International Training Centre

Safety Awareness

Before starting work, identify and take note of:
1 HAZARDS
For example:
- The presence of highly inflammable liquids and
vapours.
- Dangerous materials, acids, gases etc.
- Insecurely slung or transported loads.
- Unsafe machinery, equipment and tools.
- Unsafe floors, dust, oil spillage etc.
Cuts and abrasions will allow infection to penetrate, they
should be treated and protected.
- Eye protection must be worn when grinding, cutting,
welding etc.
- Protective hard hat to be worn when on construction
sites.
- Face masks to be worn when welding, flame cutting,
paint spraying, lubricant spraying etc.
- Ear protectors to be worn in high noise levels.

2 POTENTIAL HAZARDS
- Working with machines insecurely supported.
- Unauthorised repairs on machines.
- Selection of incorrect tools for work in progress.
- Craning of unstable loads.
- Potential oil, paint spillage etc.
- Working on unstable or makeshift platforms.
- Untidy work places.
- Release of compressed air, steam or hydraulic oil
under pressure.

Remember - working on maintenance operations in

excavations, when painting, when welding, working in
confined spaces are all regarded as HIGH RISK
ACTIVITIES.

SAFETY FIRST also includes attention to detail before

starting, during and when finishing work.
For example:
- Barrier cream will limit the degree of contact with
potential harmful substances.
- Barrier creams should NOT be relied on as sole
means of protection.
- Hygiene, always wash thoroughly with soap and hot
water. Skin cleansers should be used when soap
and water is inadequate. AVOID using sol vents
such as paraffin, thinners, petrol etc. as skin
cleansers.
 International Training Centre

Workshop Practices

- Always wear safety boots.

- Always use jury struts when working under
excavator, booms or shovel arms.
- Isolate starter systems before working' on machines.
- Do not smoke near fuels, oil storage or batteries.
- Check and warn neighbouring personnel before
starting engines.
- Release trapped hydraulic pressure before
removing hydraulic pipes or fittings.
- When using lifting gear check slings, chains etc. DO
NOT USE in the following instances.

Use correct Slinging procedures.

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Care and Safety

Component Removal

Secure all moving parts of the machine to prevent

inadvertent actions by other personnel causing dangerous
movement and possible injury.

For example: Always set buckets and shovels on the

ground or on adequate supports before work is
commenced.

Never work beneath a machine unless it is standing on

hard ground, preferably concrete. If a machine is lifted to
improve accessibility, always place substantial supports
under the main frame or track frame before work is
commenced.

Always check lifting equipment, slings, chains etc. before

components are hoisted. Always use equipment which is
adequate for the job in hand.

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Care and Safety

Hoses and Pipes

Always fit blanking plugs whenever hoses or pipes are

disconnected. Serious damage can occur if dirt or abra-
sive material enters the hydraulic system.

Test the temperature of adjacent pipework and compo-

nents with the hand prior to disconnecting a hose or
pipe. If the oil is considered too hot for safety, allow suffi-
cient time for it to cool before a connection is loosened.

Rest the digging equipment on the ground, stop the

engine and operate all control levers to vent any residual
pressure from the hydraulic circuit before hoses or pipes
are disconnected. This minimises the chance of injury
from spurting oil when a connection is loosened.

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Care and Safety

Renew hoses if any of the following faults are found

1 End fitting damaged or leaking.

If hose elbows are dented or crushed, oil flow is

restricted and the speed at which the service
operates will be reduced. Badly crushed elbows can
completely block the oil flow and prevent the service
from operating.

2 Outer covering chafed or cut and wire

reinforcing exposed.

If a hose remains in service in this condition water will

seep into the internal wire reinforcing and cause
concealed corrosion and consequent weakening of
the hose structure. This may not be apparent until the
hose subsequently fails.

3 Outer covering ballooning locally.

This is caused by failure of the hose structure which

allows hydraulic oil to leak internally. The oil
eventually forces its way into the outer layers of the
hose's construction and ultimately causes the hose to
burst.

4 Evidence of kinking or crushing on flexible part of

hose.

If a hose is deformed past its designed limits, damage

to the internal structure is caused. This can result in
restriction of oil flow or local weakening of the hose.

5 Armouring embedded in outer cover.

If armouring is deformed, internal damage similar to

that caused by crushing or kinking will almost
certainly have occurred.

6 End fittings displaced.

If the swaged sleeve of an end fitting appears to have

moved from its original position, there is a possibility
that partial failure has occurred in the area where the
sleeve grips the flexible part of the hose. Ultimately
the end fitting will pull off.

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Care and Safety

Renew pipes if any of the following faults are found.

1 Cone damaged or distorted

2 Thread damaged.

3 End fittings damaged or leaking.

4 Outer surfaces damaged or severely corroded.

Unsupported hoses or pipes must not touch each other or

adjacent components or chafing will be caused.

Loosely connect each end, settle the hose or pipe into

position and tighten connections. Clamps should be
tightened sufficiently to retain the hose or pipe without
causing crushing.

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Care and Safety

If a hose is connected to moving components, the

components should be moved over the full extent of their
travel to check that the hose does not foul as it is bent.

Hoses must never be twisted when fitting.

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Care and Safety

Dismantling and Assembly

Thoroughly clean the exterior of all components before

dismantling. If dismantling is commenced without
removing a component from the machine, cleanliness is
doubly important since the service life of a component is
drastically reduced if dirt or abrasive matter is not
excluded at all times.

Sometimes components are dismantled in adverse

conditions without workshop facilities being available. If
this is necessary, suitable precautions must be taken to
prevent dust and dirt settling on internal parts, particularly
on oiled surfaces where it will be retained and
contaminate any new oil with which a component is filled.

Select cleaning agents and solvents with care. Refer to

COSHH information from JCB distributors.

WARNING: Solvent type cleaners are dangerous when

used in a confined area. Avoid inhalation of
the vapour or contact with the skin. Do not
use near a naked flame.

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Care and Safety

No adhesives or sealants to be used in the presence of

seals and 'O' rings because they can severely damage
certain types of rubber.

Renew 'O’ rings, seals and gaskets, regardless of

condition, whenever they are disturbed, unless instructed
otherwise.

Lightly coat 'O' rings and gaskets with hydraulic oil before
fitting, unless instructed otherwise.

Coat gaskets with a suitable jointing solution before fitting,

unless instructed otherwise. Proprietary solutions which
are compatible with the various oils used by JCB are given
and are referred to where appropriate.

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Care and safety

Bearings

Removal

Do not remove bearings unless they are to be renewed

(see Inspection) or unless unavoidable in a dismantling
sequence.

Whenever possible, use a suitable puller or extractor to

minimise risk of damage to both the bearing and adjacent
parts. Keep bearings with loose rings, balls or rollers as
matched assemblies; they are selectively assembled and
parts do not interchange from one bearing to another.

Inspection

Check that the bearing has had ample lubrication and

that the lubricant has not been contaminated.

Check for discoloration and signs of overheating.

Check the bearing for excessive clearance and the cage

for wear, cracks and scuffing. If in doubt regarding the
clearance, compare this with an identical new bearing.

NOTE: Journal bearings are graded by the internal

clearance when new, this is indicated by one, two
or three feint circles marked on one ring: Ensure
that both bearings are of the same grade when
comparing new with old.

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Care and Safety

Check the finish of the locating surfaces A and B. They

may have been lightly marked on assembly but should not
be polished. Polishing indicates that the ring has been
turning relative to its seating - this is confirmed if the
seating is also polished.

If bearing rings have been turning, the mating parts must

be either renewed or built up and machined to their
original sizes.

Check the bearing tracks, rollers or balls for surface

imperfections.

Renew the needle roller bearings if:

1 Rollers, cages or rings are damaged.

2 Rollers fall from cage.

3 Rollers can be moved noticeably out of alignment.

4 The shaft surface is damaged or worn. If this has

occurred, shaft particles will have entered the bearing
and subsequent early failure is almost inevitable.

If a bearing is judged to be fit for further service, it should

be carefully cleaned and immersed in clean oil or grease
for temporary storage.

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Care and Safety

Fitting

Bearings are normally a press fit on rotating parts and a

sliding fit on static components such as housings.
Whenever possible fit the bearing to the rotating part first.

Use a tubular drift or press tool but ensure that it does not
contact the ring lip since damage may be caused.

Bearing on shaft - Exert effort against the inner ring.

Bearing in housing - Exert effort against the outer

ring.

If a press is not available when fitting large bearings, it is

preferable to either heat the bearing in hot oil or to heat
the housing rather than use a large hammer and drift.

Check that the bearing abuts squarely against the

locating face.

Any peculiarities regarding the fitting of specific bearings

are covered in the appropriate assembly sequence.

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Care and Safety

Pressure Testing

Ensure that there are no leaks from hoses or pipework

before pressure testing is carried out.

Readings should be taken using a gauge of adequate

pressure range for the test, either liquid filled or fitted with
a restrictor or damper.

Before adjusting a valve, unscrew the adjusting screw two

or three turns to release any trapped dirt.

Suction Strainers

Thoroughly wash suction strainers in paraffin using a soft

brush and air blasting if necessary.

Remove all traces of gummy deposit. It should be possible

to see light through the mesh.

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Care and Safety

Training

Training courses suitable for all grades of personnel are

held at regular intervals. Details are readily available from
JCB International Training Centre.

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Machine Production History from 1953

Machine Type Production Dates Description

MK1 1953--1956 Fordson tractor with mechanical loader and hydraulic backhoe.
Hydra-digga 1956--1960 Purpose built earthmover with separate 'Hydrachassis' mounted on a
Fordson diesel tractor.
JCB 4 1960--1962 Development of Hydra-digga, heavier construction, more powerful.
JCB 3 1961 Smaller version of JCB 4 with twin vertical stabilisers and sliding kingpost.
JCB 4C 1962--1967 Improved version of JCB 4.
JCB 3C 1963 More powerful version of JCB 3.
JCB 1 1963--1970 New small 180 deg machine powered by 2 cylinder air cooled diesel
engine.
JCB 1D 1964--1968 New range of dumpers in 15, 22.5 and 30 cwt. sizes.
JCB 2 1964 Smaller version of JCB 3.
JCB 2 and 3 1964 Change to 3 cylinder Nuffield power unit.
JCB 2B 1964--1971 Similar to JCB 2 but with detachable excavator end
JCB 3C and 4C 1965 Change to 4 cylinder Nuffield power unit.
JCB 7 1965--1966 New 360 deg. crawler excavator powered by 6 cylinder Ford power unit.
JCB 6/6C 1966--1973 360 deg. crawler excavator, smaller than JCB 7 with tumbler type tracks.
JCB 6 Perkins 4 cylinder power unit, JCB 6C6 cylinder Ford power.
(Note: JCB 6 discontinued in 1971).
JCB 7C 1966--1971 Improved version of JCB 7 with Perkins 6 cylinder engine.
JCB 3DII 1967--1977 Larger more powerful version of JCB 3C with hydraulic parallel lift.
JCB 4D 1967--1973 Similar to JCB 3D but larger. Fixed kingpost and two stage hydraulics.
JCB 6D 1968--1973 Improved version of JCB 6C with tractor chain type tracks.
JCB 702 1968--1973 A new range of wheeled loading shovels inherited from the
JCB 900/1000 1968--1970 Chaseside takeover. 702, 900 and 907 were 2WD. 704,1000 1750
JCB 907/1750 1968--1973 and 3000 were 4WD.
JCB 3000 1968--1974
JCB 5C 1969--1973 New 360 deg smaller than JCB 6/6C with Perkins 4 cylinder engine, two
stage hydraulics and automatic failsafe brakes.
JCB 7B 1969--1973 More powerful version of JCB 6D with straight line excavator geometry.
JCB 700 1970--1980 2WD loader version of the 3DII with torque converter transmission.
JCB 2D 1970--1980 Similar to JCB 2B but with 4 cylinder BLMO power unit.
JC 1250 1970--1973 Replacement for JCB 1000.
JCB 80/8D 1971--1974 More powerful version of JCB 70 with Perkins turbocharged engine.
JCB 902 1971--1973 Replacement for JCB 900.
JCB 110 1971--1973 New crawler loader with Perkins 4 cylinder engine and Dowmatic drive.
JCB 806/807 1973--1976 New 360 excavators with dual hydraulics and ‘hush-flow’ cooling.
JCB 413/418 1973--1983 New range of articulated wheeled loading shovels to replace
‘Chaseside’ models.
JCB 110B 1973--1979 Change to Supatrac running gear, geometry of loader arms altered.
JCB 808 1975--1982 Larger version of JCB 807 with turbocharged engine.
JCB 423/428 1975--1987 Larger versions of JCB 413/418.
JCB 112 1975--1979 Larger versions of JCB 110B with Perkins 6 cylinder engine.

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Machine Production History from 1953 (continued)

Machine Type Production Dates Description

JCB 114 1976--1979 Larger version of JCB 112 with Perkins 6 cylinder turbocharged engine.
JCB 806B/807B 1976--1982 Updated version of JCB 806/907 with triple hydraulic pumps.
JCB 805 1976--1979 Smaller version of JCB 806B with 4 cylinder Perkins engine.
JCB 30III and 3DIII 1977--1980 Development of Mkll with walk-in cab.
JCB 520 1977--1980 2WD Telescopic Handler, first of a new product range.
JCB 805B 1978--1982 Updated version of JCB 805. Restyled shorter mainframe. 6 cylinder
engine.
JCB 30III/3DIII 1979 Introduction of JCB Powertrain transmission.
*JCB 3C/3CX/3D 1980 New lightweight 180 deg machine range.
3DS/30X-4/3 D-4
JCB 525/525-4 1980--1983 Larger version of JCB 520.
JCB 4C Turbo 1981 Addition to 180 deg range. Larger version of 3D with fixed kingpost and
4 cylinder turbocharged engine as standard.
JCB 520-2/520-4 1981 Compact version of Telescopic Handler range utilising
JCB 520M-2/520M-4 Powertrain transmission.
JCB 410 1981 Smaller version of JCB 413.
JCB 428C 1981 Compactor variant of JCB 428.
JCB 3/3C/3CX/3D 1982 Changeover from Leyland 4/98 engine to Perkins 4.236.
3C5/40 Turbo
410/520/525
JCB 805B Turbo 1982--1984 Updated version of JCB 805B with 4 cylinder turbocharged engine.
JCB 8060/8070 1982--1984 Redesigned version of JCB 806B/807B.
JO 525B 1983 Uprated version of JCB 520.
JCB 530 1983--1984 Replacement for JCB 525.
JCB 420/430 1983-1989 Larger versions of 410 basic design, replacing 413 and 418.
JCB 423/428/4280 1984 DAF engines replace Leyland.
JCB 4CN 1984 Development of JCB 4C Turbo with knuckle boom.
JCB 530B 1984--1988 New style Telescopic Handler replacing 530.
JCB 540B-M 1984--1988 Monoboom Loadall on 530B chassis.
JCB 811/812/814/ 1985 New range of tracked excavators with servo controls.
817/818/820
JCB 4121415 1985 More powerful developments of JCB 410.
JCB 926/930 1985 New range of Rough Terrain Fork Lifts.
JCB 540B 1986--1988 Additional uprated development of JCB 530B.
JCB 814 Super 1987--1989 Variant of JCB 814 sized excavator with variable displacement
hydraulics.
JCB 410/412/415 1987 Existing machines restyled with Perkins 1000 series engines.
JCB 425 1987 New wheeled loader similar to, but larger than the JCB 415 powered by
6 cylinder 1000 series engine.
JCB 406 1987 New compact articulated wheeled loader.
* Excavator Loader 1988 Machine range updated with new hydraulics and Perkins 1000 series
Range engine.
JCB 712 1988 New 12 Tonne Articulated Dump truck.
JCB 525-58/525-67 1988 New all wheel steer Telescopic Handler range introduced.
JCB 801 1988 3 Tonne mini excavator.
JCB 530/110-120 1990 Larger version of all wheel steer range.
JCB 408 1990 Larger version of 406 with 4 cylinder engine.
JCB 2CX 1990 Small 3 cylinder backhoe loader.
JCB 716 1990 New 16 tonne articulated dump truck.

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Current Machine Model Range

3C/3CX/3CX Sitemaster
3CX Hammermaster/3D/4C/4CN
1400B
1550B USA ONLY
1600B
1700B

525-58/525-67
530-110/530-120
505-19/505-22
508/36
508/40 USA ONLY
510/40
512/40

926/930

406/408
410/412/415
425
435
428C

801
812 Super/814 Super
816 Super
818 Super/820 Super

712
716

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Colour Coding

The following colour coding, used on illustrations to

denote various conditions of oil pressure and flow, is
standardised throughout JCB Service Publications.

Light Green: Oil subjected to a partial

vacuum Green: due to a
drop in pressure
Blue: Neutral Circuit Pressure. (cavitation).

Yellow: Oil trapped within a

chamber or line,
preventing movement of
Red: Pressure generated by the operation components (lock-up).
of a service. Depending on
application this may be anything
between Neutral Circuit Pressure and
M.R.V. Operating Pressure.

Orange: Oil pressure used in a

controlling device (servo).

Pink: Pressure that is above Neutral Circuit

Pressure but lower than that denoted
by Red.

Green: Exhaust.

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Basic Circuit

We can see that a very simple circuit comprises the If there is no load on which to work then there is no
following: pressure in the system. To illustrate this, when the system
is in the neutral position, i.e. oil is flowing around the circuit
1 Oil under the influence of the pump running at full speed, the
pressure in the system will only be that created by the
2 Tank resistance to flow within the pipes and components.

3 Pump The hydraulic pump causes flow not pressure. Restriction

to flow causes pressure.
4 Main Relief Valve
The main relief valve (M.R.V.) controls full system
5 Valve Block pressure.

6 Rams or Motors The auxiliary relief valve (A.R.V.) protects circuits not in
use against back pressures caused by the leverage and
7 Filter geometry of an associated circuit.

Remember that the flow rate determines the speed at The valve block directs oil in the neutral circuit to selected
which the system will operate. The pressure will determine services.
the output force of the system. The maximum flow rate
and pressure available is dependent on the power of the
engine being used to drive the pump.

4/1-2
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Hydraulic Formula

Flow = Hydraulic Speed Generated by a Pump Hydraulic Horse Flow x Pressure

Power (kw) = (litres/mm) (bar)
Pressure = Restriction to flow 606

Force (lbf) = Pressure (Ibf/in2 ) x Area (in2)

Hydraulic Horse Flow x Pressure
Pressure (bar) x Area (mm 2) Power (hp) = (UK gal/mm) (lbf/in 2)
Force (kgf) =
98 1430

Hydraulic Horse Flow x Pressure

Power (lip) = (US gal/mm) (lbf/in2)
USA ONLY 1714

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Imperial Calculations Metric Calculations

Ram Force Ram Force

Head Side Direct Rod Side Head Side Direct Rod Side

Pressure x Area As Head Side minus Pressure x Area As Head Side minus
Area Loss Area Loss

= 138 bar x IIR2 = 138 bar x IIR2

= 2000 psi x IIR2 = 2000 psi x IIR2
= 138 x 3.14 x 50 x 50 = 138 x 3.14 x 25 x 25

= 2000 x 3.14 x 2 x 2 = 2000 x 3.l4 x l x l 1083300 = 270825

=
= 6280 lbs 98 98

= 25,120 - 6,280 = 2763.5

= 25,120 lbs Force = 18,840 lbs Force

= 11054 - 2763.5

=11054 kgf = 8290.5 kgf

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1 Hydraulic Oil

Hydraulic oil should contain the following properties F Demulsibility

either naturally or by the use of additives: This is the ability of the oil to separate rapidly from water.
Moisture may be present in the hydraulic system due to
(a) Lubricity either condensation or water entering the tank during
(b) Film strength filling. When water mixes intimately with oil, it forms an
(c) Correct viscosity emulsion which may be thin and slimy or of a sticky
(d) High viscosity index consistency. Or it may take the form of heavy gummy
(e) Pour point deposits. Emulsions such as these will interfere with the
(f) Demulsibility proper functioning of pumps and valves.
(g) Foam resistance
(h) Chemical stability G Foam Resistance
This is the rapid separation of air and oil. Air is
A Lubricity compressible and if introduced into the oil and allowed to
This is the ability to lubricate moving parts within the circulate it would quickly affect the performance of the
system, such as those found in pumps, motors, valves system.
and rams.
H Chemical Stability
B Film Strength This is the ability to prevent chemical changes in the oil. In
This is the resistance of the oil film to rupture under a hydraulic system, constant circulation and churning in
extreme pressure. In hydraulic pumps in particular there the presence of oxygen, tends to change the chemical
are metal to metal surfaces which are subjected to high composition of the oil. An oil which cannot resist this
pressures, obviously if the oil film between these surfaces tendency, thickens and becomes sluggish and eventually
were to break down wear would rapidly take place, with sludge or gummy deposits are formed which interfere with
possible pump seizure. the operation of valves and pumps. This is aggravated
even more by heat and high oil temperatures may be
C Correct Viscosity accompanied by rapid oxidation of chemical change.
This is the ability of the oil to minimise slippage and Chemical stability is achieved partly by initial blending and
leakage and to ensure a ready flow of oil around the partly by oxygen inhibitors.
circuit. Valves used in hydraulic systems are machined to
very close tolerances, so the viscosity of the oil itself is The above factors distinguish a good hydraulic oil from its
used as a seal. An oil which is too thick would not flow cheaper counterparts. JCB 'Special' Hydraulic Fluid has
easily round the circuit and thus more power from the been specifically developed to ensure that all the above
pump would be required; if the oil is too thin problems requirements are fulfilled.
arise from possible leakage which would be aggravated
as the oil temperature rose.

D High Viscosity Index

This is the ability of the oil to resist changes in viscosity
due to temperature changes. Heat is imparted to the
hydraulic oil by the energy of the pumps and friction
between the oil flow and the walls of the pipes and
components. This heat will make the oil thinner as the
temperature rises. Ideally the viscosity of the oil should
remain constant regardless of temperature changes.

E Pour Point
This is the ability of the oil to retain fluidity at low
temperatures. Ideally the pour point of the oil should be
low, this means that the oil will still continue to flow around
the circuit even at very low temperatures. An oil which
congeals at low temperatures is useless in hydraulic
systems as it means that time must be allowed for the oil
temperature to rise before the system will respond as
promptly as required.

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Notes:

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2 Hydraulic Tanks

Two basic types of hydraulic tank are fitted to JCB

machines, one being a separate tank bolted to the
machine structure, whilst the other forms an integral part
of the machine chassis known as the 'Hydrachassis'.
Although an oil cooler is fitted on certain machines, the
wall areas of the hydraulic tank also play an important part
in cooling the oil.

It is therefore essential to maintain the oil in the tank at the

correct level not only to ensure adequate cooling but also
to prevent cavitation at the pump.

Some machines have a suction strainer fitted in the

hydraulic tank.

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2 Hydraulic Tanks

Check Level

Before checking level, place the machine on firm, level

ground. Put shovel down and retract extending dipper (if
fitted). Raise boom, slew to one side and close bucket.
Stop engine.

Fluid level should be between two marks on sight tube A.

If required, top up tank with hydraulic fluid.

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3 Hydraulic Pumps

A Single Hamworthy
Wheeled Loading Shovels 410/412/415

B Double Hamworthy
Excavator Loaders 3CX/4C/4CN
425 Loading Shovels

C Sundstrand
Telescopic Handlers
Rough Terrain Fork Lifts
406/408 Wheeled Loading Shovel
2CX Exc/Loader
712/716 Artic. Dumper

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3 Hydraulic Pumps

To make the hydraulic oil work it is necessary to propel it

around the circuit and at times to pressurise it. To do this
efficiently a pump is installed in the system. The pump is
driven by an external force and on earth moving machines
this external source is a diesel engine. The speed at which
the pump is driven governs the speed at which the system
will operate; thus the faster the pump is driven, the faster
the system will operate: FLOW then effects the speed of
the system.

The position of the pump in relation to the tank is also very

important, ideally the pump inlet should be below the oil
level in the tank. This ensures that a head of oil is always
provided at the pump inlet. If the pump were to become
starved of oil due to low oil levels, cavitation would result
with consequent damage to the pump. Cavitation occurs
when the oil temporarily fails to fill the space created
inside the pump as it rotates. This condition allows the
pump to overspeed and through the lack of oil, accelerate
wear on moving parts.

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3 Pump Operation

The pump is a gear type, mounted at the rear of the

machine and driven by the engine.

The working principle of a gear pump depends upon the

meshing of two spur gears A and B. Oil is picked up on the
suction side of the pump by the gears and carried round
between the gear teeth and the pump body. As the gears
come into mesh the oil is forced out through the outlet
port.

Some oil is allowed to circulate behind the bearings C to

hold them against the gears and minimise oil slippage.
Lubrication oil is drawn through the recess D and around
the counter bore. The oil then flows along the scrolled
grooves E in the bushes, induced by the viscous drag of
the rotating shaft.

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3 Hydraulic Gear Pumps

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3 Hydraulic Gear Pumps Gear Pump Testing

The illustration shows a double section gear pump as
fitted to the JCB range of Excavator Loaders. Both
sections of the pump P1 and P2 operate as follows:
The basic principle of the gear pump depends on the
meshing of two spur gear wheels A, one of which is
engine driven, the other being an idler.
Oil is picked up by the gear teeth on the suction side of the
pump body and carried around between teeth and pump
body. As the gears come round into mesh, the space
carrying the oil is filled by a gear tooth on the mating gear,
forcing the oil out of the space and through the pump
outlet.
Install flow meter (see Service Tools) in pressure delivery
line from pump.
Ensure there is at least 1 metre of straight hose before
flow meter. Run engine at 2200 rev/min and progressively
increase pressure to machine system setting. Check
pump displacement against figures quoted in the technical
data section of the relevant service manual. Pump
displacement should be within 10% of specification. If not
remove the pump, dismantle and investigate.

As the pump displacement is pressurised the wear plates

B are loaded towards the gears by pressurised oil being
sensed behind them via channels C. Seals E prevent this
pressure leaking across the back face of the wear plates
to the low pressure suction side of the pump, whilst holes
F located in the end of the pressurised strip vent excess
pressure back into the gear teeth spaces so preventing
uneven wear of the wear plates.

The kidney shaped recesses D on the front face of the

wear plates and located on the suction side assists the
flow of oil into the pump gear spaces. Recesses D on the
pressure side allow the oil that is trapped in the
diminishing space between the meshing gear teeth an
escape route, so preventing mechanical damage caused
by a hydraulic lock-up condition.

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3 Hydraulic Gear Pumps

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3 Hydraulic Gear Pumps When

Dismantling

When Dismantling Gear Pump Fault Diagnosis

Remove sharp edges and burrs from the shaft to avoid
seal damage.
Mark covers and housings to ensure correct replacement.
Use a soft-faced hammer to separate components. Do not
use levers, or machined surfaces may be damaged.
Mark adjacent teeth of gears with indelible ink before
removal. Do not use a centre punch or similar tool.
Remove bearings only if they require replacement, using
correct puller (see Service Tools).
When Assembling
Renew gears in pairs. Gears should be renewed if:
(a) The journal area of the shaft is pitted or worn in
excess of 0.025 mm (0.001 in.).
(b) The keyway or gears are badly worn or cracked.
Renew bearings if worn or damaged or if gears are
renewed. Bearings must fit flush with or be not more than
0.05 mm (0.002 in.) below the face of the bearing bore.
Renew wear plates 4, 9, 17 and 21 if scored or eroded,
ensuring that oil holes B are clear.
(1) If shaft seal 27 is leaking check shaft 20 for nicks and
burrs before replacing seal.
Also check seal housing counterbore D for damage or
marks. If marks evident coat external diameter of seal
with Plastic Gasket prior to installation.
(2) If pump is leaking between body joints, renew 'O'
rings 13 and 25.
(3) If pump is noisy in operation check shaft support
bearings 12, 14, 24 and 26 renew if necessary.
(4) If pump displacement is lower than specified (see
previous page) check wear plates items 4, 9, 17 and
21. Renew if showing signs of errosion or damage.
Also renew wear plate seals 5, 6, 10, 11, 18, 19, 22
and 23.
(5) Measure geartrack C-C on suction side of pump
housing, pump remains serviceable if undercut is
0.01 mm (0.004 in.) or less.
(6) If cavitation is evident i.e. errosion of body on inlet
side, check suction hose/suction strainer (if fitted) for
blockages, and ensure hydraulic oil level is correctly
maintained.

6, 11, 19 and 23, and back-up strips 5, 10, 18 and 22 must

be fitted as follows, using JCB MPL' Grease to retain
them.

First fit the seal into the wear plate with the flat side
facing downwards.
Then fit the back-up strip on top of the seal with the
shoulder at each end of the back-up facing down-
wards to seat on the base of the groove.
Fit wear plates with recesses A facing the gears and the
seal and back-up strips to the pressure side (outlet port) of
the pump. Ensure that the seal and back-up are not
trapped between the plate and the bore. Check also that
wear plates 9 and 21 are fully home in the bore and are
free to move.
Smear lips of seal 27 with Mobilplex 47 or equivalent
grease containing MoS 2.
Align gears, housings and covers using marks made when
dismantling.
Torque set through bolts to required figure (see relevant
Service Manual).

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4 Main Relief Valves
The force that can be exerted by a hydraulic service
whether it is a ram or a hydraulic motor is determined by
the oil pressure.
If an obstruction is placed in the way of a ram for instance,
thereby preventing it from moving, the pump will continue
to force oil into the ram until the pressure is sufficient to
overcome the obstruction or a component in the hydraulic
circuit bursts. So to protect the system an overload
protection device is built into the circuit immediately
downstream of the pump. This is called a Main Relief
Valve and is designed to vent excess pressure back to the
tank whenever it rises to a preset value.
There are two types of Main Relief Valve (MRV) in service,
Pilot operated and Direct acting.
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Main Relief Direct Acting
Figure 1 shows that the services are in neutral and
pressure in the neutral circuit gallery is not sufficient to
operate the M RV which is held closed by spring A.
In figure 2 a service has been operated and the pressure
generated has exceeded the setting of the MRV. The
pressure has acted on the periphery of the hollow dump
valve B which is pushed up against the spring, venting
excess pressure and full pump flow into the exhaust
gallery.
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4 Main Relief Valves - Direct Acting

(Typical)

When Dismantling

The MRV shown may be dismantled for cleaning and

inspection only, no replacement parts are available. Care
must be taken not to damage seal Y.

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Main Relief Valve Pilot Operated

Figure 1 shows neutral circuit pressure at C with pilot

valve A and dump valve B held onto their seats by spring
force.

In figure 2, as the pump pressure increases it reaches a

value sufficient to force the pilot valve A from its seat,
chamber E is then vented into exhaust gallery D. Flow to
the pilot valve is controlled by a small pressure sensing
orifice in dump valve B. This maintains the pilot pressure
at a constant value even if the system pressure rises
above the pilot setting.

In figure 3 the pressure has risen by approximately 20%

over the pilot setting, this causes the dump valve to lift
against spring force, dumping excess pressure and full
pump flow back to tank.

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4 Main Relief Valves

Note: The illustrated sequence is for a typical pilot When Assembling

operated MRV. For specific valve details refer
to relevant machine Service Manual. Renew all 'O’ rings.

Dismantling and Assembly
The numerical sequence shown on the illustration is
intended as a guide to dismantling.
For Assembly the sequence should be reversed.
Lubricate parts with JCB Special Hydraulic Fluid before
assembling.
Ensure that the small drilling X in the dump valve B is
clear.
After replacement into the valve block adjust pressure to
the correct valve quoted in the Service Manual.

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4 Main Relief Valves - Pilot and Direct

Acting

Pressure Testing

Lower booms, excavator ends or loader arms to the

ground for safety stop engine. Ensure transmission is in
neutral and parking brake firmly applied. Chock wheels.

With engine stopped operate all hydraulic services to

vent residual pressures.

Locate 'snap on' or 'screw on' pressure testing self seal

connector and attach a 0-400 bar (0-6000 lbf/in 2) pressure
gauge.

With adequate warning given to nearby personnel, start

engine, select a service that has no other pressure
controlling devices: for example, Loader Arms lower or
stabiliser leg raise on Excavator Loader machines, boom
down Telescopic Handler machines and Mast tilt Rough
Terrain Fork Lift machines.

(1) With engine at maximum speed, (1500 rev/mm

excavator loader machines) progressively select
service whilst watching pressure gauge. With the
service fully selected the pressure recorded should
be as specified in the relevant service manual.

(2) Adjust M RV by releasing locknut A and screwing

adjuster in to raise pressure or out to lower pressure.
Re-check pressure, tighten locknut A and re-check
pressure again.

Note: DO NOT allow pressure to rise above quoted

MRV pressure setting whilst testing as
damage to components may result.

If pressure recorded is less than specified, reduce MRV

adjustment by two full turns, fully operate service at
maximum engine speed. This will flush away any debris
that may be interferring with the relief valve setting. Then
re-adjust MRV to correct pressure.

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5 Loader Valve - A.R.V. Operation
Under normal operating conditions, with the shovel in the
carry' position, the mechanical linkage keeps the shovel
level as the arms are raised, to prevent spillage of the
load.
If, as illustrated, the shovel is fully tipped when the arms
are being raised, the shovel is unable to tip further,
producing back pressure in the head side of the shovel
rams 31 and 32 and cavitation in the rod side.
9808/0507
As the arms continue to rise, the back pressure increases
until it reaches the setting of A.R.V. 3F. This A.R.V. then
opens, allowing the excess back pressure to be dumped
to exhaust and prevent the rams and linkage from being
damaged.
The rod side A.R.V. 3G senses a higher pressure in the
exhaust gallery than in the service port and therefore
opens to allow exhaust oil to overcome the cavitation.
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Notes:

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5 A.R.V. OPERATION

In fig. 1 a service is selected but pressure in the service

gallery A has not reached the setting of the A.R.V. which
is held closed by spring B.

In fig. 2 the setting of the A.R.V. is exceeded by the

service pressure which causes the poppet to rise against
spring force allowing the pressure to be vented into the
exhaust gallery C.

Fig. 3 shows the A.R.V. in anti-cavitation mode. When a

service is operated in such a way that low pressure, or
cavitation, exists in the service line A, the higher pressure
oil in the exhaust gallery C acts on the A.R.V. cartridge
which moves down against its spring allowing exhaust oil
to make up the deficiency in the service gallery A.

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Loader Valve A.R.V.'s

Dismantling and Assembly

1 A.R.V.'s are fitted at 3F and 3G as shown on page

5/3-3. Unscrew cap and lift out A.R.V. Renew seals C
before re-assembling.

2 Hold valve in clamp 992/10100 when removing and

replacing the adjusting screw.

3 If any parts are worn, renew valve complete.

Pressure Testing - Loader A.R.V.'s

(using hand pump)

Auxiliary relief valves (A.R.V.s) are set to 15 bar 220

lbf/in2 ) below the nominal figure stated on the technical
Data page in the relevant service manual when using a
hand pump. For example:

Shovel ram rod A.R.V. - 303-317 bar

(3500-3700 lbf/in 2)

Nominal figure - 310 bar (4500 lbf/in2 )

Hand pump setting - 310-15 = 295 bar

(4280 lbf/in 2)

Insert the A.R.V. B into test block A, part no. 992/10200.

Connect hand pump 892100223 and a 0-400 bar (0-6000
lbf/in2 ) pressure gauge.

Pressurise until oil begins to escape at C when the gauge

will indicate the A.R.V. setting. Remember to set the
A.R.V. 15 bar (220 lbf/in2) below the nominal figure shown
on the Technical Data page.

If required, adjust the pressure by holding the valve in

clamp 992/10100 and turning the adjusting screw using an
Allen key as shown.

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Notes:

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Pressure Testing - Loader A.R.V.'s A.R.V. Adjustment

(in position)
Remove the A.R.V. from the control valve and hold in
clamp 992/10100 as shown. Turn the adjusting screw
Shovel Ram Rod Side A.R.V.
using an Allen key. Adjust clockwise to increase the
setting and anti-clockwise to decrease the setting.
Testing of A.R.V.'s on the machine should be avoided (use
hand pump method as described on page 6/2-4).
Shovel Ram Head Side A.R.V.
However, the procedure described below is a secondary
checking method which can be used if no hand pump is
* Testing of A.R.V.'s on the machine should be avoided
available.
(use hand pump method as described on page 4/3-5).
However, the procedure described below is a secondary
The shovel ram rod side A.R.V. is set at a higher pressure
checking method which can be used if no hand pump is
than the M.R.V. (maximum system pressure). To raise the
available.
pressure in the shovel ram rod side service line above
system pressure it is necessary to disconnect/connect
When checking the shovel ram head side A.R.V. on the
hoses (as shown in the following procedures) so that oil
machine using main pump flow, the following tolerances
displaced from the lift ram (rod side) is fed through the
must apply:
A.R.V.
* Pump Type Engine Revs Temperature Pressure
The following procedures show the pressure test done on
the left hand side of the machine, however, the procedure P2AJ190705 1000 r.p.m. 50~80 ºC 170-192 bar
is the same if done on the right hand side of the machine (122-176 ºF) (2465-2785 Ibf/in2)
but make sure that the correct hoses are P2AJ190606 1000 r.p.m. 50~80 ºC 170-195 bar
disconnected/connected. (122-176 ºF) (2465-2830 Ibf/in2)

Rest the shovel on the ground, stop the engine and vent P2AJ190706 1000 r.p.m. 50~80 ºC 170-200 bar
(122-176 ºF) (2465-2900 Ibf/in2)
all services. Remove hydraulic tank filler cap, to vent tank
pressure, and replace. P2AJ190906 1000 r.p.m. 50-80 ºC 170-205 bar
(122-176 ºF) (2465-2970 Ibf/in2)
Disconnect hoses B and C from metal pipes B1and C1
respectively, shown at X.
Procedure
Screw a tee piece fitted with a 0-400 bar (0-6000 lbf/ in2 )
pressure gauge to metal pipe B1, shown at Y. Connect a 0-400 bar (0-6000 lbf/in2 ) pressure gauge to
test connector A on the loader valve.
Fit cap 81 6/00190 to metal pipe C1 and fit plug 892/
00057 to hose B. * Run the engine at 1000 revs/mm, hold the shovel ram
fully open and check the maximum gauge reading, which
Note: For reference, C is the service hose for the should equal the operating pressure shown in Technical
shovel ram, rod side. B is the service hose Data. If necessary, adjust as detailed below.
for the lift ram, rod side.
A.R.V. Adjustment
With the engine running at 1000 revs/mm, select and
operate slowly the loader arms lift service until the ram Remove the A.R.V. from the control valve and hold in
creeps, keep raising the arms slowly until a reading on the clamp 992/10100 as shown. Turn the adjusting screw
pressure gauge is obtained. using an Allen key. Adjust clockwise to increase the
setting and anti-clockwise to decrease the setting.
The highest pressure value shown on the gauge will be
the setting of the shovel ram rod side A.R.V. (see
Technical Data). If necessary, adjust as detailed below.

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5 Valve Blocks

Basically a valve block is a metal casting in which there

are a number of oil-ways or galleries A which are
intersected by the valve spools B. The number of spools
required depends on the number of services to be
controlled. Spools are operated either by direct leverage
or remote control. A design patent feature of some JCB
valve blocks is that more than one service can be
controlled by one lever.

Several types of valve blocks are fitted to JCB machines,

the internal valve arrangement and other features being
designed to suit the operating requirements of the circuit
to which they are fitted.

Generally valve blocks used are either 'parallel circuit' C or

'tandem' circuit D type depending on the operating
requirements of the machine to which they are fitted.

1 Parallel Circuit

Parallel circuit valve blocks are designed so that more

than one service can be operated simultaneously. If one
service is selected, it will operate at full pressure and at
maximum speed. If more than one service is selected,
each will operate at full pressure but the speed of the
services will be reduced as the oil flow is now divided.

2 Tandem Circuit

Tandem circuit valve blocks are used so that only one

service can be operated at a time. The service selected
receives the whole of the oil supply at full pressure and
maximum speed. If more than one service is selected oil
flows to the one nearest the valve inlet, cutting off supply
to spools downstream.

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Notes:

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5 Valve Blocks

Circuit Operation

The internal operation of each type of valve block is

basically similar.

In all JCB valve blocks, the spools are so designed that

when they are in the neutral position, they allow the oil
from the pump to flow around them through the centre or
neutral circuit' gallery C of the valve block. This
configuration is known as an 'open centre' valve.

If a service is selected by moving a spool either up or

down, the neutral circuit flow C is stopped by the spool
moving across it. The oil then passes into a blind gallery D
known as the 'parallel circuit' or 'tandem circuit' which is in
effect two blind galleries for each spool. The spools are so
designed that when they are moved up or down waisted
sections E around them connect the parallel circuit gallery
with the service port F at one end of the spool, whilst a
second waisted section connects the opposing service
port G with the exhaust gallery H at the other end of the
spool. This means that when a service is selected by
moving a spool, oil passes under pressure into the parallel
or tandem circuit, from here the oil is directed via waisted
sections of the spool to the ram or motor to be operated.
Simultaneously oil returning from the ram or motor enters
the valve block and passes around the waisted section of
the spool at the opposite end where it returns to tank via
the exhaust gallery H.

The number of spools in the valve block or number of

valve blocks in a circuit depends on the services to be
controlled.

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5 Valve Blocks

'D Spools

The double acting or 'D' spool is used in circuits that need

to be isolated from the exhaust gallery when the spool is
returned to the neutral position. This means that the spoof
will hold the load in neutral, oil trapped between spool and
service whether it be a ram or a motor will be 'locked up'
preventing the ram or motor from moving.

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Notes:

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5 Valve Blocks

'F' Spools

The 'F' spool or float spool is used on Loading Shovel

machines and also on the Loader end of Excavator
Loaders. This means that many shovelling duties can be
simplified by leaving the loader arms free to follow ground
contours.

When the 'float' position is selected the spool is held in

position by spring loaded detent balls leaving the
operators hands free to control other services.

When in the float position both sides of the loader rams

are connected to the exhaust gallery A, allowing the arms
to float up when conditions dictate, that is displacing oil
from the rod side of the lift rams B and expelling it into the
exhaust gallery. And at the same time sucking oil into the
head side of the lift rams 33/34 from the other branch of
the exhaust gallery. When the arms float down then oil
displacement' suction is reversed.

The neutral circuit gallery is re-opened whilst the float

position is selected, thereby allowing full pump flow to be
available to services downstream of the float spool.

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5 Loader Hold Check Valves

Operation 1

The illustration shows ‘arms raise’ being selected by the

lift ram spool.

The weight of the loaded shovel, as indicated by the

arrows, produces a higher pressure in service line D than
in parallel gallery B. This pressure differential causes load
hold check valve 3J to close, thus preventing the load
from dropping.

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Notes:

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5 Load Hold Check Valves

Operation 2

As the neutral circuit has been blocked by the central land

of the selected spool the pressure in parallel gallery B
increases until it is greater than that in service line D.

At this point, load hole check valve 3J opens, allowing oil

to flow from the parallel gallery into the service line and
operate the lift rams 33 and 34.

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Notes:

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Notes:

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5 Excavator valve

One Way Restrictor Operation 1

Because of its weight the excavator end could take over

control when boom lower was selected. Then the falling
boom would tend to push the oil out of the ram faster than
the head side was being filled. Consequently, when the
excavator had reached the ground there would be a time
lapse while the ram filled up with oil before the service
would operate again.

To prevent this from happening, the boom service is fitted

with a one way restrictor. When the boom is being raised,
the shuttle in restrictor E is held off its seat and the flow
past is unrestricted.

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5 Excavator Valve

One way restrictor operation 2

When the boom is being lowered the oil flow through the
one way restrictor E re-seats the shuttle, restricting the oil
flow through the small drilling. This slows the boom down
to a more controllable speed.

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5 Excavator Valve - A.R.V. Operation

The illustration shows the bucket spool 4F selected to See pages 8/1-2 to 8/1-6 for detailed descriptions of the
operate the service against an immovable object. This A.R.V. operations.
forces the dipper away from the obstruction and
pressurises the head side of the dipper ram. When this Note: A.R.V. 4Q is only fitted to machines equipped
pressure reaches the setting of A.R.V. 4M, this valve with a Powerbreaker.
opens, relieving the pressure into the exhaust gallery.

Cavitation occurs in the rod side of the dipper service

until A.R.V. 4N opens, allowing the higher pressure in the
exhaust gallery to supplement that in the service line.

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Excavator A.R.V.
Pressure Relief Operation
1 Valve at rest
A.R.V.’s are positioned in the excavator valve block in
order to relieve excessive pressure in the services.
When he service is in neutral and there are no excessive
forces acting on the equipment, service pressure at A will
be acting on the lower face of poppet B and will also be
felt inside the valve via hollow piston C.
The force of springs D and F, combined with the service
pressure acting on the upper faces of poppet B and piston
C, keeps poppets B and E tightly seated.
The force of spring F is adjustable to suit the relevant
service by means of cap-nut G.
9808/0507
2 Pilot Valve Opens
As service pressure reaches the pilot setting of the valve,
pilot poppet E lifts, allowing oil to escape into cavity H and
pass down the sides of sleeve J into the exhaust gallery
K.
3 Main Poppet Opens
As service pressure continues to rise and oil escapes from
cavity L, the pressure differential between the upper and
lower surfaces of piston C causes this piston to rise and
seat on the point of pilot poppet E.
Oil continues to escape from cavity L but the incoming
flow to the cavity has been cut off. This produces a
pressure drop above poppet B, causing the poppet to lift
and release service pressure into exhaust galley K.
8/1-4
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5 Excavator valve A.R.V.
Anti-Cavitation Operation
The left hand view shows the A.R.V. subjected to normal
operating pressure in service gallery A. This pressure is
transferred to cavity L via the hollow piston C and
combines with force of spring D to keep the valve closed.
9808/0507
If cavitation occurs as shown in the right hand view, the
exhaust pressure K acting on the lower surfaces of sleeve
M exceeds the service pressure inside cavity L and the
sleeve moves upwards, allowing oil from the exhaust
gallery to enter the service port and limit the effects of
cavitation.
8/1-6
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5 Excavator Valve

Dismantling and Assembly - Relief Valves

Eight A.R.V.s are fitted at positions 4H to 4Q. These are Note: The shims are only intended to limit the
identical in design but have various pressure settings (see maximum pressure setting to which it is
relevant Service Manual). possible to adjust the valve.

Note: Valve 4Q is only fitted to machines equipped The specified pressure setting of each valve is achieved
with a Powerbreaker. by adjusting capnut 2. If the specified pressure cannot be
achieved under test, it is permissible to add further shims
The numerical sequence shown on the illustration is as required.
intended as a guide to dismantling.
Torque Settings
For assembly the sequence should be reversed.
Item Nm kgf m Ibf ft
When Dismantling 1 60 6.2 45
8 81-108 8.3-11 60-80
Renew all seals and back up rings, using JCB Hydraulic
fluid as a lubricant.

Fit back-up ring 16 on the lower side of ‘O’ ring 15.

Fit chamfered end of spring 6 towards head of poppet 7.

Fit shims 5 to the same total thickness as those removed.

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Notes:

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5 Excavator Valve

Dismantling and Assembly

The numerical sequence shown on the illustration is

intended as a guide to dismantling.

For assembly the sequence should be reversed.

Check Valves

Each of the identical load hold check valves 4R to 4W can

be removed as shown at 4W. Make-up check valve 4X is
a smaller size but otherwise identical.

Ensure good condition of seating faces on poppets 4 and

8 and on the mating faces in the valve block.

Spools

Spools 4A, 4B, 4E and 4F are identical but must not be

interchanged as they are matched to their bores.
Stabiliser spools 4C and 4D are identical to each other but
different from the excavator spools.

All spools have the same centreing and sealing

components items 9 to 21.

To completely dismantle a spool, follow the sequence 9 to

21. To prevent spool rotation when turning screw 15, hold
a rod through the eye end of the spool.

If only renewing the seals, dismantle as far as cap 14 then

remove items 15 to 22 as an assembly.

Lubricate new seals with JCB Hydraulic Fluid and take

care to prevent them from being damaged by the sharp
edges of the spool.

Apply JCB Lock and Seal to threads of screw 15.

Relief Valves

A.R.V.'s 4H to 4P appear identical but have various

pressure settings. Ensure that they are correctly adjusted
and fitted in their specified positions.

For dismantling and assembly procedures, see page 8/1-

7.

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6 Rod End Damping

Where a ram is particularly subject to shock loading, a

'damping' system is used to minimise the effect.

As the piston rod approaches full stroke, the displacement

oil flow is cut off by a restrictor A which locates against the
gland bearing where it is held by spring force B. A reduced
flow of oil continues through a groove machined in the
restrictor.

The volume of oil built up in the space between the piston

and the gland bearing provides a considerable
'cushioning' effect which slows the piston at full travel.

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6 Typical Ram

Dismantling and Assembly

When Dismantling Apply Loctite Activator N to the threads of the piston head.
Allow to dry for 15 minutes before bringing into contact
If a split replacement seal is available it is not necessary with Loctite.
to remove the piston head in order to renew the wiper seal
H. Renew snap ring J. Note: Loctite and Activator must not contact seals,
bearing rings or '0' rings.
WARNING: If air or hydraulic pressure is used to force
out the piston assembly ensure that the end Apply Loctite 262 to all threads of the piston rod. Fit and
cap is fitted securely. torque-tighten the piston head. Fit a new wire clip C. Do
Severe injury can be caused by a rod being not re-use the original wire clip.
released suddenly.
Note: The end damping spring and collar X are
Select the required spanner sizes from the table below. fitted to the dipper ram only. ensure that the
Refer to Section 11 for the appropriate part numbers. spring is engaged with he collar and piston
head.
Ram End Piston
Cap Head
mm mm
Boom (1700B) 125 85
Boom (other machines) 95 75
Dipper 95 75
Extending Dipper 65 55
Excavator Bucket (1700B) 95 75
Excavator Bucket (other machines) 75 65
Stabiliser (sideshift) 65 55
Stabiliser (centremount) 95 75
Loader Lift 75 65
Loader Shovel (1700B) 75 65
Loader Shovel (other machines) 65 55
Clam 65 55

When Assembling

Thoroughly clean threads of piston head, piston rod, end

cap and cylinder with a wire brush. Ensure that all threads
are free from grease, hydraulic oil and old Loctate using
Super clean Safety Solvent. Allow Solvent to dry for 15
minutes before applying Loctate Activator.

Ensure that lubricants used during assembly do not come

into contact with Loctate.

Before fitting the end cap onto the piston rod, wrap tape
around the piston rod threads to protect the gland seal
from damage and the threads from oil and grease.

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6 Typical Ram

When Assembling (continued)

Fit new seals to the piston head. Insert back-up ring B and
gland seal A into end cap E. Slide gland bearing into
engagement with the end cap. Install rod assembly into
cylinder whilst ensuring that seals and bearing rings are
not displaced from the piston head.

Taking care to retain the end cap at the further end of the
piston rod from the cylinder, coat thread of cylinder with
Loctite Activator N. Next apply Loctite 932 to thread of end
cap. Wait 15 minutes before bringing the two together and
then torque-tighten the end cap into the cylinder.

Note: If hydraulic oil contacts uncured Loctite, a

weakening of the bond will result. Cure times
vary according to the ambient temperature
and type of Activator used. The following
approximate cure times apply at 20 ºC and
are the minimum periods between assembly
and filling the ram with oil.

Loctite 262 or 932 with Activator N - 1 hour

Loctite 262 or 932 with Activator T - 2 hours

Torque Settings

Item Nm kgf m lbf ft

D 405 41 300
E 678 69 500

Note: When fitting cylinder and piston eye bushes,

ensure that the split in the bush is set at 90º
to the longitudinal centreline of the cylinder.

Note: Cold weather operation. When operating in

conditions which are consistently below
freezing, it is recommended that the rams are
operated slowly to their full extent before
commencing normal working.

9808/0507 9/1-3
 International Training Centre

Notes:

9808/0507
 International Training Centre

Hydraulic Oil Filter

Unfiltered oil enters the head at A and circulates round the

filter bowl. It passes through the micron paper element B
and out to the tank.

Should the paper element become blocked the restriction

causes a pressure build up which forces the element
down allowing oil to flow to tank past seal C ensuring full
flow.

10/1-1
 International Training Centre

GENERAL ( BASIC & FUNCTIONAL)

SYMBOLS

Spring

Flow restriction
affected by viscosity

Direction of flow

Indication of rotation

Indication of direction or paths of flow

Variable control

PUMPS. MOTORS. CYLINDERS. ETC.

Fixed pump
one direction of flow Single acting

Fixed pump
two directions of flow Double acting

Variable pump
one direction of flow Double ended

Variable pump Double acting with

two directions of flow damping at rod area end

Fixed capacity motor

Uni-Directional

Fixed capacity motor

reversing

Variable capacity motor

Uni-Directional

Variable capacity motor

reversing

9808/0507 11/1-1
 International Training Centre

CONTROL VALVES
Can be used to indicate
valves or a number of
valves. The number One way restrictor
refers to an index on a
drawing where the unit
is shown in detail

Used to enclose several High pressure selector (shuttle

valves indicating that valve)
they are supplied as
one unit eg-Power pack
Throttling orifice normally
Spring centered pilot closed
operated valve with ‘L’
piston

3 Position spring Throttling orifice normally

centered hand operated open
valve with B piston

3 Position double
solenoid operated pilot Relief valve
valve with ‘LLBLL'
piston

3 Position detent hand

operated directional Variable restrictor
valve with ‘LLLB’ piston

4 Port single stage

Electro-hydraulic servo
valve

4 port two stage

Electro-hydraulic servo
valve

3 port spring
offset tracer valve

Non - return valve

Non - return valve C/W

back pressure spring

Pilot operated
Non - return valve

9808/0507 11/1-2
 International Training Centre

ENERGY TRANSMISSION ETC

Working pressure returns Reservoir

return above fluid level
Pilot control
(Can be as above) Reservoir
return below fluid level
Drain lines

Flexible
Header tank

Pressure sealed
Line junction

Accumulator

Crossing lines

Filter or strainer

Air bleed

Line plugged Water trap

Line plugged with

take off line
Heat exchanger

Coupled line with

self sealing couplings
Water cooler
Uncoupled line with
self sealing couplings
Heater
Rotary connection one way

Air blast cool

Rotary connection three ways

11/1-3
 International Training Centre

CONTROL MECHANISMS

Rotating shaft-one direction Solenoid one winding

Rotating shaft-two directions

Solenoid two winding

Detent

Electronic motor operated

Locking device

Internal pressure pilot operated

Over centre device

External pressure pilot operated

Simple linkage

Pilot operated by solenoid pilot valve

General control

Pilot operated by solenoid or separate

pilot valve
Push button operated

Pressure gauge
Lever operated

Pedal operated Pressure switch

Stem operated

Spring operated

Roller operated

Roller trip operated

(Uni directional)

9808/0507 11/1-4