control eight electro proportional solenoid valves auxiliary, or extend retract service spool. The supply is at a
which operate the four service spools in the valve block. pressure in relation to the amount the operator moves the
joystick or thumbwheel switch. K Electro Servo Control
In the control lever assembly is the joystick controller ECU Lever ( T E6-17)
2. The ECU receives analogue electrical inputs in relation
B4 A4
B3 A3
B2 A2
B1 A1
LS
4
P
T
CANBus
C094310
Fig 4. Electro Servo Control Lever
Control lever - AXIS Two Proportional analogue Hydraulic control ECU via CAN
electrical signal message from the joystick
controller ECU
No Services Operated
K Fig 5. ( T E6-19)
C09450-C1
ACC
T1
P1
TP2
BAR
BAR
0.7
0.7
30 BAR
T2
2 P
P2
Service Operation
K Fig 6. ( T E6-21)
Oil from the other side of the ram 5 flows across the service
spool and back to the tank in the normal way.
C094150-C2
ACC
T1
P1
TP2
BAR
BAR
0.7
0.7
30 BAR
T2
2 P
P2
Servo
Neutral
Exhaust
C094150-C3
ACC
T1
P1
TP2
BAR
BAR
0.7
T2
2 P
P2
A405030-1
Fig 8.
With the spools in the neutral position oil from the pump P
flows to each service spool S and is dead ended. This
generates sufficient pressure (about 15 bar) to overcome
the spring E1 and oil flows across the flushing valve spool
assembly E to tank T. Any load acting on the service ram
R is held by the service spool S.
A405041-1
Fig 9.
Pump pressure = Pressure in load sense gallery LS + pressure from spring E1.
When the service spool S is moved the oil from the pump
P is connected to the gallery P1. The pressure in this
chamber opens the pressure compensator valve PC
allowing oil into the load sense gallery LS. Oil pressure
builds in the gallery LS and the flushing valve spool E
begins to close under the combined action of the oil
pressure and spring force, causing the pump pressure to
rise as follows:
714761-1
Fig 10.
714771-1
Fig 11.
When another service with a higher load is operated Should the oil flow demanded by the sum of the combined
simultaneously, a typical example is the lifting of the boom services operating ever exceed that of the pump, all the
X and simultaneous operation of the tilt Y as shown. pressure compensator valves will partially close
K Fig 11. ( T E6-27) accordingly, effectively dividing the available flow between
all the services proportionally.
The higher load pressure in the tilt service causes the
pressure compensator valve PC in the boom service to In this condition the service ram with the highest load will
partially close, reducing the size of the opening through not stop, because the speed of the other service rams
which the oil must flow, and in this way maintains a operating will have been reduced proportionally by the
pressure drop across the pressure compensator equal to action of the pressure compensator valves to compensate.
the pressure drop across the boom service spool.
When one of the service spools is returned to neutral, the
In this example, because of the action of the pressure speed of the other service rams still operating will all
compensator valve the boom service is always kept increase proportionally.
independent of the other services, the boom ram speed
remains constant (as controlled by the boom service
spool) and is not affected by the greater operating
pressure in the tilt service.
C051000-C3
Fig 12.
Variflow Hydraulic Pump - Power Control C. The control pressure is derived from the pump
operating pressure (red) by the action of the flow
The pump output flow and operating pressure are compensator spool D. The flow compensator spool
controlled by varying the angle of the tilting swashplate A. regulates the angle of the swashplate automatically in
The swashplate is moved in one direction by the force of response to changes in the hydraulic load sense pressure
the spring B, and in the opposite direction by control (yellow) from the hydraulic service.
pressure (orange) acting behind the swash control piston
C051000-C2
Fig 13. Sectioned View
The pump flow output is reduced for a given system In this way the valve spool X moves at flow and pressure
pressure to remain below the maximum torque available to values on the torque limit slope T shown on the graph. For
turn the pump. example we can see that if the system pressure is 190bar
the torque control valve will set the maximum flow to 40cc.
D LS
P(bar)
260
T
190
P 113
S
V(cc/rev)
27.5 40 63
C093990
Fig 15.
Variflow Hydraulic Pump - HVCS C. The control pressure is derived from the pump
operating pressure (red) by the action of the flow
The pump output flow and operating pressure are compensator spool D. The flow compensator spool
controlled by varying the angle of the tilting swashplate A. regulates the angle of the swashplate automatically in
The swashplate is moved in one direction by the force of response to changes in the hydraulic load sense pressure
the spring B, and in the opposite direction by control (yellow) from the hydraulic service.
pressure (orange) acting behind the swash control piston
C051000
Fig 16. Sectioned View
C094840
Fig 17. Single displacement ram at the rear of the
boom pivot.
C094820
Fig 18. Boom Raise Cycle (Single displacement ram at the rear of the boom pivot)
C094820-C1
Fig 19. Boom Lower Cycle (Single displacement ram at the rear of the boom pivot)
C094810
Fig 20. Twin displacement rams forward of the boom
pivot.
Oil is forced out of the rod side of displacement rams 9 and Auxiliary relief valve (ARV) 2J opens to protect the tilt ram
9A as the boom rises. The oil cannot flow past the tilt spool from over pressurisation. The anti-cavitation feature of
2F, as the spool is not selected. Instead, it flows to the valve 2H ensures that, in these circumstances, the tilt and
head side of tilt ram 10. Oil displaced from the rod side of displacement rams will not cavitate.
C094800-C1
Fig 21. Boom Raise Cycle (Twin displacement rams forward of the boom pivot)
C094800
Fig 22. Boom Lower Cycle (Twin displacement rams forward of the boom pivot)
C083280
Fig 23. Single displacement ram forward of the boom
pivot.
C094880
Fig 24. Boom Raise Cycle (Single displacement forward of the boom pivot)
C094880-C1
Fig 25. Boom Lower Cycle (Single displacement ram forward of the boom pivot)
C053110
Fig 26. HVCS Warning Light
C051010-C1
Fig 27. Electrical Schematic - HVCS
Component Key:
4008 Pump Controller ECU
6017/4002 Instrument panel (Centre cluster)
4012/4013 Instrument panel (J1/J2 cluster) - HVCS
`Active' warning light
3047 HVCS Proportional solenoid valve (Variflow
pump)
5014 Hydraulic fluid temperature sensor (Variflow
pump - suction port)
C050942-C2
Fig 28. Wires and Connectors - HVCS
4 1
3 2
1 2 3 4 5 6
12 11 10 9 8 7
C094140
Fig 29.
A Main control lever handle K Axis 1 - Raise Lower
B CAN joystick controller ECU L Axis 2 - Carriage tilt
C Electrical connector - Thumbwheels M Electrical connector - CAN joystick controller ECU
D Electrical connector - Joystick buttons
Movement of the control lever A causes an electrical signal
E Electrical connector - CAN joystick controller ECU proportional to the lever movement. The controller ECU B
F Constant flow button monitors these signals (inputs) and converts the voltage
into a corresponding CAN message (output) which is
G Auxiliary II button
broadcast on the machine CAN bus.
H Axis 3 - Thumbwheel
J Axis 4 - Thumbwheel
Fig 30.
4019 - J1
P002 8004
FUSE 18 11
2 15
3 16
-008
4 17
5
6
ECU
FUSE 2
22
+025
+ve
4020 - J2
IGN +VE
C094080
Fig 31. Electrical Schematic - Hydraulic Control ECU Power and Ground
- 008
2 1
4019 - J1
3064
SHUT OFF SOLENOID 13
10
22
6
5
2
1
1049
TILT ISOLATION SWITCH
27
1 2
ECU
1032B
HYDRAULIC STOP SWITCH 5
31
20
6
5
2
1
1047
JOYSTICK ISOLATION SWITCH
4020 - J2
C094110
Fig 32. Electrical Schematic - System Enable and Isolation
-008
4019 - J1
34
4022B CAN H
33
CAN L
2 12
CAN L
1 11
CAN H
ECU
4022A ECU
CAN JOYSTICK
-001
CONTROLLER
3 2 8004
9
1077A 6
2nd AUXILIARY BUTTON
3
4020 - J2
8004
HYDRAULIC CONTROL ECU
P002 68
FUSE 6
P001
FUSE 4
-004
IGN +VE
C094120
Fig 33. Electrical Schematic - Auxiliary Changeover
-008
4019 - J1
34
CAN H
ECU
33
2 CAN L
12
CAN L
11
1 CAN H
1
7
4022B
CAN JOYSTICK
8004 CONTROLLER
P002 68 27
+12v
FUSE 6
ECU
3 1
1077B
CONSTANT AUX BUTTON
35
6
5
3
2
1015
CONSTANT AUX SWITCH
4020- J2
C94130
Fig 34. Electrical Schematic - Constant Auxiliary
-008
4019 - J1
34
CAN H
ECU
33
2 CAN L
12
CAN L
11
1 CAN H
8032
12
12
35
6
+5V 4
7
GND
5 ECU
6
4022B
5
CAN JOYSTICK
CONTROLLER
4
9
3038 3019
1076A RETRACT SOLENOID EXTEND SOLENOID
AUX THUMBWHEEL
10
11
1076B
EXTEND/RETRACT 3008 3007
THUMBWHEEL
AUX A SOLENOID AUX B SOLENOID
8004
P002 68 4020 - J2
FUSE 6
HYDRAULIC CONTROL ECU
IGN + VE
C094070
Fig 35. Electrical Schematic - Extend/Retract and Auxiliary Services (Thumbwheel Switches)
-008
4019 - J1
34
CAN H
ECU
33
2 CAN L
12
CAN L
11
1 CAN H
4022B
CAN JOYSTICK 8032
1
CONTROLLER
7
8004
P002 68
FUSE 6
ECU
3017 3015
1 DUMP SOLENOID CROWD SOLENOID
23
12
3032 3030
24 LOWER SOLENOID RAISE SOLENOID
4020 - J2
IGN +ve
C094060
The table shows the harness connectors that connect to the electrical devices. The connectors are shown looking at the
mating face when disconnected. Remember that the drawings show the harness connectors NOT the device connectors.
Use the table and the relevant electrical schematic to identify the pins in the harness connectors. Continuity checks on
the harness wires can be carried out using a multi-meter. Do not touch ECU connector pins. Do not use a multi-meter on
ECU connector pins.
Device Description Location Harness Connector
-001 Chassis Harness Ground Refer to Section C - Electrical Harness
SYSTEM. K Related Topics ( T E6-3)
-008
M10
1015 Constant Auxiliary Enable Control lever console.
Switch
Fault Finding
Tables
Fault Descriptions:
K Table 9. ALL services lack power. ( T E6-64)
K Table 10. ALL services slow to operate. ( T E6-65)
K Table 11. ONE service fails, or is slow to operate. ( T E6-65)
K Table 12. The engine tends to stall when hydraulics are under load. ( T E6-66)
K Table 13. Low flow from auxiliary service ( T E6-66)
K Table 14. Boom operation is “Fierce” ( T E6-66)
K Table 15. Servo operated spool services slow to operate or low auxiliary flow ( T E6-66)
K Table 16. Forks creep down ( T E6-66)
K Table 17. Parallel lift faulty ( T E6-67)
– Due to blocked servo pilot filter element. – Renew the servo pilot filter element.
– Due to faulty servo regulating valve. – Renew the pilot pressure supply valve.
Insufficient output flow from variflow pump because the – Check and adjust, or renew the LSRV as required.
pump is not receiving the correct load sense pressure: – Measure the load sense pressure.
Table 15. Servo operated spool services slow to operate or low auxiliary flow
– Due to blocked servo pilot filter element. – Renew the servo pilot filter element.
– Due to proportional solenoid valve cartridge damaged, – Renew the pilot pressure supply valve.
or sticking due to contamination.
– Due to faulty pilot pressure supply valve.
Note: The maximum auxiliary service flow available operation, and upto 65 litre min. with `constant' operation
should be upto 95 litre min. with `manual' thumbwheel selected.
Test Procedures
Main System Pressures 2 Working under the RH side of the machine, connect a
0 - 400 bar (5801 lbf/in2) pressure transducer to the
To investigate any hydraulic performance issues you must pump output test point B and connect to ‘Channel 1’
complete the pressure tests. on the test set.
– Stand-by Pressure - This is the pressure measured at 3 Connect another 0 - 400 bar (5801 lbf/in2) pressure
the pump when the hydraulic services are not transducer to the pump load sense pressure test
operated. point A and connect to ‘Channel 2’ on the test set.
– Delta P Pressure - This is the pressure setting of the
pump controller. The controller makes sure that the
pump delivers a pressure above what is required by
the hydraulic services. This extra pressure is the delta
P pressure.
– Load Sense Relief Valve Pressure - This is the
maximum pressure that can be achieved within the
hydraulic system.
!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2 C075860
Fig 37.
1 Park the machine and make it safe. Vent the hydraulic
system. Obey the care and safety procedures. 4 Press button D to switch the test set ON, then press
K Related Topics ( T E6-3) button E to set the screen to display delta-P between
channels 1 and 2.
!MCAUTION
Make sure the load valve is in the OPEN position, (the
adjusting knob screwed fully OUT), before starting the
following pressure test. Failure to do this could
damage the pump.
HYD-4-4_1
C075900
Fig 39.
Example:
9
Table 18.
Standby Load Sense Delta-P Steering
Relief
the pressure.
B1 A1
LS
P
T
C
C094030
Fig 41.
C075860-C1
Fig 40.
Auxiliary Relief Valve Pressure (ARV) - Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure
gauge to the tee piece.
ARV’s set higher than the maximum
pump pressure Note: Locate a connection in the tilt ram circuit at the rear
of the boom. The illustrations show typical locations.
Some ARVs are set at a higher pressure than the
maximum pump pressure. This is usually one of the tilt ram
ARVs. Because the tilt ram is smaller than the lift ram, K Fig 43. Tilt ram hose at the rear boom bulkhead
higher hydraulic pressure is required on one side of the tilt bracket ( T E6-74)
ram to prevent the load tilting the forks forward.
4 Start the engine and tilt the forks fully back. Remove
Check the pressure setting and ARV location for the the safety strut and slowly lower the boom. As the
applicable machine. K Specifications ( T E6-4) boom is lowered the pressure gauge will show the
A.R.V. pressure, which should be as stated.
1 Park the machine and make it safe. Raise the boom K Specifications ( T E6-4)
and fit the safety strut. Tilt the forks fully forward.
Obey the care and safety procedures. K Related
Topics ( T E6-3)
!MWARNING
Take care when disconnecting hydraulic hoses and
2 Vent residual hydraulic pressure. Obey the care and fittings as the oil will be HOT.
safety procedures. K Related Topics ( T E6-3) TRANS-1-2
3 Locate the hydraulic line for the high pressure side of 5 After completing the test, fully lower the boom, switch
the tilt ram. Fit a tee piece in the hydraulic line. OFF the engine and vent residual hydraulic pressure.
Disconnect the pressure gauge and reconnect the tilt
ram hose.
331440-1
Fig 43. Tilt ram hose at the rear boom bulkhead bracket
Testing the HVCS System Operation 7 Connect the black connector 4 of the test lead to the
negative lead of the electrical multimeter connected
The Variable Pump Control System (HVCS) automatically to the negative or COM terminal.
reduces the swashplate angle if the engine is overloaded,
or if the hydraulic oil temperature is high. Use the following
test procedure to check the HVCS is operating correctly.
C082990
Fig 44. Test Lead (A) - JCB Part No. 332/E0800
Preparation
T040560-2
1 Make the machine safe with the boom lowered to the Fig 45.
ground.
6 Connect the red connector 3 of the test lead to the Fig 46.
positive lead of the electrical multimeter connected to
the A (Amp) terminal. Test Procedure
Note: Do not connect the positive lead to the mA terminal 1 Operate the machine to increase the temperature of
as this can affect the recorded values. the hydraulic oil to the working temperature of 50°C
(122°F).
Important: Do not set the multimeter to mA as this can For each test, measure then record the engine speed
affect the recorded values. and current values at the pump solenoid.
Table 19.
Test Required Values Recorded Values
Engine Speed Pump Signal Engine Speed Pump Signal
(rpm) (Amp) (rpm) (Amp)
Ignition ON 0 0.6 - 0.7
Engine Idle (No hydraulic functions operated) 850 1.7 - 1.83
Maximum Engine Speed (No hydraulic functions 2370 1.7 - 1.83
operated)
Transmission Stall (Maximum throttle applied) 1900 - 2100 1.25 - 1.35
Combined Transmission Stall (1)
1500 - 1700 0.95 - 1.05
(1) Combined Transmission stall refers to stalling the transmission with the dump and retract services fully selected.
The pump signals are dependant on the output from the Task: Complete a continuity test between pin #10 of Pump
ECU and the resistance of the wiring and other ECU connector 5 and pin #1 of Pump Solenoid connector
components in the circuit. 2.
K Table 19. ( T E6-76). If the recorded values are outside Result: Continuity OK?
of the required values, then the HVCS cannot operate
correctly. You must test the electrical circuit to identify – Yes. Continue to Test 3.
which component is at fault. Complete the Tests 1 to 5 (as – No. Examine the items shown:
necessary) to find the cause of the fault.
Examine the Engine Harness to Chassis Harness
Note: A schematic drawing and photographs to show Connection 6.
component locations are provided. K HVCS Schematic
and Component Locations ( T E6-80). Examine the Chassis Harness to Transmission
Harness Connection 7.
Before you Start the Fault Diagnosis Procedure
Examine the engine, chassis and transmission
1 Disconnect the test lead A. harness wiring for damage.
Task: Measure the resistance of the pump solenoid coil 1. Result: Continuity OK?
T040570-1
Fig 47.
T040620-1
Fig 49.
Test 4b
Expected Values:
T040940-1
Fig 55.
Bleed Procedures
This topic contains information about a machine SYSTEM. The system has some devices that connect either
mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications
table. K Related Topics ( T E7-3).
Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer
to the relevant topics. K Related Topics ( T E7-3)
This topic is intended to help you understand what the system does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
K Auxiliary Relief Valve Pressure (ARV) - ARV’s set lower than the MRV ( T E7-49)
K Auxiliary Relief Valve Pressure (ARV) - ARV’s set higher than the MRV ( T E7-50)
K Relief Valve Adjustment ( T E7-52)
K Checking the Servo Pilot Pressure ( T E7-53)
Related Topics
(1) You must obey all of the relevant care and safety procedures.
(1) Tool available from JCB Service, refer to Section 1 - Service Tools
Specifications
764190-2-C2
Fig 1.
SD 63 kW engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 15 cc/rev
Fan Speed (at maximum engine rev/min): 1800
Maximum Pressure Setting 56 bar (812 lbf/in2)
Body Colour Red
SD 74 kW and SF engines:
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 12 cc/rev
Fan Speed (at maximum engine rev/min): 2500
Maximum Pressure Setting 120 (1740 lbf/in2)
Body Colour Black
SD 63 kW engines :
Type: Gear motor
Direction of Rotation: Clockwise
Motor Displacement 19 cc/rev
Fan Speed (at maximum engine rev/min): TBA
Maximum Pressure Setting 56 bar (812 lbf/in2)
Body Colour Red
SD 63 kW engines :
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 19 cc/rev
Fan Speed (at maximum engine rev/min): TBA
Maximum Pressure Setting 55 bar (797 lbf/in2)
Colour Code (See sticker) Red
SD 74 kW and SF engines:
Type: Gear motor
Direction of Rotation: Clockwise or Bi directional
Motor Displacement 15 cc/rev
Fan Speed (at maximum engine rev/min): TBA
Maximum Pressure Setting 80 bar (1160 lbf/in2)
Body Colour Black
Operation Overview
The following explains the basic operation of servo parallel As well as providing the main hydraulic services the
machines with a gearpump driven hydraulic system. There system also operates a hydraulic steering system. Refer to
are other types of hydraulic systems. Make sure you are Section 1 - Applications. K Related Topics ( T E7-3)
referring to the correct system, refer to Section 1 -
Applications. K Related Topics ( T E7-3) Some machines have a smooth ride system (SRS). This
system is described in a separate topic. K Related
Topics ( T E7-3)
Return to tank
C087620
Fig 2. Component Location and Identification
The pump has two sections, 1A and 1B. Oil from the larger The proportional solenoid regulates the incoming servo
pump section 1A flows direct to the control valve block 2. pressure from the pilot manifold block 5 to move the
Pump section 1B has an integral priority valve which selected service spool the required amount. The pilot
always gives priority demand to the steer circuit. With the pressure is proportional in relation to the amount the
steering in the straight ahead position (i.e. with no steering operator moves the thumbwheel switch.
demand), oil from pump section 1B flows through the
priority valve and joins with the flow from 1A to feed the ECU Controlled ‘Flowshare’
control valve block 2. Pump section 1B also supplies the
cooling fan. Oil from pump section 1B flows to the cooling K Fig 2. ( T E7-9). To prevent excessive load on the
fan hydraulic motor 4. hydraulic pump, the system has the facility to slow down
the operation of the boom extend/retract service while the
In neutral circuit conditions (i.e. no service selected), the lift service is being operated.
oil flows through the control valve block neutral gallery into
the return or exhaust line and back to tank T through an in- This prevents the extend/retract service from reducing the
tank filter F. flow available to the lift service, allowing the lift service to
operate at an acceptable speed.
Control Valve Block
The machine control ECU 4 receives a signal from the lift
K Fig 2. ( T E7-9). The control valve block 2 controls the pressure switch to indicate the lift service is being
boom hydraulic services. operated. If the ECU receives a signal at the same time
from the extend/retract thumbwheel 2 it reduces the
When the control valve spools are actuated, oil from the maximum current available for the operation of the
pump passes into the service ports, operating the relevant proportional solenoids which control the extend/retract
hydraulic ram. spool operation. Refer to the correct topic for information
on PWM and ECU control. K Related Topics ( T E7-3)
The control valve contains the main pressure relief valve
(MRV) and the auxiliary pressure relief valves (ARV’s).
These valves prevent the hydraulic pressure increasing to
a level which would cause damage to the hydraulic
components and pipework.
Control Lever
The control lever operates in two axis. It also incorporates
two thumbwheel switches. The control is configured as
follows:
Control Lever - AXIS Two Servo pilot oil Control valve - SPOOL Two
E7-12
Lift/Lower and Crowd/Dump Services Table 5. Colour Key to Oil Flow and Pressure
Full Pressure
To make the description as clear as possible the
diagram shows only part of the complete hydraulic
Servo
system. For the complete hydraulic schematics, refer
to the schematics topic. K Related Topics ( T E7-3)
Neutral
No Services Operated
Exhaust
K Fig 3. ( T E7-13). Oil from the primary pump 1A
flows to the inlet-outlet section of the control valve 2
through the valve spool 2E and returns to tank T.
Service Operation
9803/3760-07 (E-01-07)
pressure valve 2B supplies a low pressure supply to
the manifold block via filter 3A.The system isolation
solenoid 3C is energised allowing the oil to flow to the
control lever 4. When a service is operated, boom lift
for example, the movement of the control lever 4
allows the pilot oil to flow to the control valve spool 2E
via the pilot manifold 3. The hydraulic oil flows through
the valve spool 2E to the lift ram 5.
Oil from the other side of the ram 5 flows across the
service spool and back to tank T.
E7-12
Hydraulic Operation and Schematics
Section E7 - Hydraulics
Servo Parallel Hydraulic SYSTEM
Hydraulic Operation and Schematics
C087330
Fig 3. No Services Operated
C087330-C1
Fig 4. One Service Operated
C087330-C4
Fig 5. Tilt Isolation
E7-16
Neutral
To make the description as clear as possible the
diagram shows only part of the complete hydraulic
Exhaust
system. For the complete hydraulic schematics, refer
to Section 1. K Related Topics ( T E7-3)
No Services Operated
Service Operation
9803/3760-07 (E-01-07)
solenoid 3C is energised allowing the oil to flow to the
control lever. When a service is operated, boom
extend for example, the movement of the control lever
thumbwheels sends an electrical signal to the ECU
which energises the applicable proportional control
solenoid. The proportional solenoid allows the pilot oil
from the pilot manifold 3 to flow to the control valve
spool 2E. The hydraulic oil flows through the valve
spool 2E to the extend ram 7.
Oil from the other side of the ram 7 flows across the
service spool and back to tank T.
E7-16
Hydraulic Operation and Schematics
Section E7 - Hydraulics
Servo Parallel Hydraulic SYSTEM
Hydraulic Operation and Schematics
C087360
Fig 6. No Services Operated
C087360-C1
Fig 7. One Service Operated
E7-19
To make the description as clear as possible the
diagram shows only part of the complete hydraulic
system. For the complete hydraulic schematics, refer
to Section 1. K Related Topics ( T E7-3)
System Isolation
9803/3760-07 (E-01-07)
Full Pressure
Servo
Neutral
Exhaust
Servo Parallel Hydraulic SYSTEM
Section E7 - Hydraulics
E7-19
Hydraulic Operation and Schematics
Section E7 - Hydraulics
Servo Parallel Hydraulic SYSTEM
Hydraulic Operation and Schematics
C087360-C2
Fig 8. Main System Pressure Relief
C087360-C3
Fig 9. System Isolation
When the spools are actuated, oil from the pump passes
into the service ports A or B, operating the relevant
hydraulic ram. See the applicable hydraulic schematic for
service port connections.
Oil from the pump enters the control valve at P, passing the
adjustable main relief valve (MRV) 2A, the pressure
reduction valve 2B and pressure maintaining valve 2C.
Valves 2B and 2C are not adjustable.
As the spools 2D, 2E, 2F and 2G, are in neutral, the oil
passes round their central waists, the spool lands
preventing the oil from entering the service ports. On
reaching the end housing the oil enters the exhaust gallery
and is discharged back to tank T. The control valve also
incorporates adjustable auxiliary relief valves (ARV's) 2H,
2J, 2K and 2L.
C085160-C2
Fig 10. 4 Spool Control Valve (Single Lever Control)
Parallel Lift
Ram Operation
C083280-C3
Fig 11. Single displacement ram forward of ram pivot.
416480-C1
Fig 12. Boom Raise Cycle (Single displacement ram forward of ram pivot)
416480-C2
Fig 13. Boom Lower Cycle (Single displacement ram forward of ram pivot)
The valve current signal from the ECU is controlled by If the thumbwheel is moved further, the valve current signal
varying the duty cycle of the PWM output. For a detailed will increase proportionally (linear), until the thumbwheel
explanation of the duty cycle and PWM inputs and outputs reaches its end stop and maximum valve current is
refer to the correct topic.K Related Topics ( T E7-3) reached. As the valve current signal increases, similarly
the servo pilot pressure from the solenoid valve also
The theoretical PWM duty cycle required to produce a increases proportionally, until maximum servo pilot
given valve current signal (output) is already pre- pressure is reached.
programmed into the ECU memory (ROM). The ECU uses
a closed-loop control algorithm to constantly compare the When the servo pilot pressure is increased, the boom
actual valve current (via a current sense resistor) with the service spool E is displaced further, which allows more
theoretical valve current (stored in memory), and flow from the main hydraulic system to the boom extension
automatically increases or decreases the PWM duty cycle ram F, causing the ram to move at a faster rate.
if necessary, to compensate for variations the resistance of
the solenoid coil windings (due to changes in ambient
temperature), or fluctuations in the machine's 12 volt
supply.
C044280-C1
Fig 14. Boom Extend and Retract - Example
C063460-C2
Fig 15. Extend/Retract and Auxiliary Services (Thumbwheel Switches)
Key
B Joystick constant auxiliary flow switch
1015 Constant auxiliary enable switch
1032A Control isolation switch
3008 Auxiliary B proportional solenoid
4019 Machine control ECU connector J1
4020 Machine control ECU connector J2
7028 Joystick/control lever connector B
8004 Chassis harness to panel harness
connector
9001 Fusebox A
C063430-C2
Fig 16. Constant Auxiliary. Status = constant auxiliary enabled.
Key
1032A Control isolation switch
1049 Tilt isolation switch (if fitted)
3020 Tilt lock solenoid (if fitted)
3023 Full lock solenoid
4020 Machine control ECU connector J2
8004 Chassis harness to panel harness
connector
9002 Fusebox B
9003 Fusebox C
C061590-C3
Fig 18. System Isolation. Status = system enabled
ECU 4019 provides thumbwheel switches A and B with a The flowshare service is also dependant on the engine
5V power supply via pin 28. RPM. The engine RPM value is transmitted to ECU 4020
vai the machine CANbus.
The thumbwheels send a voltage between 0.7V and 4.3V
to the ECU 4020 on pin 18 (switch A) and pin 30 (switch
C063460-C3
Fig 19. ECU Controlled flowshare. Status = Lower and extend services operative
4019 Machine control ECU The ECU connectors are located behind inside
connector J1 the battery compartment below the cab. Be sure
to identify the correct connector. Connector J1 is
coloured Black. 12
23
1
13
35 24
4020 Machine control ECU The ECU connectors are located behind inside
connector J2 the battery compartment below the cab. Be sure
to identify the correct connector. Connector J2 is
coloured white. 12
23
1
13
35 24
Fault Finding
Tables
Fault:
K Table 9. Lack of power at all hydraulic functions ( T E7-41)
K Table 10. All solenoid/servo operated hydraulic services slow to operate ( T E7-42)
K Table 11. One solenoid/servo operated hydraulic services fails to operate ( T E7-43)
K Table 13. The engine tends to stall when hydraulics are under load ( T E7-44)
K Table 14. Ram creep ( T E7-44)
K Table 15. Forks creep down ( T E7-44)
K Table 16. Parallel lift faulty ( T E7-45)
Table 13. The engine tends to stall when hydraulics are under load
Possible Cause Action
MRV valve setting incorrect Check and adjust as required.
Engine performance. Check engine performance.
Test Procedures
Checking Pump Flow discharge line from each pump section in turn as
described below:
Double Pump
Main Services Pump (Section 1): Disconnect hose
The separate sections of the gear pump assembly supply 21-A from the pump. Fit the flow meter and load valve
hydraulic oil to the main services circuits, to the steering between hose 21-A and the pump.
circuit and to the hydraulic cooling fan circuit. To determine
the source of a problem i.e pump, steer circuit or services Cooling Fan Pump (Section 2): Disconnect hose 21-
circuit, measure the output flow at system pressure from B from the pump. Fit the flow meter and load valve
each pump outlet port in turn. between hose 21-B and the pump.
!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.
!MWARNING
Hydraulic Pressure 416111-C9
Hydraulic fluid at system pressure can injure you. Fig 21. Typical Double Pump
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service Note: Make sure the load valve and flow meter is installed
hose line must be vented. Make sure the hose service the correct way round i.e. with the direction arrow pointing
line has been vented before connecting or removing away from the pump.
hoses. Make sure the engine cannot be started while
the hoses are open. !MCAUTION
INT-3-1-11_2
Make sure the load valve is in the OPEN position, (the
2 Vent the hydraulic pressure, see Section 2 - General adjusting knob screwed fully OUT), before starting the
Procedures. K Related Topics ( T E7-3) following pressure test. Failure to do this could
damage the pump.
HYD-4-4_1
A326060-1
Fig 20. Test Equipment
!MWARNING
Take care when disconnecting hydraulic hoses and
fittings as the oil will be HOT.
TRANS-1-2
416111-C10
Fig 23. Test Point (Typical Double Pump)
A296360-1
Fig 27. Relief Valve Adjuster Screw and Locknut
C087200-C1
Fig 28.
!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.
This topic contains information about a machine SYSTEM. The system has some devices that connect either
mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications
table. K Related Topics ( T E8-2).
Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer
to the relevant topics. K Related Topics ( T E8-2)
This topic is intended to help you understand what the system does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
Specifications
Accumulators
Although identical in appearance, the accumulators are accumulator make sure that it is charged to the correct
charged to different pressures. When renewing an pressure.
Fig 2.
Important: Upon installation of new accumulator the
correct decal stating charge pressure must be attached.
Remove original decal which states a zero charge
pressure. Decals may be in the form of a large plate or
small plate. K Fig 1. ( T E8-4), K Fig 2. ( T E8-4).
C033720
Fig 1.
Operation Overview
711060-1
Fig 3.
A356811-1
Fig 4. Typical Installation
732990-1
Fig 5. Typical Installation
A356011-1
Fig 6.
The schematic diagrams in this section show how the drain valve solenoid 5 and the accumulator valve solenoid
electrical circuit works when different functions are 6 which both then de-energise.
operated.
Component Key:
The wire numbers and colours, where appropriate, are
shown as an aid to identification while fault finding. The 1 Neutral relay
wires coloured red show the electrical live feeds. The wires 2 Microswitch (lift/lower spool)
coloured green show the electrical returns to earth.
3 Microswitch (crowd/dump spool)
K Fig 7. Neutral ( T E8-10) 4 Dump relay
5 Drain valve solenoid
K Fig 8. Crowd or Dump ( T E8-10)
6 Accumulator valve solenoid
K Fig 9. Boom Lower ( T E8-10) 7 SRS Latching relay
8 Pressure switch (lift ram)
K Fig 10. Wires and Connectors ( T E8-11)
9 SRS On/Off switch
K Table 3. Device and Connector Key ( T E8-12) 10 SRS `Active' warning light
Before fault finding make sure that you understand how the Table 2. Solenoid Status Table
electrical circuits work. Most potential faults can be traced Control Lever Accumulator Drain Valve
using a multimeter to carry out continuity checks on wires, Position: Valve Solenoid Solenoid (item 5):
switches and solenoids. (item 6):
Control lever in Neutral: When the SRS system is Neutral Energised Energised
switched ON, if the pressure in the lift ram is within limits, Crowd or Dump Energised De-energised
current flows from the switch 9 through pressure switch 8
Boom Lower De-energised De-energised
and energises SRS relay 7.
The current flows through diodes and latches the SRS The above table shows the status of the accumulator valve
relay 7, and illuminates a warning light 10 to show that the and drain valve solenoids (either Energised or De-
SRS system is active. At the same time, the neutral relay energised) for given control lever positions with the SRS
1 is also energised via service spool microswitch 2 (if the system activated.
lift spool is in neutral). The neutral relay 1 in turn energises
the drain valve solenoid 5, and the accumulator valve
solenoid 6 (via a diode).
C028500-C2
Fig 10. Wires and Connectors
M10
-004 Panel Harness Ground B Refer to Section C - Electrical Harness
SYSTEM. K Related Topics ( T E8-2)
M10
1034 Pressure Switch Lift Ram TBA
1039 Spool End Switch Crowd/ Located on the control valve block
Dump
1040 Spool End Switch Lift/ Located on the control valve block
Lower
4012 LMS Display ECU The ECU connectors are located behind the LMS
Connector J1 (Grey) display unit. Be sure to identify the correct 11 20
connector. Connector J1 is coloured Grey.
1 10
Fault Finding
Tables
Note: The system will not engage until the lift ram is fully
closed or the weight of the boom is fully supported.
Charging and Discharging 5 Do not twist the hose, connect the charging tool to the
TE-003
gas valve. Tighten to 1.36 Nm (1.0 lbf ft).
Charging
6 Connect charging tool to a bottle of compressed
1 Remove the accumulator(s) from the machine. nitrogen gas.
2 Remove gas valve guard 12-A and gas valve cap 12- 7 Screw valve 12-C all the way in (clockwise), this will
B. depress the core in the gas valve. Check charge
pressure which should be set to suit the boom and the
attachment fitted to the machine.
!MCAUTION
Fig 11. To reduce pressure use the recommended charging
tool or the charge valve could be damaged which may
3 Screw valve 12<-C all the way out (counter result in rapid discharge of the accumulator.
clockwise) before attaching charging tool (part no. HYD-2-4
892/00948) to accumulator gas valve.
10 When complete screw valve 12-C all the way out
4 Close bleed valve 12-D. (counter clockwise) then open the bleed valve 12-D to
vent the hose.
Fig 12.
2 Remove gas valve guard 12-A and gas valve cap 12-
B.
Replacement
Replacement is a the opposite of the removal procedure.
A356820-1
This topic contains information about a machine SYSTEM. The system has some devices that connect either
mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications
table. K Related Topics ( T E9-2).
Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer
to the relevant topics. K Related Topics ( T E9-2)
This topic is intended to help you understand what the system does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
Specifications
Accumulators
Although identical in appearance, the accumulators are accumulator make sure that it is charged to the correct
charged to different pressures. When renewing an pressure.
Operation Overview
711060-1
Fig 3.
A356811-1
Fig 4.
A356011-1-C1
Fig 6.
C028500-C2
Fig 10. Wires and Connectors
M10
-004 Panel Harness Ground B Refer to Section C - Electrical Harness
SYSTEM. K Related Topics ( T E9-2)
M10
1034 Pressure Switch Lift Ram TBA
1039 Spool End Switch Crowd/ Located on the control valve block
Dump
1040 Spool End Switch Lift/ Located on the control valve block
Lower
4012 LMS Display ECU The ECU connectors are located behind the LMS
Connector J1 (Grey) display unit. Be sure to identify the correct 11 20
connector. Connector J1 is coloured Grey.
1 10
Fault Finding
Tables
Note: The system will not engage until the lift ram is fully
closed or the weight of the boom is fully supported.
Charging and Discharging 5 Do not twist the hose, connect the charging tool to the
TE-003
gas valve. Tighten to 1.36 Nm (1.0 lbf ft).
Charging
6 Connect charging tool to a bottle of compressed
1 Remove the accumulator(s) from the machine. nitrogen gas.
2 Remove gas valve guard 12-A and gas valve cap 12- 7 Screw valve 12-C all the way in (clockwise), this will
B. depress the core in the gas valve. Check charge
pressure which should be set to suit the boom and the
attachment fitted to the machine.
!MCAUTION
Fig 11. To reduce pressure use the recommended charging
tool or the charge valve could be damaged which may
3 Screw valve 12<-C all the way out (counter result in rapid discharge of the accumulator.
clockwise) before attaching charging tool (part no. HYD-2-4
892/00948) to accumulator gas valve.
10 When complete screw valve 12-C all the way out
4 Close bleed valve 12-D. (counter clockwise) then open the bleed valve 12-D to
vent the hose.
Fig 12.
Specifications
Accumulators
Although identical in appearance, the accumulators are accumulator make sure that it is charged to the correct
charged to different pressures. When renewing an pressure.
Fig 2.
Important: Upon installation of new accumulator the
correct decal stating charge pressure must be attached.
Remove original decal which states a zero charge
pressure. Decals may be in the form of a large plate or
small plate. K Fig 1. ( T E10-4), K Fig 2. ( T E10-4).
C033720
Fig 1.
Operation Overview
711060-1
Fig 3.
A356811-1
Fig 4.
Hydraulic Schematic
A356011-1
Fig 5.
The schematic diagrams in this section show how the solenoid 3016 or the accumulator valve solenoid 3005
electrical circuit works when different functions are which both then de-energise.
operated.
Component Key:
The wire numbers and colours, where appropriate, are
shown as an aid to identification while fault finding. The 1034 Pressure switch (lift ram)
wires coloured red show the electrical live feeds. The wires 1041 SRS On/Off switch
coloured green show the electrical returns to earth.
2037 SRS relays - front console
K Fig 6. Neutral ( T E10-9) 2038 SRS latching relay
2039 SRS relays - pod
K Fig 7. Crowd or Dump ( T E10-9)
3005 Accumulator valve solenoid
K Fig 8. Boom Lower ( T E10-9) 3016 Drain valve solenoid
4011 Joystick power base ECU
K Fig 9. Wires and Connectors ( T E10-10)
4012 SRS `Active' warning light
K Table 3. Device and Connector Key ( T E10-11) 7003 Diode pack
7036 Diode pack
7048 Diode pack
Before fault finding make sure that you understand how the
electrical circuits work. Most potential faults can be traced Table 2. Solenoid Status Table
using a multimeter to carry out continuity checks on wires, Control Lever Accumulator Drain Valve
switches and solenoids. Position: Valve Solenoid Solenoid 3016:
3005:
Control Lever in Neutral: When the SRS system is
Neutral Energised Energised
switched ON, if the pressure in the lift ram is within limits,
current flows from the switch 1041 through pressure switch Crowd or Dump Energised De-energised
1034 and energises SRS relay 2038. Boom Lower De-energised De-energised
C050490-C2
Fig 9. Wires and Connectors
4012 LMS Display ECU The ECU connectors are located behind the LMS
Connector J1 (Grey) display unit. Be sure to identify the correct 11 20
connector. Connector J1 is coloured Grey.
1 10
Fault Finding
Tables
Note: The system will not engage until the lift ram is fully
closed or the weight of the boom is fully supported.
Charging and Discharging 5 Do not twist the hose, connect the charging tool to the
TE-003
gas valve. Tighten to 1.36 Nm (1.0 lbf ft).
Charging
6 Connect charging tool to a bottle of compressed
1 Remove the accumulator(s) from the machine. nitrogen gas.
2 Remove gas valve guard 11-A and gas valve cap 11- 7 Screw valve 11-C all the way in (clockwise), this will
B. depress the core in the gas valve. Check charge
pressure which should be set to suit the boom and the
attachment fitted to the machine.
!MCAUTION
Fig 10. To reduce pressure use the recommended charging
tool or the charge valve could be damaged which may
3 Screw valve 11<-C all the way out (counter clockwise) result in rapid discharge of the accumulator.
before attaching charging tool (part no. 892/00948) to HYD-2-4
accumulator gas valve.
10 When complete screw valve 11-C all the way out
4 Close bleed valve 11-D. (counter clockwise) then open the bleed valve 11-D to
vent the hose.
Fig 11.
Replacement
Replacement is the opposite of the removal procedure.
A356820-1
Fig 12. Typical Installation
This topic contains information about a machine SYSTEM. The system has some devices that connect either
mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications
table. K Related Topics ( T E11-2).
Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer
to the relevant topics. K Related Topics ( T E11-2)
This topic is intended to help you understand what the system does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
Specifications
Accumulators
Although identical in appearance, the accumulators are accumulator make sure that it is charged to the correct
charged to different pressures. When renewing an pressure.
Fig 2.
Important: Upon installation of new accumulator the
correct decal stating charge pressure must be attached.
Remove original decal which states a zero charge
pressure. Decals may be in the form of a large plate or
small plate. K Fig 1. ( T E11-4), K Fig 2. ( T E11-4).
C033720
Fig 1.
Operation Overview
Piston type accumulators operate as a liquid springs Note: If the pressure in the lift ram is greater than the
absorbing displaced fluid from the lift ram. specified limit when the SRS switch is pressed, the system
will not be activated (the solenoid valves will not energise).
The system is controlled by the hydraulic control ECU 7.
Once the SRS system is activated, the boom can then be
To activate the SRS system, the pressure in the lift ram raised to the travelling position as required.
must be less than 40 bar (580 psi), typically when the
C094470
Fig 3.
Hydraulic Schematic
A356011-1
Fig 4.
Central to the system is the hydraulic control ECU (4019/ Boom Lower Selected: When the control lever is moved
4020). The ECU monitors the status of the lift and tilt from neutral to lower the boom, ECU 4020 de-energises
(crowd/dump) spools, pressure transducer 7079 and SRS drain valve solenoid 3016 and accumulator valve solenoid
on/off switch 1041. The ECU energises and de-energises 3005.
drain and accumulator solenoids 3016 and 3005 to control
the smooth ride system as applicable.
Component key: K Electrical Schematic - SRS
System ( T E11-8)
Control Lever in Neutral: When the SRS system is
switched ON, if the pressure in the lift ram is within limits, 1041 SRS On/Off switch
ECU 4020 energises the drain valve solenoid 3016, and 3005 Accumulator valve solenoid
the accumulator valve solenoid 3005.
3016 Drain valve solenoid
The ECU 4019 sends a message via the CANbus and the 4019 Hydraulic control ECU - connector J1
SRS indicator light comes ON. 4020 Hydraulic control ECU - connector J2
Crowd or Dump Selected: When the control lever is 7079 Pressure transducer
moved from neutral, to either crowd or dump ECU 4020
de-energises drain valve solenoid 3016.
4019 - J1
8004
27
+12v
4
8033 1
69 14
7
28 2
+5v
1
3
1041 4
SRS SWITCH 4
7079
ECU
PRESSURE TRANSDUCER
28
29
17 21
70 8033
10 1 2
- 008
3 8
3005
ACCUMULATOR SOLENOID
11 1 2
- 008
3016
4020 - J2 DRAIN SOLENOID
C094460
Fig 5. Electrical Schematic - SRS System
M10
1041 SRS Switch Located on the instrument panel. Remove the
switch to get access to the connector.
12 1
23 13
35 24
12 1
23 13
35 24
Fault Finding
Tables
Note: The system will not engage until the lift ram is fully
closed or the weight of the boom is fully supported.
Charging and Discharging 5 Do not twist the hose, connect the charging tool to the
TE-003
gas valve. Tighten to 1.36 Nm (1.0 lbf ft).
Charging
6 Connect charging tool to a bottle of compressed
1 Remove the accumulator(s) from the machine. nitrogen gas.
2 Remove gas valve guard 7-A and gas valve cap 7-B. 7 Screw valve 7-C all the way in (clockwise), this will
depress the core in the gas valve. Check charge
pressure which should be set to suit the boom and the
attachment fitted to the machine.
Fig 6.
!MCAUTION
To reduce pressure use the recommended charging
3 Screw valve 7<-C all the way out (counter clockwise) tool or the charge valve could be damaged which may
before attaching charging tool (part no. 892/00948) to result in rapid discharge of the accumulator.
accumulator gas valve. HYD-2-4
4 Close bleed valve 7-D. 10 When complete screw valve 7-C all the way out
(counter clockwise) then open the bleed valve 7-D to
vent the hose.
Fig 7.
2 Remove gas valve guard 7-A and gas valve cap 7-B.
A356820-1
Fig 8. Typical Installation
This topic contains information about a machine SYSTEM. The system has some devices that connect either
mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications
table. K Related Topics ( T E12-2).
Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer
to the relevant topics. K Related Topics ( T E12-2)
This topic is intended to help you understand what the system does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
Specifications
Accumulators
Although identical in appearance, the accumulators are accumulator make sure that it is charged to the correct
charged to different pressures. When renewing an pressure.
Fig 2.
Important: Upon installation of new accumulator the
correct decal stating charge pressure must be attached.
Remove original decal which states a zero charge
pressure. Decals may be in the form of a large plate or
small plate. K Fig 1. ( T E12-4), K Fig 2. ( T E12-4).
C033720
Fig 1.
Operation Overview
K Fig 3. ( T E12-6)
A356011-1
Fig 4.
To activate the SRS system, the pressure in the lift ram 5 Drain solenoid valve (chassis mounted)
must be less than 40 bar (580 psi), typically when the
boom is fully lowered. This is sensed by the pressure 6 Valve block return line
switch 8. Once the SRS system is activated, the boom can 8 Pressure switch
then be raised to the travelling position as required. 9 Hose burst check valve
When the system is active the machine control ECU
energises the accumulator solenoid valve 3, connecting
the piston head side of the lift ram with accumulators 2.
The drain solenoid valve 5 (chassis mounted) will also
energise and connect the rod side of the lift ram to the
valve block return line 6 to make up or dissipate oil as
required.
The schematic diagrams in this section show how the The machine control ECU transmits a CANbus message to
electrical circuit works when different functions are the LMS ECU to turn on the SRS indicator light.
operated.
Crowd or Dump Selected: When the control lever is
Central to the system is the machine control ECU (4019/ moved from neutral, to either crowd or dump, the crowd/
4020). Inputs from pressure switches/transducers (1071, dump pressure switch/transducer 1071 closes and sends
1072) are used to determine the status of the lower and an input to the machine control ECU 4019 at pin 19. The
crowd (tilt) services. The ECU energises the applicable ECU de-energises the drain solenoid 3016.
SRS solenoids (3005, 3016) depending on the status of
the lower and crowd services and the status of the SRS on/ Boom Lower Selected: When the control lever is moved
off switch (1041). from neutral to lower the boom, the boom lower pressure
switch/transducer 1072 closes and sends an input to the
K Fig 5. SRS System Off ( T E12-9) machine control ECU 4019 at pin 31. The ECU de-
energises the accumulator solenoid 3005 and the drain
K Fig 6. SRS System On (Neutral) ( T E12-10) solenoid 3016.
C087450
Fig 5. SRS System Off
C087450-C1
Fig 6. SRS System On (Neutral)
C087450-C2
Fig 7. SRS Crowd/Dump
C087450-C3
Fig 8. SRS Lift/Lower
Electrical Connectors
The table shows the harness connectors that connect to the electrical devices. The connectors are shown looking at the
mating face when disconnected. Remember that the drawings show the harness connectors NOT the device connectors.
Use the table and the relevant electrical schematic to identify the pins in the harness connectors. Continuity checks on
the harness wires can be carried out using a multi-meter. Do not touch ECU connector pins. Do not use a multi-meter on
ECU connector pins.
Device Description Location Harness Connector
1041 SRS switch Located on the instrument panel. Remove the
switch to get access to the connector.
4019 Machine Control ECU The ECU connectors are located behind the LMS
Connector J1 display unit. Be sure to identify the correct
connector. Connector J1 is coloured Black.
12 1
23 13
35 24
4020 Machine Control ECU The ECU connectors are located behind inside
Connector J2 the battery compartment below the cab.Be sure
to identify the correct connector. Connector J2 is
coloured white. 12
23
1
13
35 24
7079 SRS pressure transducer Located on the pilot manifold (SRS machines
only)
Tables
Note: The system will not engage until the lift ram is fully
closed or the weight of the boom is fully supported.
Charging and Discharging 5 Do not twist the hose, connect the charging tool to the
TE-003
gas valve. Tighten to 1.36 Nm (1.0 lbf ft).
Charging
6 Connect charging tool to a bottle of compressed
1 Remove the accumulator(s) from the machine. nitrogen gas.
2 Remove gas valve guard 10-A and gas valve cap 10- 7 Screw valve 10-C all the way in (clockwise), this will
B. depress the core in the gas valve. Check charge
pressure which should be set to suit the boom and the
attachment fitted to the machine.
!MCAUTION
Fig 9. To reduce pressure use the recommended charging
tool or the charge valve could be damaged which may
3 Screw valve 10<-C all the way out (counter result in rapid discharge of the accumulator.
clockwise) before attaching charging tool (part no. HYD-2-4
892/00948) to accumulator gas valve.
10 When complete screw valve 10-C all the way out
4 Close bleed valve 10-D. (counter clockwise) then open the bleed valve 10-D to
vent the hose.
Fig 10.
2 Remove gas valve guard 10-A and gas valve cap 10-
B.
Replacement
Replacement is the opposite of the removal procedure.
A356820-1
Fig 11. Typical Installation
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
(1) Procedure variant. Make sure you refer to the correct procedure.
(1) The table lists procedure and specification variants and the applicable machine models. Use the table to make sure
you refer to the correct information.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
1 Position the boom and fit the safety strut, see Section
2 - General Procedures. K Related
Topics ( T E13-2)
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose, A296350-1
residual hydraulic pressure trapped in the service Fig 1. Mechanical Control Linkages
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
!MWARNING
This component is heavy. It must only be removed or
handled using a suitable lifting method and device.
BF-4-1_1
Replacement
Replacement is the opposite of the removal procedure.
C068070
Fig 2. Valve Location
Removal
1 Park the machine and make it safe. Lower the boom.
Obey the General Safety procedures, see Section 2
- General Procedures. K Related
Topics ( T E13-2)
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
!MWARNING
This component is heavy. It must only be removed or
handled using a suitable lifting method and device.
BF-4-1_1
Replacement
Replacement is the opposite of the removal procedure.
A347890-1
Fig 5. Tie Rods
The tie rods have a shorter thread length at one end. The
end with the shorter thread length must be assembled into
the outlet section of the valve.
One of the rods has a dimple 5-2 machined into the end.
The tie rod with the dimple must be fitted in the position
shown with the dimple at the inlet section, or early failure
of the valve block can occur.
262070-1-C2
Fig 6.
Dismantle Assemble
K Fig 6. ( T E13-10) 1 Renew all `O' rings.
The spools and their components can be removed without 2 Ensure the spools are fitted in their original bores.
separating the valve sections but tie rod 2 must be
removed to release load hold check valve plugs 2Q. Do not 3 If filter 8 is not fitted it could result in the solenoid
remove back-up ring A as this cannot be renewed in failing to operate. Check the filter is clean and fitted
service. correctly.
It is important to identify the spools with their respective Table 6. Torque Settings
bores to ensure correct replacement as some valve blocks Item Nm kgf m lbf ft
have motor spools. Failure to fit spools correctly could
4 6 0.5 4
result in machines not operating correctly and damage to
components. 6 9 - 12 0.9 - 1.2 7-9
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
Replacement
Replacement is the opposite of the removal procedure.
A296350-1
Table 2. Torque Settings
Fig 2. Mechanical Control Linkages
Item Nm kgf m lbf ft
1-A 91 9.3 67
262060-1
Fig 3. Typical 6 Spool Valve Block
Assemble
Ensure that load hold check valve plugs 2Q are located on
tie rod 2 and that inter-section seals are located in their
grooves as shown at X.
Tie Rods
A347890-1
Fig 4. Tie Rods
The tie rods have a shorter thread length at one end. The
end with the shorter thread length must be assembled into
the outlet section of the valve.
One of the rods has a dimple 4-2 machined into the end.
The tie rod with the dimple must be fitted in the position
shown with the dimple at the inlet section, or early failure
of the valve block can occur.
262070-1-C2
Fig 5.
Dismantle Assemble
K Fig 5. ( T E14-7). The spools and their components can 1 Renew all `O' rings.
be removed without separating the valve sections but tie
rod 2 must be removed to release load hold check valve 2 Ensure the spools are fitted in their original bores.
plugs 2Q. Do not remove back-up ring A as this cannot be
renewed in service. 3 If filter 8 is not fitted it could result in the solenoid
failing to operate. Check the filter is clean and fitted
It is important to identify the spools with their respective correctly.
bores to ensure correct replacement as some valve blocks
have motor spools. Failure to fit spools correctly could Table 4. Torque Settings
result in machines not operating correctly and damage to Item Nm kgf m lbf ft
components.
4 6 0.5 4
6 9 - 12 0.9 - 1.2 7-9
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
!MWARNING !MWARNING
You could be killed or injured if the boom drops while
This component is heavy. It must only be removed or
you are working under it. Fit the boom maintenance
handled using a suitable lifting method and device.
strut as instructed before doing any maintenance
BF-4-1_1
work with the boom raised.
9 With the valve block suitably supported, undo the
Keep people away from the machine while you fit or
mounting bolts C. Carefully lift out the valve block
remove the boom maintenance strut.
clear of the machine. K Handling ( T E15-3).
5-3-1-2_2
1 Raise the boom and fit the safety strut, see Section 2 Replacement
- General Procedures. K Related
Topics ( T E15-2) Replacement is the opposite of the removal procedure.
2 Carry out General Safety procedures, see Section 2 During the replacement procedure do this work also:
- General Procedures. K Related
Topics ( T E15-2) – Ensure that the electrical connectors and hoses are
correctly installed, and phased in the same position
as removal to prevent chafing.
!MWARNING – Operate the machines hydraulic system. Check for
Hydraulic Pressure correct operation and leaks.
Hydraulic fluid at system pressure can injure you. – Replenish the hydraulic system with the
Before connecting or removing any hydraulic hose, recommended hydraulic fluid as required, see
residual hydraulic pressure trapped in the service Section 3 - Routine Maintenance. K Related
hose line must be vented. Make sure the hose service Topics ( T E15-2)
line has been vented before connecting or removing
– After replacement, check MRV and ARV pressures.
hoses. Make sure the engine cannot be started while
Refer to the correct SYSTEM topic. K Related
the hoses are open.
Topics ( T E15-2)
INT-3-1-11_2
C050620-C2
Fig 1. Typical Flowshare (LSP+) Valve Block
E15-5
Valve Block Sections Assemble 8 Service Spool (Electrically Operated)
9 Service Spool (Manually Operated)
K Fig 2. ( T E15-6). The valve block is a `sectional' Assembly is the opposite of the dismantle procedure.
type, which is made up of a number of separate 10 Flushing Valve
sections. The illustration is intended as a guide to During the assembly procedure do this work also: 11 Load Sense Relief Valve
identifying the components.
– Clean the valve components in an appropriate 12 Flow Regulator Valve
Be sure to note the location of all components when solvent. Ensure that the mating faces of the valve 13 Auxiliary Relief Valves
dismantling. Although some components may appear sections are thoroughly clean before assembly.
to be identical they are not interchangeable. Make – Renew the `O' rings located between the valve
sure that components are assembled in their original sections. Make sure the `O' ring seals are not
positions. trapped or damaged.
– Check the Load Hold Check Valve `O' rings and
Great care should be taken when dismantling and replace if necessary. K Load Hold Check
assembling a valve to avoid the following: Valves ( T E15-20)
9803/3760-07 (E-06-01)
Table 3. Torque Settings
Dismantle Item Nm kgf m lbf ft
E15-5
Flowshare (LSP) Control Valve
Section E15 - Hydraulics
Section E15 - Hydraulics
Flowshare (LSP) Control Valve
Dismantle and Assemble
714830-C1
1
13
6
8
6
13
13
6
9
6
11
12
7
13
4
10
764720-1
Fig 3.
Dismantle Inspection
It is possible to remove a spool without removing the valve Inspect the valve components for scratches, pitting,
block from the machine. corrosion or any other type of damage. Replace as
necessary.
1 Raise the boom and fit the safety strut, see Section 2
- General Procedures. K Related Assemble
Topics ( T E15-2)
Assembly is the opposite of the dismantling procedure.
2 Carry out General Safety procedures, see Section 2
- General Procedures. K Related During the assembly procedure do this work also:
Topics ( T E15-2)
– Clean the valve components in an appropriate
3 Vent the hydraulic pressure, see Section 2 - General solvent.
Procedures. K Related Topics ( T E15-2) – Lubricate parts with JCB Hydraulic Fluid before
assembling. Make sure that all the parts move freely.
4 Gain access to the valve and disconnect and blank
any hoses or pipes which may interfere with the – Renew 'O' rings 2 and 5.
removal of the spool. – Ensure the spools are correctly orientated before
inserting into the valve block body. K Spools
5 Disconnect the electrical connector from the solenoid Orientation ( T E15-8)
1.
Table 4. Torque Settings
6 Unscrew the mounting screws 3 and remove the Item Nm kgf m lbf ft
mounting plate 4 and solenoid 1. Unscrew solenoid 1 3 10 1 7.4
from mounting plate 4.
764760-1
Fig 4.
2 Remove the screws 1 and carefully lift off the end cap 2
2. Retrieve the spring 4 and spring retainer 5, then
withdraw the spool 6 from the valve body.
C089440
Fig 5.
764710-1
Fig 6.
Dismantle
1 Hold the spool assembly 8-5 in a vice using the spool Inspect the valve components for scratches, pitting,
clamp 8-8. corrosion or any other type of damage. Replace as
necessary.
2 Loosen the tongue 5K with an open ended wrench. It
may be necessary to pre-heat the spool to 200°C in Assemble
an oven or with a heat gun to dismantle the spool.
1 Clean the valve components in an appropriate
solvent.
Note: The seal must be fitted carefully onto the end of the 764790-1
spool to ensure that it is not damaged by the spool lands Fig 11. Position C
and that its tightness property does not deteriorate. The
metal part of the seal should be on the outside.
764770-1
Fig 9. Position A
764780-1
Fig 10. Position B
1 Raise the boom and fit the safety strut, see Section 2
- General Procedures. K Related
Topics ( T E15-2)
Dismantle
A403860-1
Fig 13.
Note: If any part other than `O' rings are damaged the
entire valve must be renewed.
1 Raise the boom and fit the safety strut, see Section 2
- General Procedures. K Related
Topics ( T E15-2)
Dismantle
A403870-1
Fig 14.
Note: If any part other than `O' rings are damaged the
entire valve must be renewed.
1 Raise the boom and fit the safety strut, see Section 2
- General Procedures. K Related
Topics ( T E15-2)
Dismantle
A403850-1
Note: When removing 'O' Rings and seals, use an Assembly is the opposite of the dismantling procedure.
appropriately rounded tool that will not cause any damage
to the seal grooves. Discard all 'O' Rings and back-up During the assembly procedure do this work also:
rings. Do not use worn or damaged items.
– Clean the valve components in an appropriate
Inspection solvent.
– Renew all 'O' rings and back-up rings.
1 Inspect the valve components for scratches, pitting, – Lubricate parts with JCB Hydraulic Fluid before
corrosion or any other type of damage. assembling. Make sure that all the parts move freely.
– Be sure to fit filter gauze 5 the correct way round.
2 Clean the filter gauze 5 fitted in the end of the valve
body.
Table 10. Torque Settings
Item Nm kgf m lbf ft
Note: If any part other than `O' rings are damaged the
entire valve must be renewed. 6 20 2 14.8
Inspection
764750-1
Inspect the valve components for scratches, pitting, Fig 16.
corrosion or any other type of damage. Replace as
necessary.
Replacement
Inspection
Replacement
Related Topics
(1) You must obey all of the relevant care and safety procedures.
Keep people away from the machine while you fit or Replacement
remove the boom maintenance strut.
Replacement is the opposite of the removal procedure.
5-3-1-2_2
1 Raise the boom and fit the safety strut, see Section 2 During the replacement procedure do this work also:
- General Procedures. K Related
Topics ( T E16-2) – Operate the machines hydraulic system. Check for
correct operation and leaks.
2 Carry out General Safety procedures, see Section 2 – Replenish the hydraulic system with the
- General Procedures. K Related recommended hydraulic fluid as required, see
Topics ( T E16-2) Section 3 - Routine Maintenance. K Related
Topics ( T E16-2)
!MWARNING – After replacement, check MRV and ARV pressures.
K LSP Electro Servo Hydraulic SYSTEM
Hydraulic Pressure (S1) ( T E5-1)
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
C048010
Fig 1.
Valve Block Sections 4 If the tie rods 2-8 were removed, apply JCB
Threadlocker and Sealer to the threads before
K Fig 2. ( T E16-6) installing.
The valve block is made up of a number of sections. The 5 Screw the tie rods 2-8 into the inlet section 2-2 until
illustration is intended as a guide to identifying the they are tight. Unscrew them 1 turn. Once the valve
components. block is fully assembled these rods may be adjusted
to allow sufficient thread for the tie rod nuts 2-1 to
Be sure to record the location of all components when tighten.
dismantling. Although some components look the same
they are not interchangeable. The service spools for 6 Torque tighten the tie rod nuts.
example are of two different types. Make sure that the
components are assembled in the correct position. Table 3. Torque Settings
Item Nm kgf m lbf ft
Take care when dismantling and assembling a valve to
1 35 3.5 26
prevent damage to seals and seal grooves. Damage or
contamination can cause problems with valve operation.
Component Key:
Dismantle 1 Tie Rod Nuts
2 Inlet Section
1 Remove the valve block from the machine.
3 Auxiliary section
2 Remove the four tie rod nuts 2-1. 4 Tilt section
5 Extend / Retract Section
3 Carefully disconnect and remove the outlet section 2-
6 Lift / Lower Section
7.
7 Outlet Section
4 If the outlet section 2-7 is to be replaced, remove and 8 Tie Rods
retain the tie rods 2-8
9 Load Hold Check valves
5 Disconnect and remove the remaining service 10 Pressure Compensator Valves
sections 2-3,4,5 & 6 and the inlet section 2-2. 11 Service Spool (Electrically Operated)
Solenoid Valves
The solenoid valves are not serviceable parts. Replace the
solenoid valve assembly if it is defective.
Removal
C051620
Fig 3.
Replacement
E16-8
C051700
Fig 4.
9803/3760-07 (E-06-02)
Dismantle 6 Remove the spool end screw 4-11, centring
spring 4-9 and spring retainers 4-8 and spring
1 Remove the solenoid assembly 4-1. K Solenoid cup 4-10. If necessary pre-heat the spool to
Valves ( T E16-7) 200°C in an oven or with a heat gun to remove
the spool end.
2 Remove the mounting screws 4-2 and the
mounting plate 4-3. 7 Carefully remove the spool 4-7 from the valve 1
body.
3 Remove the cover plate screws 4-14. 2
Note: When removing 'O' Rings and seals, use a
4 Remove the housing 4-13 and ‘O’ ring 4-12 from rounded tool that will not cause damage to the seal
the valve block 4-6. grooves. Discard all 'O' Rings and back-up rings. Do A403950-1-C1
not use worn or damaged items. Fig 5. Holding the Spool Assembly
5 Hold the spool assembly 5-1 in a vice using the
spool clamp 5-2.
Dismantle and Assemble
Electro Servo (LSP) Control Valve (S1)
E16-8
Section E16 - Hydraulics
Section E16 - Hydraulics
Electro Servo (LSP) Control Valve (S1)
Dismantle and Assemble
Load Sense Relief Valve 3 Lubricate the parts with JCB Hydraulic Fluid before
assembling.
The load sense relief valve is not serviceable. Replace the
complete valve if it is defective. 4 Adjust the pressure setting as required. K LSP
Electro Servo Hydraulic SYSTEM (S1) ( T E5-1)
Important: Do not remove or damage the tamper proof
cap as this may invalidate a warranty claim. Table 6. Torque Settings
Item Nm kgf m lbf ft
Removal 7-4 45 4.5 33
1 Remove the valve assembly 7-4 from the valve block.
2 Remove the ‘O’ rings 7-1 & 3 and thrust ring 7-2.
C051640
Fig 7.
Replacement
1 Make sure the tamper proof cap 7-5 supplied with the
valve is fitted.
Removal
2 Remove the ‘O’ rings 8-2 & 4 and thrust ring 8-3.
Replacement
1 Make sure the tamper proof cap 8-6 supplied with the
valve is fitted.
Removal
3 Remove the ‘O’ rings 9-1 & 3 and thrust ring 9-2.
!MWARNING
You could be killed or injured if the boom drops while
you are working under it. Fit the boom maintenance
strut as instructed before doing any maintenance
work with the boom raised.
1 Raise the boom and fit the safety strut, see Section 2
- General Procedures. K Related C051660
Topics ( T E16-2) Fig 10.
3 Remove the load hold check valve plug 11-4 from the
valve block section 11-1.
Inspection C051670
Fig 11.
Examine the valve components for scratches, pitting,
corrosion or damage. Make sure the seating faces on
poppets 11-2, and on the mating faces in the valve block
are in good condition. Replace as necessary.
Replacement
Note: When removing 'O' Rings and seals, use an Table 11. Torque Settings
appropriately rounded tool that will not cause any damage Item Nm kgf m lbf ft
to the seal grooves. Discard all 'O' Rings and back-up
12-1 100 10 73.7
rings. Do not use worn or damaged items.
C051680
Fig 12.
Replacement
Shuttle Valve
Removal
2 Remove the shuttle ball 13-4 and the inner seat 13-2.
C051690
Fig 13.
Replacement
C051710
Fig 14.
Removal Replacement
1 Remove the end cap 14-12 and discard the O ring 14- 1 Lubricate the parts with JCB Hydraulic Fluid before
11. assembling.
2 Remove the plunger 14-10 and washer 14-9. 2 Apply JCB Threadlocker to the screw 14-2 and
tighten into the housing 14-1.
3 Remove the spring 14-8.
3 Install the ball 14-3 and spring 14-4 into the housing
4 Carefully remove the spool 14-5 from the valve body 14-1.
14-1.
4 Put the filter 14-6 into the spool assembly 14-5.
5 Use an allen key to remove the retaining screw 14-7
and then remove the filter 14-6. 5 Apply JCB Threadlocker to the screw 14-7 and
tighten into the spool 14-5.
Note: When removing the retaining screw 14-7 hold the
spool carefully to prevent damage. 6 Put the spring 14-8, washer 14-9 and plunger 14-10
into the valve block 14-1.
6 Remove the spring 14-4, ball 14-3 and screw 14-2.
7 Replace the ‘O’ ring 14-11.
Note: When removing 'O' Rings and seals, use a rounded
tool that will not cause any damage to the seal grooves. 8 Install the end cap 14-12 into the valve housing 14-1.
Discard all 'O' Rings and back-up rings. Do not use worn
or damaged items.
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
C068070-C2
Fig 1. Valve Location
Removal
1 Park the machine and make it safe. Lower the boom.
Obey the General Safety procedures, see Section 2
- General Procedures. K Related
Topics ( T E17-2)
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
!MWARNING
This component is heavy. It must only be removed or
handled using a suitable lifting method and device.
BF-4-1_1 C087220
Fig 2.
9 With the valve block supported, undo the mounting
screws A. Carefully lift the valve block C away from
the mounting bracket B and out of the machine.
Replacement
Replacement is the opposite of the removal procedure.
C087220
Fig 3.
C087480
Fig 4.
C087480-C1
Fig 6.
Note: Do not dismantle the valve block or components 2 Clean all parts with clean hydraulic fluid and do an
unless a replacement seal/’O’ ring kit A is available. inspection for signs of wear or damage.
K Fig 6. ( T E17-9) If the end cap C is worn or damaged the valve slice E
must be replaced. The end cap is not serviceable.
The spools are not serviceable parts. Replace the valve
slice E if the spool assembly is defective. 3 Fit new seals B.
End Caps 4 Install the end caps C to the valve slice E and torque
tighten screws D. K Table 4. Torque Settings
The pilot supply end caps C (lift/lower and crowd/dump ( T E17-10)
valve slices) are not serviceable parts. The seals B are
available if a leak occurs from the end cap.
C087480-C2
Fig 7.
1 Unscrew the valve cartridge D from the valve block A. 6 Check the MRV and ARV pressure settings and
adjust as necessary. K Test Procedures ( T E7-46)
2 If necessary unscrew the end screw G.
Inloader Valve
Introduction
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
Operation Overview
K Fig 1. ( T E18-3)
The valve senses the pressure in the load sense circuit via
port LS and the P1 working pressure via port C.
747500A
Fig 2.
Component Key:
1 Inloader valve block
1a Inloader valve spool
1b Inloader valve spool spring
1c Inloader override solenoid valve
2 Steer priority valve
LS Load sense gallery
P1 Primary hydraulic pump
P2 Secondary hydraulic pump
T Tank
747500B
Fig 3.
747500C
K Graph of System Pressures ( T E18-6) Fig 4.
E18-6
K Fig 5. ( T E18-7)
9803/3760-07 (E-28-00)
P2 working pressure
E18-6
Section E18 - Hydraulics
E18-7
Y
250
200
150
Pressure (bar)
100
X
9803/3760-07 (E-28-00)
50
0
14.6 14.8 15 15.2 15.4 15.6 15.8 16 16.2
Time (secs) 747240-C1
747240-C1
Fig 5. Graph of System Pressures
E18-7
Section E18 - Hydraulics
Electrical Operation Note: Any wire numbers stated are for illustration only,
refer to Section C - Electrics - Harness SYSTEM for the
The IFT ECU 1 receives an input from the engine applicable wire numbers for the vehicle variant. K Related
alternator 3 and calculates the engine speed (rpm). The Topics ( T E18-2)
ECU is programmed to energise the solenoid 2 when the
engine speed is within pre-determined values.
Electrical Schematic
C051570
Fig 6.
Item
1 IFT ECU
2 Inloader Solenoid
3 Alternator
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
Removal
1 Park the machine and make it safe. Vent the hydraulic
pressure, see Section 2 - General Procedures.
K Related Topics ( T E18-2)
Replacement
Replacement is the opposite of the removal procedure.
772970-2
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
Operation Overview
C044270-C1
Fig 1. Servo Pilot Pressure Supply Valve
3 Servo pilot pressure test point
Component Key:
4 Accumulator
1 Servo pressure regulating valve
2a Proportional solenoid valve - Boom `extend'
2b Proportional solenoid valve - Auxiliary service
2c Proportional solenoid valve - Auxiliary service
2d Proportional solenoid valve - Boom `retract'
A372530-1
Fig 2.
Replacement
Replacement is the opposite of the removal procedure.
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
Operation Overview
K Fig 1. ( T E20-3)
C047940-C2
Fig 1.
C047950
Fig 2.
Removal Replacement
1 Raise the boom and fit the safety strut, see Section 2 Replacement is the opposite of the removal procedure.
- Boom Safety Strut. K Related Topics ( T E20-2)
During the replacement procedure do this work also:
2 Make sure that all residual hydraulic pressure has
been vented, see Section 2 - General Procedures. – Ensure that the hoses are reconnected to the correct
K Related Topics ( T E20-2) ports.
– After replacement, check the servo pressure.
3 Disconnect electrical harness at the solenoid
electrical connector 2-B. Important: The extent of permissible servicing is the
renewal of the solenoid coil 2-E and accumulator 2-F.
4 Label the hoses 2-C to ensure correct position on Further dismantling of the valve is not recommended. If the
replacement. Disconnect the hoses. Cap all open valve is suspected as being faulty it must be renewed as a
hoses and ports.
complete assembly.
5 Support the valve block 2-A. Undo and remove the 4
screws 2-D and lift out the valve.
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
Operation Overview
K Fig 1. ( T E21-3) period with a stopped engine. This allows for attachments
to be lowered safely to the ground should the engine stop.
The servo pilot pressure supply valve 3 is supplied from
the fan section of the hydraulic pump. Supply of pilot oil can be isolated from the main control
valve by de-energising solenoid 1. The solenoid is
The pressure regulating valve maintains servo pilot controlled by switch in the cab. When the valve is de-
pressure by regulating the incoming supply pressure. Oil at energised trapped pilot oil in the main control valve is
servo pilot pressure is supplied to the main control valve diverted to tank. The service spools are `locked' and
inlet section. services cannot be operated with or without the engine
running.
The pressure regulating valve incorporates accumulator 2
The accumulator traps and stores servo pilot pressure to Note: Oil stored in the accumulator 2 is isolated from the
enable the service spools to be operated for a limited servo pilot system when solenoid 1 is de-energised
1
2
C106950
Fig 1.
Replacement
Replacement is the opposite of the removal procedure.
F
C106950-C1
Fig 2.
Removal
1 Raise the boom and fit the safety strut, see Section 2
- Boom Safety Strut. K Related Topics ( T E21-2)
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
Operation Overview
K Fig 1. ( T E22-3) The hydraulic isolation (full lock) solenoid E isolates the
pilot supply to the servo control lever when de-energised
The pilot manifold A is supplied with oil at pilot pressure by via a switch in the cab.
the hydraulic control valve. The pressure regulating valve
located in the control valve block maintains servo pilot On machines with SRS an additional solenoid D is fitted
pressure by regulating the incoming supply pressure. which isolates the carriage tilt (crowd/dump) hydraulic
services when de-energised via a switch in the cab.
The servo accumulator B with its associated non-return
valve is located on the pilot manifold. The accumulator Pressure transducers/switches E, F and G are used to
traps and stores servo pilot pressure to enable the service sense operation of pilot services for ECU controlled
spools to be operated for a limited period with a stopped systems such as SRS, Flowshare and LCS. Refer to the
engine. This allows the attachments to be lowered safely applicable topic for details.
to the ground should the engine stop.
IN
T
T
T
PS PR T
TP JO LoO LiO CO DO JO T
C087200-C3
Fig 1. Pilot Manifold
Component Key:
A Pilot manifold
B Accumulator
C Hydraulic isolation (Full lock) solenoid
D Tilt isolation solenoid (if fitted)
E Boom lower spool pilot pressure transducer/switch
F Boom lift spool pilot pressure transducer/switch
G Crowd/dump spool pilot pressure transducer/switch
C085250-C3
Fig 2.
4 Put a label on each hose before disconnecting to help During the replacement procedure do this work also:
identification when replacing.
C087200-C2
Fig 3.
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
Note: The fan pump 1-B is bolted to the variflow pump. 5 Disconnect the electrical connector 1-C at the pump
This procedure describes removing the variflow pump and control solenoid (HVCS).
fan pump as one unit.
6 Disconnect the electrical connector 1-D at the
Carry out General Safety procedures, see Section 2 - hydraulic fluid temperature switch.
General Procedures. K Related Topics ( T E23-2)
7 Undo the clips 1-E and disconnect the suction hose
Before removing the pump, make sure the exterior of the from the pump inlet manifold. Plug the open port and
pump and working area is thoroughly cleaned and free of cap the hose to prevent loss of fluid and ingress of
possible sources of contamination. dirt.
Removal 8 Remove flange bolts 1-F (4 off) and remove the outlet
hose from the pump body. Plug the open port and cap
1 Park the machine on firm level ground, engage the the hose to prevent loss of fluid and ingress of dirt.
parking brake and set the transmission to neutral.
Raise the boom and fit the safety strut. Stop the 9 Disconnect the load sense hose 1-G at the pump.
engine and remove the starter key. Plug the open port and cap the hose to prevent loss
of fluid and ingress of dirt.
!MWARNING 10 Disconnect the case drain hose 1-H at the pump. Plug
Make the machine safe before working underneath it. the open port and cap the hose to prevent loss of fluid
Park the machine on level ground, lower the and ingress of dirt.
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.
!MWARNING
This component is heavy. It must only be removed or
Disconnect the battery, to prevent the engine being handled using a suitable lifting method and device.
started while you are beneath the machine. BF-4-1_1
GEN-4-1_1
11 Secure the pump assembly using a sling around the
pump body. With the pump suitably supported, undo
!MWARNING the four mounting bolts 1-J and carefully withdraw the
Hydraulic Pressure pump clear of the gearbox.
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose, Note: Two bolts 1-J are hexagon head and two are
residual hydraulic pressure trapped in the service caphead bolts. Record the position of the bolts for correct
hose line must be vented. Make sure the hose service replacement.
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while Replacement
the hoses are open.
INT-3-1-11_2 Important: Before starting the engine the variflow pump
body must be filled with hydraulic fluid. If the engine is
2 Vent any residual hydraulic pressure from the hoses started with no fluid in the pump, damage to the pump can
and valves, see Section 2 - General Procedures. occur. Obey the replacement procedures.
K Related Topics ( T E23-2)
1 Ensure the pump flange and gearbox mating face are
3 Drain the hydraulic fluid from the hydraulic tank into a clean and free from oil and grease prior to assembly.
suitable clean container.
4 Remove cap 1-K and fill the pump case with clean
hydraulic fluid. Refit the cap
C051580
Fig 1.
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
9808_6163-1
Fig 2. Typical Gear Pump Section
Exhaust
C065900
Fig 3.
Carry out General Safety procedures, see Section 2 - 3 Drain the hydraulic fluid from the hydraulic tank into a
General Procedures. K Related Topics ( T E24-2) suitable clean container.
Before removing and dismantling the pump, check the flow 4 Remove flange bolts A (4 off) and disconnect the
and pressure. If either of these are low and cannot be suction hose flange from the pump body. Plug the
corrected at the relief valve, the appropriate pump section open port and cap the hose to prevent loss of fluid
must be renewed completely. Renewal of components and ingress of dirt.
such as gears, bearings and housings will not effect a
permanent cure. If the pump output is satisfactory but 5 Disconnect the feed hoses. Plug the open ports and
there is external leakage, the pump should be removed cap the hoses to prevent loss of fluid and ingress of
and dismantled for re-sealing only. dirt. Label each hose before disconnecting to ensure
correct replacement.
Before removing or dismantling the pump, make sure the
exterior of the pump and working area is thoroughly 6 Triple Pump Only: Remove socket head screws C
cleaned and free of possible sources of contamination. and disconnect the outlet pipe D from the pump body.
Plug the open port and cap the pipe to prevent loss of
Removal fluid and ingress of dirt.
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
A313800-C5
Replacement
Replacement is the opposite of the removal procedure.
2 Remove priority valve 6-2 and discard O-rings 6-4. 17 Wash all components and immediately apply a
coating of hydraulic oil to prevent corrosion.
3 Remove the four bolts 6-5 and washers 6-6 which
clamp pump body 6-7 to pump body 6-3. Inspection
4 Use a soft faced hammer to separate pump body 6-3 1 Generally check all pump parts for damage and/or
from pump body 6-7. wear. The O-ring grooves, the seal recess in the
mounting flange and all sealing faces must be free of
5 Remove splined coupling 6-8 and O-rings 6-9. burrs and scores which could result in seal damage
Discard the O-rings. and hence hydraulic oil leakage.
6 Use a soft faced hammer to separate pump body 6-7 2 Renew the pump if any of the following symptoms
from end cover 6-10. exist:
7 Remove drive gear 6-11 from its bore. Pushing it out a The PTFE coated bearings in the pump bodies,
of the rear body will also remove balance plate 6-12 the mounting flange and the end cover are worn
complete with seal 6-13 and seal energiser 6-14. through to reveal the bronze backing.
Discard the seal and seal energiser. Note the position
of the driveshaft and the balance plate to ensure b The gear side faces are scored. Often
correct re-assembly. contaminated fluid results in a distinct wear step
coincident with the gear root diameter. This can
8 Remove driven gear 6-15, followed by balance plate normally be felt by drawing a sharp point across
6-16 complete with seal 6-17 and seal energiser 6-18. the gear side face from the journal towards the tip
Discard the seal and seal energiser. of the gear.
1 Fit shaft seal 6-24 into mounting flange 6-20 with its 12 Fit drive gear 6-11 so that it locates with splined
garter spring facing into the pump. Fit circlip 6-23 into coupling 6-8. Fit driven gear 6-15.
its groove in the flange. Coat the seal lips with high
melting point grease. 13 Fit balance plate 6-12 in its original position (i.e. with
the two small holes to the low pressure side). Fit seal
Note: If the seal recess is scored, it is permissible to seal 6-13 and seal energiser 6-14 into the balance plate.
outside diameters with JCB Multigasket to prevent
leakage. 14 Fit O-ring 6-19 into end cover 6-10.
2 Stand pump body 6-3 on its rear face. Fit seal 6-27 15 Apply a small amount of JCB Threadlocker and
and seal energiser 6-28 into balance plate 6-26. Sealer to the exposed face of pump body 6-7 (i.e. the
face containing the clamping bolt holes).
3 Ensuring that the seals do not fall out, carefully feed
the balance plate into the bores of pump body 6-3 16 Fit end cover 6-10 in its original position, as marked
with the two small holes through the balance plate to earlier.
the low pressure side of the body (i.e. side with the
large 4-bolt port pattern). 17 Install bolts 6-5, each with a serrated washer 6-6, and
tighten evenly and progressively.
4 Insert driveshaft 6-25 and driven gear 6-29 into the
original bores. 18 Refit the priority valve 6-2 to the pump body 6-3. Be
sure to fit new `O' rings 6-4. Tighten the three
5 Fit balance plate 6-30 over the driveshaft and gear capscrews 6-1 evenly and progressively.
stub. Insert seal 6-31 and seal energiser 6-32 into the
balance plate. 19 Pour a small amount of clean JCB Special Hydraulic
Fluid into the ports. Check that driveshaft 6-23 rotates
6 Fit O-ring 6-33 into the groove on mounting flange 6- without undue force. If excessive force is required it is
22.Apply a small amount of JCB Threadlocker and possible that one or more of the balance plate seals
Sealer to the face of pump body 6-3 which seals with are trapped, in which case it will be necessary to
mounting flange 6-22 (i.e. the face containing the dismantle and assemble the pump again.
clamping bolt holes).
Before removing or dismantling the pump, check that its 12 Use a soft faced hammer to separate end cover 7-8
performance is as stated in Specifications. If the from pump body 7-11.
performance is below that specified, the pump should be
renewed. Renewal of individual components such as 13 Remove drive gear 7-24 from its bore. Pushing it out
gears, bearings and housings will not effect a permanent of the pump body will also remove balance plate 7-25
cure. If a pump's output is satisfactory but there is complete with seal 7-26 and seal energiser 7-27.
evidence of external leakage, it should be dismantled for Discard the seal and seal energiser. Note the position
re-sealing only. of the driveshaft and the balance plate to ensure
correct re-assembly.Remove driven gear 7-28,
Prior to dismantling the unit, ensure that the exterior of the followed by balance plate 7-29 complete with seal 7-
pump and the working area are thoroughly cleaned and 30 and seal energiser 7-31. Discard the seal and seal
free of possible sources of contamination. energiser.
Mark all sections to ensure correct assembly and keep 14 Discard O-ring 7-32.
pump components with their relative pump section.
15 Use a soft hammer to separate mounting flange 7-33
Dismantle from pump body 7-12.
1 Remove the three capscrews 7-A which attach the 16 Remove circlip 7-1 and shaft seal 7-34.
priority valve 7-B to the pump body 7-11.
17 Remove driveshaft 7-35 from pump body 7-12.
2 Remove priority valve 7-B and discard O-rings 7-C. Removal will also remove balance plate 7-36
complete with seal 7-37 and seal energiser 7-38.
3 Remove the four bolts 7-2 and serrated washers 7-3 Discard the seal and seal energiser.
which clamp the units together.
18 Remove driven gear 7-39 followed by balance plate
4 Use a soft faced hammer to separate pump body 7-7 7-40, seal 7-41 and seal energiser 7-42. Discard the
from end cover 7-8. seal and seal energiser.
5 Remove splined coupling 7-9 and O-rings 7-10. 19 Discard O-ring 7-43.
Discard the O-rings.
20 Remove all sealant from the contact faces of the
6 Use a soft faced hammer to separate pump body 7- mounting flange/pump body and end cover/pump
11 from pump body 7-12. body interfaces.
7 Remove splined coupling 7-13 and O-rings 7-14. 21 Wash all components and immediately apply a
Discard the O-rings. coating of hydraulic oil to prevent corrosion.
1 Fit shaft seal 7-34 into mounting flange 7-33 with its 12 Fit drive gear 7-24 so that it locates with splined
garter spring facing into the pump. Fit circlip 7-1 into coupling 7-13. Fit driven gear 7-28.
its groove in the flange. Coat the seal lips with high
melting point grease. 13 Fit balance plate 7-25 in its original position (i.e. with
the two small holes to the low pressure side). Fit seal
Note: If the seal recess is scored, it is permissible to seal 7-26 and seal energiser 7-27 into the balance plate.
outside diameters with JCB Multigasket to prevent
leakage. 14 Fit O-ring seal into end cover 7-8.
2 Stand pump body 7-12 on its rear face. Fit seal 7-37 15 Apply a small amount of JCB Threadlocker and
and seal energiser 7-38 into balance plate 7-36. Sealer to the exposed face of pump body 7-11 (i.e.
the face containing the clamping bolt holes).
3 Ensuring that the seals do not fall out, carefully feed
the balance plate into the bores of pump body 12 with 16 Fit end cover 7-8 in its original position, as marked
the two small holes through the balance plate to the earlier.
low pressure side of the body (i.e. side with the large
4-bolt port pattern). 17 Fit O-rings 7-10 into the grooves on the face of pump
body 7-7. Install splined coupling 7-9.
4 Insert driveshaft 7-35 and driven gear 7-39 into the
original bores. 18 Fit pump body 7-7 onto end cover 7-8 in its original
position, as marked earlier, ensuring that it locates on
5 Fit balance plate 7-40 over the driveshaft and gear the dowels and that the clamping bolt holes line up.
stub. Insert seal 7-41 and seal energiser 7-42 into the
balance plate.
C
A
11 B
14
C024880-C1
Fig 7. Typical Triple Pump
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
(2) Refer to the relevant hydraulic system topic for fan motor location and specifications.
Specifications
Operation Overview
K Fig 1. ( T E25-5)
Item
1 Main Pump
2 Hydraulic Tank
3 Pump Pressure Supply
4 Fan Motor Case Drain Line
5 Fan Motor Pressure Relief Valve
6 Fan Motor
Neutral
Exhaust
C066320
Fig 1.
Removal
1 Park the machine and make it safe. Fit the boom
safety strut. Vent the hydraulic pressure. Obey the
care and safety procedures. K Related
Topics ( T E25-2)
764200-1
2 Vent the hydraulic pressure, see Section 2 - General Fig 2.
Procedures. K Related Topics ( T E25-2)
7 Withdraw the fan from the motor shaft. Retain the
3 Disconnect and plug the feed and return hoses 4-A drive key (not shown).
and 4-B. Disconnect and plug the case drain hose 4-
C (reversible fan option only). Label each hose before 8 Undo motor retaining bolts 3-A and remove the motor.
disconnecting to ensure correct replacement.
5 Undo 4 bolts 4-D and lift away the fan and motor
assembly.
764210-1
Fig 3.
Replacement
Replacement is the opposite of the removal procedure.
C025090-C4
Fig 4.
Prior to dismantling the unit make sure that the exterior of 3 The motor must be renewed if any of the following
the motor and the working area are thoroughly cleaned faults are found:
and free from possible sources of contamination.
a The PTFE coated bearing in the bushes are worn
Dismantle through so that the bronze base is visible.
Nut 5-1, tab washer 5-2 and key 5-3 secure the fan and are b The gear side faces or bush faces are scored or
replaced when the motor is re-installed in the machine. chipped.
K Removal and Replacement ( T E25-6)
c The drive shaft has a noticeable wear groove
1 Remove sharp edges and burrs from the drive shaft where the shaft seal lips run.
5-11 to avoid seal damage.
Assemble
2 Remove relief valve 5-23.
Nut 5-1, tab washer 5-2 and key 5-3 secure the fan and are
3 Mark end cover 5-20, body 5-17 and flange 5-5 to replaced when the motor is re-installed in the machine.
ensure correct assembly. K Removal and Replacement ( T E25-6)
4 Undo bolts 5-22 and spring washers 5-21 and remove 1 Wash all components. Apply hydraulic oil immediately
end cover 5-20. Take care not to damage the afterwards to prevent moisture collecting.
machined faces by prising them apart - use a soft
faced hammer. 2 Renew all seals and 'O' rings using JCB Special
Hydraulic fluid as a lubricant.
5 Remove back-up seal 5-15, bush seal 5-14 and body
'O' ring 5-19. 3 Fit shaft seal 5-4 into the mounting flange 5-5 with
gaiter spring facing the motor. Fit circlip 5-3 and coat
6 Remove flange 5-5, slide the flange off square to the seal lips with JCB HP Grease.
shaft. Take care not to damage the machined faces
by prising them apart - use a soft faced hammer to 4 Fit bush 5-9 in it's original positions. Place end cover
free flange from dowels. 5-20 temporarily against main body 5-17 and stand
assembly upright with dowels uppermost.
7 Remove back-up seals 5-7, bush seal 5-8, and body
'O' ring 5-16. 5 Fit drive shaft 5-11 and idler gear 5-10. Fit bush 5-13
in it's original positions. Fit 'O' ring 5-16, bush seal 5-
8 Remove drive shaft 5-11, bushes 5-13 and idler gear 8 and back-up seal 5-7. Make sure that the flat face
5-10. Push out bush 5-9 from the body. Note the of back-up seal is uppermost.
position of bushes to ensure correct assembly.
6 Fit protective sleeve over drive shaft. Locate flange 5-
9 Remove circlip 5-3 and shaft seal 5-4. Take care not 5 to main body with a square fit on the dowels. Turn
to damage the shaft seal recess. the assembly over and support on the flange, not on
the drive shaft. Remove end cover.
Inspection
7 Fit 'O' ring 5-19, bush seal 5-14 and back-up seal 5-
1 Inspect all 'O' ring grooves and shaft seal recesses in 15. Make sure that the flat face of back-up seal is
mounting flange 5-5. Make sure they are free from uppermost. Fit end cover 5-20 with relief valve
burrs. tapping on the same side as the outlet port. Secure
with spring washers 5-21 and bolts 5-22. Torque
2 Check that the mating faces of the end cover 20, body tighten to 47Nm (4.8 lbf ft., 36 lbf ft).
5-17 and flange 5-5 are not scored.
710370-1
Fig 5.
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
Removal
K Fig 1. ( T E26-3)
Replacement
Replacement is the opposite of the removal procedure.
C048470-C1
Fig 1.
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
Removal
Note: The control lever D and attached powerbase is a
non serviceable part. If it is faulty it must be renewed.
2 Remove screws E.
Replacement
Replacement is the opposite of the removal procedure.
A B
J C
H D
G E
F
C106940
Fig 1.
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
Operation Overview
C052030-C1
Fig 1.
Exhaust
C087070
Fig 2.
Component Key:
1 Lift pilot port
2 Crowd pilot port
3 Lower pilot port
4 Dump pilot port
T Tank return
P Servo pressure supply from control valve block
Removal
1 Park the machine and make it safe. Lower the boom.
Obey the General Safety procedures, see Section 2
- General Procedures. K Related
Topics ( T E28-2)
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
Replacement
Replacement is the opposite of the removal procedure.
C087210
Fig 3.
Extension Ram
Introduction
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
Obey the general care and safety procedures for rams drive out pivot pin 2-F and to support the other side of the
during the removal and replacement procedures. boom.
K Related Topics ( T E29-2)
Removal
!MWARNING
This component is heavy. It must only be removed or
1 Remove any attachments from the carriage. handled using a suitable lifting method and device.
BF-4-1_1
2 Extend the boom sufficiently to gain access to the
extension ram rod end pivot pin 1-A. 9 Prepare suitable lifting equipment and withdraw the
extension ram from the boom.
3 Lower the boom to the ground.
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
A294030-1
7 Disconnect and plug extension ram hydraulic hoses
Fig 1.
2-D. Label each hose before disconnecting to ensure
correct replacement.
8 Remove nut and bolt 2-E and withdraw main pivot pin
2-F sufficiently to allow the extension ram to be
removed.
711210-1
Fig 2.
Replacement
Replacement is the opposite of the removal procedure.
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
!MWARNING
This component is heavy. It must only be removed or
handled using a suitable lifting method and device.
BF-4-1_1
7 Remove nut and bolt 3-G and withdraw pivot 3-F from
cylinder end.
Replacement
345790-1
Fig 3. Machines with 3 Stage Boom - Outer Ram
Inner Ram
Removal
S293671-C2
Fig 4.
The following procedure must be strictly adhered to, to 5 Raise the boom and operate the retract control to
prevent damage to the internal ram and auxiliary feed slowly retract the extension ram. The inner boom
hoses. section should retract with the hydraulic cylinder
under its own weight.
1 Park the machine on firm level ground. Apply the
parking brake and remove the carriage. If the inner boom section will not retract under its own
weight, lower the boom and carefully push the boom
2 Raise the boom to just above the horizontal. Extend against an outside force (i.e. another machine).
the boom to gain access to the front pivot pin 4-A.
Note: The length of the inner and intermediate boom
3 Remove bolt 4-B. Knock pin the through the boom sections protruding from the outer section must be kept
using a drift. equal to avoid damage to the internal hoses.
4 Remove the boom rear cover plate (HiViz Machines). 6 Lower the boom to align the inner ram rear pivot pin
For this procedure see Section B - Boom. with the access holes 4-C in the chassis.
K Related Topics ( T E29-2)
A332150-1
Fig 6.
Replacement
A332140-1
Ensure the head side and rod side bushes are aligned
Fig 5. before fitting the cylinder. If a new cylinder is to be fitted,
transfer the hose tray to the new cylinder.
11 Disconnect the hoses 6-H from the rear of the
extension cylinder. Plug the open ports and label the 1 Position the cylinder inside the inner boom.
connections.
2 Grease the rear pivot pin 5-G. See Section 3 -
12 Remove the two bolts 6-J securing the guide on the Lubricants & Capacities. K Related
hose tray. Topics ( T E29-2)
13 Support the ram. Remove bolt 4-K and knock pin 6-L 3 Fit the pin and secure in place with bolt 6-K.
through the boom using a drift. Note the location of
spacers 6-M. 4 Operate the extend control to slowly extend the
cylinder and push out the inner boom section.
14 Carefully withdraw the ram from the boom using Release the control when the front pivot pin is visible.
suitable lifting equipment. Take care not to damage
any hoses inside the boom. Note: The length of the inner and intermediate boom
sections protruding from the outer section must be kept
equal to avoid damage to the internal hoses.
Lift Rams
Introduction
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
Removal !MWARNING
K Fig 2. ( T E30-4) Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
The illustration shows a typical machine. The procedure is Before connecting or removing any hydraulic hose,
the same for all machines. residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
Obey the general care and safety procedures for rams line has been vented before connecting or removing
during the removal and replacement procedures. hoses. Make sure the engine cannot be started while
K Related Topics ( T E30-2) the hoses are open.
INT-3-1-11_2
1 Remove any attachments from the carriage.
4 Operate the controls back and forth several times to
2 Lower the boom onto a suitable support as shown. vent residual hydraulic pressure.
K Fig 1. ( T E30-3)
5 Disconnect and plug lift ram hydraulic hoses 2-D.
Label each hose before disconnecting to ensure
correct replacement.
6 Support the lift ram 2-A. Remove nut and bolt 2-B and
withdraw the pivot pin 2-C from rod end.
!MWARNING
This component is heavy. It must only be removed or
handled using a suitable lifting method and device.
BF-4-1_1
Fig 1.
9 Remove bolts 2-E and 2-F, spacer 2-G and lock plate
2-H. Withdraw the pivot pin 2-J from cylinder end,
3 Carry out General Safety Procedures, see Section 2
remove ram from the machine.
- General Procedures. K Related
Topics ( T E30-2)
Tilt Ram
Introduction
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
(1) Procedure variant. Make sure you refer to the correct procedure.
(1) The table lists procedure and specification variants and the applicable machine models. Use the table to make sure
you refer to the correct information.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
(2) Refer to the correct machine hydraulic system.
IMPORTANT: This procedure is only applicable to some 11 Remove the ram from the machine.
machine models. Refer to the table at the front of this topic
for the applicable machine models. K Table 1. Procedure Replacement
Variants ( T E31-1)
Replacement is the opposite of the removal procedure.
Removal
During the replacement procedure do this work also:
1 Remove attachments from the carriage.
– Grease the ram pivot pins. K Related
2 Extend the tilt ram fully. Topics ( T E31-2)
– Check the hydraulic fluid level. K Related
3 Extend the boom to get access to the cap screw 1-A. Topics ( T E31-2)
– Using the bleed procedures bleed the ram.
4 Lower the boom and carriage to the ground.
K Related Topics ( T E31-2).
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
!MWARNING
This component is heavy. It must only be removed or
handled using a suitable lifting method and device.
BF-4-1_1
9 Remove the bolt 1-C and remove the pivot pin 1-D
from rod end.
C043950
C043950
Fig 1. Tilt Ram - 2 Stage Boom (P1)
Removal
1 Remove all attachments fitted on the tool carrier, tilt
back and lower the boom to the ground.
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
!MWARNING
This component is heavy. It must only be removed or
handled using a suitable lifting method and device.
BF-4-1_1
5 Support the ram, undo bolt 2-C and withdraw pivot pin
2-D from cylinder end, remove ram from machine.
Replacement
Replacement is the opposite of the removal procedure.
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
!MWARNING
This component is heavy. It must only be removed or
handled using a suitable lifting method and device.
BF-4-1_1
8 Remove nut and bolt 3-D and withdraw pivot pin 3-E
from cylinder end, remove the ram from the machine.
Replacement
Replacement is the opposite of the removal procedure.
A293270-1
Fig 3. Tilt Ram - 3 Stage Boom
Displacement Ram
Introduction
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
(1) Procedure variant. Make sure you refer to the correct procedure.
(1) The table lists procedure and specification variants and the applicable machine models. Use the table to make sure
you refer to the correct information.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
IMPORTANT: This procedure is only applicable to some 10 Remove the ram from the machine.
machine models. Refer to the table at the front of this topic
for the applicable machine models. K Table 1. Procedure Replacement
Variants ( T E32-1)
Replacement is opposite of the removal procedure.
Removal
During the replacement procedure do this work also:
1 Raise the boom to get access to the lower pivot of the
displacement ram. Fully retract the boom. Support – Grease the ram pivot pins. K Related
the front end of the boom. Topics ( T E32-2)
– Check the hydraulic fluid level. K Related
2 Park the machine and make it safe. Obey the care Topics ( T E32-2)
and safety procedures. K Related Topics ( T E32-2)
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
!MWARNING
This component is heavy. It must only be removed or
handled using a suitable lifting method and device.
BF-4-1_1
8 Remove the lock bolt 1-B and remove the pivot pin 1-
C from rod end.
9 Remove the lock bolt 1-D and remove the pivot pin 1-
E from cylinder end.
S293640-1
Fig 1. Single Displacement Ram (P1)
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
!MWARNING
This component is heavy. It must only be removed or
handled using a suitable lifting method and device.
BF-4-1_1
8 Remove the lock bolt 2-B and remove the pivot pin 2-
C from rod end.
9 Remove the lock bolt 2-D and remove the pivot pin 2-
E from cylinder end, remove ram from the machine.
C075750
Fig 2. Single Displacement Ram (P2)
Removal
1 Remove any attachments from the carriage.
A711140-1
Fig 4.
!MWARNING
This component is heavy. It must only be removed or
handled using a suitable lifting method and device.
BF-4-1_1
8 Remove bolt 5-B and withdraw the pivot pin 5-A from
765430 the rod end of the displacement rams. Remove the
Fig 3. rams from the machine.
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
716910-1
INT-3-1-11_2 Fig 5.
Removal
Note: The illustration and procedure describes removal of
one displacement ram. The procedure for the second ram
is identical.
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
!MWARNING
This component is heavy. It must only be removed or
handled using a suitable lifting method and device.
BF-4-1_1
5 Remove nut and bolt 6-E and withdraw pivot pin 6-F
from cylinder end, remove ram from the machine.
773270-1
Fig 6.
Replacement
Replacement is opposite of the removal procedure.
Sway Ram
Introduction
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
Removal 9 Remove nut and bolt 1-E and withdraw pivot pin 1-F
from rod end, remove the ram from the machine.
1 Park the machine and make it safe. Vent the hydraulic
pressure. Obey the care and safety procedures.
K Related Topics ( T E33-2)
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
!MWARNING
This component is heavy. It must only be removed or
handled using a suitable lifting method and device.
BF-4-1_1
Replacement
Replacement is the opposite of the removal procedure.
Stabiliser Rams
Introduction
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
Removal !MWARNING
Obey the general care and safety procedures for rams This component is heavy. It must only be removed or
during the removal and replacement procedures. handled using a suitable lifting method and device.
K Related Topics ( T E34-2) BF-4-1_1
Note: The illustration and procedure describes removal of 8 Remove nut and bolt 1-C and withdraw pivot pin 1-D
one stabiliser ram. The procedure for the second ram is from rod end.
identical.
9 Remove nut and bolt 1-E and withdraw pivot pin 1-F
Note: The stabiliser ram can be removed with the from cylinder end, remove the ram from the machine.
stabiliser leg still attached to the machine.
Replacement
1 Park the machine and make it safe. Vent the hydraulic
pressure. Obey the care and safety procedures. Replacement is the opposite of the removal procedure.
K Related Topics ( T E34-2)
During the replacement procedure do this work also:
2 Lower the boom and carriage to the ground.
Grease the ram pivot pins. K Related Topics ( T E34-2)
3 Lower the stabilisers as far as the ground. Do not
allow them to support the machine. Check the hydraulic fluid level. K Related
Topics ( T E34-2)
!MWARNING Checking Pressure Switch Operation
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. The pressure switches (if fitted) are pre-set and must not
Before connecting or removing any hydraulic hose, be adjusted.
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service To check for correct operation, raise and lower each
line has been vented before connecting or removing stabiliser in turn to ensure that the warning light illuminates
hoses. Make sure the engine cannot be started while when both stabilisers are making firm ground contact and
the hoses are open. extinguishes when one or both stabilisers are raised clear
INT-3-1-11_2 of the ground.
S293700-1
Fig 1. Stabiliser Ram (if fitted)
Ram Maintenance
Introduction
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
(1) Procedure variant. Make sure you refer to the correct procedure.
(1) The table lists procedure and specification variants and the applicable machine models. Use the table to make sure
you refer to the correct information.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
(1) Tool available from JCB Service, refer to Section 1 - Service Tools
(2) For the applicable JCB part number refer to Section 1 - Service Tools
Operation Overview
Ram End Damping To make the ram operate smoothly, electro servo
machines have a “damping” system.
When operating the lift and extension rams a jolt can occur
when the ram is at full travel. This could cause load The flow through the ram is gradually decreased as the
instability and operator discomfort. ram moves to the end of its travel until the ram is at full
travel.
C078940-C1
Fig 1. Ram Retracting (Cylinder End of Ram)
A restrictor probe 1-G fitted to the end of the cylinder 1-C rod 2-H. This flow pushes the orifice plate 2-D away from
aligns with a groove 1-H in the piston rod 1-F. the counterbore 2-E increasing the area on which the oil
pushes on the ram decreasing the pressure necessary to
As the ram closes to full retract the probe 1-G engages extend the ram (pressure spike).
with the hole 1-H in the piston rod, the damping effect is
caused as the orifice plate 1-D seats on the face of the The flow rate, pressure, load and viscosity of the oil have
piston rod counterbore 1-E. The holes in the probe 1-G an effect on the damping rate.
control the speed of the ram by restricting the flow of oil at
a gradual rate until the ram is fully closed.
To extend the ram, oil goes into the feed port 2-A and
through the centre of the probe 2-G to the hole in the piston
C078940
Fig 2. Ram Extending (Cylinder End of Ram)
C078950
Fig 3.
To retract the ram oil flows through the feed port 3-D, this
pushes the anti extrusion ring 4-B and compresses the ‘o’
ring 4-A letting oil flow through the four galleries which
pushes on the piston head. Also the oil flows through the
four holes in the end cap 3-H through the flats 3-E of the
tapered collar 3-D. The function of the flats and oil
pathways is to decrease the pressure necessary to retract
the ram from full open centres (pressure spike).
C078950-C1
Fig 4.
Dismantle
The dismantle and assemble procedures for many JCB 4 Extract dowel 6-5 from the piston head using the
hydraulic rams are the same. BEFORE you follow the appropriate sized screw threaded into the extractor
procedures given in this topic make sure they are hole.
applicable. The applicable rams are given in the related
topics table. K Related Topics ( T E35-2) 5 Using the correct size spanner, remove piston head
6-6 from rod 6-12 and remove `O' ring 6-7.
Important: The ram must be removed from the machine
before you dismantle it. K Related Topics ( T E35-2) Extension rams only: Slide spacer 6-20 off piston
rod 6-12, after removal of piston 6-6.
K Fig 6. ( T E35-7)
6 Remove gland bearing and end cap 6-8 from piston
The illustration shows a ram which is not fitted with a hose rod and remove the `O' ring 6-9, wiper seal 6-11 and
burst check valve (HBCV). If a HBCV is fitted the ram rod seal 6-10. Check end cap bearing for damage,
dismantling/assembly procedures are unaffected and can scores or nicks. If damaged, the bearing must be
be carried out without the need to remove the check valve. replaced as part of the end cap assembly.
1 Place ram assembly on a locally manufactured strip/ 7 Ensure that metal components are free from scoring,
rebuild bench. K Fig 5. ( T E35-6) nicks and burrs. A damaged piston rod will impair the
life of gland seals. Check the bore of the ram cylinder
for damage.
S263670-1
Fig 5.
!MWARNING
If air or hydraulic pressure is used to force out the
piston assembly, ensure that the end cap is securely
fitted. Severe injury can be caused by a suddenly
released piston rod.
HYD-1-2
S314091-1
Fig 6. Typical Ram
Assemble
1 Clean threads of piston rod, piston head, end cap and Table 4. Torque Settings
cylinder using a wire brush. Use JCB Cleaner and De- Item Nm Kgf m lbf ft
greaser to ensure that all threads are free from
grease, hydraulic oil and old sealing/retaining 6-6 405 41 300
compounds. Allow 15 minutes for solvent to dry 6-8 678 69 500
before applying JCB Threadlocker and Sealer (High
Strength).
Use seal fitting tool 7-A to fit rod seals, the size
(diameter) and position of pins 7-B is determined by
the diameter and radial width of the rod seal being
fitted.
153212-1
Fig 9.
S216250-1
Fig 7. Seal Fitting Tool
a Open the tool and insert the new rod seal 8-A. The S161750 Y-1
seal must be fitted behind the two front pins but in Fig 10.
front of the rear pin as shown.
c Before fitting the rod seals check the seal grooves
are free of contamination and sharp edges.
S161750 X-1
Fig 8.
Note: Later ram end caps and piston heads are metric
threads. The seals are also different, make sure the
correct seals are fitted. On metric threaded rams make
sure the seals are fitted the correct way round, as shown
at 9-A and 9-B.
S161750 Z-1
Fig 11.
e Fit rod wiper seal 9-A into seal groove. Make sure
the seal is correctly installed as shown.
187361-1
Fig 12.
3 Fit the piston rod and head assembly into the cylinder.
338480-1
Fig 13.
Note: Ensure that the top of the dowel is below the level of
the bearing ring groove and use an undersized pilot drill
before drilling to the final size shown in the table.
as at Y. Fig 16.
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
Related Topics
(1) You must obey all of the relevant care and safety procedures.
Component Location
C084990-C1
Fig 1.
E36-5
The engine cooling fan hydraulic oil supply is also Operation of the switch energises the solenoids A and
used to operate the sway system when fitted. When B in the sway/fan changeover valve. Solenoid A
the sway system is operated the supply to the engine diverts the fan hydraulic supply to feed the sway
cooling fan is diverted to the sway system. The system. Solenoid B is a double acting solenoid which
hydraulic fan does not operate while the sway system controls the direction of the supply to the correct side
is in use.The sway ram will stay in position until the of the sway ram C.
switch is operated.
A proximity switch located on the boom operates
when the boom is at an angle of 10° or higher. The
A Sway/Fan Selection Solenoid
proximity switch prevents the sway relay from
B Sway Direction Control Solenoid energising and operating the sway system solenoid A
C Sway Ram until the boom is lowered.
F Fan Hydraulic Supply
P Pump Hydraulic Supply
T Tank Return
C084970-C2
Fig 4. Left Sway Switch Operated
9803/3760-07 (E-32-01)
Table 2. Colour Key to Oil Flow and Pressure
Full Pressure
Neutral
Exhaust
C084970-C1
Fig 3. Right Sway Switch Operated
C084970
Fig 2. Sway Switch Not Operated
E36-5
Section E36 - Hydraulics
The harness connector pin numbers are shown on the schematic. Harness connector details are shown on a separate
page. K Electrical Connectors ( T E36-7)
Key Key
-003 Panel Harness Ground A 3057 Sway Direction Control Solenoid
-001 Chassis Harness Ground 3058 Sway Direction Control Solenoid
1046 Sway Switch 8004 Panel Harness to Chassis Harness
Connector
1069 Sway Proximity Switch
8031 Chassis Harness to Sway harness
2046 Sway Isolation Relay
connector
3056 Sway/Fan Changeover Solenoid
9001 Fuse Box A
C084980
Fig 5.
Electrical Connectors
The table shows the harness connectors that connect to the electrical devices. The connectors are shown looking at the
mating face when disconnected. Remember that the drawings show the harness connectors NOT the device connectors.
Use the table and the relevant electrical schematic to identify the pins in the harness connectors. Continuity checks on
the harness wires can be carried out using a multi-meter. Do not touch ECU connector pins. Do not use a multi-meter on
ECU connector pins.
Device Description Location Harness Connector
-001 Chassis Harness Ground Refer to Section C - Electrical Harness
SYSTEM. K Related Topics ( T E36-2)
M10
-003 Panel Harness Ground A Refer to Section C - Electrical Harness
SYSTEM. K Related Topics ( T E36-2)
M10
1046 Sway Switch Located on the instrument panel. Remove the
switch to get access to the connector.
G
F
C110660
Fig 7. Typical Sway Valve Harness
C085000 Replacement
Fig 6.
Replacement is the opposite of the removal procedure.
!MWARNING During the replacement procedure do this work also:
A raised and badly supported machine can fall on you.
Position the machine on a firm, level surface before – Discard old seals and fit new seals and `O' rings.
raising one end. Ensure the other end is securely
chocked. Do not rely solely on the machine hydraulics When refitting adaptors, do not overtighten as this
or jacks to support the machine when working under distorts the body and the valve may fail to operate
it. correctly.
Disconnect the battery, to prevent the engine being – Reconnect the hoses in the correct positions as
started while you are beneath the machine. labelled during removal.
GEN-1-1
– Make sure to route the harness G correctly and
replace the retaining clips F.
1 Park the machine and make it safe. Fit the boom
safety strut. Vent the hydraulic pressure. Obey the – Reconnect electrical harness.
care and safety procedures. K Related – After replacement, check that the valve operates
Topics ( T E36-2) correctly and there are no hydraulic leaks.
Note: It is not normally recommended to remove the spool 1 Remove the solenoid assembly screws 8-B and
from the valve body. None of the component parts of the remove the solenoid assemblies 8-A and 8-C from
CETOPS valve assembly can be renewed individually. The the valve block 8-D.
extent of permissible servicing is cleaning and the
consequential renewal of `O' ring seals. If damage to any 2 Remove the surface mounted `O' rings 9-7.
component or distortion of the spool is evident the
complete valve assembly must be renewed. 3 Unscrew the knurled nut 9-1and remove O-ring 9-2.
Great care should be taken when dismantling and 4 Withdraw the solenoid 9-3 and O-ring 9-5.
assembling the valve to avoid the following:
– Contamination
– Damage to spools
– Damage to seal grooves
Dismantle
C085020
Fig 9.
C085010
Fig 8.
5 Inspect the spool 9-4 for signs of wear, nicks
scratches etc.
Assemble
Assembly is the opposite of the dismantling procedure.