Binder6 PDF

Section E
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-0 9803/3760-07 E-0

Contents Page No.

Applications
Table ...................................................................................................... E0 - 1
Systems and Schematics

Introduction ............................................................................................ E1 - 1
Systems ................................................................................................. E1 - 2
Applications ........................................................................................... E1 - 6
Schematics - Parallel System with Dual Lever Controls ........................ E1 - 8
Schematics - Parallel System with Single Lever Controls ................... E1 - 15
Schematics - LSP Gearpump System ................................................. E1 - 22
Schematics - LSP Variflow System ..................................................... E1 - 28
Schematics - LSP Electro Servo System (S1) ..................................... E1 - 38
Schematics - LSP Electro Servo System (S2) ..................................... E1 - 41
Parallel Hydraulic SYSTEM

Introduction ............................................................................................ E2 - 1
Related Topics ....................................................................................... E2 - 3
Specifications ........................................................................................ E2 - 4
Operation Overview ............................................................................. E2 - 15
Hydraulic Operation and Schematics .................................................. E2 - 19
Fault Finding ........................................................................................ E2 - 37
Test Procedures ................................................................................... E2 - 42
Bleed Procedures ................................................................................ E2 - 53
LSP Gearpump Hydraulic SYSTEM

Introduction ............................................................................................ E3 - 1
Related Topics ....................................................................................... E3 - 3
Operation Overview ............................................................................... E3 - 9
Electrical Operation and Schematics ................................................... E3 - 33
Fault Finding ........................................................................................ E3 - 38
LSP Variflow Hydraulic SYSTEM

Introduction ............................................................................................ E4 - 1
Related Topics ....................................................................................... E4 - 3
Fault Finding ........................................................................................ E4 - 46
LSP Electro Servo Hydraulic SYSTEM (S1)

Introduction ............................................................................................ E5 - 1
Related Topics ....................................................................................... E5 - 3
Fault Finding ........................................................................................ E5 - 51
E-i E-i
Contents Page No.


Introduction ............................................................................................ E6 - 1
Related Topics ....................................................................................... E6 - 3
Fault Finding ........................................................................................ E6 - 63
Servo Parallel Hydraulic SYSTEM

Introduction ............................................................................................ E7 - 1
Related Topics ....................................................................................... E7 - 3
Fault Finding ........................................................................................ E7 - 40
Smooth Ride SYSTEM (SRS) - Parallel

Introduction ............................................................................................ E8 - 1
Related Topics ....................................................................................... E8 - 2
Hydraulic Operation and Schematics .................................................... E8 - 8
Electrical Operation and Schematics ..................................................... E8 - 9
Fault Finding ........................................................................................ E8 - 14
Accumulator Charging and Discharging .............................................. E8 - 17
Accumulator Removal and Replacement ............................................ E8 - 19
Smooth Ride SYSTEM (SRS) - LSP

Introduction ............................................................................................ E9 - 1
Related Topics ....................................................................................... E9 - 2
Hydraulic Operation and Schematics .................................................... E9 - 8
Electrical Operation and Schematics ..................................................... E9 - 9
Fault Finding ........................................................................................ E9 - 14
Accumulator Charging and Discharging .............................................. E9 - 17
Accumulator Removal and Replacement ............................................ E9 - 19
Smooth Ride SYSTEM (SRS) (S1) - Electro Servo

Introduction .......................................................................................... E10 - 1
Related Topics ..................................................................................... E10 - 2
Specifications ...................................................................................... E10 - 3
Fault Finding ...................................................................................... E10 - 13
Accumulator Charging and Discharging ............................................ E10 - 16
Accumulator Removal and Replacement .......................................... E10 - 18
E - ii E - ii
Contents Page No.

Introduction ...........................................................................................E11 - 1
Related Topics ......................................................................................E11 - 2
Specifications .......................................................................................E11 - 3
Operation Overview ..............................................................................E11 - 5
Hydraulic Operation and Schematics ...................................................E11 - 6
Electrical Operation and Schematics ....................................................E11 - 7
Fault Finding .......................................................................................E11 - 10
Accumulator Charging and Discharging .............................................E11 - 13
Accumulator Removal and Replacement ...........................................E11 - 15
Smooth Ride SYSTEM (SRS) - Servo Parallel

Introduction .......................................................................................... E12 - 1
Related Topics ..................................................................................... E12 - 2
Fault Finding ...................................................................................... E12 - 15
Accumulator Charging and Discharging ............................................ E12 - 19
Accumulator Removal and Replacement .......................................... E12 - 21
Parallel Control Valve - 4 Section

Introduction .......................................................................................... E13 - 1
Related Topics ..................................................................................... E13 - 2
Removal and Replacement (P1) ......................................................... E13 - 3
Removal and Replacement (P2) ......................................................... E13 - 5
Dismantle and Assemble - Valve Block ............................................... E13 - 8
Dismantle and Assemble - Spools and Load Hold Check Valves ...... E13 - 10
Dismantle and Assemble - Pilot Pressure Reducing Valve ................E13 - 11

Introduction .......................................................................................... E14 - 1
Related Topics ..................................................................................... E14 - 2
Removal and Replacement ................................................................. E14 - 3
Dismantle and Assemble - Valve Block ............................................... E14 - 5
Dismantle and Assemble - Spools and Load Hold Check Valves ........ E14 - 7
Flowshare (LSP) Control Valve

Introduction .......................................................................................... E15 - 1
Related Topics ..................................................................................... E15 - 2
Dismantle and Assemble ..................................................................... E15 - 5
Electro Servo (LSP) Control Valve (S1)

Introduction .......................................................................................... E16 - 1
Related Topics ..................................................................................... E16 - 2
Servo Parallel Control Valve

Introduction .......................................................................................... E17 - 1
Related Topics ..................................................................................... E17 - 2
Dismantle and Assemble - Valve Block Slices .................................... E17 - 6
E - iii E - iii
Contents Page No.

Dismantle and Assemble - Spools and Load Hold Check Valves ........ E17 - 9
Inloader Valve
Introduction .......................................................................................... E18 - 1
Related Topics ..................................................................................... E18 - 2
Servo Pilot Valve

Introduction .......................................................................................... E19 - 1
Related Topics ..................................................................................... E19 - 2
Servo Pilot Pressure Supply Valve (S1)

Introduction .......................................................................................... E20 - 1
Related Topics ..................................................................................... E20 - 2

Introduction .......................................................................................... E21 - 1
Related Topics ..................................................................................... E21 - 2
Pilot Manifold Block

Introduction .......................................................................................... E22 - 1
Related Topics ..................................................................................... E22 - 2
Main Pump - Variflow

Introduction .......................................................................................... E23 - 1
Related Topics ..................................................................................... E23 - 2
Main Pump - Gearpump

Introduction .......................................................................................... E24 - 1
Related Topics ..................................................................................... E24 - 2
Dismantle, Inspection and Assemble .................................................. E24 - 8
Steering Priority Valve ....................................................................... E24 - 15
Cooling Fan Motor

Introduction .......................................................................................... E25 - 1
Related Topics ..................................................................................... E25 - 2
E - iv E - iv
Contents Page No.

Dismantle, Inspection and Assemble .................................................. E25 - 8
Control Lever - Electro Servo (S1)

Introduction .......................................................................................... E26 - 1
Related Topics ..................................................................................... E26 - 2

Introduction .......................................................................................... E27 - 1
Related Topics ..................................................................................... E27 - 2
Control Lever - Servo Parallel

Introduction .......................................................................................... E28 - 1
Related Topics ..................................................................................... E28 - 2
Extension Ram
Introduction .......................................................................................... E29 - 1
Related Topics ..................................................................................... E29 - 2
Removal and Replacement - 2 Stage Boom ....................................... E29 - 3
Lift Rams
Introduction .......................................................................................... E30 - 1
Related Topics ..................................................................................... E30 - 2
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
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
Stabiliser Rams
Introduction .......................................................................................... E34 - 1
Related Topics ..................................................................................... E34 - 2
E-v E-v
Contents Page No.

Ram Maintenance
Introduction .......................................................................................... E35 - 1
Related Topics ..................................................................................... E35 - 2
Dismantle ............................................................................................. E35 - 6
Assemble ............................................................................................. E35 - 8
Piston Head Retention ........................................................................E35 - 11
Extension Ram Make-Up Valve (if fitted) ........................................... E35 - 12
Sway/Fan Changeover Valve

Introduction .......................................................................................... E36 - 1
Related Topics ..................................................................................... E36 - 2
Component Location ........................................................................... E36 - 3
Electrical Connectors ........................................................................... E36 - 7
Dismantle and Assemble ................................................................... E36 - 10
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
2010(1)
E12 Smooth Ride SYSTEM (SRS)Servo Parallel SLC z
Table
Section E0 - Hydraulics
Applications
E0-1
Machine models
E0-2
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
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
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
Applications
E0-2
Machine models
E0-3
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
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
Applications
E0-3
Applications
Table
Page left intentionally blank
E0-4 9803/3760-07 (AE-00-00) E0-4


Introduction
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)
E1-1 9803/3760-07 (E-00-01) E1-1

Systems
Systems
K Table 1. System Variants - Identification References K Table 2. System Variants - Identification References
- Hydraulics ( T E1-2) - LLMC ( T E1-5)
Table 1. System Variants - Identification References - Hydraulics

SYSTEM Type SYSTEM Topic Main Pump Type Control Lever Type
Parallel System K Parallel Fixed flow double or triple gear pump. Parallel control valve (black) with four
with Dual Lever Hydraulic manual spools. Separate control levers
Controls SYSTEM ( T E2-1) for boom and auxiliary services.
K Schematics -
Parallel System
with Dual Lever
Controls ( T E1-8)
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)
E1-2 9803/3760-07 (E-00-01) E1-2

Systems
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)
E1-3 9803/3760-07 (E-00-01) E1-3

Systems
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)
E1-4 9803/3760-07 (E-00-01) E1-4

Systems
Table 2. System Variants - Identification References - LLMC
SYSTEM Type LLMI Display
Non LLMC
X
C094300-C14
Fig 1.
LLMC
X
C094300-C13
Fig 2.
E1-5 9803/3760-07 (E-00-01) E1-5

Applications
E1-6
K Systems ( T E1-2)
Table 3. Specification Variants - Hydraulic Schematics

Machine models
Schematic (1) 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 Parallel Dual Lever Control 160/02300-7 (531- All non LLMC machines z
70) ( T E1-10) LLMC machines up to October
2010(2)
2010(2)
2010(2)
K Parallel Dual Lever Control 160/02301-8 (536-70, 541- All non LLMC machines z z
2010(2)
K Parallel Dual Lever Control 332/C6641-3 (526-
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
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
2010(2)
K LSP Gearpump 160/15656-4 (531-70) ( T E1-24) Machines up to November 2009 z
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 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
November 2009
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
2009
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.
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)
2H Auxiliary relief valve (ARV) 13 Second Auxiliary (option) - if fitted

For machine applications refer to the applications
table. K Applications ( T E1-6) 2J Auxiliary relief valve (ARV) 13A Diverter valve (boom)
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
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)
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)
K Table 4. Component Key: ( T E1-8) K Applications ( T E1-6)

E1-10
E1-11
9803/3760-07 (E-00-01)
20A
20
20D
20B
20C
160-12719-8-sheet1

E1-11
E1-12
9803/3760-07 (E-00-01)
160-13379-5-sheet1

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
332-C6641-3
Fig 7. Parallel Dual Lever Control 332/C6641-3 (526-56)
K Table 4. Component Key: ( T E1-8)
E1-14 9803/3760-07 (E-00-01) E1-14

Schematics - Parallel System with Single Lever Controls
E1-15
The schematics show a number of options, check the 2A Main relief valve (MRV) 11B Auxiliary relief valve (ARV) - if fitted
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
2E Extension spool 13 Auxiliary 1 with Sway (option) - if fitted

table. K Applications ( T E1-6) 2F Tilt spool 13A Sway ram - if fitted
2G Auxiliary spool 13B Sway ram check valve - if fitted

2H Auxiliary relief valve (ARV) 13C Auxiliary 1 boom quick release couplings
K Fig 8. Parallel Single Lever control 160/02046-
13 (536-70, 541-70) ( T E1-17) 2J Auxiliary relief valve (ARV) 13D Diverter valve (chassis mounted)
K Fig 9. Parallel Single Lever control 160/01792- 2K Auxiliary relief valve (ARV) 13E Diverter valve
14 (531-70) ( T E1-18) 13G Sway/auxiliary spool
2L Auxiliary relief valve (ARV)
K Fig 12. Parallel Single Lever Control 333/ 14 Auxiliary 1 and 2 (option) - if fitted
2M Load hold check valves (L.H.C.V's)
C9759-1 (531-70 Russia Build Specification)
2N Accumulator 14A Diverter valve (boom mounted)
( T E1-21)
3 Steering Unit 14B Auxiliary 2 boom quick release couplings
K Fig 10. Parallel Single Lever control 333/
C1454-4 (535-95) ( T E1-19) 3A Steer valve 14C Auxiliary 1 boom quick release couplings
K Fig 11. Parallel Single Lever Control 332/ 3B Shock valves (option) - if fitted 15 Auxiliary 1 and 2 with Hydraulic Pin Lock
E9601-3 (526-56) ( T E1-20) (option) - if fitted
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
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
20 Restricted Non Return Valve
21 Rear Power Track Rod
22 Lift Circuit with optional Smooth Ride
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)
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
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
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 èxtend' 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
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
24A Solenoid valve
24B Solenoid valve
24C Accumulators
24D Pressure switch
25 Servo Pilot Filter
26 Oil Cooler
9803/3760-07 (E-00-01)
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
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 èxtend' 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
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
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)
( 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)
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
E1-28
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)
23C Relief valve
23E Sway cylinder
24B Brake valve
9803/3760-07 (E-00-01)
24C Pilot valve
System (SRS) - if fitted(1)
25A Solenoid valve
25B Solenoid valve
25C Accumulators
25D Pressure switch
27 Oil Cooler
28 Load Pressure Sense Valve (up to June
2009)
29 Pump Shut-Off Valve
E1-29
E1-30
9803/3760-07 (E-00-01)
160/16083-3
Fig 17. LSP Variflow 160/16083-3 (531-70)

E1-30
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
E1-32
9803/3760-07 (E-00-01)
332/C2606-1
Fig 19. LSP Variflow 332/C2606-1 (535-95)

E1-32
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
M 240 310 BAR

B A T F P
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
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
E1-34
9803/3760-07 (E-00-01)
160/16347-1
Fig 21. LSP Variflow 160/16347-1 (536-60)

E1-34
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
A M 260 310 BAR

B
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
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

E1-35
E1-36
9803/3760-07 (E-00-01)
160/16082-3
Fig 23. LSP Variflow 160/16082-3 (541-70)

E1-36
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
A M 260 310 BAR

B T F P
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
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

E1-37
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)
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
8J Auxiliary relief valve (ARV) 19 Twin Auxiliary (option) - if fitted

table. K Applications ( T E1-6) 8M Auxiliary relief valve (ARV) 19A Solenoid diverter valve (boom mounted)
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
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)
7B Fan pump 13A Accumulator
7C Pump Control Solenoid 13B Relief valve
7D Pressure regulator spool 14 Lift Cylinder
23 Sway Mode Valve (option) - if fitted(1)
7E Flow regulator spool 14A Counterbalance valve
7F Steer Priority Valve 14B Counterbalance valve
8 Control Valve Block(1) 14C Lift Assist Valve
23C Relief valve
8A Flushing valve 15 Displacement Cylinder(s)
8B Flow regulator valve 16 Tilt Cylinder
23E Sway cylinder
8C Load sense relief valve 16A Counterbalance valve
8D Raise/lower spool 17 Extension Cylinder(s)
E1-38
24B Brake valve
24C Pilot valve
E1-39
System (SRS) - if fitted(1)
25A Solenoid valve
25B Solenoid valve
25C Accumulators
25D Pressure switch
27 Oil Cooler
28 Bi-Directional Check Valve - if fitted
(1) For information about this device refer to Related

Topics.
9803/3760-07 (E-00-01)
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 Table 8. Component Key: ( T E1-38)
E1-40
E1-41
The schematics show a number of options, check the 8 Control Valve Block 13E Accumulator
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)
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 èxtend' 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
E1-41
E1-42
23 Sway Mode Valve (option) - if fitted
23C Relief valve
23E Sway cylinder
24B Brake valve
24C Pilot valve
25A Solenoid valve
25B Solenoid valve
25C Accumulators
9803/3760-07 (E-00-01)
25D Pressure switch
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)
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

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

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

Introduction
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.
K Related Topics ( T E2-3)

K Specifications ( T E2-4)
K 4 Spool Valve Block (S1) ( T E2-4)(1)
K Hydraulic Pump ( T E2-10)
K Cooling Fan Motor ( T E2-12)
K Operation Overview ( T E2-15)
K Component Location and Identification ( T E2-16)
K Control Valve Block ( T E2-18)
K Dual Lever Control ( T E2-18)
K Single Lever Control ( T E2-18)
K Main Relief Valve (MRV) Operation ( T E2-25)
K Auxiliary Relief Valve (ARV) Operation ( T E2-26)
K Hydraulic Operation and Schematics ( T E2-19)
K No Services Operated ( T E2-19)
K Service Operation ( T E2-19)
K Main System Pressure Relief ( T E2-19)
K 4 Spool Control Valve (Dual Lever Control) ( T E2-22)
K 6 Spool Control Valve (Machines with Stabilisers) ( T E2-24)
K Parallel Lift (S1) ( T E2-27)(1)
K Boom Regenerative Valve (3 Stage Booms) ( T E2-33)
K Fault Finding ( T E2-37)
E2-1 9803/3760-07 (E-01-04) E2-1

Introduction
K Test Procedures ( T E2-42)

K Checking Pump Flow ( T E2-42)
K Main Relief Valve (MRV) Pressure ( T E2-46)
K Auxiliary Relief Valve Pressure (ARV) - ARV’s set lower than the MRV ( T E2-47)
K Auxiliary Relief Valve Pressure (ARV) - ARV’s set higher than the MRV ( T E2-48)
K Relief Valve Adjustment ( T E2-50)
K Servo Pilot Pressure (Single lever controls) ( T E2-51)
K Measuring Spool Displacement (Manual Spools) ( T E2-52)
K Bleed Procedures ( T E2-53)
K 3-Stage Boom Extension Ram Circuit ( T E2-53)
K Tilt Ram Circuit ( T E2-55)
K Sway Ram Circuit ( T E2-56)
(1) Specification variant. Make sure you refer to the correct specification.
Table 1. Specification Variants

Procedures, Specifications (1) Machine Model Application
531-70, 535-95, 541-70, 533-105 536-70, 526-56
531-T70 535-T95 541-T70 536-T70
K 4 Spool Valve Block (S1) ( T E2-4) z
K 4 Spool Valve Block (S2) ( T E2-6) z z
K Parallel Lift (S1) ( T E2-27) z z z
(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.
E2-2 9803/3760-07 (E-01-04) E2-2

Related Topics
Related Topics
Table 2. Related Topics in This Publication

The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to
complete your procedures. Where applicable the text in this section contains cross references to this page to help you find
the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer
to Section 1 - Applications.
Sections Topic Titles Sub Titles
1 Applications ALL
1 Service Tools ALL
2 ALL (Care and Safety) (1) ALL
3 Hydraulic System Checking the Hydraulic Fluid Level
B Boom ALL
B Stabilisers ALL
E K Systems and Schematics ( T E1-1)
E K Parallel Control Valve - 4 Section ( T E13-1) ALL
E K Main Pump - Gearpump ( T E24-1) ALL
E K Cooling Fan Motor ( T E25-1) ALL
E K Smooth Ride SYSTEM (SRS) - Parallel ( T E8-1) ALL
E K Inloader Valve ( T E18-1) ALL
E K Sway/Fan Changeover Valve ( T E36-1) ALL
H Manual Steer Mode SYSTEM ALL
H Auto Steer Mode SYSTEM ALL
H Priority Valve Test Procedures
(1) You must obey all of the relevant care and safety procedures.
Table 3. Service Tools

The table lists the service tools you will need to do some of the procedures in this topic. Make sure you have the correct
service tools BEFORE you start the procedures
Tool Part Number Description
892/00268 (1) Flow Monitoring Kit and Relevant Adaptors
892/00253 (1) Hydraulic Pressure Test Kit and Relevant Adaptors
892/00270 (1) Load Valve
(1) Tool available from JCB Service, refer to Section 1 - Service Tools
E2-3 9803/3760-07 (E-01-04) E2-3

Specifications
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
4 Spool, parallel service, double acting spools

Machines with dual lever Machines with single lever
controls: controls:
Spool 1 Boom Raise & Lower Service Manually operated Manually operated
Spool 2 Carriage Tilt Service Manually operated Manually operated
Spool 3 Boom Extend & Retract Service Manually operated Solenoid, Servo pilot operated
Spool 4 Auxiliary Service Manually operated Solenoid, Servo pilot operated
Note: Spools 2 and 3 are reversed on machines fitted with

a placing control pattern.
Relief Valve Pressures: K Fig 1. ( T E2-5), K Fig 2. ( T E2-5)

bar kgf/cm2 lbf/in2
2A - Main Relief Valve (MRV) 241 245 3500
Auxiliary Relief Valves (ARV's)
2K - Auxiliary Ram Rod Side 138 (220(1)(2)) 140 (223(1)) 2000 (3200(1))
2L - Auxiliary Ram Head Side 138 140 2000
11B - Boom Extend Ram Rod Side (3)
11C - Boom Extend Ram Head Side (3)
2J - Carriage Tilt Ram Rod Side 276 281 4000
2H - Carriage Tilt Ram Head Side 138 140 2000
(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
E2-4 9803/3760-07 (E-01-04) E2-4

Specifications
764190-2
Fig 1. Loading Control Pattern
764190-1
Fig 2. Placing Control Pattern

E2-5 9803/3760-07 (E-01-04) E2-5

Specifications

Machines with dual lever Machines with single lever
controls: controls:
Spool 1 Boom Raise & Lower Service Manually operated Manually operated
Spool 2 Carriage Tilt Service Manually operated Manually operated
Spool 3 Boom Extend & Retract Service Manually operated Solenoid, Servo pilot operated
Spool 4 Auxiliary Service Manually operated Solenoid, Servo pilot operated


bar kgf/cm2 lbf/in2
2K - Auxiliary Ram Rod Side 138 (220(1)) 140 (223(1)) 2000 (3200(1))
11B - Boom Extend Ram Rod Side (2)
11C - Boom Extend Ram Head Side (3)

(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

E2-6 9803/3760-07 (E-01-04) E2-6

Specifications

Spool 1 Auxiliary / Sway Service Manually operated
Spool 2 Boom Extend & Retract Service Manually operated
Spool 3 Carriage Tilt Service Manually operated
Spool 4 Boom Raise & Lower Service Manually operated
Relief Valve Pressures: K Fig 5. ( T E2-7)

bar kgf/cm2 lbf/in2
2K - Auxiliary Ram Rod Side 180 183.5 2610
2L - Auxiliary Ram Head Side 180 183.5 2610
C068090
Fig 5.
E2-7 9803/3760-07 (E-01-04) E2-7

Specifications

Spool 4 Auxiliary Service Manually operated
Relief Valve Pressures: K Fig 6. ( T E2-8),

bar kgf/cm2 lbf/in2
2K - Auxiliary Ram Rod Side 220 225 3190
11 B - Carriage Tilt Ram Rod Side 250 255 3625
11 C - Carriage Tilt Ram Head Side 276 281 4000
764190-2-C1
Fig 6.
E2-8 9803/3760-07 (E-01-04) E2-8

Specifications

Spool 4 Auxiliary Service Manually operated
Spool 5 RH Stabiliser Manually operated
Spool 6 LH Stabiliser Manually operated


bar kgf/cm2 lbf/in2
2K - Auxiliary Ram Rod Side 220 224.3 3190
2L - Auxiliary Ram Head Side 220 224.3 3190
A296260-1
Fig 7.
E2-9 9803/3760-07 (E-01-04) E2-9

Specifications
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)
Type Triple gear pump
Mounting: Gearbox
Steering pump 19 1.16
Steering pump 37.6 8.3 9.9
Maximum Pressure: bar kg/cm 2 lb/in2
port EF 265 270 3840
port P 200 204 2900
Weight: 33.3 kg (73.4 lbs)
E2-10 9803/3760-07 (E-01-04) E2-10

Specifications
Table 6. 105 litres/min (531-70 - Russia Build Specification)
Type Double Gear pump
Mounting: Gearbox
Main services pump (mounting flange end) TBA TBA TBA
Cooling fan pump TBA TBA TBA
port EF 260 265 3770
port P 180 183 2610
Weight: TBA

Mounting: Gearbox
port EF 265 270 3840
port P 200 204 2900
E2-11 9803/3760-07 (E-01-04) E2-11

Specifications
Cooling Fan Motor

Up to March 09
Machines with SE Engines
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
Machines with SD and SF Engines
SD 63 kW engines :
Type: Gear motor
Body Colour Red
SD 74 kW and SF engines:
Type: Gear motor
Maximum Pressure Setting 120 (1740 lbf/in2)
Body Colour Black
From March 09 to Jan 2011
SE engines :
Type: Gear motor
E2-12 9803/3760-07 (E-01-04) E2-12

Specifications

Body Colour Black
Weight: TBA
SD 63 kW engines :
Type: Gear motor
Direction of Rotation: Clockwise
Fan Speed (at maximum engine rev/min): TBA
Body Colour Red
SD 74 kW and SF engines: From March 09

Type: Gear motor
Body Colour Black
From Jan 2011
SE 97kW engines :
Type: Gear motor
Colour Code (See sticker) None
SD 63 kW engines :
Type: Gear motor
E2-13 9803/3760-07 (E-01-04) E2-13

Specifications

Colour Code (See sticker) Red
Type: Gear motor
Body Colour Black
E2-14 9803/3760-07 (E-01-04) E2-14

Operation Overview
Operation Overview
The following explains the basic operation of machines

fitted with a parallel hydraulic system and gearpump
hydraulic pump. There are other types of hydraulic
systems. Make sure you are referring to the correct
system. K Related Topics ( T E2-3)
The main components of the hydraulic system are the

tank, the pump, the control valves and hydraulic rams.
As well as providing the main hydraulic services the

system also operates a hydraulic steering system. Refer to
Section H - Steering. K Related Topics ( T E2-3)
Some machines have hydraulically operated stabilisers.

This system is described in a separate topic. Refer to
Section B - Body and Framework. K Related
Topics ( T E2-3)
Some machines have a smooth ride system (SRS). This

system is described in a separate topic. K Related
Topics ( T E2-3)
E2-15 9803/3760-07 (E-01-04) E2-15

Operation Overview
Component Location and Identification

K Fig 8. ( T E2-17)
Table 8. Component Key

Item Description
1 Pump assembly Three section gearpump 1A, 1C, 1B K Main Pump -
Gearpump ( T E24-1)
2 Control valve block Parallel valve block with manual spools K Parallel Control Valve - 4
Section ( T E13-1)
4 Fan motor Driven by pump section 1B K Cooling Fan Motor ( T E25-1)
5 Hydraulic Oil Cooler Oil from pump section 1B flows through the oil
cooler
F Hydraulic oil filter Positioned in the return line to tank
T Hydraulic tank
Table 9. Hydraulic Connections Colour Key

Oil from pump section 1A Oil from pump section 1C Oil from pump section 1B
Oil suction line from the tank to Return to tank

the pump sections
E2-16 9803/3760-07 (E-01-04) E2-16

Operation Overview
C026640-C2
Fig 8. Typical Machine
E2-17 9803/3760-07 (E-01-04) E2-17

Operation Overview
Hydraulic Pump Dual Lever Control
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.
Note: Some smaller machines may have a hydraulic pump

with only two sections, in this case the larger pump section
1A has the integral priority valve, and operates in the same
way as section 1C described above.
In neutral circuit conditions (i.e. no service selected), the

oil flows through the control valve block neutral gallery into
the return or exhaust line and back to tank 8-T through an
in-tank filter 8-F.
Note that some machine variants also have a hydraulic oil

cooler 8-5 in the return line from the fan hydraulic motor 8-
4, to cool the system hydraulic oil as it is continually
circulated around the cooling fan circuit.
Control Valve Block

The control valve block 8-2 controls the boom hydraulic
services. For machines with stabilisers the valve has two
more spools to control the stabiliser hydraulic services.
When the control valve spools are actuated, oil from the
pump passes into the service ports, operating the relevant
hydraulic ram.
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.
E2-18 9803/3760-07 (E-01-04) E2-18

Hydraulic Operation and Schematics
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.
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
E2-19 9803/3760-07 (E-01-04) E2-19

C080460-C4
Fig 10. One Service Operated
E2-20 9803/3760-07 (E-01-04) E2-20

C080460-C5
Fig 11. Main System Pressure Relief
E2-21 9803/3760-07 (E-01-04) E2-21

4 Spool Control Valve (Dual Lever

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.
Depending on your machine some sections are pilot

operated and controlled by an electrical switch.
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.
E2-22 9803/3760-07 (E-01-04) E2-22

4 Spool Control Valve (Single Lever enables operation of the service spools a limited number
of times with the engine stopped.
Control)
C085160
C085250-C1 Fig 15. 4 Spool Control Valve (Single Lever Control)
Fig 14. Typical 4 Spool Control Valve Schematic
adjustable main relief valve (MRV) 2A, the pressure
reduction valve 2B and pressure maintaining valve 2C.
Valves 2B and 2C are not adjustable.
Pressure reduction valve 2B provides oil at pilot pressure

for control of spools 2E and 2G. Pressure maintaining
valve 2C ensures that the system pressure is sufficient to
supply oil at pilot pressure when no services are operating.
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.
A remote manifold mounted to the rear of the cab houses

a micro pilot oil filter 15C and accumulator 15D. The
accumulator traps and stores oil at pilot pressure and
E2-23 9803/3760-07 (E-01-04) E2-23

6 Spool Control Valve (Machines with

Stabilisers)
S296330-2
Fig 16. Typical 6 Spool Control Valve
C085140
service port connections. Fig 17. 6 Spool Control Valve Schematic
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.
The unloader section isolates the stabilisers when

solenoid 2P is energised.
E2-24 9803/3760-07 (E-01-04) E2-24

Main Relief Valve (MRV) Operation
C021880-C2
Fig 18.
The main relief valve (M.R.V.) 2A is situated in the control

valve 2, bridging the neutral and exhaust galleries, and is
designed to prevent the circuitry from damage that could
be caused by excessive pressures.
1 Valve at Rest:
The services are in neutral and pressure in the neutral

gallery (blue) is not sufficient to operate the M.R.V. which
is held closed by its spring A.
2 Poppet Opens:
A service has been selected and the pressure generated

exceeds the setting of the M.R.V. Pressure acts on the
periphery of the hollow poppet B which is forced
downwards against the spring, venting pressure into the
exhaust gallery (green).
E2-25 9803/3760-07 (E-01-04) E2-25

Auxiliary Relief Valve (ARV) Operation
C021910-C2
Fig 19.
The Auxiliary Relief Valves (A.R.V.'s) are situated in the

control valve to limit potentially damaging pressures within
specified services due to external loadings.
A.R.V.'s may also be used to limit the maximum pressure

in a specified service to less than the L.S.R.V. setting.
1 Valve at Rest:
A service is selected but pressure in the service gallery

(yellow) has not reached the setting of the A.R.V. which is
held closed by its spring.
2 Poppet Opens:
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 (green).
3 Anti-cavitation Mode:
When a service is operated in such a way that low

pressure, or cavitation, exists in the service line (light
green), the relatively high pressure oil in the exhaust
gallery (darker green) acts on the lower poppet and flows
into the service gallery to make up the deficiency.
E2-26 9803/3760-07 (E-01-04) E2-26

Parallel Lift (S1)

Ram Operation
The parallel lift system operates when the boom raises or

lowers.
When the boom ram C raises or lowers the boom

displacement ram A extends or retracts. Oil displaced by
the ram A flows to the tilt ram D which extends or retracts
keeping the forks E parallel with the ground.
C094840
Fig 20. Single displacement ram at the rear of the
boom pivot.
E2-27 9803/3760-07 (E-01-04) E2-27

Boom Raise Cycle ram raises pilot pressure in HBCV 10A. This allows oil to
feed back to the rod side of the displacement ram.
When lift spool 2D is selected, the neutral circuit is blocked
and oil feeds lift ram hose-burst check-valve 8A. Oil flows Displacement/lift link valve 20 is fitted between lift spool 2D
through free flow direction of hose burst check valve and tilt spool 2F. The function of this valve is to allow a
(HBCV) 8A and lifts the boom. restricted flow of oil into the tilt circuit to increase the lift
force available by utilising the displacement ram.
Oil is forced out of the head side of displacement ram 9 as
the boom rises. The oil cannot flow past the tilt spool 2F, Auxiliary relief valve (ARV) 2J opens to protect the tilt ram
as the spool is not selected. Instead, it flows to the head from over pressurisation. The anti-cavitation feature of
side of tilt ram 10. Oil displaced from the rod side of the tilt valve 2H ensures that, in these circumstances, the tilt and
displacement rams will not cavitate.
416480-1
Fig 21. Boom Raise Cycle (Single displacement ram at the rear of the boom pivot)
E2-28 9803/3760-07 (E-01-04) E2-28

Boom Lower Cycle flow direction of HBCV 10A to the rod side of the tilt ram
10.
When raise/lower spool 2D is selected, the neutral circuit
is blocked and oil feeds the rod side of lift ram 8. Oil Displaced oil from the displacement ram closes the check
displaced from the head side of the lift ram raises pilot valve in displacement/lift link valve 20.
pressure in HBCV 8A and allows oil out of the lift ram back
to tank, lowering the boom. Auxiliary relief valve (ARV) 2H opens to protect the tilt ram
from over pressurisation. The anti-cavitation feature of
As the boom lowers, oil is forced from the rod side of the valve 2J ensures that, in these circumstances, the tilt and
displacement ram 9. The oil cannot flow past tilt spool 2F, displacement rams will not cavitate.
as the spool is not selected. Instead, it flows through free
416490-1
Fig 22. Boom Lower Cycle (Single displacement ram at the rear of the boom pivot)
E2-29 9803/3760-07 (E-01-04) E2-29

Parallel Lift (S2)

Ram Operation

lowers.

C083280-C3
Fig 23. Single displacement ram forward of ram pivot.
E2-30 9803/3760-07 (E-01-04) E2-30

Boom Raise Cycle raises pilot pressure in HBCV 10A. This allows oil to feed
back to the head side of the displacement ram.
Oil is forced out of the rod side of displacement ram 9 as
as the spool is not selected. Instead, it flows to the rod side from over pressurisation. The anti-cavitation feature of
of tilt ram 10. Oil displaced from the head side of the tilt ram valve 2H ensures that, in these circumstances, the tilt and
416480-C1
Fig 24. Boom Raise Cycle (Single displacement ram forward of ram pivot)
E2-31 9803/3760-07 (E-01-04) E2-31

Boom Lower Cycle flow direction of HBCV 10A to the head side of the tilt ram
10.
As the boom lowers, oil is forced from the head side of the valve 2J ensures that, in these circumstances, the tilt and
displacement ram 9. The oil cannot flow past tilt spool 2F, compensating rams will not cavitate.
416480-C2
Fig 25. Boom Lower Cycle (Single displacement ram forward of ram pivot)
E2-32 9803/3760-07 (E-01-04) E2-32

Boom Regenerative Valve (3 Stage

Booms)
K Boom Extend Cycle ( T E2-34)
K Boom Retract Cycle ( T E2-36)
The regenerative valve is fitted to the outer extension ram

to increase the speed of the boom during the extend cycle,
under light load conditions. Hydraulic oil is displaced from
the rod side of the inner extension ram to supplement the
pump flow to the head side of the outer extension ram. The
speed of the extending boom is increased.
The only servicing possible in the event of external oil

leakage is the renewal of oil seals, or the renewal of a
faulty screw-in cartridge.
A318880-1
Fig 26.
Screw-in Cartridge Components:
26-A Outer extension ram hose burst check valve
26-B Pilot operated check valve
26-C Pressure relief valve
26-D Non-return valve
E2-33 9803/3760-07 (E-01-04) E2-33

Boom Extend Cycle K Heavy Load ( T E2-35)
K Light Load (Regenerative Cycle) ( T E2-34)
Light Load (Regenerative Cycle)
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.
Oil is displaced from the rod side of outer extension ram 12

and passes through inner extension ram HBCV 11A to the
head side of inner extension ram 11. Inner extension ram
11 starts to extend and oil is displaced from the rod side of
the cylinder. Pressure relief valve 13B prevents oil leaving
the regenerative valve block and returning to tank.
Pilot operated check-valve 13C opens to allow the oil to

supplement the main pump flow via 13D and increase the
speed of extension.
E2-34 9803/3760-07 (E-01-04) E2-34

Heavy Load
334130
Fig 28.
As the boom extends, oil under high pressure closes

check-valve 13D. Oil flows through the outer extension
ram hose-burst check-valve 13A to the head side of outer
extension ram 12.
Oil is displaced from the rod side of outer extension ram 12

and passes through inner extension ram HBCV 11A to the
head side of inner extension ram 11. Inner extension ram
11 starts to extend and oil is displaced from the rod side of
the cylinder. Pilot pressure opens pressure relief valve
13B.
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.
E2-35 9803/3760-07 (E-01-04) E2-35

Boom Retract Cycle
334140
Fig 29.
As the boom is retracted, oil flows through pressure relief

valve 13B to the rod side of inner extension ram 11. Oil is
prevented from entering the regenerative valve block by
pilot operated check-valve 13C. Oil is displaced from the
head side of inner extension ram 11 through HBCV 11A
and 13A and back to tank through the extension spool. Oil
cannot flow through the regenerative valve because non-
return valve 13D is closed.
E2-36 9803/3760-07 (E-01-04) E2-36

Fault Finding
Fault Finding
The purpose of this section is to help you trace a particular

fault. The tables identify possible causes and give a
suggested action with specific tests where applicable.
Go to the relevant topic for fault finding procedures for

other related systems and devices. K Related
Topics ( T E2-3)
1 Before you begin fault finding, read the safety

information at the beginning of this manual.
2 Make any relevant electrical checks before moving on

to the hydraulics.
3 Make simple checks before say, stripping a major

hydraulic component.
4 Make sure that the hydraulic fluid is at the correct

working temperature (50ºC, 122ºF).
5 If hydraulic contamination is found, be sure to remove

ALL debris, and if possible identify its origin. It may be
part of a component from elsewhere in the hydraulic
circuit.
6 What ever the fault, check the condition of the

hydraulic fluid. Drain and replace if necessary.
7 Renew any seals such as O-rings when re-

assembling hydraulic components.
E2-37 9803/3760-07 (E-01-04) E2-37

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 11. Lack of power at all hydraulic functions

Possible Cause Action
Insufficient hydraulic fluid. Check for leaks and top up as required.
Hydraulic leaks in system. Check hoses, renew as required.
Engine performance. Check engine performance.
MRV setting incorrect. Check and adjust as required.
Low pump flow. – Check pump flow.
– Check for external leaks, renew seals.
– Priority valve sticking, see Section H - Steering.
– Renew pump.
Table 12. All mechanically operated hydraulic services slow to operate

Neutral circuit or low pressure lines leaking, damaged, Check pipe lines and renew as required.
trapped or kinked.
– Renew pump.
E2-38 9803/3760-07 (E-01-04) E2-38

Fault Finding
Table 13. All solenoid/servo operated hydraulic services slow to operate
K Table 12. All mechanically operated hydraulic
services slow to operate ( T E2-38).
Low pilot pressure. – Check that the pressure maintenance valve is not
sticking open.
– Check the pressure reducing valve.
– Check servo pressure.
Solenoid power supply not present. Check fuse 2.
Table 14. One mechanically operated hydraulic service fails to operate or is slow to operate
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)
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
MRV valve setting incorrect Check and adjust as required.
Table 17. Ram creep

Associated ram or pipe lines from ram leaking. Check and rectify as required.
Check valve. Check operation and rectify as required.
E2-39 9803/3760-07 (E-01-04) E2-39

Fault Finding
Table 18. 3 stage boom extend retract system
Action Yes No
1 Is the machine experiencing boom extend or retract Go to 2 Done
problems?
2 Bleed air from hydraulic cylinders. OK now? Done Go to 3
3 Does the inner/intermediate boom extend or retract? Go to 7 Go to 4
4 Pressure test hydraulic pump. Rectify if required. OK now? Done Go to 5
5 Check MRV in valve block and for leakage passed pistons Done Go to 6
in both rams. Investigate and rectify as required. OK now?
6 Replace hose-burst check valve(s) on inner/outer Done Go to 7
extension ram(s). OK now?
7 Are the inner/intermediate booms over-running after de- Go to 8 Go to 9
selecting extend lever or is there an unexpected surge
after a retract operation?
8 Renew motor spool in extend slice. See TI 5/197. OK now? Done
9 Do the inner/intermediate booms go out of phase? Go to 10 Go to 2
10 Does the operator periodically fully retract inner and Go to 12 Go to 11
intermediate booms to re-phase hydraulic cylinders?
11 Fully retract inner and intermediate booms to re-phase Done Go to 12
hydraulic cylinders. OK now?
12 Does the inner boom fully retract leaving intermediate Go to 13 Go to 14
boom slightly extended?
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
15 Strip outer extension cylinder and ensure make-up valve in Done Go to 2
Table 19. Forks creep down

Possible Cause Remedy
Circuit hosed incorrectly. Has any work been completed on Check circuit. Re-route the hoses if necessary.
the machine recently?
Tilt ram HBCV leaking, tilt ram seals leaking, control valve Check for leakage in the tilt ram circuit.
spool leaking or valve block section leaking internally.
E2-40 9803/3760-07 (E-01-04) E2-40

Fault Finding
Table 20. Parallel lift faulty
Displacement/lift link valve broken or leaking. – Examine valve; is ball OK? Fit blank to isolate valve
from circuit.
– Fit latest type valve.
– Check pipes, tilt spool, HBCV for missing ball.
Tilt section ARVs set incorrectly, causing oil to exit from tilt/ Check tilt ARV setting. Adjust if required.
compensating ram circuit.
Tilt section ARVs could be sticking open due to Clean or new as required.
contamination.
Leaking seals in tilt ram or compensation ram. Check tilt/compensation rams for leakage (use hand pump
if available). Renew seals as required.
Note: The forks will continue to crowd back when the

boom reaches maximum elevation angle, if the lift lever is
not deselected on machines fitted with displacement link
valve 20. This is normal and is caused by oil bleeding from
the lift circuit to the tilt circuit. K Parallel Lift
(S1) ( T E2-27)
E2-41 9803/3760-07 (E-01-04) E2-41

Test Procedures
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.
Disconnect the battery, to prevent the engine being

started while you are beneath the machine.
GEN-4-1_1
1 Carry out General Safety procedures, see Section 2

- General Procedures. K Related Topics ( T E2-3)
!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
4 Start the engine and bring the hydraulic system up to

working temperature 50º C (122º F).
5 Select the steering and control valve block spools to

the neutral position.
6 Set the engine speed to 2200 rev/min., then carefully

adjust the load valve 30-C so that the gauge reading
increases to 240 bar (3500 lbf/in2).
A326060-1
Fig 30. Test Equipment
3 Connect a flow meter 30-A, 0-400 bar (0-6000 lbf/in2)

pressure gauge 30-B and load valve 30-C into the
E2-42 9803/3760-07 (E-01-04) E2-42

Test Procedures
7 Check the flow reading which should be as stated in
Specifications. K Specifications ( T E2-4)
If the flow reading is low or you are unable to obtain

the pressure required, K Fault Finding ( T E2-37).
For testing the Priority Valve, see Section H -

Steering. K Related Topics ( T E2-3)
!MWARNING
Take care when disconnecting hydraulic hoses and
fittings as the oil will be HOT.
TRANS-1-2
8 After completing the test, switch OFF the engine and

allow to cool before disconnecting the test equipment
and reconnecting the hydraulic hoses.
E2-43 9803/3760-07 (E-01-04) E2-43

Test Procedures
Triple Pump 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 33-A from the pipe 33-B. Fit the flow meter and load
the source of a problem i.e pump, steer circuit or services valve between hose 33-A and the pipe 33-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 33-C from the pipe 33-B. Cap the
!MWARNING open port in the pipe, then connect a suitable slave
hose 34- D to hose 33-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 34-D inside
attachments to the ground. Apply the park brake, put the filler tube as shown. K Fig 34. ( T E2-45).
both sides of all four wheels. Steering Pump (Section 2): Disconnect hose 33-C
from the priority valve 33-E (port EF). Fit the flow
Disconnect the battery, to prevent the engine being meter and load valve between hose 33-C and the
started while you are beneath the machine. priority valve 33-E.
GEN-4-1_1
Cooling Fan Pump (Section 3): Disconnect hose 33-
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 E2-3) between hose 33-F and the pump.
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
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
the hoses are open.
INT-3-1-11_2
2 Vent the hydraulic pressure, see Section 2 - General

Procedures. K Related Topics ( T E2-3)
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.
HYD-4-4_1
4 Start the engine and bring the hydraulic system upto


E2-44 9803/3760-07 (E-01-04) E2-44

Test Procedures



!MWARNING
TRANS-1-2

A326080-C2
Fig 34.
E2-45 9803/3760-07 (E-01-04) E2-45

Test Procedures
Main Relief Valve (MRV) Pressure

1 Park the machine and make it safe. Vent the hydraulic
pressure, see Section 2 - General Procedures.
2 Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure

gauge to the test point A.

4 Select boom lower service and hold ram fully closed.

Gradually increase the engine speed to 2200 rev/min.
while checking maximum gauge reading, which
should be as stated in Specifications.
K Specifications ( T E2-4) A335530-C4
Fig 36. Test Point (Typical Triple Pump)
416111-C10
Fig 35. Test Point (Typical Double Pump)
E2-46 9803/3760-07 (E-01-04) E2-46

Test Procedures
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).
2 Vent residual hydraulic pressure. Obey the care and

safety procedures. K Related Topics ( T E2-3)
!MWARNING
3 Locate the hydraulic line for the high pressure side of fittings as the oil will be HOT.
the tilt ram. Fit a tee piece in the hydraulic line. TRANS-1-2
Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure
gauge to the tee piece. 6 After completing the test, fully lower the boom, switch
OFF the engine and vent residual hydraulic pressure.
Note: Locate a connection in the tilt ram circuit at the rear Disconnect the pressure gauge and reconnect the tilt
of the boom. The illustrations show typical locations. ram hose.
331440-1
Fig 39. Tilt ram hose at the rear boom bulkhead bracket
E2-48 9803/3760-07 (E-01-04) E2-48

Test Procedures
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
E2-49 9803/3760-07 (E-01-04) E2-49

Test Procedures
Relief Valve Adjustment

7 If the pressure is incorrect, adjust the relief valve as
described below:
a Position the boom and fit the Safety Strut, see

Section 2 - General Procedures. K Related
Topics ( T E2-3)
b Vent the hydraulic pressure, see Section 2 -

General Procedures. K Related
Topics ( T E2-3)
c Loosen the locknut B and turn the adjuster screw

C. Turn the adjuster screw clockwise to increase
pressure and anti-clockwise to decrease the
pressure. When the pressure is correct, tighten
the locknut and check the pressure again. Adjust
as required.
The location of the relief valve is dependant on the

machine type. K Specifications ( T E2-4)
A296360-1
Fig 42. Relief Valve Adjuster Screw and Locknut
E2-50 9803/3760-07 (E-01-04) E2-50

Test Procedures
Servo Pilot Pressure (Single lever

controls)
!MWARNING
Hydraulic Pressure
the hoses are open.
INT-3-1-11_2
1 Turn the ignition key switch to ON, but do not start the
engine.
Vent the hydraulic pressure, see Section 2 - General

2 Separate hose 43-A from filter 43-B and install tee-

piece 43-C between the two. Connect a 0 - 50 bar (0
- 1000 lbf/in2) pressure gauge 43-D to the tee-piece.

4 Gradually increase the engine speed to 2200 rev/min.

while checking maximum gauge reading, which
should be as stated in Specifications.
Note: It is important that the pressure does not fall below

the lower limit at engine idle speed.
Cleaning the Valve
The servo pilot pressure reducing valve is not adjustable.

A313980-1
The valve cartridge is not serviceable beyond cleaning. A Fig 43.
cartridge should be renewed complete if wear or damage
is evident.
For dismantling and cleaning procedure, see Pilot

Pressure Reducing Valve. K Servo Pilot
Valve ( T E19-1)
E2-51 9803/3760-07 (E-01-04) E2-51

Test Procedures
Measuring Spool Displacement (Manual

Spools)
Note: This procedure is only applicable to manually
operated spools.
!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
Note: Two people are required to complete the procedure.

Person 1 should be sat in the operator cab, whilst Person
2 requires access to the control valve assembly.
1 Raise the boom and fit the safety strut, see Section 2
764810-1
2 Carry out General Safety procedures, see Section 2 Fig 44. Manual Spool Displacement
6 Repeat the procedure for each manual spool as
3 Vent the hydraulic pressure, see Section 2 - General necessary.
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)
b Person 1 - Measure spool displacement 44-A. Adjustment

5 Check spool displacement 44-B. Spool displacement is influenced by the control lever
linkage. Check, adjust and replace if necessary.
a Person 2 - Using the control lever, move and hold
the spool in position 44-3. If sufficient adjustment can not be achieved it may be
necessary to replace the spool assembly. K Related
b Person 1 - Measure spool displacement 44-B. Topics ( T E2-3)
E2-52 9803/3760-07 (E-01-04) E2-52

Bleed Procedures
Bleed Procedures
3-Stage Boom Extension Ram Circuit

Whenever a hydraulic component is removed or
disconnected from the boom extension circuit, the circuit
must be bled to ensure that any residual air is removed.
Important: During the following procedure it is important

that the inner ram is not allowed to extend more than the
outer ram, to prevent damage to the inner ram and
auxiliary feed and return hoses.
1 Park the machine on firm level ground. Engage the

park brake and set the transmission to neutral.
A293741-C2
2 Raise the boom to the horizontal position. Fig 46.
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
Bleed Hose Specification: Fig 47.
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.
E2-53 9803/3760-07 (E-01-04) E2-53

Bleed Procedures
!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
11 Slowly remove the hydraulic tank filler cap 49-H to

vent the hydraulic system and release any residual
pressure. Check the hydraulic fluid level and top-up
the tank if necessary. Refit hydraulic tank filler cap.
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.
10 Ensure that the hoses are located correctly in the

roller assembly 49-G at the base of the boom.
732380-C3
Fig 49.
E2-54 9803/3760-07 (E-01-04) E2-54

Bleed Procedures
Tilt Ram Circuit

2 Raise the boom to a convenient height to access the

tilt ram.
3 Stop the engine and remove the starter key
4 Operate the controls back and forth several times to

vent residual hydraulic pressure.
5 Release locknut 50-A and back-off the screw 50-B.
Note: Later machines have locknut 50-A and screw 50-B

on the side of the block.
6 Start the engine and operate the tilt lever several

times.
7 Tighten the screw 50-B and locknut 50-A.
8 Operate the tilt lever several times again. Stop the

engine.
9 Repeat steps 5 to 8 if necessary. Ensure that screw

50-B is finally tightened to 15 Nm (11.4 lbf ft) and
locknut 50-A is tightened to 12 Nm (9 lbf ft). A372490-1
Fig 50.
E2-55 9803/3760-07 (E-01-04) E2-55

Bleed Procedures
Sway Ram Circuit 3 K Fig 51. ( T E2-56) Get an assistant to carefully

unscrew the bleed valve 1, be prepared for hydraulic
The sway ram has an integral bleed valve, which can be oil to escape. DO NOT unscrew more than 6.5 mm
used to bleed the sway hydraulic circuit. (0.25 in).
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
1 Park the machine and make it safe. Lower the boom.

766840-C1
Vent the hydraulic pressure. Obey the care and safety Fig 51. Unscrewing the Bleed Valve
procedures. K Related Topics ( T E2-3)
5 Operate the sway ram fully in both directions 10 times
Important: Opening the sway ram bleed valve can cause
the machine to sway unexpectedly. Only open the bleed 6 Repeat steps 2, 3 and 4.
valve when the machine is swayed fully to the left or the
right. 7 Stop the engine and remove the starter key.
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.
Important: The bleed valve should only be completely

removed from the valve body to allow cleaning of the
integral 1.2mm orifice.
2 Start the engine and operate the sway lever to sway

the machine fully to the operator's left side (sway ram
extended). Stop the engine and vent the hydraulic
pressure. Follow the correct procedure, see Venting
the Hydraulic Pressure, Section 2.
E2-56 9803/3760-07 (E-01-04) E2-56


Introduction

K Servo Pilot Valve ( T E3-11)
K Manual Control ( T E3-11)
K Electronic Proportional Control ( T E3-11)
K Load Sensing ( T E3-11)
K Inloader Operation ( T E3-11)
K Pressure Compensation (Flowshare) ( T E3-12)
K Control Lever ( T E3-13)
K Inloader Operation ( T E3-16)
K Multiple Service Operation ( T E3-16)
K Pressure Compensator Valves Operation ( T E3-18)
K Electrical Operation and Schematics ( T E3-33)
K Thumbwheel Controls ( T E3-33)
E3-1 9803/3760-07 (E-01-01) E3-1

Introduction

K Checking the Servo Pilot Pressure ( T E3-45)
K Load Sense Relief Valve (LSRV) ( T E3-46)
K Auxiliary Relief Valve Pressure (ARV) - ARV’s set lower than the LSVR ( T E3-47)
K Auxiliary Relief Valve Pressure (ARV) - ARV’s set higher than the LSRV ( T E3-48)
K 3-Stage Boom Extension Ram Circuit ( T E3-50)

531-70, 535-95, 536-60, 541-70, 536-70,
531-T70 535-T95 536-T60 541-T70 536-T70
K Parallel Lift (S2) ( T E3-27) z
E3-2 9803/3760-07 (E-01-01) E3-2

Related Topics
Related Topics

1 Applications ALL
1 Service Tools ALL
E K Flowshare (LSP) Control Valve ( T E15-1) ALL
E K Inloader Valve ( T E18-1) ALL
E K Servo Pilot Valve ( T E19-1) ALL
H Priority Valve Test Procedures
M CANbus SYSTEM ALL

892/00268(1) Flow Monitoring Kit and Relevant Adaptors
892/00270 (1) Load Valve
E3-3 9803/3760-07 (E-01-01) E3-3

Specifications
Specifications
Control Valve Block
Type: 4 Spool, load sense - pressure compensated, double acting spools.

Spool 3 Boom Extend & Retract Service Proportional servo pilot operated
Spool 4 Auxiliary Service Proportional servo pilot operated
Note: The maximum auxiliary service flow available is up

to 95 litre min. with `manual' thumbwheel operation, and up
to 65 litre min. with `constant' operation selected.
Relief Valve Pressures: K Fig 1. ( T E3-5) Machine Model Application

bar kgf/ lbf/in 2 531-70, 535-95, 536-60, 541-70, 536-70,
cm2 531-T70 535-T35 536-T60 541-T70 536-T70
2C - Load Sense Relief Valve (1) 240 244 3480 z z
260 265 3770 z z z
2N - Auxiliary Ram Rod Side 220 224 3190 z z z z z
2M - Auxiliary Ram Head Side 220 224 3190 z z z z z
2J - Carriage Tilt Ram Head Side 140 143 2030 z z z z
240 z
2H - Carriage Tilt Ram Rod Side 276 281 4000 z z z z
250 z
(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.
E3-4 9803/3760-07 (E-01-01) E3-4

Specifications
C093420
Fig 1.
E3-5 9803/3760-07 (E-01-01) E3-5

Specifications
Hydraulic Pump
Mounting: Gearbox
port EF 265 270 3840
port P 200 204 2900

Mounting: Gearbox
Main services pump (mounting flange end) TBA
Steering pump TBA
Cooling fan pump TBA
Main services pump (mounting flange end) TBA
Steering pump TBA
Cooling fan pump TBA
port EF TBA
port P TBA
Weight: TBA kg (lbs)
E3-6 9803/3760-07 (E-01-01) E3-6

Specifications
Cooling Fan Motor

Up to March 09
SE engines :
Type: Gear motor
Body Colour Black
Weight: TBA
SD 63 kW engines :
Type: Gear motor
Body Colour Red
Type: Gear motor
Body Colour Black
SE engines :
Type: Gear motor
E3-7 9803/3760-07 (E-01-01) E3-7

Specifications

Body Colour Black
Weight: TBA
SD 63 kW engines :
Type: Gear motor
Body Colour Red

Type: Gear motor
Body Colour Black
E3-8 9803/3760-07 (E-01-01) E3-8

Operation Overview
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.
Table 6. Component Location and Identification

Item Description
K Fig 2. ( T E3-10)
1 Oil Cooler Oil from pump section 3B flows through the oil
cooler
2 Fan motor Driven by pump section 3B
3 Pump assembly Three section gearpump 3A, 3C, 3B K Hydraulic Pump ( T E3-11)
4 Inloader valve Controls flow from pump section 3C K Inloader Operation ( T E3-11)
5 Control Lever Two axis control lever K Control Lever ( T E3-13)
6 PWM ECU's Electronic control for servo pilot valve K Thumbwheel Controls ( T E3-33)
6A 5v voltage regulator Power supply for thumbwheel controls
6B Current sense resistors Enables ‘closed loop control’ of proportional
solenoids
7 Control valve block Flowshare valve with manual and servo K Manual Control ( T E3-11)
spools K Electronic Proportional
Control ( T E3-11)
7A Load Sense Relief Valve Controls maximum system pressure K Load Sensing ( T E3-11)
8 Servo Pilot Valve Controls servo valve spools using proportional K Servo Pilot Valve ( T E3-11)
electro servo pilot valves
8A Hydraulic Oil Filter Positioned in the servo pilot valve feed line
9 Hydraulic Oil Filter Positioned in the return line to tank
10 Hydraulic Tank
11 Proportional Control K Thumbwheel Controls ( T E3-33)
Thumbwheels K Control Lever ( T E3-13)
12 IFT ECU Electronic control unit controls inloader K Inloader Operation ( T E3-11)
electric solenoid depending on engine speed

OIl from pump section 3A OIl from pump section 3C OIl from pump section 3B
Oil at servo pressure Oil suction line from the tank Return to tank
to the pump sections
E3-9 9803/3760-07 (E-01-01) E3-9

Operation Overview
C048040-C2
Fig 2. Component Location
E3-10 9803/3760-07 (E-01-01) E3-10

Operation Overview
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.
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.
E3-11 9803/3760-07 (E-01-01) E3-11

Operation Overview
Pressure Compensation (Flowshare)

Each service spool incorporates a pressure compensator
valve. When services are operated simultaneously the
system ensures consistent operating speed for all
services, even when the limit of the hydraulic pump
performance is approached.
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.
When one or more services are selected the pressure

compensator valves F detect the service generating the
highest pressure and allows the pump to deliver oil at
sufficient pressure to move the load. Load hold check
valves G prevent the load falling back if the load pressure
is greater than the pump pressure.
The closed centre design ensures consistent service

operation regardless of load.
For a full description of service spool and pressure

compensator valve operation, see K Pressure
Compensator Valves Operation ( T E3-18)
Note: Any pressure values stated are for illustration only,

please see relevant specifications or schematic layout for
correct pressures for the vehicle variant.
A405000-C1
Fig 3. Servo Pilot Operated Spool
E3-12 9803/3760-07 (E-01-01) E3-12

Operation Overview
Control Lever
The control lever operates in two axis. It also incorporates
two thumbwheel switches. The control is configured as
follows:
Control Mode Control System Actuation

Control Lever - AXIS One Mechanical linkage Control valve - SPOOL One
Control Lever - AXIS Two Mechanical linkage Control valve - SPOOL Two
Thumbwheel One Proportional analogue PWM ECU

electrical signal
Thumbwheel Two Proportional analogue PWM ECU

electrical signal
E3-13 9803/3760-07 (E-01-01) E3-13

To make the description as clear as possible the diagrams

show only part of the complete hydraulic system. For the
complete hydraulic schematics refer to the schematics
topic. K Related Topics ( T E3-3)
K Fig 4. ( T E3-15)
Oil from the primary pump 1A flows to the inlet-outlet

section of the control valve 3. When the main system
pressure reaches 15 bar the spring 3B in flushing valve 3A
is overcome and oil is returned back to tank.
Note that oil from secondary pump 1C supplies the steer

circuit via steer priority valve 1D as normal, but is not
connected to the main hydraulic system. Its flow is dumped
to tank via inloader valve 2.
Oil from pump 1B flows to the servo pressure supply valve

4. The valve supplies servo pilot oil pressure regulated at
30 bar to the control valve solenoids.
E3-14 9803/3760-07 (E-01-01) E3-14

C047530-C1
E3-15 9803/3760-07 (E-01-01) E3-15

Service Operation
K Fig 5. ( T E3-17)
When a service is operated, boom extend for example, the

movement of the thumbwheel, triggers the ECU and pilot
pressure oil actuates the service spool 3E. Oil passes
across the service spool to the applicable pressure
compensator valve 3F. The valve opens and diverts oil to
the load sense gallery and load hold check valve 3D.
Pressure in the load sense gallery increases and the
flushing valve 3A begins to close. Main system pressure
continues to rise until load hold check valve 3D opens and
the boom extend ram 5 operates.
The main system pressure will now be equal to the load

sense pressure (load from the boom lift ram) plus the force
of flushing valve spring 3B (15 bar).
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)
When high flow operation is required, if operating multiple

hydraulic services simultaneously at full speed for
example, the inloader valve 2 operates to connect the
output from pump 1C. The valve operates when the
pressure difference between the load sense and service
galleries reduces. This causes the inloader valve spool 2
to close, directing the oil from pump 1C into the main
hydraulic system.
Multiple Service Operation

In the normal hydraulic system the services are connected
in parallel, this means that when multiple services are
operated simultaneously, the speed of one service can be
affected by the operating pressure of another service. This
is not the case with flowshare.
The pressure compensator valves for each service react to

the differing load pressures. For example, when a
pressure compensator valve is subjected to a higher load
sense pressure from another service, it reacts to reduce
the flow to its service, ensuring that the associated ram
operates at a constant speed, regardless of the increase in
the main system pressure.
E3-16 9803/3760-07 (E-01-01) E3-16

C047530-C2
Fig 5. One service Operated
E3-17 9803/3760-07 (E-01-01) E3-17

Pressure Compensator Valves

Operation
No Service Selected (All Spools in Neutral)
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.
Oil in the load sense gallery LS is vented to tank across the

flow regulator valve F, at approximately 0.7 l/min. This
allows the load sense pressure to decay when no service
is selected. If the flow regulator valve is blocked, a reduced
flow rate will be evident.
The pressure compensator valve PC and load hold check

valves CV are closed.
E3-18 9803/3760-07 (E-01-01) E3-18

Operating a Service
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:
When the pump pressure has risen sufficiently i.e. to a

pressure equal to the load + spring pressure (15 bar) the
load hold check valve CV moves off its seat and allows oil
to flow into the service gallery A, initiating movement of the
service ram R. Exhaust oil from the other side of the
service ram is directed by the service spool S to tank.
The maximum load sense pressure and hence pump

pressure is set by the load sense relief valve G.
E3-19 9803/3760-07 (E-01-01) E3-19

Operating an Individual Service
714761-1
Fig 8.
It must be noted that the load sense gallery LS is

connected to all the pressure compensator valves PC (one
for each service) as shown. The pressure in the load sense
gallery LS will always be equal to the highest load from any
of the services.
The pressure compensator valves are fitted between each

service spool and service ram and sense the pressure
acting on either side of the particular service spool. The
pressure compensator valve will move in response to the
pressure drop (pressure differential) created across the
spool.
When one service only is operated the pressure

compensator valve PC is FULLY opened as shown,
connecting the gallery P1 to gallery P2 and to the ram
service port without any pressure drop.
E3-20 9803/3760-07 (E-01-01) E3-20

Operating Multiple Services
714771-1
Fig 9.
Normal Condition With Insufficient Flow from Pump
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.
E3-21 9803/3760-07 (E-01-01) E3-21

E3-22
K Fig 10. ( T E3-23)
The maximum main system pressure is controlled by

limiting the maximum load sense pressure.
When a service ram reaches the end of its stroke, or

the service meets resistance and generates pressure
above 235 bar in the load sense line, the load sense
relief valve 3C opens and load sense oil is dumped to
tank, preventing further pressure rise. The flushing
valve 3A operates as normal. Since the main system
pressure required to open the flushing valve is 15 bar
above the load sense pressure it follows that the main
system pressure will be limited to 235 bar + 15 bar, a
total of 250 bar.
Note: Note: The pressure values given are examples

for the purpose of explanation only. For the correct
applicable values see Technical Data. The load sense
pressure relief valve is factory set and sealed with a
plastic tamper proof cap. No adjustment is normally
required. See also Service Procedures - Testing the
Main System Pressure.
9803/3760-07 (E-01-01)
Table 8. Colour Key to Oil Flow and Pressure
Full Pressure
Load Sense Line
Servo
Neutral
Exhaust
E3-22
C047530-C3
E3-23 9803/3760-07 (E-01-01) E3-23

Parallel Lift (S1)

Ram Operation

lowers.

C094840
boom pivot.
E3-24 9803/3760-07 (E-01-01) E3-24

C094820
E3-25 9803/3760-07 (E-01-01) E3-25

10.
C094820-C1
E3-26 9803/3760-07 (E-01-01) E3-26

Parallel Lift (S2)

Ram Operation

lowers.

displacement rams A extend or retract. Oil displaced by
the rams A flows to the tilt ram D which extends or retracts
C094810
Fig 14. Twin displacement rams forward of the boom
pivot.
E3-27 9803/3760-07 (E-01-01) E3-27

Boom Raise Cycle the tilt ram raises pilot pressure in HBCV 10A. This allows
oil to feed back to the rod side of the displacement ram 9.
When lift spool 2D is selected, oil feeds lift ram hose-burst
check-valve 8A. Oil flows through free flow direction of Displacement/lift link valve 20 is fitted between lift spool 2D
hose burst check valve (HBCV) 8A and lifts the boom. Oil and tilt spool 2F. The function of this valve is to allow a
also flows directly to the head side of displacement ram 9A restricted flow of oil into the tilt circuit to increase the lift
to increase lift force. force available by utilising the displacement ram.
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)
E3-28 9803/3760-07 (E-01-01) E3-28

Boom Lower Cycle Oil from the head side of displacement ram 9A flows back
to tank via raise/lower spool 2D.
When raise/lower spool 2D is selected oil feeds the rod
side of lift ram 8. Oil displaced from the head side of the lift Displaced oil from the displacement ram 9 closes the
ram raises pilot pressure in HBCV 8A and allows oil out of check valve in displacement/lift link valve 20.
the lift ram back to tank, lowering the boom.
Auxiliary relief valve (ARV) 2H opens to protect the tilt ram
As the boom lowers, oil is forced from the head side of the from over pressurisation. The anti-cavitation feature of
displacement rams 9 and 9A. The oil cannot flow past tilt valve 2J ensures that, in these circumstances, the tilt and
spool 2F, as the spool is not selected. Instead, it flows displacement rams will not cavitate.
through free flow direction of HBCV 10A to the rod side of
the tilt ram 10.
C094800
Fig 16. Boom Lower Cycle (Twin displacement rams forward of the boom pivot)
E3-29 9803/3760-07 (E-01-01) E3-29

Parallel Lift (S3)

Ram Operation

lowers.

C083280
Fig 17. Single displacement ram forward of the boom
pivot.
E3-30 9803/3760-07 (E-01-01) E3-30

C094880
Fig 18. Boom Raise Cycle (Single displacement forward of the boom pivot)
E3-31 9803/3760-07 (E-01-01) E3-31

10.
C094880-C1
Fig 19. Boom Lower Cycle (Single displacement ram forward of the boom pivot)
E3-32 9803/3760-07 (E-01-01) E3-32

Electrical Operation and Schematics
Thumbwheel Controls neither the boom èxtend' or `retract' solenoid valves

will energise.
K Thumbwheel Control Fault Codes (‘Blink’ – When moved forwards, the thumbwheel output
codes) ( T E3-36) voltage increases to between 2.5 and 4.3 volts. When
the ECU input voltage is greater than 2.5 volts, it
K Fig 20. ( T E3-35) sends a corresponding output current to energise the
boom èxtend' solenoid valve.
The control lever incorporates two thumbwheel switches. – When moved backwards, the thumbwheel output
The switches enable proportional control of the boom voltage decreases to between 2.5 and 0.7 volts.
extend/retract and auxiliary hydraulics. Both thumbwheels When the ECU input voltage is less than 2.5 volts, it
operate in the same way. sends a corresponding output current to energise the
boom `retract' solenoid valve.
The thumbwheel A is connected to an electrical
potentiometer. A 5v supply is provided by a voltage As the operator moves the thumbwheel A from the neutral
regulator. As the thumbwheel A is operated a variable position (plus a small dead band), the valve current signal
voltage signal (depending on thumbwheel position) is sent from the ECU B will step from 0 to 250 mA. The relevant
to the ECU B. The ECU sends a variable electrical current solenoid valve C will respond and direct servo pilot oil to
to the applicable proportional solenoids C and D. one end of the boom service spool E (as applicable). The
spool is displaced a small amount, which allows flow from
The ECU uses two pulse width modulated (PWM) outputs the main hydraulic system to the boom extension ram F,
to control two proportional solenoids C and D. The causing the ram to move at a steady rate.
proportional solenoids regulate servo pilot oil (at a
pressure proportional to the valve current signal) to move If the thumbwheel is moved further, the valve current signal
the applicable service spool E the required amount, will increase proportionally (linear), until the thumbwheel
thereby controlling the speed and direction of the reaches its end stop and maximum valve current is
applicable service ram F. reached. As the valve current signal increases, similarly
the servo pilot pressure from the solenoid valve also
The valve current signal from the ECU is controlled by increases proportionally, until maximum servo pilot
varying the duty cycle of the PWM output. For a detailed pressure is reached.
explanation of the duty cycle and PWM inputs and outputs
refer to the correct topic.K Related Topics ( T E3-3) When the servo pilot pressure is increased, the boom
service spool E is displaced further, which allows more
The theoretical PWM duty cycle required to produce a flow from the main hydraulic system to the boom extension
given valve current signal (output) is already pre- ram F, causing the ram to move at a faster rate.
programmed into the ECU memory (ROM). The ECU uses
a closed-loop control algorithm to constantly compare the
actual valve current (via a current sense resistor) with the
theoretical valve current (stored in memory), and
automatically increases or decreases the PWM duty cycle
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.
Boom Extend and Retract - Example
The PWM controller (ECU) B monitors the output voltage

of the boom èxtend' and `retract' thumbwheel A.
Note: The graphs show the different voltage and current

outputs for given thumbwheel positions.
– In the mid position (neutral), the thumbwheel output

voltage is 2.5 volts. When the ECU input voltage is 2.5
volts, the ECU output current is 0 mA, therefore
E3-33 9803/3760-07 (E-01-01) E3-33

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
Table 9. Expected Values

Thumbwheel Thumbwheel Solenoid Servo
Position: Output: Valve Pilot
Current: Pressure:
FULL Èxtend' 4.3V +/- 0.15 1050mA 23.5bar
(or Auxiliary
`Forward'
direction)
NEUTRAL 2.5V +/- 0.2 0mA < 1bar
FULL `Retract' 0.7V +/- 0.15 1050mA 23.5bar
(or Auxiliary
`Reverse'
direction)
E3-34 9803/3760-07 (E-01-01) E3-34

C044280
Fig 20. Boom Extend and Retract - Example
E3-35 9803/3760-07 (E-01-01) E3-35

Thumbwheel Control Fault Codes (‘Blink’ codes) indicate the blink code. Alternatively, if a test relay is not
available, place a solenoid tester pen (with an LED or
K Single Auxiliary Machines ( T E3-36) bleeper) against the 2nd auxiliary (AUX2) relay to read the
code.
K Twin Auxiliary Machines ( T E3-37)
Note: Machines with an electronic instruments system will

log a fault code, see Section M - CANbus SYSTEM.
Single Auxiliary Machines
Machines with thumbwheel controls incorporate PWM

Controllers (ECU's). The ECU's have the facility to detect
faults with the pilot control valve electrical system and
generate a blink code.
Auxiliary Control Faults: The blink code is indicated

using the AUX1 indicator light 21-A in the control lever.
The blink code sequence consists of the light being

switched ON for approximately one second followed by a
number of flashes (the code). The sequence is repeated
until the fault is cleared.
Boom Extend/Retract Faults: In order to read the blink

code, it is necessary to replace the existing 2nd auxiliary
C044340-C3
(AUX2) relay in the front console with a test relay (see
Fig 21.
Service Tools). If there is a fault, the test relay LED will
Blink Code Cause Action

1 flash Boom Èxtend' / Auxiliary Òut' pilot solenoid valve Check the condition of the related harness wiring
coil or associated wiring faulty (open or short circuit). and connectors for damage. K Electrical
2 flashes Boom `Retract' / Auxiliary Ìn' pilot solenoid valve coil Operation and Schematics ( T E3-33) Measure
or associated wiring faulty (open or short circuit). the solenoid coil resistance. Renew the solenoid
coil.
5 flashes Thumbwheel voltage too high (greater than 4.725v). Check the relevant voltage regulator output. Check
6 flashes Thumbwheel voltage too low (less than 0.275v). the condition of the harness wires and connectors
for damage. Check relevant thumbwheel wires and
connectors for damage, see Section C - Electrics,
Harness Data. K Related Topics ( T E3-3) Renew
the thumbwheel switch.
E3-36 9803/3760-07 (E-01-01) E3-36

Twin Auxiliary Machines


Boom Extend/Retract Faults: The blink code is indicated

using the AUX2 indicator light 22-B in the control lever.

C044340-C2
Fig 22.

coil or associated wiring faulty (open or short circuit). and connectors for damage. K Electrical
2 flashes Boom `Retract' / Auxiliary Ìn' pilot solenoid valve coil Operation and Schematics ( T E3-33)Measure
or associated wiring faulty (open or short circuit). the solenoid coil resistance. Renew the solenoid
coil.
connectors for damage, see Section C - Electrics,
Harness Data. K Related Topics ( T E3-3) Renew
the thumbwheel switch.
E3-37 9803/3760-07 (E-01-01) E3-37

Fault Finding
Fault Finding



to the hydraulics.



circuit.


Electronic Fault Codes

Servo Operated Spools: The thumbwheel PWM
controllers (ECU's) will generate a blink code for some
fault conditions. K Thumbwheel Control Fault Codes
(‘Blink’ codes) ( T E3-36)
Electronic Instruments System: Machines with an

electronic instruments system will log some system faults
as an error code. These error codes can be accessed with
the correct diagnostics software tool, using a laptop
computer connected to the machine CAN system, see
Section M - CANbus System. K Related
Topics ( T E3-3)
E3-38 9803/3760-07 (E-01-01) E3-38

Fault Finding
Tables
K Table 10. ALL services lack power. ( T E3-39)

K Table 11. ALL services slow to operate. ( T E3-39)
K Table 12. ONE service fails, or is slow to operate. ( T E3-40)
K Table 13. The engine tends to stall when hydraulics are under load. ( T E3-40)
K Table 14. Boom Ext/Ret slow, or low flow from auxiliary service (Servo operated spools). ( T E3-41)
Table 10. ALL services lack power.

Load sense relief valve (LSRV) out of adjustment or Check and adjust as required.
defective.
Internal leakage fault in the load sense circuit. Measure the load sense pressure.
Flushing valve piston within the control valve block inlet Dismantle and inspect the flushing valve piston.
section sticking open due to contamination.
– Renew pump.
Table 11. ALL services slow to operate.

Flow from steer pump not in circuit because the inloader – Check and adjust, or renew the LSRV as required.
valve is not receiving the correct load sense pressure: – Measure the load sense pressure.
– Due to load sense relief valve (LSRV) out of

adjustment or defective.
– Due to internal leakage fault in the load sense circuit.
Flow from steer pump not in circuit because the inloader – Check the condition of the associated electrical wiring
valve solenoid is permanently energised: for damage and short circuits.
– Renew the IFT controller (ECU).
– Due to faulty IFT controller (ECU).
Inloader valve faulty. Renew the inloader valve.
– Renew pump.
E3-39 9803/3760-07 (E-01-01) E3-39

Fault Finding
Table 12. ONE service fails, or is slow to operate.

Associated service pipework or hoses leaking, damaged, Check pipework and hoses, replace as required.
trapped or kinked.
Auxiliary relief valve (ARV) out of adjustment or defective. Check and adjust as required.
Associated ram leaking. Carry out ram leakage checks, renew seals as required.
Associated service spool not operating correctly. – Manual Spools: Check that the control lever and
associated linkage is operating the spool to full
displacement, rectify as required.
– Servo Operated Spools: K Table 14. ( T E3-41)
Pressure compensator piston sticking due to contamination. Dismantle and inspect the associated pressure
compensator piston.
Service spool or associated load hold check valves Dismantle and inspect the associated service spool or load
damaged or sticking due to contamination. hold check valves.
Table 13. The engine tends to stall when hydraulics are under load.

defective.
Poor engine performance. – Check engine performance.
– Check engine High and Low idle speeds.
– Check LSRV setting and adjust as required.
– Check ARV setting and adjust as required.
E3-40 9803/3760-07 (E-01-01) E3-40

Fault Finding
Table 14. Boom Ext/Ret slow, or low flow from auxiliary service (Servo operated spools).

Fault in electrical circuit wiring, or operation of PWM Check the condition of the associated electrical wiring for
controller (ECU): damage and that the fuses are intact.
– Thumbwheel switch defective. – Check the function of the applicable thumbwheel

– Solenoid at the pilot pressure supply valve not switch.
energising. – Check the condition of the associated electrical wiring
– Solenoid coil faulty. for damage.
– Faulty PWM controller (ECU). – Check the applicable solenoid coil for open or short
circuits. Measure the solenoid coil resistance. Renew
Note: The PWM Controller (ECU) will generate a blink code the solenoid coil.
for some fault condition. K Thumbwheel Control Fault – Renew the PWM controller (ECU).
Codes (‘Blink’ codes) ( T E3-36)
Servo pilot pressure too low: Measure the servo pilot pressure.
– 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.
Table 15. 3 stage boom extend retract system

Action Yes No
1 Is the machine experiencing boom extend or retract Go to 2 Done
problems?
2 Bleed air from hydraulic cylinders. OK now? Done Go to 3
3 Does the inner/intermediate boom extend or retract? Go to 7 Go to 4
4 Pressure test hydraulic pump. Rectify if required. OK now? Done Go to 5
5 Check MRV in valve block and for leakage passed pistons Done Go to 6
in both rams. Investigate and rectify as required. OK now?
6 Replace hose-burst check valve(s) on inner/outer Done Go to 7
extension ram(s). OK now?
7 Are the inner/intermediate booms over-running after de- Go to 8 Go to 9
selecting extend lever or is there an unexpected surge
after a retract operation?
8 Renew motor spool in extend slice. See TI 5/197. OK now? Done
9 Do the inner/intermediate booms go out of phase? Go to 10 Go to 2
10 Does the operator periodically fully retract inner and Go to 12 Go to 11
intermediate booms to re-phase hydraulic cylinders?
11 Fully retract inner and intermediate booms to re-phase Done Go to 12
hydraulic cylinders. OK now?
12 Does the inner boom fully retract leaving intermediate Go to 13 Go to 14
E3-41 9803/3760-07 (E-01-01) E3-41

Fault Finding
Action Yes No
13 Strip inner extension cylinder and ensure make-up valve in Done Go to 2
14 Does the outer boom fully retract leaving intermediate Go to 15 Go to 2
15 Strip outer extension cylinder and ensure make-up valve in Done Go to 2
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.


from circuit.
contamination.
E3-42 9803/3760-07 (E-01-01) E3-42

Test Procedures
Test Procedures
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).
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
the hoses are open.
INT-3-1-11_2

A335530-C3
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
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

E3-43 9803/3760-07 (E-01-01) E3-43

Test Procedures




!MWARNING
TRANS-1-2

A326080-C2
Fig 25.
E3-44 9803/3760-07 (E-01-01) E3-44

Test Procedures
Checking the Servo Pilot Pressure
!MWARNING

GEN-4-1_1
Make sure that the hydraulic oil is at working temperature,

i.e. 50°C (122°F).
1 Working under the machine, connect a 0 - 70 bar (0 -

1000 lbf/in2) pressure gauge to the servo pressure
test point A (at the servo pressure supply valve as
shown).
C050600
Fig 26.
2 With the engine running at 1500 rpm, check the
reading on the pressure gauge. The servo pressure
should be as stated below:
30 bar (30.6 kgf/cm2, 435 lbf/in2)
Note: The servo pressure regulating valve B is factory set

and sealed with a plastic tamper proof cap.
Important: The extent of permissible servicing is the

renewal of the solenoid coils. Further dismantling of the
valve is not recommended. If the valve is suspected as
being faulty it must be renewed as a complete assembly.
Note also that the pilot circuit accumulator is a non
serviceable part and is sealed for life. It is not possible to
recharge the accumulator with nitrogen.
E3-45 9803/3760-07 (E-01-01) E3-45

Test Procedures
Load Sense Relief Valve (LSRV)

The maximum pressure that can be achieved within the
main hydraulic system is set by the load sense relief valve
(LSRV) B at the control valve block inlet section. To check
the load sense relief valve setting carry out the procedure
described below:
!MWARNING

GEN-4-1_1
Make sure that the hydraulic fluid is at working

temperature, i.e. 50°C (122°F).
1 Working under the machine, connect a 0 - 400 bar (0

- 6000 lbf/in2) pressure gauge to the main system
pressure test point A (at the control valve block as
shown).
C050620
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
3 If the maximum pressure is incorrect, adjust the relief

valve as described below:

Topics ( T E3-3)
b Switch OFF the engine and vent residual

hydraulic pressure.
c Remove the plastic cap from the load sense relief

valve B. Loosen the locknut and turn the adjuster
screw clockwise to increase pressure and
counter-clockwise to decrease the pressure.
When the pressure is correct, tighten the locknut
and check the pressure again. Adjust as required.
E3-46 9803/3760-07 (E-01-01) E3-46

Test Procedures
Auxiliary Relief Valve Pressure (ARV) -

ARV’s set lower than the LSVR
ARV's which are set below the LSRV pressure can be
tested simply by operating the relevant service. For tilt ram
ARV's which are set above the LSRV pressure a different
procedure is required. K Auxiliary Relief Valve Pressure
(ARV) - ARV’s set higher than the LSRV ( T E3-48)
Important: The engine must not be run at maximum

speed as a significant increase in pressure will be
recorded.


gauge to the test point. K Load Sense Relief Valve
(LSRV) ( T E3-46)

4 Set the engine to idle rev/min. and operate the

relevant service to full travel. Hold while checking the
maximum gauge reading which should be as stated in
5 If the pressure is incorrect, adjust the relevant A.R.V.

E3-47 9803/3760-07 (E-01-01) E3-47

Test Procedures
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
ram is smaller than the lift ram, higher hydraulic pressure
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.
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.
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.
E3-48 9803/3760-07 (E-01-01) E3-48

Test Procedures

described below:

Topics ( T E3-3)

Topics ( T E3-3)

as required.

A296360-1
E3-49 9803/3760-07 (E-01-01) E3-49

Bleed Procedures
Bleed Procedures
3-Stage Boom Extension Ram Circuit

Whenever a hydraulic component is removed or
disconnected from the boom extension circuit, the circuit
must be bled to ensure that any residual air is removed.
Important: During the following procedure it is important

that the inner ram is not allowed to extend more than the
outer ram, to prevent damage to the inner ram and
auxiliary feed and return hoses.

A293741-C2
2 Raise the boom to the horizontal position. Fig 32.
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
Bleed Hose Specification: Fig 33.
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.
E3-50 9803/3760-07 (E-01-01) E3-50

Bleed Procedures
!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
11 Slowly remove the hydraulic tank filler cap 35-H to

vent the hydraulic system and release any residual
pressure. Check the hydraulic fluid level and top-up
the tank if necessary. Refit hydraulic tank filler cap.
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.
10 Ensure that the hoses are located correctly in the

roller assembly 35-G at the base of the boom.
732380-C3
Fig 35.
E3-51 9803/3760-07 (E-01-01) E3-51

Bleed Procedures
Tilt Ram Circuit


tilt ram.



times.

engine.

Fig 36.
E3-52 9803/3760-07 (E-01-01) E3-52

Bleed Procedures

cylinder.
!MWARNING
Communications
INT-3-1-5

766840-C1
operated.


E3-53 9803/3760-07 (E-01-01) E3-53

Bleed Procedures
E3-54 9803/3760-07 (E-01-01) E3-54


Introduction

K Variflow Pump ( T E4-5)
K Component Location ( T E4-9)
K Manual Control ( T E4-11)
K Electronic Proportional Control ( T E4-11)
K Control Lever ( T E4-13)
K Variflow Pump Operation ( T E4-26)
E4-1 9803/3760-07 (E-01-06) E4-1

Introduction
K Hydraulic Variable Control System (HVCS) ( T E4-42)

K Device and Connector Key ( T E4-45)
K Main System Pressures ( T E4-51)

531-70, 535-95, 536-60, 541-70, 536-70,
531-T70 535-T95 536-T60 541-T70 536-T70
E4-2 9803/3760-07 (E-01-06) E4-2

Specifications
Specifications
Control Valve Block
Type: 4 Spool, load sense - pressure compensated, double acting spools.

Spool 3 Boom Extend & Retract Service Proportional servo pilot operated
Spool 4 Auxiliary Service Proportional servo pilot operated

Relief Valve Pressures: K Fig 1. ( T E4-4) Machine Model Application

bar kgf/cm 2 lbf/in 2 531-70, 536-60, 541-70, 536-70, 535-95
531-T70 536-T60 541-T70 536-T70
2C - Load Sense Relief Valve (1) 240 244 3480 z z
260 265 3770 z z z
2N - Auxiliary Ram Rod Side 220 224 3190 z z z z z
2M - Auxiliary Ram Head Side 220 224 3190 z z z z z
2J - Carriage Tilt Ram Head Side 140 143 2030 z z z z
2H - Carriage Tilt Ram Rod Side 276 281 4000 z z z z
2J - Carriage Tilt Ram Head Side 250 255 3625 z
2H - Carriage Tilt Ram Rod Side 240 245 3480 z
(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.
E4-4 9803/3760-07 (E-01-06) E4-4

Specifications
Variflow Pump
Type: EK.DS Variable displacement pump with integral gear

pump for cooling fan motor operation
Mounting: Bevel Gearbox
Maximum 63
Minimum 11.2
Flow at 2200 rev/min (90% min. displacement): litres/min UK gal/min US gal/min
Main services pump variable
Continuous 250 254 3625
Peak 315 321 4568
Cooling fan pump 250 254 3625
Swivel Angle Control Modes: Description
Electric EK1 Proportional computer controlled 12V solenoid
valve (PWM)
Hydraulic DS Pressure control and flow control (load sense)
Pressure Settings: bar kg/cm2 lb/in2
Maximum Pressure (Main pump relief valve) 295 301 4277
Standby Pressure 26 - 29 26.5 - 29.6 377 - 420
Delta P Pressure 19.5 - 20.5 19.9 - 20.9 282 - 297
Maximum Steering Pressure 200 204 2900
Cooling Fan Motor

Up to March 09
SE engines :
Type: Gear motor
E4-5 9803/3760-07 (E-01-06) E4-5

Specifications

Body Colour Black
Weight: TBA
SD 63 kW engines :
Type: Gear motor
Body Colour Red
Type: Gear motor
Body Colour Black
SE engines :
Type: Gear motor
Body Colour Black
Weight: TBA
SD 63 kW engines :
Type: Gear motor
E4-6 9803/3760-07 (E-01-06) E4-6

Specifications

Body Colour Red

Type: Gear motor
Body Colour Black
E4-7 9803/3760-07 (E-01-06) E4-7

Operation Overview
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

OIl from pump section 3A OIl from pump section 3B Oil at servo pressure
Oil suction line from the tank to Return to tank

the pump
E4-8 9803/3760-07 (E-01-06) E4-8

Operation Overview
Component Location
Item Description
K Fig 2. ( T E4-10)
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)
5B Current sense resistors Enables ‘closed loop control’ of proportional

solenoids
6 Control valve block Flowshare valve with manual and servo K Manual Control ( T E4-11)
spools K Electronic Proportional
Control ( T E4-11)
7 Servo Pilot Valve Controls servo valve spools using proportional K Servo Pilot Valve ( T E4-11)
electro servo pilot valves
7A Hydraulic Oil Filter Positioned in the servo pilot valve feed line
8 Hydraulic Oil Filter Positioned in the return line to tank(1)
8A Hydraulic Oil Filter Positioned in the hydraulic tank(2)
9 Hydraulic Tank
10 Proportional Control K Electronic Proportional
Thumbwheels Control ( T E4-11) K Control
Lever ( T E4-13)
11 Pump control ECU K Hydraulic Variable Control
(HVCS) System (HVCS) ( T E4-42)
12 Steer priority valve Machines up to June 2009 See Section H - Steering.
Machines from June 2009 shown at X K Flowshare (LSP) Control
Valve ( T E15-1)
13 Steer valve feed See Section H - Steering.
(1) Machines upto November 2009

(2) Machines from November 2009
E4-9 9803/3760-07 (E-01-06) E4-9

Operation Overview
8A
12
C048480-C4
E4-10 9803/3760-07 (E-01-06) E4-10

Operation Overview




compensator valve operation, see K Pressure
Compensator Valves Operation ( T E4-22)

A405000-C1
E4-12 9803/3760-07 (E-01-06) E4-12

Operation Overview
Control Lever
follows:

Control Lever - AXIS One Mechanical linkage Control valve - SPOOL One
Control Lever - AXIS Two Mechanical linkage Control valve - SPOOL Two

electrical signal

electrical signal
E4-13 9803/3760-07 (E-01-06) E4-13

Operation Overview
Variflow Pump
C051000-C1
Fig 4.
Table 6. Component Key Item Description

Item Description
G1 Flow compensator valve adjuster cover (not
A Drive shaft. Driven from the bevel gearbox adjustable)
B Inlet (suction) port H Swash control piston
C Outlet port J Swash plate control spring
D Separate gearpump (cooling fan circuit) driven by K Swash plate
drive shaft A.
L Axial pistons
E Hydraulic variable control solenoid valve (HVCS)
E1 Solenoid valve coil - HVCS The hydraulic services pump is a variable displacement
axial piston pump, which uses the swash plate design
F Pressure cut off safety valve spool
principle.
F1 Pressure cut off safety valve adjuster cover (not
adjustable) Rotation of the input drive shaft A produces linear
G Flow compensator valve spool movement of the axial pistons L. The pump output is
controlled via the swash control piston H. The piston varies
the angle of the tilting swash plate K, which alters the
E4-14 9803/3760-07 (E-01-06) E4-14

Operation Overview
displacement (stroke) of the pistons L. This has the effect
of changing the hydraulic oil flow in the system.
The swash control piston is controlled by two systems:
– The flow compensator valve G. The valve is actuated

by load sense hydraulic pressure.
This system controls the pump in response to the

demands of the hydraulic services.
– The hydraulic variable control solenoid valve E

(HVCS).
This system controls the pump in response to engine

power output and in case of high hydraulic oil
temperature.
E4-15 9803/3760-07 (E-01-06) E4-15

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 the schematics
K Fig 5. ( T E4-17)
With all the services in neutral, there is no demand for flow

from the hydraulic pump 1A, and consequently the pump
internal tilting swashplate is at its minimum angle. In this
condition the pump delivers only the minimum flow that is
needed to satisfy normal system internal leakage, and to
generate a system stand-by pressure. A small amount of
oil from the pump 1A flows to the inlet-outlet section of the
control valve 3 When the main system pressure reaches
25 bar the spring 3B in flushing valve 3A is overcome and
oil is returned back to tank. Note that the pump also
supplies the steer circuit via the steer priority valve 1F.
Oil from the gear pump 1B flows through the chassis

mounted filter assembly 2 to the servo control valve 4.
E4-16 9803/3760-07 (E-01-06) E4-16

C047550-C1
E4-17 9803/3760-07 (E-01-06) E4-17

Service Operation
K Fig 6. ( T E4-19)
When a service is operated, boom extend for example,

movement of the thumbwheel triggers the ECU and pilot
pressure oil actuates the service spool 3E. Oil passes
across the service spool to the applicable pressure
compensator valve 3F. The valve opens and diverts oil to
flushing valve 3A begins to close. At the same time, the
pump 1A responds to the load sense pressure by
increasing the angle of the tilting swashplate. As the
swashplate angle increases, the output flow from the pump
increases proportionally, and the main system pressure
continues to rise until load hold check valve 3D opens and
the boom extend ram 5 operates.
The main system pressure will now be equal to the load

sense pressure (load from the boom extend ram) plus the
force of flushing valve spring 3A (25 bar).
spool and back to tank in the normal way.

in parallel, this means that when multiple services are
operated simultaneously, the speed of one service can be
affected by the operating pressure of another service. This
is not the case with flowshare.
The pressure compensator valves for each service react to

the differing load pressures. For example, when a
pressure compensator valve 3F is subjected to a higher
load sense pressure from another service, it reacts to
reduce the flow to its service, ensuring that the associated
ram operates at a constant speed, regardless of the
increase in the main system pressure.
E4-18 9803/3760-07 (E-01-06) E4-18

C047550-C2
E4-19 9803/3760-07 (E-01-06) E4-19


K Fig 7. ( T E4-21)
The maximum main system pressure is controlled by

limiting the maximum load sense pressure.
When a service ram reaches the end of its stroke, or the

service meets resistance and generates pressure above
215 bar in the load sense line, the load sense relief valve
3C opens and load sense oil is dumped to tank, preventing
further pressure rise. The flushing valve 3A operates as
normal.
At the same time, the pump flow compensator valve 1E

responds to the load sense pressure by decreasing the
angle of the tilting swashplate towards its minimum angle.
As the swashplate angle decreases, the output flow from
the pump reduces accordingly so that the pump delivers
only the minimum flow needed to maintain the system
pressure at the maximum setting.
Since the main system pressure required to open the

flushing valve is 25 bar above the load sense pressure it
follows that the main system pressure will be limited to 215
bar + 25 bar, a total of 240 bar.
Note: Note: The pressure values given are examples for

the purpose of explanation only. For the correct applicable
values see Technical Data. The load sense pressure relief
valve is factory set and sealed with a plastic tamper proof
cap. No adjustment is normally required. See also Service
Procedures - Testing the Main System Pressure.

Full Pressure
Load Sense Line
Servo
Neutral
Exhaust
E4-20 9803/3760-07 (E-01-06) E4-20

C047550-C3
E4-21 9803/3760-07 (E-01-06) E4-21


Operation
A405030-1
Fig 8.


E4-22 9803/3760-07 (E-01-06) E4-22

Operating a Service
A405041-1
Fig 9.
rise as follows:


E4-23 9803/3760-07 (E-01-06) E4-23

714761-1
Fig 10.

of the services.

spool.

E4-24 9803/3760-07 (E-01-06) E4-24

714771-1
Fig 11.
E4-25 9803/3760-07 (E-01-06) E4-25

Variflow Pump Operation
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.
E4-26 9803/3760-07 (E-01-06) E4-26

Pressure Cut-Off Valve: The pressure cut-off valve is a
secondary safety device to limit the maximum operating
pressure, and thereby protect the pump from over
pressurisation. If the pump operating pressure P (i.e. main
system pressure) ever reaches the setting of the valve
springs F, the pressure cut-off spool G will be pushed to
the left, this in turn, increases the control pressure acting
on the swash control piston C, which decreases the angle
of the swashplate, and reduces the pump output flow to
minimum. While the pressure cut-off valve is operating, the
pump will remain hydraulically stalled i.e. maintaining
maximum operating pressure at minimum flow.
Hydraulic Variable Control Solenoid Valve: The

proportional solenoid valve X is part of the hydraulic
variable control system (HVCS). The system automatically
adjusts the pump performance (power curve
characteristic) to limit the hydraulic power available to the
hydraulic services under conditions of high engine load or
high hydraulic fluid temperature.
The solenoid valve is controlled by a current signal output

from a pump controller electronic control unit (ECU). The
solenoid valve works as a separate pressure regulating
valve and increases the control pressure acting on the
swash control piston C by a set amount, according to the
valve current signal. Because the control pressure is
regulated by the solenoid valve independently (down
stream) of the flow compensator spool D, this means that
when it is operating, it will alter the way that the pump
swashplate normally responds to changes in the hydraulic
load sense pressure.
In this way, the hydraulic power curve of the pump can be

adjusted electrically by the current signal from the pump
controller ECU. K Electrical Operation and
Schematics ( T E4-37)
E4-27 9803/3760-07 (E-01-06) E4-27

Parallel Lift (S1)

Ram Operation

lowers.

C094840
boom pivot.
E4-28 9803/3760-07 (E-01-06) E4-28

C094820
E4-29 9803/3760-07 (E-01-06) E4-29

10.
C094820-C1
E4-30 9803/3760-07 (E-01-06) E4-30

Parallel Lift (S2)

Ram Operation

lowers.

C094810
pivot.
E4-31 9803/3760-07 (E-01-06) E4-31

C094800-C1
E4-32 9803/3760-07 (E-01-06) E4-32

the tilt ram 10.
C094800
E4-33 9803/3760-07 (E-01-06) E4-33

Parallel Lift (S3)

Ram Operation

lowers.

C083280
pivot.
E4-34 9803/3760-07 (E-01-06) E4-34

C094880
E4-35 9803/3760-07 (E-01-06) E4-35

10.
C094880-C1
E4-36 9803/3760-07 (E-01-06) E4-36

Thumbwheel Controls neither the boom èxtend' or `retract' solenoid valves

will energise.
K Thumbwheel Control Fault Codes (‘Blink’ – When moved forwards, the thumbwheel output
codes) ( T E4-40) voltage increases to between 2.5 and 4.3 volts. When
the ECU input voltage is greater than 2.5 volts, it
K Fig 22. ( T E4-39) sends a corresponding output current to energise the
boom èxtend' solenoid valve.
The control lever incorporates two thumbwheel switches. – When moved backwards, the thumbwheel output
The switches enable proportional control of the boom voltage decreases to between 2.5 and 0.7 volts.
extend/retract and auxiliary hydraulics. Both thumbwheels When the ECU input voltage is less than 2.5 volts, it
operate in the same way. sends a corresponding output current to energise the
boom `retract' solenoid valve.
The thumbwheel A is connected to an electrical
potentiometer. A 5v supply is provided by a voltage As the operator moves the thumbwheel A from the neutral
regulator. As the thumbwheel A is operated a variable position (plus a small dead band), the valve current signal
voltage signal (depending on thumbwheel position) is sent from the ECU B will step from 0 to 250 mA. The relevant
to the ECU B. The ECU sends a variable electrical current solenoid valve C will respond and direct servo pilot oil to
to the applicable proportional solenoids C and D. one end of the boom service spool E (as applicable). The
spool is displaced a small amount, which allows flow from
The ECU uses two pulse width modulated (PWM) outputs the main hydraulic system to the boom extension ram F,
to control two proportional solenoids C and D. The causing the ram to move at a steady rate.
proportional solenoids regulate servo pilot oil (at a
pressure proportional to the valve current signal) to move If the thumbwheel is moved further, the valve current signal
the applicable service spool E the required amount, will increase proportionally (linear), until the thumbwheel
thereby controlling the speed and direction of the reaches its end stop and maximum valve current is
applicable service ram F. reached. As the valve current signal increases, similarly
The valve current signal from the ECU is controlled by increases proportionally, until maximum servo pilot
varying the duty cycle of the PWM output. For a detailed pressure is reached.
explanation of the duty cycle and PWM inputs and outputs
refer to the correct topic.K Related Topics ( T E4-3) When the servo pilot pressure is increased, the boom
service spool E is displaced further, which allows more
The theoretical PWM duty cycle required to produce a flow from the main hydraulic system to the boom extension
given valve current signal (output) is already pre- ram F, causing the ram to move at a faster rate.
a closed-loop control algorithm to constantly compare the
actual valve current (via a current sense resistor) with the
theoretical valve current (stored in memory), and
automatically increases or decreases the PWM duty cycle
supply.


– In the mid position (neutral), the thumbwheel output

volts, the ECU output current is 0 mA, therefore
E4-37 9803/3760-07 (E-01-06) E4-37

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

Current: Pressure:
(or Auxiliary
`Forward'
direction)
(or Auxiliary
`Reverse'
direction)
E4-38 9803/3760-07 (E-01-06) E4-38

C044280
E4-39 9803/3760-07 (E-01-06) E4-39

Thumbwheel Control Fault Codes (‘Blink’ codes) indicate the blink code. Alternatively, if a test relay is not
available, place a solenoid tester pen (with an LED or
K Single Auxiliary Machines ( T E4-40) bleeper) against the 2nd auxiliary (AUX2) relay to read the
code.
K Twin Auxiliary Machines ( T E4-41)
Note: Machines with an electronic instruments system will

log a fault code, see Section M - CANbus SYSTEM.
Single Auxiliary Machines



Boom Extend/Retract Faults: In order to read the blink

code, it is necessary to replace the existing 2nd auxiliary
C044340-C3
(AUX2) relay in the front console with a test relay (see
Fig 23.
Service Tools). If there is a fault, the test relay LED will

coil or associated wiring faulty (open or short circuit). and connectors for damage. Measure the solenoid
2 flashes Boom `Retract' / Auxiliary Ìn' pilot solenoid valve coil coil resistance. Renew the solenoid coil.
or associated wiring faulty (open or short circuit).
connectors for damage. Renew the thumbwheel
switch.
E4-40 9803/3760-07 (E-01-06) E4-40

Twin Auxiliary Machines


Boom Extend/Retract Faults: The blink code is indicated

using the AUX2 indicator light 24-B in the control lever.

C044340-C2
Fig 24.

coil or associated wiring faulty (open or short circuit). and connectors for damage. Measure the solenoid
2 flashes Boom `Retract' / Auxiliary Ìn' pilot solenoid valve coil coil resistance. Renew the solenoid coil.
or associated wiring faulty (open or short circuit).
connectors for damage. Renew the thumbwheel
switch.
E4-41 9803/3760-07 (E-01-06) E4-41

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
E4-42 9803/3760-07 (E-01-06) E4-42

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
Àctive' warning light
3047 HVCS Proportional solenoid valve (Variflow
pump)
5014 Hydraulic fluid temperature sensor (Variflow
pump - suction port)
E4-43 9803/3760-07 (E-01-06) E4-43

C050940-C1
Fig 27. Wires and Connectors - HVCS
E4-44 9803/3760-07 (E-01-06) E4-44

Device and Connector Key
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.
4008 HVCS ECU Inside the engine compartment. Fixed to the

chassis to the rear of the engine.
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
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.
7023 HVCS Flyback Diode TBA
8000 Harness interconnections Refer to Section C - Electrical Harness

System. K Related Topics ( T E4-3)
9000 Fuses Refer to Section C - Fuses and Relays.
E4-45 9803/3760-07 (E-01-06) E4-45

Fault Finding
Fault Finding



to the hydraulics.



circuit.



Servo Operated Spools: The thumbwheel PWM
controllers (ECU's) will generate a blink code for some
fault conditions. K Thumbwheel Control Fault Codes
(‘Blink’ codes) ( T E4-40)

Section M - Electronic Data Systems. K Related
Topics ( T E4-3)
E4-46 9803/3760-07 (E-01-06) E4-46

Fault Finding
Tables

K Table 13. Low flow from auxiliary service ( T E4-48)
K Table 14. Boom operation is “Fierce” ( T E4-48)
K Table 15. Boom Ext/Ret slow, or low flow from auxiliary service ( T E4-49)

defective.

Servo pilot pressure too low: (1) Measure the servo pilot pressure.
– 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.

Insufficient output flow from variflow pump: – Check the function of the variable pump solenoid
(HVCS) electrical circuit. Check the throttle position
– Pump horsepower solenoid is permanently energised. sensor. Check condition of the associated electrical
– Failure of the pump, or internal tilting swashplate wiring for damage and short circuits.
mechanism due to contamination. – Renew the pump and flush the hydraulic system to
remove all contamination.
(1) Servo operated service spools.
E4-47 9803/3760-07 (E-01-06) E4-47

Fault Finding

trapped or kinked.
Associated service spool not operating correctly. (1) – Check the condition of the related harness wiring and
connectors for damage. Check the solenoid coil for
– Due to faulty service spool solenoid. open or short circuits. Measure the solenoid coil
– Due to a fault with the electronic control lever resistance. Renew the solenoid coil.
assembly. – Check the condition of the related harness wiring and
connectors for damage. Renew the electronic control
lever assembly.
compensator piston.
(1) Servo operated service spools.

defective.
Table 13. Low flow from auxiliary service

Variflow pump Delta-P pressure setting too low. Test the system pressures and adjust as required.
Table 14. Boom operation is “Fierce”

Variflow pump Delta-P pressure setting too high. Test the system pressures and adjust as required.
E4-48 9803/3760-07 (E-01-06) E4-48

Fault Finding
Table 15. Boom Ext/Ret slow, or low flow from auxiliary service

Fault in electrical circuit wiring, or operation of PWM Check the condition of the associated electrical wiring for
controller (ECU): (1) damage and that the fuses are intact.

– Faulty PWM controller (ECU). – Check the applicable solenoid coil for open or short
Note: The PWM Controller (ECU) will generate a blink code the solenoid coil.
for some fault conditions. K Thumbwheel Control Fault – Renew the PWM controller (ECU).
Codes (‘Blink’ codes) ( T E4-40)
(1) For a detailed description of the PWM controller (ECU) and thumbwheel operation, and expected output current and
input voltages, see Circuit Descriptions.


from circuit.
contamination.
E4-49 9803/3760-07 (E-01-06) E4-49

Test Procedures
Test Procedures
Checking Pump Flow

It is not possible to measure maximum flow at system
pressure because the pump swashplate will return to
minimum angle (minimum flow) when the system reaches
full pressure. A practical method to determine the hydraulic
pump performance is to measure the cycle times for the
main hydraulic services.
E4-50 9803/3760-07 (E-01-06) E4-50

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.
Note: This procedure describes the correct method to

check the main system pressure, load sense pressure,
pump standby pressure, steering pressure and delta-P
pressure. A multi-channel digital pressure test set will be
required to measure the pressures accurately (see
Service Tools).
!MWARNING

GEN-4-1_1
!MWARNING
Hydraulic Pressure
the hoses are open.
INT-3-1-11_2 C075860
Fig 28.
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.
E4-51 9803/3760-07 (E-01-06) E4-51

Test Procedures
of the machine. Connect the flow meter correctly according
to the flow direction marked on the body. Do not push the
auxiliary thumbwheel 30-J towards the rear of the machine
as this will change which couplings are flow and return.
!MCAUTION
adjusting knob screwed fully OUT), before starting the
damage the pump.
HYD-4-4_1
6 Start the engine. Make sure that the hydraulic oil is at

working temperature, i.e. 50°C (122°F).
7 Measure the standby pressure:
a Press the throttle pedal to give maximum engine

speed.
C047960
Fig 29. b Do not operate any hydraulic services.
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:
a Set the pressure test unit to measure the

difference between channel 1 and channel 2
(Delta P).
b Push the auxiliary thumbwheel 30-J towards the

front of the machine.
c Slowly increase the engine speed to 2350 rpm

(Maximum).
d Note the reading shown as the Delta P pressure.
Note: On test units where the Delta P option is not

available record the pump pressure (channel 1) and the
load sense pressure (channel 2).
e Using the pump pressure and load sense

pressure figures obtained subtract the Load
sense pressure figure from the pump pressure
figure. The resulting figure is the delta-P pressure.
C075900
Fig 30. Example:
Important: Find out which coupling is the flow and which

is the return with the thumbwheel pushed towards the front
E4-52 9803/3760-07 (E-01-06) E4-52

Test Procedures
9
Pump Load Sense Delta-P

Pressure Pressure Pressure
240 bar - 220.5 bar = 19.5 bar
10 Measure the load sense relief valve pressure:

speed.
b Select and hold the boom lower service. Make

sure that the boom ram is closed fully.
c Note the pressure shown on channel 2. This is the

11 Measure the Steering pressure:
a Press the throttle pedal fully to the floor.
b Turn the steering wheel.

steering pressure.
12 Record the pressures in a table as shown below:
Table 18.
Standby Load Sense Delta-P Steering
Relief
Compare the recorded pressures to those specified.

If required the pressures can be adjusted. K Pressure

Adjustment ( T E4-54)
E4-53 9803/3760-07 (E-01-06) E4-53

Test Procedures
Pressure Adjustment and check the pressure again. K Main System
Pressures ( T E4-51)
If required the hydraulic system pressures can be
adjusted. Make sure the test equipment is connected as
described in the test procedures. K Main System
1 Adjust the delta-P pressure:
To adjust the delta-P pressure, loosen the locknut 31-

A and turn the adjuster screw 31-B (at the variflow
pump as shown). Turn the adjuster screw clockwise
to increase pressure and counter-clockwise to
decrease the pressure.
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.
Note: The adjustment of the adjustment screw is very

sensitive. It is recommended to only turn the adjuster
screw 450 between checking the setting.
2 Tighten the locknut 31-A.
3 Adjust the main system pressure (Load Sense

Relief Valve):
a Switch OFF the engine and vent residual

hydraulic pressure.
b Remove the plastic cap from the load sense relief

valve 32-C. Loosen the locknut and turn the
adjuster screw clockwise to increase pressure
and counter-clockwise to decrease the pressure.
E4-54 9803/3760-07 (E-01-06) E4-54

Test Procedures
!MWARNING

GEN-4-1_1

i.e. 50°C (122°F).

shown).
C050600
Fig 33.
30 bar (30.6 kgf/cm2, 435 lbf/in2)


renewal of the solenoid coils. Further dismantling of the
E4-55 9803/3760-07 (E-01-06) E4-55

Test Procedures
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)
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
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).
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
E4-56 9803/3760-07 (E-01-06) E4-56

Test Procedures
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.
The procedure is a series of tests that measure electrical

signals from the pump controller ECU to the pump
solenoid. To do the tests a special test lead is required.
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.
2 If the machine has undershields, then you must

remove them to get access to the variable pump.
3 Disconnect the chassis harness 2 from the variable

pump solenoid 1.
4 Connect the first end of the test lead A to the solenoid

1.
5 Connect the second end of the test lead A to the

chassis harness 2.
Note: The pump solenoid harness is actually part of the

6-Speed Transmission harness.
T040550-1
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).
2 Turn ON the multimeter.
E4-57 9803/3760-07 (E-01-06) E4-57

Test Procedures
3 Set the multimeter to measure Amps. 4 Complete the tests shown in K Table 19. ( T E4-58)
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.
If the Recorded Values are lower than the Required

Values shown, carry out fault diagnosis. K HVCS
Fault Diagnosis ( T E4-59)
If the Recorded Values are within the allowable

limits, then the operation of the HVCS is correct. No
further action is required.
E4-58 9803/3760-07 (E-01-06) E4-58

Test Procedures
HVCS Fault Diagnosis Test 2
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.
2 Connect the chassis harness 2 to the variable pump Test 3

solenoid 1.
Task: Complete a continuity test between pin #2 of Pump
Test 1 Solenoid connector 2 and chassis earth stud 8.
Task: Measure the resistance of the pump solenoid coil 1. Result: Continuity OK?
Expected resistance value: 5–6 ohms. – Yes. Continue to Test 4.

– No. Examine the items shown:
Result: Is the resistance correct?
Examine the Chassis Harness to Transmission
– Yes. Continue to Test 2.
– No. Replace the Solenoid Coil.
Examine the chassis earth stud 8.
Examine the chassis and transmission harness wiring

for damage.
T040570-1
Fig 38.
E4-59 9803/3760-07 (E-01-06) E4-59

Test Procedures
Test 4
Test the Resistance in the Pump Harness. Connect the

positive lead (+) of the multimeter to pin #2 of the pump
solenoid connector 2. Connect the negative lead (-) of the
multimeter to pin #1 of the pump solenoid connector 2.
Expected resistance value: 1.8-2.2 M ohm.

– No. Continue to Test 4a.
T040620-1
Fig 40.
Test 4b
Check the Variable Pump Temperature Sender 10.

Connect the positive lead of the multimeter to pin #1 of the
temperature sender. Connect the negative lead of the
multimeter to pin #2 of the temperature sender.
Expected Values:
25°C 7600 - 8400 ohm
50°C 2650 - 2950 ohm.

T040610-1
Fig 39.
Result: Resistance correct?
Test 4a
– Yes. Examine the engine, chassis and transmission
Check the pump diode 9. With electrical multimeter set to harness wiring for damage.
check resistance, there should be an open circuit when – No. Install a new temperature sender C.
you connect the positive lead (+) of the multimeter to pin
#1 of the pump solenoid connector 2 and the negative lead Test 5
(-) connected to pin #2 of the pump solenoid connector 2.
Check the Pump Controller ECU. Check the feed voltage
Result: Open Circuit measured? on pin #12 of the ECU connector 5.
– Yes. Continue to Test 4b. Expected value: 12-14 volts

– No. Install a new diode B.
Result: Voltage correct?
E4-60 9803/3760-07 (E-01-06) E4-60

Test Procedures
– Yes. Please contact Loadall Technical Service for
further assistance.
– No. Examine fuse 13 and the wiring from the fuse box
through to the cab bulkhead connector and the
engine connector 6.
Examine the earth connection at pin #1 of the ECU

connector.
If the earth connection is incorrect, examine the earth

wiring from the ECU connector through the engine
connector 6 to the chassis earth stud 8.
E4-61 9803/3760-07 (E-01-06) E4-61

Test Procedures
HVCS Schematic and Component Locations
T040920-1
Fig 41. Schematic Drawing
T040950-1 T040580-1
Fig 42. Fig 44.
T040600-4 T040590-1
Fig 43. Fig 45.
E4-62 9803/3760-07 (E-01-06) E4-62

Test Procedures
T040940-1
Fig 46.
E4-63 9803/3760-07 (E-01-06) E4-63

Bleed Procedures
Bleed Procedures
Tilt Ram Circuit


tilt ram.



times.

engine.

Fig 47.
E4-64 9803/3760-07 (E-01-06) E4-64

Bleed Procedures

cylinder.
!MWARNING
Communications
INT-3-1-5

766840-C1
operated.


E4-65 9803/3760-07 (E-01-06) E4-65

Bleed Procedures
E4-66 9803/3760-07 (E-01-06) E4-66


Introduction

K 4 Spool Control Valve Block (S1) ( T E5-4)(1)
K 4 Spool Control Valve Block (S2) ( T E5-5)(1)
K Servo Pilot Pressure Supply Valve ( T E5-13)
K Electronic Servo Proportional Control ( T E5-15)
K Electro Servo Control Lever ( T E5-16)
K Variflow Pump Operation ( T E5-29)
K Parallel Lift ( T E5-31)
K Hydraulic Variable Control System (HVCS) ( T E5-34)
K Electro Servo Control ( T E5-37)
K Connector and Device Key ( T E5-48)
E5-1 9803/3760-07 (E-01-05) E5-1

Introduction


Procedures, Specifications(1) Machine Model Application
531-70, 531-T70 541-70, 541-T70 536-70, 536-T70
K 4 Spool Control Valve Block (S1) ( T E5-4) z
K 4 Spool Control Valve Block (S2) ( T E5-5) z z
E5-2 9803/3760-07 (E-01-05) E5-2

Related Topics
Related Topics

1 Applications ALL
1 Service Tools ALL
C Fuses and Relays ALL
C Electrical Harness SYSTEM ALL
E K Electro Servo (LSP) Control Valve ALL
(S1) ( T E16-1)
E K Main Pump - Variflow ( T E23-1) ALL
E K Control Lever - Electro Servo (S1) ( T E26-1) ALL
E K Servo Pilot Pressure Supply Valve ALL
(S1) ( T E20-1)
F Dual Control Forward, Neutral and Reverse ALL
SYSTEM
M CANbus SYSTEM ALL

892/00268 (1) Flow Monitoring Kit and Relevant Adaptors
892/00270(1) Load Valve
E5-3 9803/3760-07 (E-01-05) E5-3

Specifications
Specifications
4 Spool Control Valve Block (S1) topic for the applicable machine models. K Table 1.
Type: 4 Spool, load sense - pressure compensated, double acting spools

Spool 1 Auxiliary Service Integral proportional electro servo pilot operated
Spool 2 Carriage Tilt Service Integral proportional electro servo pilot operated
Spool 3 Boom Extend & Retract Service Integral proportional electro servo pilot operated
Spool 4 Boom Raise & Lower Service Integral proportional electro servo pilot operated


bar kgf/cm2 lbf/in2
2C - Load Sense Relief Valve (1) 240 245 3480
2N - Auxiliary Ram Rod Side 220 224 3190
2M - Auxiliary Ram Head Side 220 224 3190
2J - Carriage Tilt Ram Head Side 200 204 2900
2H - Carriage Tilt Ram Rod Side 275 280 4000
C047990
Fig 1.
E5-4 9803/3760-07 (E-01-05) E5-4

Specifications
4 Spool Control Valve Block (S2)

IMPORTANT: These specifications are only applicable to topic for the applicable machine models. K Table 1.
some machine models. Refer to the table at the front of this Specification Variants ( T E5-2)



bar kgf/cm2 lbf/in2
2J - Carriage Tilt Ram Head Side 200 204 2900
C047990
Fig 2.
E5-5 9803/3760-07 (E-01-05) E5-5

Specifications
Variflow Pump
Type: EK.DS Variable displacement pump with integral gear pump for
cooling fan motor operation
Maximum 63 3.8
Minimum 11.2 (0 )(1) 0.68 (0(1))
Maximum Pressure: bar kg/cm 2
lb/in2
Peak 315 321 4568
Maximum Speed: 3000 (2600 (1) )
rev/min
Electric EK1 Proportional computer controlled 12V solenoid valve
(PWM)
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
(1) LLMC Machines - from October 2010
E5-6 9803/3760-07 (E-01-05) E5-6

Specifications
Cooling Fan Motor

Up to March 09
SE engines :
Type: Gear motor
Body Colour Black
Weight: TBA
SD 63 kW engines :
Type: Gear motor
Body Colour Red
Type: Gear motor
Body Colour Black
SE engines :
Type: Gear motor
E5-7 9803/3760-07 (E-01-05) E5-7

Specifications

Body Colour Black
Weight: TBA
SD 63 kW engines :
Type: Gear motor
Body Colour Red

Type: Gear motor
Body Colour Black
From Jan 2011
SE 97kW engines :
Type: Gear motor
SD 63 kW engines :
Type: Gear motor
E5-8 9803/3760-07 (E-01-05) E5-8

Specifications

Type: Gear motor
Body Colour Black
E5-9 9803/3760-07 (E-01-05) E5-9

Operation Overview
Operation Overview
The following explains the basic operation of Electro Servo

Flowshare machines with a variflow pump driven hydraulic
system. There are other types of hydraulic systems. Make
sure you are referring to the correct system. K Related
Topics ( T E5-3)
The JCB Flowshare hydraulic system differs in many

Before attempting to service or fault find the system ensure
that you read and understand all the descriptions in this
section. The following descriptions make some
comparisons to the normal hydraulic system. `Normal
system' refers to standard parallel valve block
SYSTEM ( T E2-1)
E5-10 9803/3760-07 (E-01-05) E5-10

Operation Overview
Item Description
K Fig 3. ( T E5-12)
cooler
3 Pump assembly A variflow pump A with an additional K Hydraulic Pump ( T E5-13)
gearpump section B for the fan drive
4 Electro Servo Control Two axis control lever K Electro Servo Control
Lever Lever ( T E5-16)
5 PWM ECU Power Base Electronic control for servo pilot valve K Electronic Servo Proportional
Control ( T E5-15)
6 Control valve block Flowshare valve with electro servo spools K Electronic Servo Proportional
Control ( T E5-15)
7 Servo Pilot Pressure Valve Supplies pilot pressure oil to the proportional K Servo Pilot Pressure Supply
servo pilot valves Valve ( T E5-13)
7A Hydraulic Oil Filter Positioned in the servo pressure valve feed
line
8 Hydraulic Oil Filter Positioned in the return line to tank(1)
8A Hydraulic Oil Filter Positioned in the hydraulic tank(2)
9 Hydraulic Tank
10 Proportional Control K Electronic Servo Proportional
Thumbwheels Control ( T E5-15) K Electro Servo
Control Lever ( T E5-16)
11 Pump control ECU (HVCS)
12 Constant Auxiliary ECU
13 Steer Valve Feed See Section H - Steering.
14 System Enable Switch K Electrical Operation and
14A System Enable Relay K Electrical Operation and
15 Servo Isolation Switch K Electrical Operation and
(1) Machines upto November 2009

(2) Machines from November 2009
E5-11 9803/3760-07 (E-01-05) E5-11

Operation Overview
8A
C048490-C5
E5-12 9803/3760-07 (E-01-05) E5-12

Operation Overview
OIl from pump section 3A OIl from pump section 3B Return to tank
Oil at servo pressure Oil suction line from the tank

Hydraulic Pump Servo Pilot Pressure Supply Valve

The hydraulic pump 3-3 pulls oil from the hydraulic tank 3- The system supplies a low pressure hydraulic flow to move
9. The engine operates the pump which is connected to the the valve spools. The oil flows through the pilot pressure
rear of the bevel gearbox. supply valve 3-7. This valve decreases the pressure and
the oil flows to the proportional control solenoids in the
The hydraulic pump 3-3A is a variable displacement axial control valve block. The proportional control solenoids
piston type. The angle of the variable tilting swashplate control the flow to move the selected valve spool. K Servo
mechanism in the pump controls the pump output. Pilot Pressure Supply Valve (S1) ( T E20-1)
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.
On the rear of the variflow pump assembly is a gear type

pump which operates the cooling fan and supplies oil to the
servo pilot valve. Oil from the pump section 3-3B flows
directly to the cooling fan hydraulic motor 3-2 and the servo
pilot valve 3-7. On sway machines a changeover valve
switches oil supply between the sway ram service and the
fan motor.
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)
E5-13 9803/3760-07 (E-01-05) E5-13

Operation Overview




compensator valve operation. K Pressure Compensator
Valves Operation ( T E5-25)

A405000-C1
E5-14 9803/3760-07 (E-01-05) E5-14

Operation Overview
Electronic Servo Proportional Control

The control lever 1 and attached thumbwheels operate the
hydraulic services using electrical signals supplied by the
thumbwheel ECU's. The control lever on this system is
attached to the seat pod assembly.
This type of lever has two functions, Proportional

thumbwheel control and electro servo lever control.
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.
In the control lever assembly is the Power Base ECU 2.

The ECU receives analogue electrical inputs in relation to
the movement of the lever or thumbwheel switches. The
ECU changes the analogue signals and supplies a
modulated output signal (PWM) to the related proportional
solenoid valve in the control valve block.
The proportional solenoid valves operate as pressure

reducing valves. These supply servo pilot oil to move the
auxiliary, or extend retract service spool. The supply is at a
pressure in relation to the amount the operator moves the
thumbwheel switch. K Electro Servo Control
Lever ( T E5-16)
Fig 5. Electro Servo Control Lever
E5-15 9803/3760-07 (E-01-05) E5-15

Operation Overview
Electro Servo Control Lever

The control lever 1 operates in two axis. It also includes
two thumbwheel switches.

Control lever - AXIS One Proportional analogue Power base PWM ECU
electrical signal
Control lever - AXIS Two Proportional analogue Power base PWM ECU
electrical signal
Thumbwheel One Proportional analogue Power base PWM ECU

electrical signal
Thumbwheel Two Proportional analogue Power base PWM ECU

electrical signal
Note: The control lever also incorporates switches for

transmission control. Refer to Section F. K Related
Topics ( T E5-3)
E5-16 9803/3760-07 (E-01-05) E5-16

Operation Overview
Variflow Pump
C051000-C1
Fig 6.

Item Description
G1 Flow compensator valve adjuster cover (not
A Drive shaft. Driven from the bevel gearbox adjustable)
B Inlet (suction) port H Swash control piston
C Outlet port J Swash plate control spring
D Separate gearpump (cooling fan circuit) driven by K Swash plate
drive shaft A.
L Axial pistons
E Hydraulic variable control solenoid valve (HVCS)
E1 Solenoid valve coil - HVCS The hydraulic services pump is a variable displacement
axial piston pump, which uses the swash plate design
F Pressure cut off safety valve spool
principle.
F1 Pressure cut off safety valve adjuster cover (not
adjustable) Rotation of the input drive shaft A produces linear
G Flow compensator valve spool movement of the axial pistons L. The pump output is
controlled via the swash control piston H. The piston varies
E5-17 9803/3760-07 (E-01-05) E5-17

Operation Overview
of changing the hydraulic oil flow in the system.
The swash control piston is controlled by two systems:


– The hydraulic variable control solenoid valve E

(HVCS).
This system controls the pump in response to engine

power output and in case of high hydraulic oil
temperature.
K Hydraulic Operation and Schematics ( T E5-19),

E5-18 9803/3760-07 (E-01-05) E5-18


shows only part of the full hydraulic system. For the full
hydraulic schematics refer to the schematics topic.
Note: Pressures quoted are for illustration purposes only.

Refer to the specifications for the correct pressures for
machine variant. K Specifications ( T E5-4)
K Fig 7. ( T E5-20)
With all the services in neutral, there is no flow from the

hydraulic pump 1A. The pump internal tilting swashplate is
at its minimum angle. In this condition the pump supplies
only the minimum flow that is necessary to satisfy the
normal system internal leakage. The pump also supplies a
system stand-by pressure. A small amount of oil from the
pump 1A flows to the inlet section of the control valve 3.
The internal steer priority valve 3G sends the flow to the
steer circuit or the control valve circuit.
When the main system pressure is 25 bar the spring 3B in

the flushing valve 3A is compressed and oil returns back
to the tank.
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.
E5-19 9803/3760-07 (E-01-05) E5-19

C050980-C1
E5-20 9803/3760-07 (E-01-05) E5-20

Service Operation
K Fig 8. ( T E5-22)
When a service is operated, the boom extend for example,

movement of the thumbwheel sends a signal to the ECU.
The ECU energises the related proportional solenoid valve
which operates and causes pilot oil to move the spool 3E.
Oil flows across the service spool to the pressure
compensator valve 3F. The valve opens and sends oil to
flushing valve 3A starts to close. At the same time, the
pump 1A increases the angle of the tilting swashplate in
relation to the load sense pressure to increase the flow.
During service operation the main system pressure

continues to increase until the load hold check valve 3D
opens and the boom extend ram 5 operates. The main
system pressure will now be equal to the load sense
pressure (load from the boom extend ram) plus the force
spool and back to the tank in the normal way.

in parallel. When multiple services are operated at the
same time, the operating pressure of one service can have
an effect on the speed of another service. This does not
occur with flowshare.
The pressure compensator valves for each service adjust

in relation to the differing load pressures. For example,
when a pressure compensator valve 3F senses a higher
load sense pressure from another service, it decreases the
flow to its own service. The decrease in flow makes sure
that all the services operate at a stable speed
independently of the main system pressure.
E5-21 9803/3760-07 (E-01-05) E5-21

C050980-C2
E5-22 9803/3760-07 (E-01-05) E5-22


K Fig 9. ( T E5-24)
The maximum main system pressure is controlled by the

load sense pressure valve.
When a service ram is at the end of its stroke or there is a

resistance, the pressure in the load sense line increases.
When this pressure is above 215 bar, the load sense relief
valve 3C opens and load sense oil is sent to tank, to stop
an increase in pressure. The flushing valve 3A operates as
normal.
At the same time, the pump flow compensator valve 1C

decreases the tilting swashplate angle towards its
minimum angle in relation to the load sense pressure.The
decrease in the swashplate angle causes the output flow
from the pump to decrease. The pump supplies only the
minimum flow needed to keep the system pressure at the
maximum limit.
The main system pressure necessary to open the flushing

valve is 25 bar above the load sense pressure. Thus the
main system pressure will be limited to 215 bar + 25 bar, a
total of 240 bar.

the purpose of explanation only. For the correct values see
Technical Data. The load sense pressure relief valve is
factory set and sealed with a plastic tamper proof cap. No
adjustment is normally necessary.

Full Pressure
Load Sense Line
Servo
Neutral
Exhaust
E5-23 9803/3760-07 (E-01-05) E5-23

C050980-C3
E5-24 9803/3760-07 (E-01-05) E5-24


Operation
A405030-1
Fig 10.


E5-25 9803/3760-07 (E-01-05) E5-25

Operating a Service
A405041-1
Fig 11.
rise as follows:


E5-26 9803/3760-07 (E-01-05) E5-26

714761-1
Fig 12.

of the services.

spool.

E5-27 9803/3760-07 (E-01-05) E5-27

714771-1
Fig 13.
E5-28 9803/3760-07 (E-01-05) E5-28

Variflow Pump Operation
C051000
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.
E5-29 9803/3760-07 (E-01-05) E5-29

When the output flow is enough to satisfy the flow swashplate normally responds to changes in the hydraulic
demanded by the service, the pump operating pressure P load sense pressure.
(red) increases sufficiently to start to move the service ram.
The increase in the pump operating pressure pushes the In this way, the hydraulic power curve of the pump can be
flow compensator spool D back to the left, against the force adjusted electrically by the current signal from the pump
of the spring E and hydraulic load sense pressure; this in controller ECU. For details of the HVCS electrical circuit
turn increases the control pressure acting on the swash and connections K Electrical Operation and
control piston C, which decreases the angle of the Schematics ( T E5-34).
swashplate A against the force of spring B. As the
swashplate angle decreases, the output flow from the
pump decreases. In this way, the pump delivers only the
required to operate the service.
Note: The flow compensator spool D is moving constantly,

thereby regulating the pump swashplate to balance the
pressures acting on each end of the spool. The additional
force of spring E is factory set to be equivalent to 25 bar
(360 lbf/in2), therefore the pump operating pressure (i.e.
main system pressure) will always be maintained at 25 bar
above the load sense pressure. This is sometimes
referred to as the `Delta-P' pressure setting.
Pressure Cut-Off Valve: The pressure cut-off valve is a

secondary safety device to limit the maximum operating
pressure, and thereby protect the pump from over
pressurisation. If the pump operating pressure P (i.e. main
system pressure) ever reaches the setting of the valve
springs F, the pressure cut-off spool G will be pushed to
the left, this in turn, increases the control pressure acting
on the swash control piston C, which decreases the angle
of the swashplate, and reduces the pump output flow to
minimum. While the pressure cut-off valve is operating, the
pump will remain hydraulically stalled i.e. maintaining
maximum operating pressure at minimum flow.
Hydraulic Variable Control Solenoid Valve: The

proportional solenoid valve X is part of the hydraulic
variable control system (HVCS). The system automatically
adjusts the pump performance (power curve
characteristic) to limit the hydraulic power available to the
hydraulic services under conditions of high engine load or
high hydraulic fluid temperature.
The solenoid valve is controlled by a current signal output

from a pump controller electronic control unit (ECU). The
solenoid valve works as a separate pressure regulating
valve and increases the control pressure acting on the
swash control piston C by a set amount, according to the
valve current signal. Because the control pressure is
regulated by the solenoid valve independently (down
stream) of the flow compensator spool D, this means that
when it is operating, it will alter the way that the pump
E5-30 9803/3760-07 (E-01-05) E5-30

Parallel Lift
Ram Operation

lowers.

C094840
boom pivot.
E5-31 9803/3760-07 (E-01-05) E5-31

C094820
E5-32 9803/3760-07 (E-01-05) E5-32

10.
C094820-C1
E5-33 9803/3760-07 (E-01-05) E5-33

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
C053110
E5-34 9803/3760-07 (E-01-05) E5-34

C050942-C1
E5-36 9803/3760-07 (E-01-05) E5-36

Electro Servo Control

All of the machine hydraulic services are actuated
electrically. Electronic control units and proportional
solenoid valves are central to the system.
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
E5-37 9803/3760-07 (E-01-05) E5-37

Electro Servo Control - Proportional Signal
Generation
When the control lever 22-A is operated, the plunger 22-B

pushes against the return spring 22-C. A variable resistor
position sensor is allocated to each axis. Slider 22-D
moves up or down when the lever is moved changing the
electrical voltage depending on lever position.
Note: The position sensors are integral with the

Powerbase ECU. If a sensor is defective the Powerbase
must be renewed.
Fig 22.
E5-38 9803/3760-07 (E-01-05) E5-38

Electro Servo Control - Operator Interface
Electrical schematics are provided for several operational

states of the electro servo control. A description and cross
reference for the applicable schematic is given in the table.
Operator Interface Electrical Schematic Control/Indicator Function

System enable switch K System Enable and Momentary switch. Press to enable/disable joystick
Isolation ( T E5-40) control lever. System defaults to OFF when the engine
stops. The system will not enable until the engine is
running.
Joystick control lever K Electro Servo Control Proportional control of all the hydraulic services by means
Lever ( T E5-16) of moving the lever and thumbwheel switches.
Constant auxiliary system K Constant Momentary switch. Press to enable the constant auxiliary
enable switch Auxiliary ( T E5-44) system. The system will not enable until the engine is
running.
Constant auxiliary set button K Constant Momentary button. Press to set the constant auxiliary flow
Auxiliary ( T E5-44) setting. For the switch to function first enable the constant
auxiliary system.
Auxiliary II select button K Auxiliary Momentary button. Press to change between Auxiliary I
Changeover ( T E5-42) and Auxiliary II. The system will not function until the
engine is running. The system will not function if the
constant auxiliary system is enabled.
LED indicator - constant K Constant LED is ON when the constant auxiliary system is enabled.
auxiliary mode Auxiliary ( T E5-44)
LED indicator - Auxiliary II mode K Auxiliary LED is ON when Auxiliary II is enabled.
Changeover ( T E5-42)
Hydraulic system lock button K System Enable and Latching button. Latch the button to isolate hydraulic pilot
Isolation ( T E5-40) pressure from the servo system.
E5-39 9803/3760-07 (E-01-05) E5-39

System Enable and Isolation
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)
K Fig 23. ( T E5-41)
The circuit is shown with the system enabled.
The system will not enable unless the engine is running.

Alternator output A energises relay 2012 and an input at
pin 12 of ECU 4007 goes high.
The system will not enable unless switch 1032B is latched.
When momentary switch 1047 is set to the enable position

A, relay 2047 is energised. Power connects to the joystick
powerbase ECU 4011 via the switch 1047 and relay 2047.
When the switch 1047 returns to its neutral position B

power is still connected to ECU 4011 via pin 3 of the
switch. Relay 2047 is energised by ECU 4007.
When the momentary switch 1047 is set to the disable

position C power is isolated from the powerbase ECU
4011. The input at pin 11 of ECU 4007 goes low and the
ECU de-energises relay 2047.
If the hydraulic lock switch 1032B is unlatched the power

is isolated from the powerbase ECU 4011 and the servo
isolation valve solenoid 1032B, isolating servo oil pressure
to the main control valve.
E5-40 9803/3760-07 (E-01-05) E5-40

C061590-C1
Fig 23. System Enable and Isolation. Status = system enabled
E5-41 9803/3760-07 (E-01-05) E5-41

Auxiliary Changeover
Key
4013 LMS display connector J2
2035 Second auxiliary relay
1022 Joystick auxiliary changeover switch
3010 Auxiliary changeover valve solenoid
K Fig 24. ( T E5-43)
The circuit is shown with Auxiliary II enabled.
When momentary switch 1022 is operated the input at pin

9 of ECU 4007 goes high. Output at pin 10 then goes high.
Relay 2035 is energised and solenoid 3010 energises
diverting hydraulic oil to the Auxiliary II circuit.
Input at pin 17 of the LMS display ECU 4013 goes high and
the AUX II indicator LED comes ON.
When momentary switch 1022 is operated again the input

at pin 9 of ECU 4007 goes high. Output at pin 10 then goes
low. Relay 2035 is de-energised and solenoid 3010 de-
energises diverting hydraulic oil to the Auxiliary I circuit.
Input at pin 17 of the LMS display ECU 4013goes low and

the AUX II indicator LED goes OFF.
E5-42 9803/3760-07 (E-01-05) E5-42

C063410-C1
Fig 24. Auxiliary Changeover. Status = auxiliary II enabled
E5-43 9803/3760-07 (E-01-05) E5-43

Constant Auxiliary
Key
4013 LMS display connector J2
1015 Constant auxiliary enable switch
1032B Hydraulic lock switch
B Joystick constant auxiliary switch
K Fig 25. ( T E5-45)
The circuit is shown with constant auxiliary enabled.
For constant auxiliary to work switch 1015 must be set to

ON and the hydraulic lock switch 1032B must be latched.
The input at pin 8 of ECU 4007 goes high.
When momentary switch B is operated the input at pin 6of

ECU 4007 goes high. Output at pin 4 then goes high. The
input at pin 10 of the powerbase ECU 4011 goes high and
the ECU holds a constant current to the applicable
proportional solenoid for constant auxiliary flow.
Input at pin 3 of the LMS display ECU 4013 goes high and
the constant flow indicator LED comes ON.
When momentary switch B is operated again input at pin 6

of ECU 4007 goes high. Output at pin 4 then goes low.
Input at pin 10 of ECU 4011 goes low and the spool of the
auxiliary valve slice moves to stop oil flow in the auxiliary
circuit.
Input at pin 3 of the LMS display ECU 4013 goes low and
the constant flow indicator LED goes OFF.
When switch 1015 is set to OFF output at pin 4 of ECU

4007 goes low. Input at pin 10 of ECU 4011 goes low and
the spool of the auxiliary valve slice moves to stop oil flow
in the auxiliary circuit. Operation of momentary switch B
causes ECU 4007 to do nothing.
E5-44 9803/3760-07 (E-01-05) E5-44

C063430-C1
Fig 25. Constant Auxiliary. Status = constant auxiliary enabled.
E5-45 9803/3760-07 (E-01-05) E5-45

Extend/Retract and Auxiliary Services Key
(Thumbwheel Switches)
3038 Proportional control valve solenoid -
retract service
Key
4011 Joystick powerbase ECU K Fig 26. ( T E5-46)
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)
E5-46 9803/3760-07 (E-01-05) E5-46

Lift/Lower and Tilt Services, Tilt Lock Key
3032 Proportional control valve solenoid - lower
Key service
K Fig 27. ( T E5-47)
1049 Tilt isolation switch
3015 Proportional control valve solenoid - ECU 4011 produces a PWM output in proportion to the
crowd service movement of the joystick control lever to the proportional
3017 Proportional control valve solenoid - solenoid coils 3015, 3017, 3030 and 3032 for operation of
dump service the service spools.
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
Fig 27. Lift/Lower and Tilt Services, Tilt Lock
E5-47 9803/3760-07 (E-01-05) E5-47

Connector and Device Key
ECU connector pins.
A Alternator On the right side of the engine
9
D+
B+

SYSTEM. K Related Topics ( T E5-3)
M10
1015 Constant Auxiliary Enable TBA
Switch
1022 Front/Rear Auxiliary Located on the control lever

Switch
1032B Joystick Isolation Switch Located in the servo control pod.
1047 System Enable Switch Located on the servo control pod. Remove the
switch to get access to the connector.
2000 Relays Refer to Section C - Fuses and Relays.

3007 Auxiliary A Solenoid Located on the electro servo valve block.
3008 Auxiliary B Solenoid Located on the electro servo valve block.
3015 Crowd Proportional Located on the electro servo valve block.

Solenoid
E5-48 9803/3760-07 (E-01-05) E5-48

3017 Dump Proportional Located on the electro servo valve block.

Solenoid
3019 Extend Proportional Located on the electro servo valve block.

Solenoid
3030 Lift Proportional Solenoid Located on the electro servo valve block.
3032 Lower Proportional Located on the electro servo valve block.

Solenoid
3038 Retract Proportional Located on the electro servo valve block.

Solenoid
3010 Auxiliary Change Over TBA

Valve
3042 Servo Valve Located on the Servo Pressure Regulating valve.
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.
4007 Extend/Retract ECU Located in the servo control pod.

(Servo)
4008 HVCS ECU Inside the engine compartment. Fixed to the

chassis to the rear of the engine.
E5-49 9803/3760-07 (E-01-05) E5-49

4011 Joystick Powerbase ECU Located in the servo control pod.
1 10
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.
7023 HVCS Flyback Diode TBA
7036 Powerbase/SRS Diode TBA

Gate
8000 Harness interconnections Refer to Section 1 - Harness Interconnection

and Earth Points. K Related Topics ( T E5-3)
9000 Fuses Refer to Section 1 - Fuses and Relays.
E5-50 9803/3760-07 (E-01-05) E5-50

Fault Finding
Fault Finding



to the hydraulics.



circuit.



Topics ( T E5-3)
E5-51 9803/3760-07 (E-01-05) E5-51

Fault Finding
Tables
Fault Descriptions:
K Table 14. Boom Ext/Ret slow, or low flow from auxiliary service (Servo operated spools). ( T E5-54)

defective.
E5-52 9803/3760-07 (E-01-05) E5-52

Fault Finding

defective.


Table 14. Boom Ext/Ret slow, or low flow from auxiliary service (Servo operated spools).

Fault in electrical circuit wiring, or operation joystick Check the condition of the associated electrical wiring for
powerbase ECU: damage and that the fuses are intact.

– Faulty powerbase ECU. – Check the applicable solenoid coil for open or short
the solenoid coil.
– Renew the joystick powerbase ECU.

E5-54 9803/3760-07 (E-01-05) E5-54

Fault Finding


from circuit.
contamination.
E5-55 9803/3760-07 (E-01-05) E5-55

Test Procedures
Test Procedures
Checking Pump Flow

E5-56 9803/3760-07 (E-01-05) E5-56

Test Procedures
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.
operated. point 28-A and connect to ‘Channel 2’ on the test set.
P pressure.
hydraulic system.

Service Tools).
!MWARNING

GEN-4-1_1
!MWARNING
Hydraulic Pressure
the hoses are open.
INT-3-1-11_2 C075860
Fig 28.
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.
E5-57 9803/3760-07 (E-01-05) E5-57

Test Procedures
auxiliary thumbwheel 30-J towards the rear of the machine
as this will change which couplings are flow and return.
!MCAUTION
damage the pump.
HYD-4-4_1


speed.
b Do not operate any hydraulic services.

C047960
Fig 29.
5 Connect a flow meter 30-F and load valve 30-G to the pump standby pressure.
auxiliary quick release couplings 30-H on the boom.
See Section 1 - Service Tools. 8 Measure the Delta P Pressure:

(Delta P).
b Push the auxiliary thumbwheel 30-J towards the

front of the machine.

(Maximum).


pressure figures subtract the Load sense
pressure figure from the pump pressure figure.
The resulting figure is the delta-P pressure.
C075900
Fig 30. Example:

9

is the return with the thumbwheel pushed towards the front Pressure Pressure Pressure
E5-58 9803/3760-07 (E-01-05) E5-58

Test Procedures
240 bar - 220.5 bar = 19.5 bar

speed.



steering pressure.
Table 17.
Relief
Compare the recorded pressures to those specified in


Adjustment ( T E5-60).
E5-59 9803/3760-07 (E-01-05) E5-59

Test Procedures
To adjust the delta-P pressure, loosen the locknut 31-

A and turn the adjuster screw 31-B (at the variflow
pump as shown). Turn the adjuster screw clockwise
to increase pressure and counter-clockwise to
decrease the pressure.
C047990-C2
Fig 32.
C075860-C1
Fig 31.
After adjustment also check the load sense pressure


2 Tighten the locknut 31-A.

Relief Valve):

hydraulic pressure.

valve 32-C. Loosen the locknut and turn the
adjuster screw clockwise to increase pressure
and counter-clockwise to decrease the pressure.
E5-60 9803/3760-07 (E-01-05) E5-60

Test Procedures
!MWARNING

GEN-4-1_1

i.e. 50°C (122°F).

shown).
C050610
Fig 33.
30 bar (30.6 kgf/cm2, 435 lbf/in2)


renewal of the solenoid coil. Further dismantling of the
E5-61 9803/3760-07 (E-01-05) E5-61

Test Procedures
Auxiliary Relief Valve Pressure (ARV) - Note: Locate a connection in the tilt ram circuit at the rear
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)
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
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).
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
E5-62 9803/3760-07 (E-01-05) E5-62

Test Procedures

C082990
Preparation
T040560-2
ground.


pump solenoid 1.

1.

chassis harness 2.

T040550-1
(122°F).
E5-63 9803/3760-07 (E-01-05) E5-63

Test Procedures
Table 18.
operated)
1500 - 1700 0.95 - 1.05


E5-64 9803/3760-07 (E-01-05) E5-64

Test Procedures

solenoid 1.


for damage.
T040570-1
Fig 38.
E5-65 9803/3760-07 (E-01-05) E5-65

Test Procedures
Test 4


T040620-1
Fig 40.
Test 4b

Expected Values:
25°C 7600 - 8400 ohm
50°C 2650 - 2950 ohm.

T040610-1
Fig 39.
Test 4a

E5-66 9803/3760-07 (E-01-05) E5-66

Test Procedures
further assistance.
engine connector 6.

connector.

E5-67 9803/3760-07 (E-01-05) E5-67

Test Procedures
HVCS Schematic and Component Locations
T040920-1
Fig 41. Schematic Drawing
T040950-1 T040580-1
Fig 42. Fig 44.
T040600-4 T040590-1
Fig 43. Fig 45.
E5-68 9803/3760-07 (E-01-05) E5-68

Test Procedures
T040940-1
Fig 46.
E5-69 9803/3760-07 (E-01-05) E5-69

Bleed Procedures
Bleed Procedures
Tilt Ram Circuit


tilt ram.



times.

engine.

Fig 47.
E5-70 9803/3760-07 (E-01-05) E5-70

Bleed Procedures

cylinder.
!MWARNING
Communications
INT-3-1-5

766840-C1
operated.


E5-71 9803/3760-07 (E-01-05) E5-71

Bleed Procedures
E5-72 9803/3760-07 (E-01-05) E5-72


Introduction

K 4 Spool Control Valve Block ( T E6-4)
K Variflow Hydraulic Pump - Power Control ( T E6-5)(1)
K Variflow Hydraulic Pump - HVCS ( T E6-6)(1)
K Servo Pilot Pressure Supply Valve ( T E6-13)
K Electronic Servo Proportional Control ( T E6-16)
K Electro Servo Control Lever ( T E6-17)
K Variflow Hydraulic Pump ( T E6-28)
E6-1 9803/3760-07 (E-01-09) E6-1

Introduction

K Hydraulic Variable Control System (HVCS) ( T E6-44)(1)
K Electro Servo Control ( T E6-47)
K Auxiliary Relief Valve Pressure (ARV) - ARV’s set higher than the maximum pump
pressure ( T E6-74)
K Testing the HVCS System Operation ( T E6-75)(1)
(1) Specification variant. Make sure your refer to the correct specification

536-T60, 541-T70, 531-T70, 536-T70, 535-T95
SF engines SE engines
Variflow Hydraulic Pump - Power Control z
Variflow Hydraulic Pump - HVCS z
K Testing the HVCS System Operation ( T E6-75) z

531-70, 535-95, 536-60, 541-70, 536-70,
531-T70 535-T95 536-T60 541-T70 536-T70
E6-2 9803/3760-07 (E-01-09) E6-2

Related Topics
Related Topics

1 Applications ALL
1 Service Tools ALL
B Longitudinal Load Moment SYSTEM ALL
(S1) ( T E20-1)
M CANbus SYSTEM ALL
M Fault Code SYSTEM ALL
M Servicemaster Tools Loadall Machine Diagnostics, Hydraulic ECU

892/00270 (1) Load Valve
E6-3 9803/3760-07 (E-01-09) E6-3

Specifications
Specifications
4 Spool Control Valve Block

2A Flushing valve
2C Load sense relief valve
2R Steer priority valve

Relief Valve Pressures:

bar kgf/cm2 lbf/in2
2J - Carriage Tilt Ram Head Side 140
2A
2N 2M
B4 A4
B3 A3
B2 A2
B1 A1
LS
2H P
2J
T
2C
2R
C094030-C1
Fig 1.
E6-4 9803/3760-07 (E-01-09) E6-4

Specifications
Variflow Hydraulic Pump - Power Control
Type: LAXDG Variable displacement pump with integral gear

Maximum 63
Minimum 11.2
Peak 315 321 4568
Hydraulic XDG Pressure control and flow control (load sense)
Hydraulic LA Pressure control and flow control at torque limit
(power control)
Standby Pressure 25 25 362
Delta P Pressure 15 15 217
Maximum Steering Pressure TBA
E6-5 9803/3760-07 (E-01-09) E6-5

Specifications
Variflow Hydraulic Pump - HVCS
Type: EK.DS Variable displacement pump with integral gear

Maximum 63
Minimum 11.2
Peak 315 321 4568
Electric EK1 Proportional computer controlled 12V solenoid
valve (PWM)
Standby Pressure 25 25 362
Delta P Pressure 15 15 217
Maximum Steering Pressure TBA
E6-6 9803/3760-07 (E-01-09) E6-6

Specifications
Cooling Fan Motor

Up to March 09
SE engines :
Type: Gear motor
Body Colour Black
Weight: TBA
SD 63 kW engines :
Type: Gear motor
Body Colour Red
Type: Gear motor
Body Colour Black
SE engines :
Type: Gear motor
E6-7 9803/3760-07 (E-01-09) E6-7

Specifications

Body Colour Black
Weight: TBA
SD 63 kW engines :
Type: Gear motor
Body Colour Red

Type: Gear motor
Body Colour Black
From Jan 2011
SE 97kW engines :
Type: Gear motor
SD 63 kW engines :
Type: Gear motor
E6-8 9803/3760-07 (E-01-09) E6-8

Operation Overview
Operation Overview
The following explains the basic operation of ECU

controlled Electro Servo Flowshare machines with a
variflow pump driven hydraulic system. There are other
types of hydraulic systems. Make sure you are referring to
the correct system. K Related Topics ( T E6-3)
The JCB Flowshare hydraulic system differs in many

Before attempting to service or fault find the system ensure
that you read and understand all the descriptions in this
section. The following descriptions make some
comparisons to the normal hydraulic system. `Normal
system' refers to standard parallel valve block
SYSTEM ( T E2-1)
E6-10 9803/3760-07 (E-01-09) E6-10

Operation Overview
Item Description
K Fig 2. ( T E6-12)
cooler
2 Fan Motor Driven by pump section 3B K Cooling Fan Motor ( T E25-1)
3 Pump assembly A variflow pump 3A with an additional K Variflow Hydraulic Pump -
gearpump section 3B for the fan drive HVCS ( T E6-13)
K Variflow Hydraulic Pump -
Power Control ( T E6-13)
4 Servo Control Lever Two axis control lever K Electro Servo Control
Lever ( T E6-17)
5 Servo Controller CAN enabled control lever electric base unit K Electronic Servo Proportional
Control ( T E6-16) K Electrical
Operation and
6 Control Valve Block Flowshare valve with electro servo spools K Electronic Servo Proportional
controlling boom and auxiliary services Control ( T E6-16)
7 Servo Pilot Pressure Valve Supplies pilot pressure oil to the proportional K Servo Pilot Pressure Supply
servo pilot valves Valve ( T E6-13)
8 Hydraulic Oil Filter Positioned in the hydraulic return line inside
the hydraulic tank
9 Hydraulic Tank
10 Proportional Control K Electronic Servo Proportional
Thumbwheels Control ( T E6-16) K Electro Servo
Control Lever ( T E6-17)
K Electrical Operation and
11 Pump Control ECU Located on the chassis inside the engine K Electrical Operation and
(HVCS) compartment Schematics ( T E6-44)
12 Hydraulic Control ECU Located on the chassis next to the control K Electrical Operation and
valve Schematics ( T E6-44)
13 Joystick Button Switches K Electrical Operation and
14 Hydraulic Stop Switch K Electrical Operation and
15 Switches - Tilt Isolation, K Electrical Operation and
Joystick Isolation, Schematics ( T E6-44)
Constant Auxiliary
16 Pump Shut Off Valve Solenoid valve energised by the hydraulic
control ECU
E6-11 9803/3760-07 (E-01-09) E6-11

Operation Overview
6 12
16
7
6A 9
12
11 8
13
10
14
15
C094040

OIl from pump section 3A OIl from pump section 3B Return to tank
Oil at servo pressure Oil suction line from the tank

E6-12 9803/3760-07 (E-01-09) E6-12

Operation Overview
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.
E6-13 9803/3760-07 (E-01-09) E6-13

Operation Overview
Pump Cut Out Valve

K Fig 2. Component Location ( T E6-12)
The machine hydraulic control ECU monitors the machine

status. If the status is not as expected it is assumed that
there is a fault with the hydraulic system. The ECU isolates
the main hydraulic system by energising the safety cut out
solenoid valve 16. The valve allows oil to flow from the pilot
end of steer priority valve back to tank. This causes the
steer priority valve to isolate the main control valve from
the pump flow. The pump supplies only the steering
system.
Load Sensing
K Fig 2. Component Location ( T E6-12)
When a service is operated, the system senses the flow

and adjusts the pump operating pressure to move the load.
The load sense system also includes the main pressure
relief system, which is controlled by the load sense relief
valve (LSRV) 6A. This replaces the Main Relief Valve
(MRV) used in the normal system.
E6-14 9803/3760-07 (E-01-09) E6-14

Operation Overview




compensator valve operation. K Pressure Compensator
Valves Operation ( T E6-24)

A405000-C1
E6-15 9803/3760-07 (E-01-09) E6-15

Operation Overview
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
E6-16 9803/3760-07 (E-01-09) E6-16

Operation Overview
Electro Servo Control Lever

The control lever 1 operates in two axis. It also includes
two thumbwheel switches.

Control lever - AXIS One Proportional analogue Hydraulic control ECU via CAN
electrical signal message from the joystick
controller ECU
Control lever - AXIS Two Proportional analogue Hydraulic control ECU via CAN
controller ECU
Thumbwheel One Proportional analogue Hydraulic control ECU via CAN

controller ECU
Thumbwheel Two Proportional analogue Hydraulic control ECU via CAN

controller ECU
Note: The control lever also incorporates switches for

transmission control. Refer to Section F. K Related
Topics ( T E6-3)
E6-17 9803/3760-07 (E-01-09) E6-17


shows only part of the full hydraulic system. For the full
hydraulic schematics refer to the schematics topic.
K Fig 5. ( T E6-19)
With all the services in neutral, there is no flow from the

hydraulic pump 1A. The pump internal tilting swashplate is
at its minimum angle. In this condition the pump supplies
only the minimum flow that is necessary to satisfy the
normal system internal leakage.
The pump also supplies a system stand-by pressure;
– A small amount of oil from the pump 1A flows to the

end section of the control valve 3 via port P. The steer
priority valve 3G located in the end section, sends the
oil to the steer circuit control valve via port D.
– Oil from pump 1A also flows to the opposite valve
block end section via port P1. Oil flows to the flushing
valve 3A. When the main system pressure is 25 bar
the spring 3B in the flushing valve 3A is compressed
and oil returns back to the tank.
Oil from the gear pump 1B flows to the pilot pressure

control valve 4 via internal filters 2. Oil at pilot pressure
flows to the end section of the control valve 3 and flows to
the proportional solenoid valves at each service spool.
E6-18 9803/3760-07 (E-01-09) E6-18

C09450-C1
ACC
T1
P1
TP2
BAR
BAR
0.7
0.7
30 BAR

TP1
T2
2 P
P2
E6-19 9803/3760-07 (E-01-09) E6-19

Service Operation
K Fig 6. ( T E6-21)
When a service is operated, the boom extend for example,

the hydraulic control ECU energises the related
proportional solenoid valve which operates and causes
pilot oil to move the spool 3E. Oil flows across the service
spool to the pressure compensator valve 3F. The valve
opens and sends oil to the load sense gallery and load hold
check valve 3D. Pressure in the load sense gallery
increases and the flushing valve 3A starts to close. At the
same time, the pump 1A increases the angle of the tilting
swashplate in relation to the load sense pressure to
increase the flow.
During service operation the main system pressure

continues to increase until the load hold check valve 3D
opens and the boom extend ram 5 operates. The main
system pressure will now be equal to the load sense
pressure (load from the boom extend ram) plus the force
spool and back to the tank in the normal way.

in parallel. When multiple services are operated at the
same time, the operating pressure of one service can have
an effect on the speed of another service. This does not
occur with flowshare.
The pressure compensator valves for each service adjust

in relation to the differing load pressures. For example,
when a pressure compensator valve 3F senses a higher
load sense pressure from another service, it decreases the
flow to its own service. The decrease in flow makes sure
that all the services operate at a stable speed
independently of the main system pressure.
E6-20 9803/3760-07 (E-01-09) E6-20

C094150-C2
ACC
T1
P1
TP2
BAR
BAR
0.7
0.7
30 BAR

TP1
T2
2 P
P2
E6-21 9803/3760-07 (E-01-09) E6-21


K Fig 7. ( T E6-23)
The maximum main system pressure is controlled by the

load sense pressure valve.
When a service ram is at the end of its stroke or there is a

resistance, the pressure in the load sense line increases.
When this pressure is above a pre-set value (e.g. 215 bar),
the load sense relief valve 3C opens and load sense oil is
sent to tank, to stop an increase in pressure. The flushing
valve 3A operates as normal.
At the same time, the pump flow compensator valve 1C

decreases the tilting swashplate angle towards its
minimum angle in relation to the load sense pressure. The
decrease in the swashplate angle causes the output flow
from the pump to decrease. The pump supplies only the
minimum flow needed to keep the system pressure at the
maximum limit.
The main system pressure necessary to open the flushing

valve is 25 bar above the load sense pressure. For
example if the load sense relief valve opens at 215 bar, the
maximum main system pressure will be 215 bar + 25 bar,
a total of 240 bar.

the purpose of explanation only. For the correct values see
Technical Data. The load sense pressure relief valve is
factory set and sealed with a plastic tamper proof cap. No
adjustment is normally necessary.

Full Pressure
Load Sense Line
Servo
Neutral
Exhaust
E6-22 9803/3760-07 (E-01-09) E6-22

C094150-C3
ACC
T1
P1
TP2
BAR
BAR
0.7

0.7
30 BAR
TP1
T2
2 P
P2
E6-23 9803/3760-07 (E-01-09) E6-23


Operation
A405030-1
Fig 8.


E6-24 9803/3760-07 (E-01-09) E6-24

Operating a Service
A405041-1
Fig 9.
rise as follows:


E6-25 9803/3760-07 (E-01-09) E6-25

714761-1
Fig 10.

of the services.

spool.

E6-26 9803/3760-07 (E-01-09) E6-26

714771-1
Fig 11.
E6-27 9803/3760-07 (E-01-09) E6-27

Variflow Hydraulic Pump
C051000-C3
Fig 12.

Item Description
J Swash plate control spring
A Drive shaft. Driven from the bevel gearbox
K Swash plate
B Inlet (suction) port
L Axial pistons
C Outlet port
D Separate gearpump (cooling fan circuit) driven by The hydraulic services pump is a variable displacement
drive shaft A. axial piston pump, which uses the swash plate design
principle.
E Hydraulic control valve
F Pressure cut off safety valve spool Rotation of the input drive shaft A produces linear
F1 Pressure cut off safety valve adjuster cover (not movement of the axial pistons L. The pump output is
adjustable) controlled via the swash control piston H. The piston varies
G Flow compensator valve spool
G1 Flow compensator valve adjuster cover (not of changing the hydraulic oil flow in the system.
adjustable)
H Swash control piston The swash control piston is controlled by two systems:
E6-28 9803/3760-07 (E-01-09) E6-28


– The hydraulic control valve E operates to ensure the

torque required to turn the pump does not exceed the
maximum engine torque. Two types of valve are
installed depending on the machine variant. Refer to
the correct pump operation descriptions:
K Variflow Hydraulic Pump - Power

Control ( T E6-30)
K Variflow Hydraulic Pump - HVCS ( T E6-33)
E6-29 9803/3760-07 (E-01-09) E6-29

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
E6-30 9803/3760-07 (E-01-09) E6-30

Flow Compensator Valve
When the output flow is enough to satisfy the flow

demanded by the service, the pump operating pressure P
(red) increases sufficiently to start to move the service ram.
The increase in the pump operating pressure pushes the
flow compensator spool D back to the left, against the force
of the spring E and hydraulic load sense pressure; this in
turn increases the control pressure acting on the swash
control piston C, which decreases the angle of the
swashplate A against the force of spring B. As the
swashplate angle decreases, the output flow from the
pump decreases. In this way, the pump delivers only the
required to operate the service.
Note: The flow compensator spool D is moving constantly,

thereby regulating the pump swashplate to balance the
pressures acting on each end of the spool. The additional
force of spring E is factory set to be equivalent to 25 bar
(360 lbf/in2), therefore the pump operating pressure (i.e.
main system pressure) will always be maintained at 25 bar
above the load sense pressure. This is sometimes
referred to as the `Delta-P' pressure setting.
Pressure Cut-Off Valve
The pressure cut-off valve is a secondary safety device to

limit the maximum operating pressure, and thereby protect
the pump from over pressurisation. If the pump operating
pressure P (i.e. main system pressure) ever reaches the
setting of the valve springs F, the pressure cut-off spool G
will be pushed to the left, this in turn, increases the control
pressure acting on the swash control piston C, which
decreases the angle of the swashplate, and reduces the
pump output flow to minimum. While the pressure cut-off
valve is operating, the pump will remain hydraulically
stalled i.e. maintaining maximum operating pressure at
minimum flow.
E6-31 9803/3760-07 (E-01-09) E6-31

Power Control Valve – As the pump flow increases so the pressure from
springs S decreases. The valve spool X moves at a
While the pressure cut-off valve protects the pump from lower system pressure.
over pressurisation it can not prevent the torque required – As the pump flow decreases so the pressure from
to turn the pump stalling the engine. The pump torque is a springs S increases. The valve spool X will now move
function of the hydraulic flow and pressure. at a higher system pressure.
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.
L C X In reality the valve spool X is constantly cycling between its

two positions when the torque required to turn the pump is
S1 L1 L near the maximum torque available from the engine.
C094000
Fig 14.
The power control valve spool X controls the control

pressure acting on the swash control piston C. The valve
is down stream of the flow compensator valve D and has
direct control of the swash piston control pressure.
When the system pressure from the pump is sufficient to

overcome the force from springs S the valve spool X
moves to allow oil from the pump outlet to act directly on
the swash control piston C. The angle of the swashplate
decreases reducing the flow and the engine torque
required to turn the pump.
The pressure required to overcome the force from springs

S is variable. The mechanical link L increases the force on
springs depending on the position of the control piston C.
E6-32 9803/3760-07 (E-01-09) E6-32

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
E6-33 9803/3760-07 (E-01-09) E6-33

Parallel Lift (S1)

Ram Operation

lowers.

C094840
boom pivot.
E6-35 9803/3760-07 (E-01-09) E6-35

C094820
E6-36 9803/3760-07 (E-01-09) E6-36

10.
C094820-C1
E6-37 9803/3760-07 (E-01-09) E6-37

Parallel Lift (S2)

Ram Operation

lowers.

C094810
pivot.
E6-38 9803/3760-07 (E-01-09) E6-38

C094800-C1
E6-39 9803/3760-07 (E-01-09) E6-39

the tilt ram 10.
C094800
E6-40 9803/3760-07 (E-01-09) E6-40

Parallel Lift (S3)

Ram Operation

lowers.

C083280
pivot.
E6-41 9803/3760-07 (E-01-09) E6-41

C094880
E6-42 9803/3760-07 (E-01-09) E6-42

10.
C094880-C1
E6-43 9803/3760-07 (E-01-09) E6-43

Hydraulic Variable Control System Condition Light Status HVCS Status

(HVCS) Ignition On Light On Indicates HVCS system is
present
This section explains how the HVCS electrical system
works. Engine Light Off Normal HVCS Operation
Running
K Fig 27. Electrical Schematic - HVCS ( T E6-45) Engine Light On Hydraulic Oil Overheated
Running (hydraulic pump output is
K Fig 28. Wires and Connectors - HVCS ( T E6-46) automatically reduced
until oil temperature falls).
K Connector and Device Key ( T E6-60) Engine Light Flashes HVCS Fault
Running
Central to the system is the pump controller electronic
control unit (ECU) 4008 mounted in the engine
compartment. The ECU receives an engine load signal

C053110
The instrument panel HVCS warning light illuminates as

follows:
E6-44 9803/3760-07 (E-01-09) E6-44

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
Àctive' warning light
3047 HVCS Proportional solenoid valve (Variflow
pump)
5014 Hydraulic fluid temperature sensor (Variflow
pump - suction port)
E6-45 9803/3760-07 (E-01-09) E6-45

C050942-C2
E6-46 9803/3760-07 (E-01-09) E6-46

Electro Servo Control
K Joystick and Controller ( T E6-48)

K Proportional Signal Generation ( T E6-49)
K Operator Interface ( T E6-50)
K System Enable and Isolation ( T E6-52)
K Auxiliary Changeover ( T E6-53)
K Constant Auxiliary ( T E6-55)
K Extend/Retract and Auxiliary Services
(Thumbwheel Switches) ( T E6-56)
K Lift/Lower and Tilt Services ( T E6-58)
E6-47 9803/3760-07 (E-01-09) E6-47

Joystick and Controller
All of the machine hydraulic services are actuated

electrically. CAN enabled electronic control units and
proportional solenoid valves are central to the system.
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
E6-48 9803/3760-07 (E-01-09) E6-48

Proportional Signal Generation
When the control lever A is operated, the plunger B

pushes against the return spring C. A variable resistor
position sensor is allocated to each axis. Slider D moves
up or down when the lever is moved changing the electrical
voltage depending on lever position.
Note: The position sensors are integral with the joystick

controller ECU. If a sensor is defective the controller ECU
must be renewed.
Fig 30.
E6-49 9803/3760-07 (E-01-09) E6-49

Operator Interface

Joystick isolation switch K System Enable and Rocker switch. Press switch to isolate/enable the joystick
Isolation ( T E6-52) operated services.
Joystick control lever K Electro Servo Control Proportional control of all the hydraulic services by means
Lever ( T E6-17) of moving the lever and thumbwheel switches.
Constant auxiliary switch K Constant Rocker switch. Press switch to isolate/enable the constant
Auxiliary ( T E6-55) auxiliary service.
Constant auxiliary set button K Constant Momentary button. Press to set the constant auxiliary flow
auxiliary system.
Auxiliary II select button K Auxiliary Momentary button. Press to change between Auxiliary I
Changeover ( T E6-53) and Auxiliary II. The system will not function if the constant
auxiliary system is enabled.
Hydraulic system stop button K System Enable and Latching button. Latch the button to isolate the pump flow
Isolation ( T E6-52) from the main control valve.
Tilt isolation switch K System Enable and Rocker switch. Press switch to isolate/enable the tilt
Isolation ( T E6-52) service.
E6-50 9803/3760-07 (E-01-09) E6-50

Hydraulic Control ECU Power and Ground K Electrical Schematic - Hydraulic Control ECU
Power and Ground ( T E6-51)
K Electrical Schematic - Hydraulic Control ECU Key
Power and Ground ( T E6-51)
4019 Hydraulic control ECU - connector J1
Key
+025 Fuse - battery compartment
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
E6-51 9803/3760-07 (E-01-09) E6-51

System Enable and Isolation The system will not enable unless switch 1032B is latched.
When switch 1032B is not latched its input is sensed by
hydraulic control ECU via connector 4019. The ECU
K Electrical Schematic - System Enable and
energises the pump shut off valve solenoid coil 3064.
Isolation ( T E6-52)
Key Tilt isolation switch 1049 state is sensed by inputs at the
1032B Hydraulic stop switch hydraulic control ECU connector via 4019. The ECU
isolates the joystick control by switching off the PWM
1047 Joystick controls isolation switch signals to the control valve tilt spool proportional solenoids.
1049 Tilt isolation switch
3064 Pump shut off valve solenoid Joystick isolation switch 1047 state is sensed by inputs at
the hydraulic control ECU via connector 4020. The ECU
4019 Hydraulic control ECU - connector J1 isolates the joystick controls by switching off the PWM
4020 Hydraulic control ECU - connector J2 signals to the control valve proportional solenoids.
- 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
HYDRAULIC CONTROL ECU
C094110
Fig 32. Electrical Schematic - System Enable and Isolation
E6-52 9803/3760-07 (E-01-09) E6-52

Auxiliary Changeover
K Electrical Schematic - Auxiliary

Key
1077A Joystick auxiliary changeover switch
2035 Second auxiliary relay
3010 Auxiliary changeover valve solenoid
4022A CAN joystick controller ECU
4022B CAN joystick controller ECU
When momentary switch 1077A pressed the joystick

controller ECU 4022A senses the switch input. It responds
by broadcasting a message on the machine CAN bus. The
CAN message is read by the hydraulic control ECU CAN
bus interface on connector 4019. The ECU responds by
energising the relay 2035 via connector 4020. Auxiliary
changeover solenoid valve coil 3010 is energised and oil is
diverted to the Auxiliary II circuit.
A CAN message causes the LMS display AUX II indicator

LED to come ON.
When momentary switch 1077A pressed again the

hydraulic control ECU responds by de-energising the relay
2035. Auxiliary changeover solenoid valve coil 3010 is de-
energised and oil is diverted to the Auxiliary I circuit.
A CAN message causes the LMS display AUX II indicator

LED to go OFF.
E6-53 9803/3760-07 (E-01-09) E6-53

-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
P002 68
FUSE 6
P001
FUSE 4
-004
IGN +VE
C094120
Fig 33. Electrical Schematic - Auxiliary Changeover
E6-54 9803/3760-07 (E-01-09) E6-54

Constant Auxiliary hydraulic control ECU holds the auxiliary spool on a
constant position by means of the PWM signals to the
spool proportional solenoids.
K Electrical Schematic - Constant
Auxiliary ( T E6-55)
A CAN message causes the LMS display constant
Key auxiliary indicator LED to come ON.
When momentary switch 1077B pressed the joystick
1077B Joystick constant auxiliary switch controller ECU 4022B senses the switch input. It responds
4019 Hydraulic control ECU - connector J1 by broadcasting a message on the machine CAN bus. The
4020 Hydraulic control ECU - connector J2 CAN message is read by the hydraulic control ECU CAN
bus interface on connector 4019. The ECU responds by
4022B CAN joystick controller ECU holding the auxiliary spool in the position set by the
operator (thumbwheel switch position). The selected spool
The constant auxiliary switch 1049 state is sensed by position is also stored by the ECU and is automatically re-
inputs at the hydraulic control ECU via connector 4020. selected when the operator selects the constant auxiliary
When constant auxiliary is enabled by the operator the function again.
-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
IGN +VE HYDRAULIC CONTROL ECU
C94130
Fig 34. Electrical Schematic - Constant Auxiliary
E6-55 9803/3760-07 (E-01-09) E6-55

Extend/Retract and Auxiliary Services
(Thumbwheel Switches)
K Electrical Schematic - Extend/Retract and

Auxiliary Services (Thumbwheel
Switches) ( T E6-57)
Key
1076A Thumbwheel switch - auxiliary service
1076B Thumbwheel switch - extend/retract
service
auxiliary A service
auxiliary B service
extend service
retract service
ECU 4022 provides thumbwheel switches 1076A and

1076B with a 5V power supply via pin 4.
The thumbwheels send a voltage between 0.7V and 4.3V

to the ECU 4022 on pin 6 (switch 1076A) and pin 5 (switch
1076B). The voltage is determined by the position of the
thumbwheel switch. ECU 4022 responds by broadcasting
thumbwheel position as a message on the machine CAN
bus.
The CAN message is read by the hydraulic control ECU

CAN bus interface on connector 4019. The ECU responds
by producing a PWM signal in proportion to the
thumbwheel position to the proportional solenoid coils
3007, 3008, 3019 and 3038 for operation of the service
spools.
E6-56 9803/3760-07 (E-01-09) E6-56

-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
IGN + VE
C094070
Fig 35. Electrical Schematic - Extend/Retract and Auxiliary Services (Thumbwheel Switches)
E6-57 9803/3760-07 (E-01-09) E6-57

Lift/Lower and Tilt Services
K Electrical Schematic - Lift/Lower and Tilt

Services ( T E6-59)
Key
crowd service
dump service
3030 Proportional control valve solenoid - lift
service
3032 Proportional control valve solenoid - lower
service
ECU 4022 responds to operation of the joystick by

broadcasting the joystick position as a message on the
machine CAN bus.
The CAN message is read by the hydraulic control ECU

CAN bus interface on connector 4019. The ECU responds
by producing a PWM signal in proportion to the joystick
position to the proportional solenoid coils 3015, 3017,
E6-58 9803/3760-07 (E-01-09) E6-58

-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
Fig 36. Electrical Schematic - Lift/Lower and Tilt Services
E6-59 9803/3760-07 (E-01-09) E6-59

Connector and Device Key
ECU connector pins.
-008
M10
1015 Constant Auxiliary Enable Control lever console.
Switch
1032B Hydraulic Stop Switch Control lever console.
1047 Joystick Isolation Switch Control lever console.
1049 Tilt Isolation Switch Control lever console.
1076 Joystick Thumbwheels Below joystick controller.
1077 Joystick Buttons and Below joystick controller.

Switches

3007 Auxiliary A Solenoid Located at the electro servo valve block.
3008 Auxiliary B Solenoid Located at the electro servo valve block.
E6-60 9803/3760-07 (E-01-09) E6-60

Fault Finding
Fault Finding
This system has diagnostics pages in JCB

Servicemaster. Use of Servicemaster is the preferred
method for fault finding electrical or electronic faults.



to the hydraulics.



circuit.



Some system faults are logged as an error code. These
error codes can be accessed with the correct
Servicemaster diagnostics software tool.
E6-63 9803/3760-07 (E-01-09) E6-63

Fault Finding
Tables
Fault Descriptions:
K Table 15. Servo operated spool services slow to operate or low auxiliary flow ( T E6-66)

defective.
Flushing valve piston within the control valve block end Dismantle and inspect the flushing valve piston.
E6-64 9803/3760-07 (E-01-09) E6-64

Fault Finding

Flushing valve piston within the control valve block sticking Dismantle and inspect the flushing valve piston.
open due to contamination.
– 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.

Insufficient output flow from variflow pump: – Check the function of the variable pump solenoid
(HVCS) electrical circuit. Check the throttle position
– Pump horsepower solenoid (HVCS) (if fitted) is sensor. Check condition of the associated electrical
permanently energised. wiring for damage and short circuits.
– Failure of the pump, or internal tilting swashplate – Renew the pump and flush the hydraulic system to
mechanism due to contamination. remove all contamination.

trapped or kinked.
Associated service spool not operating correctly. – Check the condition of the related harness wiring and
– Due to faulty service spool solenoid. open or short circuits. Measure the solenoid coil
– Due to a fault with the electronic control lever resistance. Renew the solenoid coil.
assembly. – Check the condition of the related harness wiring and
connectors for damage. Renew the electronic control
lever assembly.
compensator piston.
E6-65 9803/3760-07 (E-01-09) E6-65

Fault Finding

defective.


Table 15. Servo operated spool services slow to operate or low auxiliary flow

Fault in electrical circuit wiring, joystick controller, hydraulic Check the condition of the associated electrical wiring for
control ECU: damage and that the fuses are intact.

– Faulty joystick controller. – Check the applicable solenoid coil for open or short
– Faulty hydraulic control ECU
the solenoid coil.
. – Renew the joystick controller.
– Renew hydraulic control ECU.
– Due to faulty pilot pressure supply valve.

E6-66 9803/3760-07 (E-01-09) E6-66

Fault Finding


from circuit.
contamination.
E6-67 9803/3760-07 (E-01-09) E6-67

Test Procedures
Test Procedures
Checking Pump Flow

E6-68 9803/3760-07 (E-01-09) E6-68

Test Procedures
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.
operated. point A and connect to ‘Channel 2’ on the test set.
P pressure.
hydraulic system.

Service Tools).
!MWARNING

GEN-4-1_1
!MWARNING
Hydraulic Pressure
the hoses are open.
INT-3-1-11_2 C075860
Fig 37.
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.
E6-69 9803/3760-07 (E-01-09) E6-69

Test Procedures
auxiliary thumbwheel J towards the rear of the machine as
this will change which couplings are flow and return.
!MCAUTION
damage the pump.
HYD-4-4_1


speed.
b Do not operate any hydraulic services.

C047960
Fig 38.
5 Connect a flow meter F and load valve G to the pump standby pressure.
auxiliary quick release couplings H on the boom. See
Section 1 - Service Tools. 8 Measure the Delta P Pressure:

(Delta P).
b Push the auxiliary thumbwheel J towards the front

of the machine.

(Maximum).

C075900
Fig 39.

is the return with the thumbwheel pushed towards the front
E6-70 9803/3760-07 (E-01-09) E6-70

Test Procedures
pressure figures subtract the Load sense
pressure figure from the pump pressure figure.
The resulting figure is the delta-P pressure.
Example:
9

Pressure Pressure Pressure
240 bar - 220.5 bar = 19.5 bar

speed.



steering pressure.
Table 18.
Relief
Compare the recorded pressures to those specified in


Adjustment ( T E6-72).
E6-71 9803/3760-07 (E-01-09) E6-71

Test Procedures

B4 A4
To adjust the delta-P pressure, loosen the locknut A

and turn the adjuster screw B (at the variflow pump as B3 A3
shown). Turn the adjuster screw clockwise to

increase pressure and counter-clockwise to decrease B2 A2
the pressure.
B1 A1
LS
P
T
C
C094030
Fig 41.
C075860-C1
Fig 40.
After adjustment also check the load sense pressure


2 Tighten the locknut A.

Relief Valve):

hydraulic pressure.

valve C. Loosen the locknut and turn the adjuster
screw clockwise to increase pressure and
counter-clockwise to decrease the pressure.
E6-72 9803/3760-07 (E-01-09) E6-72

Test Procedures

C
!MWARNING

GEN-4-1_1 A
Note: Solenoid valve C is not part of the servo pilot
pressure supply valve.
B
Make sure that the hydraulic oil is at working temperature, C094010
i.e. 50°C (122°F). Fig 42.
1 Connect a 0 - 70 bar (0 - 1000 lbf/in2) pressure gauge

to the servo pressure test point A (at the servo
pressure supply valve as shown).

30 bar (30.6 kgf/cm2, 435 lbf/in2)
If the servo pressure is not correct do the following:
– Check the fan pump pressure. The pressure must be

more than 30 bar for the servo pilot pressure
regulating valve B to work correctly.
– Install new filters at the inlet port.

and sealed with a plastic tamper proof cap. If the valve is
defective replace it with a new one.
E6-73 9803/3760-07 (E-01-09) E6-73

Test Procedures
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
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.
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)
Topics ( T E6-3)
!MWARNING
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
E6-74 9803/3760-07 (E-01-09) E6-74

Test Procedures

C082990
Preparation
T040560-2
ground.


pump solenoid 1.

1.

chassis harness 2.

T040550-1
(122°F).
E6-75 9803/3760-07 (E-01-09) E6-75

Test Procedures
Table 19.
operated)
1500 - 1700 0.95 - 1.05


E6-76 9803/3760-07 (E-01-09) E6-76

Test Procedures

solenoid 1.


for damage.
T040570-1
Fig 47.
E6-77 9803/3760-07 (E-01-09) E6-77

Test Procedures
Test 4


T040620-1
Fig 49.
Test 4b

Expected Values:
25°C 7600 - 8400 ohm
50°C 2650 - 2950 ohm.

T040610-1
Fig 48.
Test 4a

E6-78 9803/3760-07 (E-01-09) E6-78

Test Procedures
further assistance.
engine connector 6.

connector.

E6-79 9803/3760-07 (E-01-09) E6-79

Test Procedures
T040940-1
Fig 55.
E6-81 9803/3760-07 (E-01-09) E6-81

Bleed Procedures
Bleed Procedures
Tilt Ram Circuit


tilt ram.



times.

engine.

Fig 56.
E6-82 9803/3760-07 (E-01-09) E6-82

Bleed Procedures
E6-84 9803/3760-07 (E-01-09) E6-84


Introduction

K 4 Spool Valve Block ( T E7-4)
K ECU Controlled ‘Flowshare’ ( T E7-10)
K Single Lever Control ( T E7-10)
K Lift/Lower and Crowd/Dump Services ( T E7-12)
K Extend/Retract and Auxiliary Services ( T E7-16)
K Main system Pressure Relief, System Isolation ( T E7-19)
K 4 Spool Control Valve (Single Lever Control) ( T E7-22)
K Parallel Lift ( T E7-24)
K Servo Control - Operator interface ( T E7-30)
K Electronic Fault Codes ( T E7-40)
K Tables ( T E7-41)
K Main Relief Valve (MRV) Pressure ( T E7-48)
E7-1 9803/3760-07 (E-01-07) E7-1

Introduction
K Auxiliary Relief Valve Pressure (ARV) - ARV’s set lower than the MRV ( T E7-49)
E7-2 9803/3760-07 (E-01-07) E7-2

Related Topics
Related Topics

1 Applications ALL
1 Service Tools ALL
C Machine Control ECU ALL
E K Pilot Manifold Block ( T E22-1) ALL
E K Servo Parallel Control Valve ( T E17-1) ALL
E K Control Lever - Electro Servo (S1) ( T E26-1) ALL
E K Smooth Ride SYSTEM (SRS) - Servo ALL
Parallel ( T E12-1)
M Electronic Control Unit Theory ALL
M Pulse Width Modulation Theory ALL

892/00253(1) Hydraulic Pressure Test Kit and Relevant Adaptors
892/00270 (1) Load Valve
E7-3 9803/3760-07 (E-01-07) E7-3

Specifications
Specifications
4 Spool Valve Block
Spool 1 Lift and Lower Service Servo pilot operated

Spool 2 Carriage Tilt Service Servo pilot operated
Relief Valve Pressures: K Fig 1. ( T E7-4),

bar kgf/cm2 lbf/in2
2K - Auxiliary Ram Rod Side 180 183.5 2610.6
2L - Auxiliary Ram Head Side 180 183.5 2610.6
11 B - Carriage Tilt Ram Rod Side 260 265 3770
11 C - Carriage Tilt Ram Head Side 295 300.8 4278.6
Pilot Pressure Range: bar kgf/cm2 lbf/in2

All Machines 10 - 30 10.2 - 30.6 145 - 435
764190-2-C2
Fig 1.
E7-4 9803/3760-07 (E-01-07) E7-4

Specifications
Cooling Fan Motor

Up to March 09
SD 63 kW engines :
Type: Gear motor
Body Colour Red
Type: Gear motor
Body Colour Black
SD 63 kW engines :
Type: Gear motor
Body Colour Red

Type: Gear motor
Body Colour Black
E7-5 9803/3760-07 (E-01-07) E7-5

Specifications
From Jan 2011
SD 63 kW engines :
Type: Gear motor
Type: Gear motor
Body Colour Black
E7-6 9803/3760-07 (E-01-07) E7-6

Operation Overview
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)

Item Description
K Fig 2. ( T E7-9)
1 Pump assembly Two section gearpump 1A, 1B K Main Pump -
Gearpump ( T E24-1)
2 Control valve block Parallel valve block with hydraulic servo K Parallel Control Valve - 4
and electro-servo spools Section ( T E13-1)
5 Pilot manifold block K Pilot Manifold
Block ( T E22-1)
6 Pilot filter
7 Machine control ECU
8 Hydraulic control lever
9 Thumbwheel controls Operate extend/retract and auxiliary
services
10 Constant flow switch Sets required auxiliary circuit flow rate
11 Auxiliary switch Selects or de-selects hydraulic auxiliary II
circuit
12 Control isolation switch Isolates servo pilot pressure from all
control valve spools
13 Tilt isolation switch (if fitted) Isolates servo pilot pressure from the tilt
control valve spool
15 Servo accumulator Enables spool operation if the engine fails
16 Full lock (isolation) solenoid
17 Boom lower pressure switch/ Senses servo pilot pressure at the boom
transducer lower spool
18 Boom lift pressure switch/ Senses servo pilot pressure at the boom
transducer lower spool
19 Tilt lock solenoid (if fitted)
20 Spool proportional solenoids
F Hydraulic oil filter Positioned in the return line to tank (filter
housing is part of the hydraulic tank)
T Hydraulic tank
E7-7 9803/3760-07 (E-01-07) E7-7

Operation Overview
Oil from pump section 1A Oil from pump section 1B Oil suction line from the tank to
the pump sections
Return to tank
E7-8 9803/3760-07 (E-01-07) E7-8

Operation Overview
C087620
Fig 2. Component Location and Identification
E7-9 9803/3760-07 (E-01-07) E7-9

Operation Overview
Hydraulic Pump PWM controller electronic control unit (machine control

ECU) 7.
K Fig 2. ( T E7-9). Oil is drawn from the hydraulic tank T
by the hydraulic pump assembly 1. The pump assembly is The ECU receives analogue electrical inputs from the
mounted on the rear of the bevel gearbox and is driven by thumbwheel switches and supplies a modulated output
the engine. signal (PWM) to the relevant proportional solenoid.
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.
Single Lever Control

K Fig 2. ( T E7-9). The single lever control has a control
lever 8 which moves in two axis, and operates the boom lift
service and carriage tilt service by directing servo pilot oil
to actuate the spools in the control valve block 2.
The control lever incorporates two proportional control

thumbwheel switches 8. The thumbwheels operate the
boom extend/retract service and the auxiliary service.
The thumbwheels control four electro-hydraulic

proportional solenoids housed in the control valve block 2.
Central to the control of the proportional solenoids is the
E7-10 9803/3760-07 (E-01-07) E7-10

Operation Overview
Control Lever
follows:

Control Lever - AXIS One Servo pilot oil Control valve - SPOOL One
Control Lever - AXIS Two Servo pilot oil Control valve - SPOOL Two

electrical signal

electrical signal
E7-11 9803/3760-07 (E-01-07) E7-11

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
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.
Note that oil from pump 1A also supplies the steer

circuit via steer priority valve 1D. As there is no
steering load this flows through the valve spool 2E.
Service Operation
K Fig 4. ( T E7-14). The control valve block pilot
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.
Tilt Isolation (if fitted)
K Fig 5. ( T E7-15). When the machine operator

selects the tilt (crowd/dump) isolation via a switch in
cab the isolation solenoid 3D de-energises and stops
the pilot flow to the control valve spool 2E.
E7-12
C087330
E7-13 9803/3760-07 (E-01-07) E7-13

C087330-C1
E7-14 9803/3760-07 (E-01-07) E7-14

C087330-C4
Fig 5. Tilt Isolation
E7-15 9803/3760-07 (E-01-07) E7-15

Extend/Retract and Auxiliary Servo
Services
E7-16
Neutral
Exhaust
to Section 1. K Related Topics ( T E7-3)
K Fig 6. ( T E7-17). 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.
Note that oil from pump 1A also supplies the steer

circuit via steer priority valve 1D. As there is no
steering load this flows through the valve spool 2E.
Service Operation
K Fig 7. ( T E7-18). The control valve block pilot

pressure valve 2B supplies a low pressure supply to
the manifold block via filter 3A.The system isolation
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.

Full Pressure
E7-16
C087360
E7-17 9803/3760-07 (E-01-07) E7-17

C087360-C1
E7-18 9803/3760-07 (E-01-07) E7-18

Main system Pressure Relief, System
Isolation
E7-19
to Section 1. K Related Topics ( T E7-3)
K Fig 8. ( T E7-20). When a service ram reaches the

end of its stroke, or the service meets resistance and
generates pressure above a specified pressure, the
main relief valve 2A opens and oil is dumped to tank,
preventing further pressure rise.
System Isolation
K Fig 9. ( T E7-21). When the machine operator

selects the hydraulic isolation via a switch in the cab,
the isolation solenoid 3C de-energises and stops the
flow to the valve block 2 and no hydraulic services can
be operated.
9803/3760-07 (E-01-07)
Full Pressure
Servo
Neutral
Exhaust
E7-19
C087360-C2
E7-20 9803/3760-07 (E-01-07) E7-20

C087360-C3
Fig 9. System Isolation
E7-21 9803/3760-07 (E-01-07) E7-21

4 Spool Control Valve (Single Lever

Control)
K Fig 10. ( T E7-23)
adjustable main relief valve (MRV) 2A, the pressure
reduction valve 2B and pressure maintaining valve 2C.
Valves 2B and 2C are not adjustable.
Pressure reduction valve 2B provides oil at pilot pressure

from port 2N to the pilot manifold block. Pressure
maintaining valve 2C ensures that the system pressure is
sufficient to supply oil at pilot pressure when no services
are operating. On spools 2D and 2E a pilot pressure
overcomes the spool centralising spring and moves the
spool. External hoses connect pilot oil to each end of the
spools via the pilot manifold block. Spools 2F and 2G use
proportional control solenoids to control the pilot pressure
supply to the spools. The proportional solenoids are
connected to pilot oil from the pilot manifold block via port
2M.
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.
E7-22 9803/3760-07 (E-01-07) E7-22

C085160-C2
Fig 10. 4 Spool Control Valve (Single Lever Control)
E7-23 9803/3760-07 (E-01-07) E7-23

Parallel Lift
Ram Operation

lowers.

C083280-C3
Fig 11. Single displacement ram forward of ram pivot.
E7-24 9803/3760-07 (E-01-07) E7-24

416480-C1
Fig 12. Boom Raise Cycle (Single displacement ram forward of ram pivot)
E7-25 9803/3760-07 (E-01-07) E7-25

10.
displacement ram 9. The oil cannot flow past tilt spool 2F, compensating rams will not cavitate.
416480-C2
Fig 13. Boom Lower Cycle (Single displacement ram forward of ram pivot)
E7-26 9803/3760-07 (E-01-07) E7-26

Thumbwheel Controls – In the mid position (neutral), the thumbwheel output

K Fig 14. ( T E7-29) volts, the ECU output current is 0 mA, therefore
neither the boom èxtend' or `retract' solenoid valves
The control lever incorporates two thumbwheel switches. will energise.
The switches enable proportional control of the boom – When moved forwards, the thumbwheel output
extend/retract and auxiliary hydraulics. Both thumbwheels voltage increases to between 2.5 and 4.3 volts. When
operate in the same way. the ECU input voltage is greater than 2.5 volts, it
sends a corresponding output current to energise the
The thumbwheel A is connected to an electrical boom èxtend' solenoid valve.
potentiometer. A 5v supply is provided by the machine – When moved backwards, the thumbwheel output
control ECU B. As the thumbwheel A is operated a voltage decreases to between 2.5 and 0.7 volts.
variable voltage signal (depending on thumbwheel When the ECU input voltage is less than 2.5 volts, it
position) is sent to the ECU B. The ECU sends a variable sends a corresponding output current to energise the
electrical current to the applicable proportional solenoids C boom `retract' solenoid valve.
and D.
As the operator moves the thumbwheel A from the neutral
The ECU uses two pulse width modulated (PWM) outputs position (plus a small dead band), the valve current signal
to control two proportional solenoids C and D. The from the ECU B will step from 0 to 250 mA. The relevant
proportional solenoids regulate servo pilot oil (at a solenoid valve C will respond and direct servo pilot oil to
pressure proportional to the valve current signal) to move one end of the boom service spool E (as applicable). The
the applicable service spool E the required amount, spool is displaced a small amount, which allows flow from
thereby controlling the speed and direction of the the main hydraulic system to the boom extension ram F,
applicable service ram F. causing the ram to move at a steady rate.
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 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.
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.
supply.


E7-27 9803/3760-07 (E-01-07) E7-27

Component Key: K Fig 14. ( T E7-29)

A Thumbwheel switch - boom extend/retract
A1 Thumbwheel input (degrees)
A2 Thumbwheel output (volts)
B PWM controller (Machine control 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

Current: Pressure:
(or Auxiliary
`Forward'
direction)
(or Auxiliary
`Reverse'
direction)
E7-28 9803/3760-07 (E-01-07) E7-28

C044280-C1
E7-29 9803/3760-07 (E-01-07) E7-29

Servo Control - Operator interface

Electrical schematics are provided for several operational
states of the hydraulic services. A description and cross
reference for the applicable schematic is given in the table.

Extend/retract, auxiliary K Extend/Retract and Control lever thumbwheel switches. Move the
thumbwheel switches Auxiliary thumbwheel switches for proportional control of the
Services ( T E7-31) extend/retract and auxiliary services.
Constant auxiliary enable switch K Constant Momentary switch. Press to enable the constant auxiliary
Auxiliary ( T E7-32) system. The system will not enable until the engine is
running.
Constant flow switch K Constant Momentary button. Press to set the constant auxiliary flow
auxiliary system.
Auxiliary switch K Auxiliary Momentary button. Press to change between Auxiliary I
Changeover ( T E7-34) and Auxiliary II. The system will not function until the
engine is running. The system will not function if the
constant auxiliary system is enabled.
Control isolation (full lock) K System Latching switch. Latch the switch to isolate hydraulic
switch Isolation ( T E7-35) servo pilot pressure from the servo system.
Tilt isolation switch K System Latching switch. Latch the button to isolate hydraulic
Isolation ( T E7-35) servo pressure from the tilt (crowd/dump) spool.
ECU controlled Flowshare K ECU Controlled There are no operator controls or indicators for
Flowshare ( T E7-37) Flowshare. The system operates automatically.
E7-30 9803/3760-07 (E-01-07) E7-30

Extend/Retract and Auxiliary Services Key
7027 Joystick/control lever connector A
Key
A Thumbwheel switch - auxiliary service ECU 4019 provides thumbwheel switches A and B with a
5V power supply via pin 28.
B Thumbwheel switch - extend/retract
service
3007 Auxiliary A proportional solenoid to the ECU 4020 on pin 18 (switch A) and pin 30 (switch
3008 Auxiliary B proportional solenoid B). The voltage is determined by the position of the
thumbwheel switch.
3019 Extend proportional solenoid
3038 Retract proportional solenoid ECU 4020 produces a PWM signal in proportion to the
4019 Machine control ECU connector J1 input voltage to the proportional solenoid coils 3007, 3008,
4020 Machine control ECU connector J2
C063460-C2
Fig 15. Extend/Retract and Auxiliary Services (Thumbwheel Switches)
E7-31 9803/3760-07 (E-01-07) E7-31

Constant Auxiliary
Key
B Joystick constant auxiliary flow switch
1032A Control isolation switch
3008 Auxiliary B proportional solenoid
7028 Joystick/control lever connector B
8004 Chassis harness to panel harness
connector
9001 Fusebox A
The circuit is shown with constant auxiliary enabled.
For constant auxiliary to work switch 1015 must be set to

ON and the lever isolation switch 1032A must be off. The
input at pins 31and 35 of ECU 4020 go high.
When momentary switch B is operated the input at pin 19

of ECU 4020 goes high. Output at pin 7 then goes high.
and the ECU holds a constant current to proportional
solenoid 3008 for constant auxiliary flow.
The ECU transmits a CANbus message to the LMS ECU

to activate the constant flow indicator LED.
When momentary switch B is operated again input at pin

19 of ECU 4020 goes high. Output at pin 7 then goes low.
and current to proportional solenoid 3008 is isolated. The
spool of the auxiliary valve slice moves to stop oil flow in
the auxiliary circuit.
The ECU transmits a CANbus message to the LMS ECU

to de-activate the constant flow indicator LED.
When switch 1015 is set to OFF output at pin 7 of ECU

4020 goes low. Input at pins 31 and 35 of ECU 4020 go low
and the spool of the auxiliary valve slice moves to stop oil
flow in the auxiliary circuit. Operation of momentary switch
B causes ECU 4020 to do nothing.
E7-32 9803/3760-07 (E-01-07) E7-32

C063430-C2
Fig 16. Constant Auxiliary. Status = constant auxiliary enabled.
E7-33 9803/3760-07 (E-01-07) E7-33

System Isolation
Key
1032A Control isolation switch
1049 Tilt isolation switch (if fitted)
3020 Tilt lock solenoid (if fitted)
3023 Full lock solenoid
8004 Chassis harness to panel harness
connector
9002 Fusebox B
9003 Fusebox C
K Fig 18. ( T E7-36)
The circuit is shown with the system enabled.
If the operator selects the hydraulic isolation via switch

1032A, the full lock isolation solenoid 3023 on the pilot
manifold is de-energised and stops pilot oil flow to the
control valve block spools. The machine control ECU 4020
also isolates the current to the valve proportional solenoids
when switch 1032A is set to isolate the system.
On machines with SRS an additional solenoid 3020 is

provided on the pilot manifold to isolate the carriage tilt
circuit when the machine operator selects the tilt isolation
via switch 1049.
E7-35 9803/3760-07 (E-01-07) E7-35

C061590-C3
Fig 18. System Isolation. Status = system enabled
E7-36 9803/3760-07 (E-01-07) E7-36

ECU Controlled Flowshare B). The voltage is determined by the position of the
thumbwheel switch.
Key
When the lower service is operated the pressure switch
A Thumbwheel switch - auxiliary service 1072 closes and informs the ECU 4020 via pin 2 that the
B Thumbwheel switch - extend/retract lower circuit is in operation.
service
When the lift service is operated the pressure switch 1074
1072 Pressure switch/transducer lower closes and informs the ECU 4020 via pin 33 that the lift
1074 Pressure switch/transducer lift circuit is in operation.
3019 Extend proportional solenoid
If the lift/lower pressure switches are closed the ECU
3038 Retract proportional solenoid reduces the PWM signal output to the extend valve
4019 Machine control ECU connector J1 solenoid 4019 or the retract valve solenoid 3038. This
reduces the hydraulic flow to the extend/retract service
allowing a greater flow to the lift/lower circuit which takes
7027 Joystick/control lever connector A priority.
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.
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
E7-37 9803/3760-07 (E-01-07) E7-37

3019 Extend proportional Located on the control valve block.

solenoid
3020 Tilt lock solenoid Located on the pilot manifold block
3023 Full lock solenoid Located on the pilot manifold block
3038 Retract proportional Located on the control valve block.

solenoid
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
coloured white. 12
23
1
13
35 24
7027 Joystick/control lever Located below the joystick/control lever.

connector A
7028 Joystick/control lever Located below the joystick/control lever.

connector B

E7-39 9803/3760-07 (E-01-07) E7-39

Fault Finding
Fault Finding



to the hydraulics.



circuit.



Topics ( T E7-3)
E7-40 9803/3760-07 (E-01-07) E7-40

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 14. Ram creep ( T E7-44)
Table 9. Lack of power at all hydraulic functions

Hydraulic leaks in system. Check hoses, renew as required.
– Renew pump.
E7-41 9803/3760-07 (E-01-07) E7-41

Fault Finding
Table 10. All solenoid/servo operated hydraulic services slow to operate
Neutral circuit or low pressure lines leaking, damaged, Check pipe lines and renew as required.
trapped or kinked.
– Renew pump.
Low pilot pressure. – Check that the pressure maintenance valve is not
sticking open.
– Check the pressure reducing valve.
– Check servo pressure.
– Check pilot pressure supply hose between control
valve and pilot manifold block.
– Renew the servo pilot filter element.
– Renew the pilot pressure supply valve.
– Solenoid valve cartridge damaged, or sticking due to
contamination (solenoid operated spools only).
Solenoid power supply not present (solenoid operated – Check relevant electrical circuit i.e. switches, relays,
spools only). wiring, etc. and rectify as required.
Full lock solenoid valve faulty. – Check relevant electrical circuit i.e. switches, relays,
– Renew valve.
Associated service spool not operating correctly. – Check the condition of the related harness wiring and
– Due to faulty service spool solenoid (solenoid operated open or short circuits. Measure the solenoid coil
spools only). resistance. Renew the solenoid coil.
– Due to a fault with the control lever assembly. – Check the condition of the related harness wiring and
connectors for damage. Renew the control lever
assembly.
E7-42 9803/3760-07 (E-01-07) E7-42

Fault Finding
Table 12. Boom Ext/Ret slow, or low flow from auxiliary service

Fault in electrical circuit wiring, or operation of joystick: Check the condition of the associated electrical wiring for
damage and that the fuses are intact.
– Thumbwheel switch defective.
– Solenoid at the valve block not energising. – Check the function of the applicable thumbwheel
switch.
– Solenoid coil faulty.
– Check the condition of the associated electrical wiring
for damage.
– Check the applicable solenoid coil for open or short
the solenoid coil.
Boom lift/lower pressure switch/transducer faulty – Check relevant electrical circuit i.e. switches, relays,
– Renew switch/transducer.
MRV valve setting incorrect Check and adjust as required.
Table 14. Ram creep

Associated ram or pipe lines from ram leaking. Check and rectify as required.
Check valve. Check operation and rectify as required.

E7-44 9803/3760-07 (E-01-07) E7-44

Fault Finding
from circuit.
contamination.
E7-45 9803/3760-07 (E-01-07) E7-45

Test Procedures
Test Procedures
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

GEN-4-1_1

!MWARNING
Hydraulic Pressure 416111-C9
Hydraulic fluid at system pressure can injure you. Fig 21. Typical Double Pump
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.
the hoses are open. !MCAUTION
INT-3-1-11_2
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
4 Start the engine and bring the hydraulic system up to



A326060-1
Fig 20. Test Equipment
3 Connect a flow meter 20-A, 0-400 bar (0-6000 lbf/in2)

E7-46 9803/3760-07 (E-01-07) E7-46

Test Procedures


!MWARNING
TRANS-1-2

E7-47 9803/3760-07 (E-01-07) E7-47

Test Procedures
Auxiliary Relief Valve Pressure (ARV) -

ARV’s set lower than the MRV

gauge to the test point A.

4 Set the engine to idle rev/min. and operate the

relevant service to full travel. Hold while checking the
maximum gauge reading which should be as stated in
Important: The engine must not be run at maximum

speed as a significant increase in pressure will be
recorded.
5 If the pressure is incorrect, adjust the relevant A.R.V.

K Relief Valve Adjustment ( T E7-52).
416111-C10
Fig 23. Test Point (Typical Double Pump)
E7-49 9803/3760-07 (E-01-07) E7-49

Test Procedures

described below:

Topics ( T E7-3)

Topics ( T E7-3)

as required.

A296360-1
E7-52 9803/3760-07 (E-01-07) E7-52

Test Procedures
C087200-C1
Fig 28.
!MWARNING

GEN-4-1_1

i.e. 50°C (122°F).
1 Working inside the battery compartment, connect a 0

- 70 bar (0 - 1000 lbf/in2) pressure gauge to the servo
pressure test point A.

30 bar (30.6 kgf/cm2, 435 lbf/in2)
Important: The pilot circuit accumulator is a non

E7-53 9803/3760-07 (E-01-07) E7-53

Test Procedures
E7-54 9803/3760-07 (E-01-07) E7-54


Introduction

K Accumulator Charging and Discharging ( T E8-17)
K Accumulator Removal and Replacement ( T E8-19)
E8-1 9803/3760-07 (E-05-00) E8-1

Related Topics
Related Topics

1 Applications ALL
E K Parallel Hydraulic SYSTEM ( T E2-1) ALL
E8-2 9803/3760-07 (E-05-00) E8-2

Specifications
Specifications
Accumulators
Charging Gas Air Free Dry Nitrogen

Accumulator Capacity 1.0 litre (58 cu/in)
Accumulator Weight 4.4 kg (9.75 lb)
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.
Accumulator Charge Pressures Machine Model Application

Bar Psi 531-70, 535-95, 536-60, 541-70, 536-70, 526-56
531-T70 535-T95 536-T60 541-T70 536-T70
- Accumulator 1 10.3 150 z
- Accumulator 2 20 290 z
E8-3 9803/3760-07 (E-05-00) E8-3

Specifications
Replacement Accumulators
Note: Replacement accumulators will only be supplied in

an uncharged, non pressurised condition to meet Health
and Safety, and Air freight hazardous goods requirements. C047780-C1
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).
Important: When replacing the lift ram or hose burst check

valve on machines fitted with SRS, it is important that all
the hydraulic pressure in the accumulators is vented.
Failure to do this may result in the valve being forced out
of the cavity as it is unscrewed. K Removal ( T E8-19)
C033720
Fig 1.
E8-4 9803/3760-07 (E-05-00) E8-4

Operation Overview
Operation Overview
This topic is applicable to machines with parallel

hydraulics. For machines with flowshare hydraulics refer to
the correct topic. K Related Topics ( T E8-2)
The Smooth Ride System (SRS) enhances the comfort of

the ride by damping the forces imposed on the machine by
the movement of the boom as the machine travels over
uneven surfaces. This is achieved by connecting the head
side of the lift ram 4-1 to pressurised piston type
accumulators 4-2.
Piston type accumulators operate as a liquid springs

absorbing displaced fluid from the lift ram.
To activate the SRS system, the pressure in the lift ram

must be less than 40 bar (580 psi), typically when the
boom is fully lowered. This is sensed by the pressure
switch 4-8. Pressing the SRS switch 3-7 in the cab will then
energise the accumulator solenoid valve 4-3, connecting
the piston head side of the lift ram with accumulators 4-2.
The drain solenoid valve 4-5 (chassis mounted) will also
energise and connect the rod side of the lift ram to the
valve block return line 4-6 to make up or dissipate oil as
required.
Note: If the pressure in the lift ram is greater than the

specified limit when the SRS switch is pressed, the system
will not be activated (the solenoid valves will not energise).
Once the SRS system is activated, the boom can then be

raised to the travelling position as required.
711060-1
Fig 3.
E8-5 9803/3760-07 (E-05-00) E8-5

Operation Overview
A356811-1
Fig 4. Typical Installation
E8-6 9803/3760-07 (E-05-00) E8-6

Operation Overview
Service Spool Microswitches

The control valve block 5-A on machines fitted with SRS
has two microswitches 5-B and 5-C. With the SRS system
activated, the microswitches will automatically de-energise
the accumulator and drain solenoid valves momentarily
when the tilt spool or boom lower spool is operated,
allowing the services to operate correctly.
To prevent the ingress of dirt, each microswitch is

protected by a cover 5-D which should be in place during
normal operation.
Note: The microswitches are non-adjustable.
Crowd/Dump Microswitch: When the tilt service is

operated (i.e. to either crowd or dump the carriage) the
spool 5-E opens the contacts on microswitch 5-B, de-
energising the drain valve solenoid.
Boom Lower Microswitch: When the boom is lowered,

the service spool 5-F opens the contacts on microswitch 5-
C, de-energising both the accumulator valve solenoid and
the drain valve solenoid.
732990-1
E8-7 9803/3760-07 (E-05-00) E8-7

A356011-1
Fig 6.

1 Lift ram
2 Accumulators
3 Accumulator solenoid valve
5 Drain solenoid valve (chassis mounted)
6 Valve block return line
8 Pressure switch
9 Hose burst check valve
E8-8 9803/3760-07 (E-05-00) E8-8

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 Àctive' 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).
Crowd or Dump Selected: When the control lever is

moved from neutral, to either crowd or dump, the service
spool microswitch 3 breaks the electrical feed to the drain
valve solenoid 5 which then de-energises. The
microswitch contacts direct current to the accumulator
valve solenoid 6 only, which remains energised.
Boom Lower Selected: When the control lever is moved

from neutral to lower the boom, the service spool
microswitch 2 breaks the electrical feed to the neutral relay
1 which then de-energises. The microswitch contacts
direct current to the dump relay 4 which then energises.
The dump relay contacts break the electrical feed to the
E8-9 9803/3760-07 (E-05-00) E8-9

Fig 9. Boom Lower

Fig 8. Crowd or Dump
Fig 7. Neutral
E8-10 9803/3760-07 (E-05-00) E8-10

C028500-C2
Fig 10. Wires and Connectors
E8-11 9803/3760-07 (E-05-00) E8-11

Table 3. Device and Connector Key
ECU connector pins.
-003 Panel Harness Ground A Refer to Section C - Electrical Harness
M10
-004 Panel Harness Ground B Refer to Section C - Electrical Harness
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
1041 SRS Switch Located on the instrument panel. Remove the


3005 Accumulator Solenoid TBA
(SRS)
3016 Drain Solenoid (SRS) TBA
E8-12 9803/3760-07 (E-05-00) E8-12

1 10
7003 Boom Diode Gate TBA

E8-13 9803/3760-07 (E-05-00) E8-13

Fault Finding
Fault Finding


Topics ( T E8-2)


to the hydraulics.



circuit.


E8-14 9803/3760-07 (E-05-00) E8-14

Fault Finding
Tables
K Table 4. System Will No Activate ( T E8-15)

K Table 5. Unable to Lower the Boom ( T E8-15)
K Table 6. Restricted Boom Suspension Movement When System Switched ON ( T E8-15)
K Table 7. Springy Boom Operation With System Switched OFF ( T E8-15)
K Table 8. No Suspension When System Switched ON ( T E8-15)
K Table 9. Suspension Feels `Hard' (Gas Charge Pressure Increase) ( T E8-16)
K Table 10. Suspension Feels `Soft' (Gas Charge Pressure Decrease) ( T E8-16)
Table 4. System Will No Activate

Excessive pressure in lift ram. Ensure weight of boom is fully supported when activating
system.
Faulty pressure switch. Check switch. Replace as necessary
Note: The system will not engage until the lift ram is fully
closed or the weight of the boom is fully supported.
Table 5. Unable to Lower the Boom

Rod side (drain) solenoid valve open. – Check if solenoid operating, replace as required.
– Check electrical feed to solenoid/switch on back of lift
spool.
Table 6. Restricted Boom Suspension Movement When System Switched ON

Rod side solenoid valve closed. – Check if solenoid operating, replace as required.
– Check electrical feed to solenoid/switch on back of tilt
spool.
Table 7. Springy Boom Operation With System Switched OFF

Head side (accumulator) solenoid valve open. Check if solenoid operating, replace as required.
Table 8. No Suspension When System Switched ON

Electrical supply problem. – Check fuse, replace as required.
– Check for continuity in wiring.
Head side solenoid valve closed. – Check if solenoid operating, replace as required.
spool.
E8-15 9803/3760-07 (E-05-00) E8-15

Fault Finding
Table 9. Suspension Feels `Hard' (Gas Charge Pressure Increase)
Oil to gas leak across accumulator piston. – Discharge, drain and recharge.
– If frequent, replace seals in accumulator.
Table 10. Suspension Feels `Soft' (Gas Charge Pressure Decrease)

Leak across accumulator piston. – Recharge.
E8-16 9803/3760-07 (E-05-00) E8-16

Accumulator Charging and Discharging
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.
8 If charge pressure is low, release hand valve 12-E on

the nitrogen bottle and slowly fill the accumulators.
Close valve 12-E when the charge pressure is
reached on the gauge.
9 Let the pressure settle for 10 to 15 minutes. This will

allow the gas temperature to stabilise. If the charge
pressure is exceeded, with the gas bottle closed,
open bleed valve 12-D. Reduce pressure as
required, then close bleed valve.
!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.
11 Hold the gas valve to keep from turning, loosen the

nut and remove charging tool.
12 Refit gas valve cap and valve guard.
13 Install the accumulator(s) to the machine.
Fig 12.
E8-17 9803/3760-07 (E-05-00) E8-17

Discharging
1 Remove the accumulator(s) from the machine.
2 Remove gas valve guard 12-A and gas valve cap 12-
B.
3 Screw valve 12-C all the way out (counter clockwise)

before attaching charging tool (part no. 892/00948) to
accumulator gas valve.
4 Close bleed valve 12-D.
5 Either connect charging tool to a bottle of

compressed nitrogen gas which is turned off or
remove hose 12-F and fit a suitable blank on charging
tool.
6 Screw valve 12-C all the way in (clockwise), this will

depress the core in the gas valve.
7 Open bleed valve 12-D until all the gas charge is

relieved from the accumulators. Remove the charging
tool.
E8-18 9803/3760-07 (E-05-00) E8-18

Accumulator Removal and Replacement
Removal If an accumulator is suspected as being faulty it must be

renewed as a complete assembly.
!MCAUTION Important: Although identical in appearance, the

You must vent all the hydraulic pressure from the accumulators are charged to different pressures. When
accumulators before disconnecting them from the renewing an accumulator make sure that it is charged to
hydraulic system. the correct pressure.
0043
1 Switch OFF the SRS and lower the boom to the

ground.
2 Power the boom down for three minutes with the

engine at approximately 1000 rev/min. The
accumulators will gradually drain to tank during this
time.
3 Raise the boom and install the safety strut, see

Topics ( T E8-2)
4 Loosen the four nuts 13-2.
5 Disconnect hydraulic connections 13-1 and plug the

ends.
6 Remove the four nuts 13-2 and four washers 13-5

and remove the two Ù' clamps 13-3. Remove the
accumulators 13-4 from their mounting brackets.
Replacement
Replacement is a the opposite of the removal procedure.
During the replacement procedure do this work also:
– Check the accumulator nitrogen pre-charge pressure.

– Operate the machines hydraulic system. Check for
correct operation and leaks.
– Replenish the hydraulic system with the
recommended hydraulic fluid as required, see
Section 3 - Routine Maintenance. K Related
Topics ( T E8-2)
Important: It is not possible to dismantle the

accumulators. The extent of permissible servicing is
limited to checking the nitrogen gas pre-charge pressure.
E8-19 9803/3760-07 (E-05-00) E8-19

A356820-1
E8-20 9803/3760-07 (E-05-00) E8-20


Introduction

E9-1 9803/3760-07 (E-05-02) E9-1

Related Topics
Related Topics

1 Applications ALL
E K LSP Variflow Hydraulic SYSTEM ( T E4-1) ALL
E K LSP Gearpump Hydraulic SYSTEM ( T E3-1) ALL
E9-2 9803/3760-07 (E-05-02) E9-2

Specifications
Specifications
Accumulators

Accumulator Charge Pressures Hydraulic Machine Model Application

Pump
Bar Psi 531-70, 535-95, 536-60, 541-70, 536-70,
531-T70 535-T95 536-T60 541-T70 536-T70
- Accumulator 2 30.3 439.5 z
- Accumulator 1 12.1 175 Gear z
10.3 150 Variflow z
- Accumulator 2 21.4 310 Gear z
20 290 Variflow z
E9-3 9803/3760-07 (E-05-02) E9-3

Operation Overview
Operation Overview

accumulators 4-2.


required.


711060-1
Fig 3.
E9-5 9803/3760-07 (E-05-02) E9-5

Operation Overview
A356811-1
Fig 4.
E9-6 9803/3760-07 (E-05-02) E9-6

Operation Overview
Service Spool Microswitches

The control valve block mechanism 5-A on machines fitted
with SRS has two microswitches 5-B and 5-C. With the
SRS system activated, the microswitches will
automatically de-energise the accumulator and drain
solenoid valves momentarily when the tilt spool or boom
lower spool is operated, allowing the services to operate
correctly.
Crowd/Dump Microswitch: When the tilt service is

operated (i.e. to either crowd or dump the carriage) the
contacts on microswitch 5-B open, de-energising the drain
valve solenoid.
Boom Lower Microswitch: When the boom is lowered,

the contacts on microswitch 5-C open, de-energising both
the accumulator valve solenoid and the drain valve
solenoid.
Note: The microswitches need no adjustment during

normal operation. If it is necessary to remove a
microswitch measure how far the switch body protrudes C029960
from the spool housing before removing. When replacing Fig 5.
be sure screw in the switch to its original position. Test its
operation using a multimeter.
K Electrical Operation and Schematics ( T E9-9).
E9-7 9803/3760-07 (E-05-02) E9-7

A356011-1-C1
Fig 6.

1 Lift ram
2 Accumulators
5A Drain solenoid valve (chassis mounted)(1)
8 Pressure switch
(1) On later machines the drain solenoid valve is fitted

with only one check valve.
E9-8 9803/3760-07 (E-05-02) E9-8

Fig 9. Boom Lower

Fig 7. Neutral
E9-10 9803/3760-07 (E-05-02) E9-10

C028500-C2
E9-11 9803/3760-07 (E-05-02) E9-11

ECU connector pins.
M10
-004 Panel Harness Ground B Refer to Section C - Electrical Harness
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


3005 Accumulator Solenoid TBA
(SRS)
E9-12 9803/3760-07 (E-05-02) E9-12

1 10

E9-13 9803/3760-07 (E-05-02) E9-13

Fault Finding
Fault Finding


Topics ( T E9-2)


to the hydraulics.



circuit.


E9-14 9803/3760-07 (E-05-02) E9-14

Fault Finding
Tables
K Table 4. System Will No Activate ( T E9-15)

Table 4. System Will No Activate

system.

spool.

spool.


spool.
E9-15 9803/3760-07 (E-05-02) E9-15

Fault Finding

E9-16 9803/3760-07 (E-05-02) E9-16

TE-003
Charging


!MCAUTION
vent the hose.

Fig 12.
E9-17 9803/3760-07 (E-05-02) E9-17

Specifications
Specifications
Accumulators


Bar Psi 531-70, 536-60, 541-70, 536-70,
531-T70 536-T60 541-T70 536-T70
E10-3 9803/3760-07 (E-05-03) E10-3

Specifications

Fig 2.

C033720
Fig 1.
E10-4 9803/3760-07 (E-05-03) E10-4

Operation Overview
Operation Overview

accumulators 4-2.


required.


711060-1
Fig 3.
E10-5 9803/3760-07 (E-05-03) E10-5

Operation Overview
A356811-1
Fig 4.
E10-6 9803/3760-07 (E-05-03) E10-6

Hydraulic Schematic
A356011-1
Fig 5.

1 Lift ram
2 Accumulators
8 Pressure switch
E10-7 9803/3760-07 (E-05-03) E10-7

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 Àctive' 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
The current flows through diodes 7048 and latches the

The above table shows the status of the accumulator valve
SRS relay 2038, and illuminates a warning light 4012 to
and drain valve solenoids (either Energised or De-
show that the SRS system is active. At the same time, the
energised) for given control lever positions with the SRS
relay 2049B is also energised by the joystick powerbase
system activated.
ECU 4011(if the lift spool is in neutral). The relay 2049B in
turn energises the drain valve solenoid 3016, and the
accumulator valve solenoid 3005 (via a diode 7003).

moved from neutral, to either crowd or dump there is no
output from the joystick powerbase ECU to relay 2049B.
Drain valve solenoid 3016 de-energises. Accumulator
valve solenoid 3005 remains energised via relay 2049B.
Boom Lower Selected: When the control lever is moved

from neutral to lower the boom, the joystick powerbase
ECU 4011 energises relay 2049A which then energises
relay 2037A. There is no electrical feed to the drain valve
E10-8 9803/3760-07 (E-05-03) E10-8

Fig 8. Boom Lower

Fig 6. Neutral
E10-9 9803/3760-07 (E-05-03) E10-9

C050490-C2
E10-10 9803/3760-07 (E-05-03) E10-10

4011 Joystick Powerbase ECU Located in the servo control pod.
1 10
7036 Powerbase/SRS Diode Located in the servo control pod.

Gate
9000 Fuses Refer to Section 1 - Fuses and Relays.
E10-12 9803/3760-07 (E-05-03) E10-12

Fault Finding
Fault Finding
This system has a diagnostics page in JCB

Servicemaster. Use of Servicemaster is the preferred
method for fault finding electrical or electronic faults.


Topics ( T E10-2)


to the hydraulics.



circuit.


E10-13 9803/3760-07 (E-05-03) E10-13

Fault Finding
Tables
K Table 4. System Will Not Activate ( T E10-14)

Table 4. System Will Not Activate

system.

spool.

spool.


spool.
E10-14 9803/3760-07 (E-05-03) E10-14

Fault Finding

E10-15 9803/3760-07 (E-05-03) E10-15

TE-003
Charging


!MCAUTION
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
vent the hose.

Fig 11.
E10-16 9803/3760-07 (E-05-03) E10-16

Removal If an accumulator is suspected as being faulty it must be

!MCAUTION Important: Although identical in appearance, the

You must vent all the hydraulic pressure from the accumulators are charged to different pressures. When
accumulators before disconnecting them from the renewing an accumulator make sure that it is charged to
hydraulic system. the correct pressure.
0043

ground.

time.

Topics ( T E10-2)
4 Loosen the four nuts 12-2.
5 Disconnect hydraulic connections 12-1 and plug the

ends.
6 Remove the four nuts 12-2 and four washers 12-5

and remove the two Ù' clamps 12-3. Remove the
accumulators 12-4 from their mounting brackets.
Replacement
Replacement is the opposite of the removal procedure.

Topics ( T E10-2)

limited to checking the nitrogen gas pre-charge pressure.
E10-18 9803/3760-07 (E-05-03) E10-18

A356820-1
E10-19 9803/3760-07 (E-05-03) E10-19

E10-20 9803/3760-07 (E-05-03) E10-20


Introduction

E11-1 9803/3760-07 (E-05-06) E11-1

Related Topics
Related Topics

1 Applications ALL
E K LSP Electro Servo Hydraulic SYSTEM ALL
(S2) ( T E6-1)
E11-2 9803/3760-07 (E-05-06) E11-2

Specifications
Specifications
Accumulators


Bar Psi 531-T70 536-T60 541-T70 536-T70
E11-3 9803/3760-07 (E-05-06) E11-3

Specifications

Fig 2.

C033720
Fig 1.
E11-4 9803/3760-07 (E-05-06) E11-4

Operation Overview
Operation Overview
K Fig 3. ( T E11-5) boom is fully lowered. This is sensed by the pressure

transducer 8. Pressing the SRS switch 7 in the cab will
The Smooth Ride System (SRS) enhances the comfort of then energise the accumulator solenoid valve 3,
the ride by damping the forces imposed on the machine by connecting the piston head side of the lift ram with
the movement of the boom as the machine travels over accumulators 2. The drain solenoid valve 5 (chassis
uneven surfaces. This is achieved by connecting the head mounted) will also energise and connect the rod side of the
side of the lift ram 1 to pressurised piston type lift ram to the valve block return line 6 to make up or
accumulators 2. dissipate oil as required.
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
The system is controlled by the hydraulic control ECU 7.
To activate the SRS system, the pressure in the lift ram raised to the travelling position as required.
C094470
Fig 3.
E11-5 9803/3760-07 (E-05-06) E11-5

Hydraulic Schematic
A356011-1
Fig 4.

1 Lift ram
2 Accumulators
8 Pressure transducer
E11-6 9803/3760-07 (E-05-06) E11-6

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.
Table 2. SRS Status Table

SRS ON/ Lower Crowd/ Accumulator Drain Valve SRS Mode SRS
OFF Service Dump Valve Solenoid Solenoid (3016): Indicator
Switch Operation Service (3005): Light
Position Operation Status
ON NO NO Energised Energised SRS Enabled - Active ON
ON YES NO De-energised De-energised SRS Enabled - Not active ON
ON NO YES Energised De-energised SRS Enabled - Active ON
ON YES YES De-energised De-energised SRS Enabled - Not active ON
OFF - - De-energised De-energised SRS Disabled OFF
E11-7 9803/3760-07 (E-05-06) E11-7

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
E11-8 9803/3760-07 (E-05-06) E11-8

ECU connector pins.
M10
3005 Accumulator Solenoid Located on the lift ram

(SRS)
4019 Machine control ECU LH chassis next to the control valve.

connector J1 - black
12 1
23 13
35 24
4020 Machine control ECU LH chassis next to the control valve.

connector J2 - white
12 1
23 13
35 24
7079 Pressure Transducer Lift Located on the lift ram.

Ram

E11-9 9803/3760-07 (E-05-06) E11-9

Fault Finding
Fault Finding

The system is controlled by the hydraulic control ECU. Use

Servicemaster to check the fault code log for related faults.


to the hydraulics.



circuit.


E11-10 9803/3760-07 (E-05-06) E11-10

Fault Finding
Tables


system.
Faulty pressure transducer. Check transducer. Replace as necessary

spool.

Rod side (drain) solenoid valve closed. – Check if solenoid operating, replace as required.
– Check electrical feed to solenoid.


Head side (accumulator) solenoid valve closed. – Check if solenoid operating, replace as required.
– Check electrical feed to solenoid.

E11-11 9803/3760-07 (E-05-06) E11-11

Fault Finding

E11-12 9803/3760-07 (E-05-06) E11-12

TE-003
Charging
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

Close valve 7-E when the charge pressure is reached
on the gauge.

open bleed valve 7-D. Reduce pressure as required,
then close bleed valve.
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.
E11-13 9803/3760-07 (E-05-06) E11-13

Discharging
2 Remove gas valve guard 7-A and gas valve cap 7-B.


tool.


tool.
E11-14 9803/3760-07 (E-05-06) E11-14

A356820-1
E11-16 9803/3760-07 (E-05-06) E11-16


Introduction

E12-1 9803/3760-07 (E-05-04) E12-1

Related Topics
Related Topics

1 Applications ALL
E K Pilot Manifold Block ( T E22-1) ALL
E12-2 9803/3760-07 (E-05-04) E12-2

Specifications
Specifications
Accumulators

Accumulator Weight TBA

Bar Psi 526-56
E12-3 9803/3760-07 (E-05-04) E12-3

Specifications

Fig 2.

C033720
Fig 1.
E12-4 9803/3760-07 (E-05-04) E12-4

Operation Overview
Operation Overview
This topic is applicable to machines with servo parallel

hydraulics. For machines with flowshare hydraulics refer to
the correct topic.
K Fig 3. ( T E12-6)

side of the lift ram 1 to pressurised piston type
accumulators 2.

The system is controlled by the machine control ECU 14.

Switches and transducers, 10, 8, 12 and 13 all provide
ECU inputs. The ECU determines the correct output and
energises solenoid valves 3 and 5 as applicable.
Pressure switches/transducers 12 and 13 are used to

determine if the boom lower and crowd/dump (tilt) services
are operating. This is achieved by sensing the pressure in
the pilot feeds to the applicable spools.

1 Lift ram
2 Accumulators
8 Pressure switch
10 SRS on/off switch
11 Pilot manifold
12 Pressure switch/transducer - crowd/dump spool
operation
13 Pressure switch/transducer - lower spool
operation
14 Machine control ECU
E12-5 9803/3760-07 (E-05-04) E12-5

Operation Overview
E12-6 9803/3760-07 (E-05-04) E12-6

A356011-1
Fig 4.
To activate the SRS system, the pressure in the lift ram 5 Drain solenoid valve (chassis mounted)
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
valve block return line 6 to make up or dissipate oil as
required.


1 Lift ram
2 Accumulators
4 Control valve block - lift/lower spool
E12-7 9803/3760-07 (E-05-04) E12-7

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.
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.
K Fig 7. SRS Crowd/Dump ( T E12-11)

Component Key:
K Fig 8. SRS Lift/Lower ( T E12-12) 1041 SRS On/Off switch
1071 Crowd/Dump pressure switch/transducer
K Electrical Connectors ( T E12-13)
1072 Boom lower pressure switch/transducer
Control lever in Neutral: When the SRS system is 3005 Accumulator valve solenoid
switched ON, current flows from the switch 1041 to the 3016 Drain valve solenoid
machine control ECU 4020 to indicate that the SRS
system has been activated. The machine control ECU 4019 Machine Control ECU connector J1
checks that the lift ram pressure switch 7079 is closed and 4020 Machine Control ECU connector J2
that the boom lower 1072 and crowd/dump 1071 pressure 7079 Pressure switch (lift ram)
switches/transducers are open. If so the ECU 4020
energises the SRS accumulator solenoid 3005 and the
SRS drain solenoid 3016 via pins 10 and 11.
Table 2. Solenoid Status Table

SRS ON/ Lower Crowd/ Accumulator Drain Valve SRS Mode SRS
OFF Service Dump Valve Solenoid Solenoid (3016): Indicator
Switch Operation Service (3005): Light
Position Operation Status
ON NO NO Energised Energised SRS Enabled - Active ON
ON YES NO De-energised De-energised SRS Enabled - Not active ON
ON NO YES Energised De-energised SRS Enabled - Active ON
ON YES YES De-energised De-energised SRS Enabled - Not active ON
OFF - - De-energised De-energised SRS Disabled OFF
E12-8 9803/3760-07 (E-05-04) E12-8

C087450
Fig 5. SRS System Off
E12-9 9803/3760-07 (E-05-04) E12-9

C087450-C1
Fig 6. SRS System On (Neutral)
E12-10 9803/3760-07 (E-05-04) E12-10

C087450-C2
Fig 7. SRS Crowd/Dump
E12-11 9803/3760-07 (E-05-04) E12-11

C087450-C3
Fig 8. SRS Lift/Lower
E12-12 9803/3760-07 (E-05-04) E12-12

Electrical Connectors
ECU connector pins.
1041 SRS switch Located on the instrument panel. Remove the
1071 Transducer Crowd/Dump Located on the pilot manifold (SRS machines

only)
1072 Transducer Lift/Lower Located on the pilot manifold.

3005 SRS accumulator solenoid Located on the lift ram
3016 SRS drain solenoid Located on the lift ram
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
coloured white. 12
23
1
13
35 24
E12-13 9803/3760-07 (E-05-04) E12-13

7079 SRS pressure transducer Located on the pilot manifold (SRS machines
only)

9000 Fuses Refer to Section C - Electrical Harness
SYSTEM.K Related Topics ( T E12-2)
E12-14 9803/3760-07 (E-05-04) E12-14

Fault Finding
Tables


system.

spool.

spool.


spool.
E12-17 9803/3760-07 (E-05-04) E12-17

Fault Finding

E12-18 9803/3760-07 (E-05-04) E12-18

TE-003
Charging


!MCAUTION
vent the hose.

Fig 10.
E12-19 9803/3760-07 (E-05-04) E12-19

Discharging
2 Remove gas valve guard 10-A and gas valve cap 10-
B.


tool.


tool.
E12-20 9803/3760-07 (E-05-04) E12-20

Removal limited to checking the nitrogen gas pre-charge pressure.

If an accumulator is suspected as being faulty it must be
!MCAUTION
You must vent all the hydraulic pressure from the Important: Although identical in appearance, the
accumulators before disconnecting them from the accumulators are charged to different pressures. When
hydraulic system. renewing an accumulator make sure that it is charged to
the correct pressure.
0043
K Fig 11. ( T E12-22)

ground.

time.

Topics ( T E12-2)
4 Loosen the four nuts 2.
5 Disconnect hydraulic connections 1 and plug the

ends.
6 Remove the four nuts 11-2 and four washers 5 and

remove the two Ù' clamps 3. Remove the
accumulators 4 from their mounting brackets.
Replacement

Topics ( T E12-2)

E12-21 9803/3760-07 (E-05-04) E12-21

A356820-1
E12-22 9803/3760-07 (E-05-04) E12-22

Introduction

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

K Removal and Replacement (P1) ( T E13-3)(1)
K Removal ( T E13-3)
K Replacement ( T E13-4)
K Removal and Replacement (P2) ( T E13-5)(1)
K Dismantle and Assemble - Valve Block ( T E13-8)
K Dismantle ( T E13-8)
K Assemble ( T E13-8)
K Tie Rods ( T E13-9)
K Dismantle and Assemble - Spools and Load Hold Check Valves ( T E13-10)
K Dismantle and Assemble - Pilot Pressure Reducing Valve ( T E13-11)
(1) Procedure variant. Make sure you refer to the correct procedure.
Table 1. Procedure Variants

Procedures(1) Machine Model Application
531-70, 536-60, 541-70, 536-70, 526-56
531-T70 536-T60 541-T70 536-T70
K Removal and Replacement (P1) ( T E13-3) z z z z
K Removal and Replacement (P2) ( T E13-5) z
E13-1 9803/3760-07 (E-06-05) E13-1

Related Topics
Related Topics

complete your procedures. Where applicable the text in this section contains cross references to this page to help you
find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic,
refer to Section 1 - Applications.
1 Applications ALL
2 ALL (Care and Safety)(1) ALL
B Stabiliser System ALL
E13-2 9803/3760-07 (E-06-05) E13-2

Removal and Replacement (P1)
Removal 10 With the valve block suitably supported, undo the

mounting screws 1-A. Carefully lift out the valve block
clear of the machine.
!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.
Keep people away from the machine while you fit or

remove the boom maintenance strut.
5-3-1-2_2
1 Position the boom and fit the safety strut, see Section
2 - General Procedures. K Related
Topics ( T E13-2)

- General Procedures. K Related
Topics ( T E13-2)
!MWARNING
Hydraulic Pressure
Before connecting or removing any hydraulic hose, A296350-1
residual hydraulic pressure trapped in the service Fig 1. Mechanical Control Linkages
the hoses are open.
INT-3-1-11_2

4 Put a label on each hose before disconnecting to help

identification when replacing.
5 Disconnect and plug all hydraulic hoses.
6 Remove the stabiliser control lever knobs and gaiters

from inside the cab (if fitted).
7 Disconnect the control rod linkages 1-1 from the valve

spools.
8 Put a label on the electrical connectors to help

9 Disconnect all electrical connectors to the valve block

solenoids.
!MWARNING
This component is heavy. It must only be removed or
handled using a suitable lifting method and device.
BF-4-1_1
E13-3 9803/3760-07 (E-06-05) E13-3

Replacement
– After replacement check the operation of the

mechanical control linkages 1-1. The boom control
lever in the cab should be vertical when in neutral. If
the lever is not vertical undo locknuts 1-2 at each end
of the control rod 1-3. Turn the rod 1-3 to increase or
decrease the length as necessary. Tighten locknuts
1-2.
– Fill the hydraulic system with the recommended
hydraulic fluid as necessary, see Section 3 - Routine
Maintenance. K Related Topics ( T E13-2)
– After replacement, check MRV and ARV pressures.
K Parallel Hydraulic SYSTEM ( T E2-1)
Table 3. Torque Settings

Item Nm kgf m lbf ft
1-A 91 9.3 67
E13-4 9803/3760-07 (E-06-05) E13-4

C068070
Fig 2. Valve Location
E13-5 9803/3760-07 (E-06-05) E13-5

Removal
Obey the General Safety procedures, see Section 2
Topics ( T E13-2)
2 Open the battery compartment access panel. See

Topics ( T E13-2)
!MWARNING
Hydraulic Pressure
the hoses are open.
INT-3-1-11_2


C067890
C067890
Fig 3. Mechanical Control Linkages
spools.


solenoids.
!MWARNING
BF-4-1_1
9 With the valve block supported, undo the mounting

screws 3-2. Carefully lift the valve block out of the
machine.
E13-6 9803/3760-07 (E-06-05) E13-6

Replacement
During the removal procedure do this work also:

of the control rod 3-4. Turn the rod 3-4 to increase of
3-3.

3-2 TBA
E13-7 9803/3760-07 (E-06-05) E13-7

Dismantle and Assemble - Valve Block
Tie Rods
A347890-1
Fig 5. Tie Rods
The inlet and outlet sections of the valve are recessed as

shown at 5-1.
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.
Nuts 5-3 must be tightened evenly while the valve is lying

on a flat surface with the ports facing upwards. This will
allow the spool sections to assume their correct positions.

5-2 39 - 41 4.0 29 - 30
5-3 26 - 28 2.8 19 - 20
E13-9 9803/3760-07 (E-06-05) E13-9

Dismantle and Assemble - Spools and Load Hold Check Valves
262070-1-C2
Fig 6.
Dismantle Assemble
K Fig 6. ( T E13-10) 1 Renew all Ò' 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
E13-10 9803/3760-07 (E-06-05) E13-10

Dismantle and Assemble - Pilot Pressure Reducing Valve
Dismantle and Assemble - Pilot Pressure Reducing Valve
Control valves with electric servo operated spools have a

pilot pressure reducing valve.
One of three types of pilot pressure reducing valve may be

fitted. The valve cartridge in each of them is non-
adjustable. The valve cartridge is not serviceable beyond
cleaning. A cartridge should be renewed complete if wear
or damage is evident.
Faulty performance is most likely to occur if the ball valve

is sticking closed. A build-up of foreign material or incorrect
setting-up are the most likely causes of sticking.
Check the ball valve is free to move by shaking the

cartridge and listening for a mechanical rattling noise.
Fig 7. Cartridges A and B
1 Dismantle the components of the cartridge in the
numbered sequence. Clean all parts with clean
hydraulic fluid and inspect for signs of wear or
damage.
2 On cartridge C only, check that setting screw 8-F is

set at the correct depth 8-X as shown. If the depth
setting is too great this could be the cause of a
sticking ball valve. Remove the setting screw and
degrease the setting screw thread and the mating
tapped hole. Apply two or three drops of JCB Fig 8. Cartridge C
Threadlocker and Sealer to the thread of setting
screw 8-F and insert to the required depth into the Component Key:
tapped hole. Allow the thread sealant time to set 7-A Plug
(refer to the product information).
7-B Spring
3 Re-assemble the cartridge and torque tighten. Renew 7-C Pilot reducing spool
the complete cartridge if damage is evident. Refit the 7-D Roll pin
cartridge to the valve block and check for correct
7-E Ball
operation.
8-A One-way check adapter
Table 7. Torque Settings 8-B Spring
8-C Spring seat
7-A 20 - 24 2 - 2.4 14.7 - 17.7
8-D Plug
8-A 20 - 24 2 - 2.4 14.7 - 17.7
8-E Piston
8-E 6-8 0.6 - 0.8 4.4 - 5.9
8-F Setting screw
E13-11 9803/3760-07 (E-06-05) E13-11


Introduction
applications table.
relevant topics.

K Removal and Replacement ( T E14-3)
K Dismantle and Assemble - Valve Block ( T E14-5)
K Tie Rods ( T E14-6)
E14-1 9803/3760-07 (E-06-06) E14-1

Related Topics
Related Topics

1 Applications ALL
E14-2 9803/3760-07 (E-06-06) E14-2

Removal and Replacement
!MWARNING
Hydraulic Pressure
the hoses are open.
INT-3-1-11_2


6 Remove the stabiliser control lever knobs and gaiters

from inside the cab (if fitted).

spools.
S296330-1
Fig 1. Typical Parallel Service Valve Block 8 Put a label on the electrical connectors to help
Removal
solenoids.
!MWARNING
!MWARNING
strut as instructed before doing any maintenance This component is heavy. It must only be removed or
work with the boom raised. handled using a suitable lifting method and device.
BF-4-1_1
remove the boom maintenance strut. 10 With the valve block suitably supported, undo the
5-3-1-2_2
mounting screws 1-A. Carefully lift out the valve block
clear of the machine.
1 Position the boom and fit the safety strut, see Section
2 - General Procedures. K Related
Topics ( T E14-2)

Topics ( T E14-2)
E14-3 9803/3760-07 (E-06-06) E14-3

Replacement

of the control rod 2-3. Turn the rod 2-3 to increase or
2-2.
A296350-1
Fig 2. Mechanical Control Linkages
1-A 91 9.3 67
E14-4 9803/3760-07 (E-06-06) E14-4

262060-1
Fig 3. Typical 6 Spool Valve Block
Dismantle Nuts 1A must be tightened evenly while the valve is lying

on a flat surface with ports A facing upwards. This will
The exploded view shows a typical 6 spool control valve allow the spool sections to assume their correct positions.
block containing lift spool 2D, extension spool 2E, tilt spool For correct assembly of the tie rods and nut tightening
2F, sway/auxiliary spool 2G, stabiliser spools 2J and 2K. torques. K Tie Rods ( T E14-6)
The Main Relief Valve (MRV) 2A and the Auxiliary Relief

Valves (ARV's) 2L, 2M, 2N and 2P are screw adjustable.
For pressure settings, refer to the applicable system topic.
MRV 2A and ARV's 2L, 2M, 2N and 2P may be dismantled

only for cleaning and inspection as no parts can be
serviced.
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.
Shim 3 is fitted between all sections including end sections

but only over tie rod 2.
E14-5 9803/3760-07 (E-06-06) E14-5

Tie Rods
A347890-1
Fig 4. Tie Rods
The inlet and outlet sections of the valve are recessed as

shown at 4-1.
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.
Nuts 4-3 must be tightened evenly while the valve is lying


4-2 39 - 41 4.0 29 - 30
4-3 26 - 28 2.8 19 - 20
E14-6 9803/3760-07 (E-06-06) E14-6

262070-1-C2
Fig 5.
Dismantle Assemble
K Fig 5. ( T E14-7). The spools and their components can 1 Renew all Ò' 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
E14-7 9803/3760-07 (E-06-06) E14-7

E14-8 9803/3760-07 (E-06-06) E14-8


Introduction
applications table.
relevant topics.

K Handling ( T E15-3)
K Dismantle and Assemble ( T E15-5)
K Valve Block Sections ( T E15-5)
K Electrically Operated Spool ( T E15-7)
K Servo Operated Spool ( T E15-9)
K Manually Operated Spool ( T E15-10)
K Load Sense Relief Valve ( T E15-14)
K Auxiliary Relief Valves (ARV's) ( T E15-16)
K Flow Regulator Valve ( T E15-18)
K Pressure Compensator Valves ( T E15-19)
K Load Hold Check Valves ( T E15-20)
K Steer Priority Valve - if fitted ( T E15-21)
E15-1 9803/3760-07 (E-06-01) E15-1

Related Topics
Related Topics

1 Applications ALL
E15-2 9803/3760-07 (E-06-01) E15-2

Handling 5 Gain access to the valve and disconnect and blank

any hoses or pipes which may interfere with the
K Fig 1. ( T E15-4). Incorrect handling will result in removal of the valve assembly.
permanent damage to the valve assembly. The valve block
should be lifted by holding either end of the valve body. DO 6 Disconnect the control rod linkages from the valve
NOT pull on the valve spool solenoids and microswitches spools.
A (if fitted) to lift the valve.
7 Disconnect the electrical connectors from the valve
When handling the valve assembly, extreme care should spool solenoids and microswitches A (if fitted). Label
be taken to avoid damaging the valve spool solenoids and the connectors to ensure correct replacement.
microswitches (if fitted).
8 Disconnect and blank the servo pilot hoses B (if fitted)
from the valve spools. Label the hoses to ensure
Removal
correct replacement.
!MWARNING !MWARNING
BF-4-1_1
9 With the valve block suitably supported, undo the
mounting bolts C. Carefully lift out the valve block
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
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:
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)
Refer to the correct SYSTEM topic. K Related
the hoses are open.
Topics ( T E15-2)
INT-3-1-11_2

4 Remove the hydraulic filler cap.
E15-3 9803/3760-07 (E-06-01) E15-3

C050620-C2
Fig 1. Typical Flowshare (LSP+) Valve Block

C 47.5 4.8 35
E15-4 9803/3760-07 (E-06-01) E15-4

Dismantle and Assemble
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 Ò' rings located between the valve
sure that components are assembled in their original sections. Make sure the Ò' ring seals are not
positions. trapped or damaged.
– Check the Load Hold Check Valve Ò' 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)
– Contamination – Lubricate parts with JCB Hydraulic Fluid before

assembling. Make sure that all the parts move
– Damage to spools freely.
– Damage to seal grooves – If the tie rods 2-5 were removed, apply JCB
Threadlocker and Sealer to the threads before
Any of the above may result in possible problems with refitting. Torque tighten.
the operation of the valve.
9803/3760-07 (E-06-01)
Dismantle Item Nm kgf m lbf ft
1 Remove the valve block from the machine. 1 42 4.3 31

5 42 4.3 31
2 Remove the three tie rod nuts 1.
3 Carefully separate and remove the end plate 2 Component Key:

followed by the remaining service sections 3. If 1 Tie Rod Nuts
the inlet section 4 is to be replaced, remove and
2 End Section
retain the tie rods 5.
3 Service Sections
4 Inlet - Outlet Section
5 Tie Rods
6 Load Hold Check valves
7 Pressure Compensator Valves
E15-5
714830-C1
1
13
6
8
6
Fig 2. Flowshare (LSP+) Valve Block Components

3
7
13
13
6
9
6
11
12
7
13
4
10
E15-6 9803/3760-07 (E-06-01) E15-6

Electrically Operated Spool
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.
- General Procedures. K Related Assemble
Topics ( T E15-2)
Assembly is the opposite of the dismantling procedure.
- 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.
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.
7 Carefully withdraw the spool 6 from the valve body.
Note: When removing 'O' Rings and seals, use an

appropriately rounded tool that will not cause any damage
to the seal grooves. Discard all 'O' Rings and back-up
rings. Do not use worn or damaged items.
E15-7 9803/3760-07 (E-06-01) E15-7

Spools Orientation
764760-1
Fig 4.
Each spool has an identification mark 4-A, which should

be used to orientate the spool before insertion into the
valve block body.
Important: although the spools are similar in appearance

they must not be interchanged.
E15-8 9803/3760-07 (E-06-01) E15-8

Servo Operated Spool

1
Removal
1 Remove the valve block from the machine.
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.
3 Inspect the valve components for scratches, pitting

corrosion or any other type of damage. Replace as
necessary. 3
Replacement
4

5
solvent.
– Renew all 'O' rings and back-up rings.
– Lubricate parts with JCB Hydraulic Fluid before
assembling. Make sure that all the parts move freely. 6
C089440
Fig 5.

1 10 1 7.4
E15-9 9803/3760-07 (E-06-01) E15-9

Manually Operated Spool
764710-1
Fig 6.
Dismantle
2 Remove screws 6-1, boot 6-2 and plate 6-3.
3 Remove screws 6-6, cover 6-7 and carefully withdraw

the spool assembly (items 6-5A to 6-5K) from the
valve body, in the direction indicated by arrow 6-X.
4 Hold the spool assembly 7-5 in a vice using the spool

A403950-1
clamp 7-8.
Fig 7. Holding the Spool Assembly
5 Unscrew the spool end 6-5A and remove the centring
spring 6-5C with spring retainers 6-5B and 6-5D. It
may be necessary to pre-heat the spool to 200°C in
an oven or with a heat gun to remove the spool end.

E15-10 9803/3760-07 (E-06-01) E15-10

Tongue Removal (if necessary) Inspection
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.
2 Lubricate parts with JCB Hydraulic Fluid before

3 Renew 'O' rings 6-5.
4 Ensure the spools are correctly orientated before

inserting into the valve block body. K Spools
Orientation ( T E15-8)
5 Renew the valve spool seals 6-4. K Renewing the

Valve Spool Seals ( T E15-12)
6 Reassemble the centering mechanism. Assembly is

the opposite of the dismantling procedure.
A404060-1
Fig 8. Tongue Replacement 7 Check the spool displacement. K Measuring Spool
Displacement (Manual Spools) ( T E15-13)
Important: Do not use a welding torch to heat the tongue
as deformation of the spool may result. Table 6. Torque Settings
6-1 10 1 7.4
6-5A 10 1 7.4
6-5K 10 1 7.4
6-6 10 1 7.4
E15-11 9803/3760-07 (E-06-01) E15-11

Renewing the Valve Spool Seals
Note that the procedure described below is applicable for

manually operated spools only.
1 K Fig 9. ( T E15-12) Lubricate the spool 5H, bore

and seal groove with JCB Hydraulic Fluid. Move the
spool to position A and then install the seal 4A in its
groove.
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
2 K Fig 10. ( T E15-12) Move the spool to the position

shown and then install the seal 4B. It is important to
note that the spool must not be moved beyond
position B, otherwise the edge of the spool (face D)
may damage the seal fitted first (item 4A).
764780-1
Fig 10. Position B
3 K Fig 11. ( T E15-12) Position the spool in its central

position C. Reassemble the spool centering spring
mechanism. K Assemble ( T E15-11)
E15-12 9803/3760-07 (E-06-01) E15-12

Load Sense Relief Valve

Removal
It is possible to remove a valve without removing the valve

block from the machine.
Topics ( T E15-2)

Topics ( T E15-2)


removal of the load sense relief valve.
5 Unscrew the load sense relief valve from the valve

block. Cover the ports to prevent the ingress of dirt
and remove to a clean working area.
Dismantle
1 Loosen locknut 1, unscrew and remove adjuster nut 2

and adjuster screw 3.
2 Carefully remove spring 4 and poppet 5 from valve

body.

A403860-1
Fig 13.
E15-14 9803/3760-07 (E-06-01) E15-14

Inspection
Inspect the valve components for scratches, pitting,

corrosion or any other type of damage.
Note: If any part other than Ò' rings are damaged the
entire valve must be renewed.
Assembly and Replacement
During the assembly procedure do this work also:

solvent.
– Adjust the pressure setting as required. Refer to the
correct SYSTEM topic. K Related
Topics ( T E15-2).

6 45 4.6 33.2
E15-15 9803/3760-07 (E-06-01) E15-15


Removal

Topics ( T E15-2)

Topics ( T E15-2)


removal of the auxiliary relief valve(s).
5 Unscrew the auxiliary relief valve(s) from the valve

Dismantle
1 Prise off plastic locking cap.
2 Loosen locknut 1 and remove adjuster screw 2.
3 Carefully remove spring 3 and poppet 4.
4 Unscrew upper valve body 5 and remove springs 6

and piston 7.

A403870-1
Fig 14.
E15-16 9803/3760-07 (E-06-01) E15-16

Inspection

corrosion or any other type of damage.
entire valve must be renewed.
Assembly and Replacement
Important: The ARV's appear identical but have various

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

solvent.
– Adjust the pressure setting as required. Refer to the
correct SYSTEM topic. K Related
Topics ( T E15-2).

8 70 7.1 51.6
E15-17 9803/3760-07 (E-06-01) E15-17

Flow Regulator Valve

Removal

Topics ( T E15-2)

Topics ( T E15-2)


removal of the flow regulator valve.
5 Unscrew the flow regulator valve from the valve

Dismantle
A403850-1
1 Unscrew and remove top plug 1. Fig 15.
2 Carefully remove shims 2, spring 3 and piston 4. Assembly and Replacement
Note: When removing 'O' Rings and seals, use an Assembly is the opposite of the dismantling procedure.
to the seal grooves. Discard all 'O' Rings and back-up During the assembly procedure do this work also:
Inspection solvent.
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.
entire valve must be renewed. 6 20 2 14.8
E15-18 9803/3760-07 (E-06-01) E15-18


Removal
Note: The Pressure Compensator valve can not be

removed unless the tie rod has been extracted from hole
A.
2 Gain access to the Pressure Compensator Valves 3

by separating the valve sections. K Valve Block
Sections ( T E15-5)
3 Unscrew the compensator plug 1 from the valve block

section 2.
4 Using a magnet, extract the compensator piston 3

from its bore.
Inspection
764750-1
Inspect the valve components for scratches, pitting, Fig 16.
corrosion or any other type of damage. Replace as
necessary.
Replacement
Important: Although the Pressure Compensator valves

appear to be identical in appearance, they are not
interchangeable.

solvent.

1 60 6.1 44.3
E15-19 9803/3760-07 (E-06-01) E15-19

Load Hold Check Valves

Removal
2 Gain access to the Load Hold Check Valves 4 by

separating the valve sections. K Valve Block
Sections ( T E15-5)
3 Unscrew the load hold check valve plug 1 from the

valve block section 2.
764740-1
4 Remove spring 3 and poppet 4. Fig 17.
Inspection

corrosion or any other type of damage. Ensure good
condition of seating faces on poppets 4, and on the mating
faces in the valve block. Replace as necessary.
Replacement

solvent.

1 30 3 22.1
E15-20 9803/3760-07 (E-06-01) E15-20

E15-22 9803/3760-07 (E-06-01) E15-22

Related Topics
Related Topics

1 Applications ALL
B Chassis Panels Removal and Replacement
(S1) ( T E5-1)
E16-2 9803/3760-07 (E-06-02) E16-2

Handling 5 Remove the valve cover panels, See Section B -

Valve Block Covers. K Related Topics ( T E16-2)
Incorrect handling will result in permanent damage to the
valve assembly. The valve block should be lifted by holding 6 Label and disconnect the hoses and pipes at the
either end of the valve body. Do not use the electric valve assembly.
solenoids 1-B to the lift the valve.
7 Label and disconnect the electrical connectors from
Extreme care should be taken to avoid damaging the the valve block solenoids 1-B.
electric solenoids 1-B when handling the valve assembly.
!MWARNING
Removal
!MWARNING BF-4-1_1

8 With the valve block suitably supported, undo the
mounting bolts 1-A. Carefully lift the valve block clear
of the machine. K Handling ( T E16-3)
Keep people away from the machine while you fit or Replacement
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:
Topics ( T E16-2) – Operate the machines hydraulic system. Check for
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)
the hoses are open.
INT-3-1-11_2

E16-3 9803/3760-07 (E-06-02) E16-3

C048010
Fig 1.

Item Adaptor to Valve Hose to Adaptor or Adaptor to Adaptor
Nm lbf. ft Nm lbf. ft
1-E 27 20 33-40 24-29
1-F 48 35 33-40 24-29
1-G 122 90 58-65 43-48
1-H 122 90 84-92 62-68
1-J 48 35 44-50 32-37
1-L 27 20 24-27 18-20
1-M 200 147 115-126 & 44-50 85-93 & 32-37
1-N 24-27 18-20
E16-4 9803/3760-07 (E-06-02) E16-4

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
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
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)
Assemble 12 Flushing Valve

13 Load Sense Relief Valve
Assembly is the opposite of the dismantling sequence but 14 Flow Regulator Valve
obey the procedures that follow:
15 Auxiliary Relief Valves
1 Clean the valve components in an applicable solvent. 16 Steer Priority valve
Make sure that the mating faces of the valve sections
17 Spool Activation Solenoids
are fully clean before assembly.
18 Shuttle Valve
2 Replace the ‘O’ rings located between the valve
sections. Install the ‘O’ rings correctly. Incorrectly
installed ‘O’ rings will be damaged.
3 Lubricate the parts with JCB Hydraulic Fluid before

E16-5 9803/3760-07 (E-06-02) E16-5

Solenoid Valves
The solenoid valves are not serviceable parts. Replace the
solenoid valve assembly if it is defective.
Removal
This procedure is the same for all of the solenoid valves.
1 Disconnect the solenoid valve electrical connections.
2 Remove the screws 3-3 and remove the end casing

3-4.
3 Support the clamping plate 3-2 and remove the screw

3-1.
4 Pull the solenoid valve 3-5 out from the housing.
C051620
Fig 3.
Replacement

3-1 4.5 0.45 3.3
3-3 1 0.10 0.75
E16-7 9803/3760-07 (E-06-02) E16-7

Electrically Operated Spool
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.
E16-8
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
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.
Note: When removing 'O' Rings and seals, use a rounded

tool that will not cause any damage to the seal grooves.
Discard all 'O' Rings and back-up rings. Do not use worn
or damaged items.
C051640
Fig 7.
Replacement
1 Make sure the tamper proof cap 7-5 supplied with the
valve is fitted.
2 Replace all 'O' rings and back-up rings.
E16-10 9803/3760-07 (E-06-02) E16-10

Auxiliary Relief Valves (ARV’s)

The auxiliary relief valves are not serviceable. The
complete valve must be replaced if it is defective.
Important: Do not remove or damage the tamper proof

cap as this may invalidate a warranty claim.
Removal
3 If necessary remove the check valve assembly 8-1.

K Load Hold Check Valves ( T E16-14).

or damaged items.
Replacement

C051630
During the replacement procedure do this work also: Fig 8.
1 Make sure the tamper proof cap 8-6 supplied with the
valve is fitted.

assembling.
4 Adjust the pressure setting as required. K LSP

Electro Servo Hydraulic SYSTEM (S1) ( T E5-1)

8-5 70 7.13 52
E16-11 9803/3760-07 (E-06-02) E16-11

Flow Regulator Valve

The flow regulator valve is not serviceable. The flow
regulator valve is not adjustable. The complete valve must
be replaced if it is defective.
Removal
2 Remove and discard the regulator filter 9-4.

or damaged items. C051650
Fig 9.
Replacement
1 Clean the valve components in an applicable solvent.

assembling.

9-5 20 2 14.75
E16-12 9803/3760-07 (E-06-02) E16-12


Removal
Note: This procedure can be carried out with the valve

block removed or in situ.
!MWARNING

5-3-1-2_2
- General Procedures. K Related C051660
Topics ( T E16-2) Fig 10.
2 Carry out General Safety procedures, see Section 2 Inspection

Topics ( T E16-2) Examine the valve components for scratches, pitting,
corrosion or damage. Replace as necessary.
!MWARNING Replacement
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Replacement is the opposite of the removal procedure.
residual hydraulic pressure trapped in the service During the replacement procedure do this work also:
line has been vented before connecting or removing Important: Although the Pressure Compensator valves
hoses. Make sure the engine cannot be started while look identical, they are not interchangeable.
the hoses are open.
INT-3-1-11_2 – Clean the valve components in an applicable solvent.
– Replace all 'O' rings and back-up rings.
Procedures. K Related Topics ( T E16-2) – Lubricate the parts with JCB Hydraulic Fluid before
assembling.
5 Put a label on the hoses that are connected to the Item Nm kgf m lbf ft
valve slice. 10-1 60 6.1 44.3
6 Disconnect the hoses.
7 Remove the compensator plug 10-1 from the valve

block section 10-4.
8 Use a magnet to remove the compensator piston 10-

3 from its bore.
E16-13 9803/3760-07 (E-06-02) E16-13


Removal
2 Remove the auxiliary relief valve assembly.

K Auxiliary Relief Valves (ARV’s) ( T E16-11)
3 Remove the load hold check valve plug 11-4 from the
valve block section 11-1.
4 Remove the spring 11-3 and poppet 11-2.
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
– Clean the valve components in an applicable solvent.

– Lubricate the parts with JCB Hydraulic Fluid before

11-1 15 1.5 11
E16-14 9803/3760-07 (E-06-02) E16-14

Flushing Valve During the replacement procedure do this work also:
Removal – Clean the valve components in an applicable solvent.

– Replace all 'O' rings.
1 Unscrew the end cap 12-1 from the outlet valve slice – Lubricate the parts with JCB Hydraulic Fluid before
12-6 and discard the ‘O’ ring 12-2. assembling.
– Make sure to install the shims 12-4 into the valve slice
2 Remove the spring 12-3 and the shims 12-4.
12-6.
3 Pull the valve 12-5 from the valve slice 12-6. – Torque tighten the end cap 12-1.
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
12-1 100 10 73.7
C051680
Fig 12.
Replacement
E16-15 9803/3760-07 (E-06-02) E16-15

Shuttle Valve
Removal
1 Use an Allen Key to remove the outer seat 13-3 from

the valve block 13-1.
2 Remove the shuttle ball 13-4 and the inner seat 13-2.
C051690
Fig 13.
Replacement
– Clean the valve components in an applicable solvent.

– Lubricate the parts with JCB Hydraulic Fluid before
assembling.
– Apply JCB Threadlocker to the inner seat 13-2 and
torque tighten into the housing 13-1.
– Put the shuttle ball 13-4 into the housing 13-1.
– Apply JCB Threadlocker to the outer seat 13-3 and
tighten into housing 13-1.

13-2 20 2 14.75
E16-16 9803/3760-07 (E-06-02) E16-16

Steer Priority Valve
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.
tool that will not cause any damage to the seal grooves. 8 Install the end cap 14-12 into the valve housing 14-1.
or damaged items.
E16-17 9803/3760-07 (E-06-02) E16-17


Introduction
applications table.
relevant topics.

K Dismantle and Assemble - Valve Block Slices ( T E17-6)
E17-1 9803/3760-07 (E-06-09) E17-1

Related Topics
Related Topics

1 Applications ALL
1 Hydraulic Schematics ALL
1 Service Tools ALL
C Battery Removal and Replacement
E K Servo Parallel Hydraulic SYSTEM ( T E7-1) ALL
E17-2 9803/3760-07 (E-06-09) E17-2

C068070-C2
Fig 1. Valve Location
E17-3 9803/3760-07 (E-06-09) E17-3

Removal
Topics ( T E17-2)
2 Open the battery compartment access panel. See

Topics ( T E17-2)
!MWARNING
Hydraulic Pressure
the hoses are open.
INT-3-1-11_2

4 Working below the cab, remove the battery.




solenoids.
!MWARNING
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.
E17-4 9803/3760-07 (E-06-09) E17-4

Replacement

K Servo Parallel Hydraulic SYSTEM ( T E7-1)

A 47 4.79 34.6
C087220
Fig 3.
E17-5 9803/3760-07 (E-06-09) E17-5

Dismantle and Assemble - Valve Block Slices
C087480
Fig 4.
Dismantle MRV 2F and ARV's 2L, 2M, 2N and 2P may be dismantled

only for cleaning and inspection as no parts can be
The exploded view shows a 4 spool control valve block serviced. K Auxiliary Relief Valves and Main Relief
containing lift spool 2A, extension spool 2C, tilt spool 2B Valve ( T E17-11)
and auxiliary spool 2E.
Note: A pilot pressure reducing valve cartridge 2G is fitted
The Main Relief Valve (MRV) 2F and the Auxiliary Relief to the inlet section 2H. The valve cartridge cannot be
Valves (ARV's) 2L, 2M, 2N and 2P are screw adjustable. adjusted. K Pilot Pressure Reducing Valve ( T E17-12)
E17-6 9803/3760-07 (E-06-09) E17-6

Remove the tie rod nuts 1A and slide each valve slice from Assemble
the tie rods 2. K Tie Rods ( T E17-8)
Make sure that load hold check valve plugs 2Q are located
Retrieve and discard the inter section seals 2R.
on tie rod 2. K Load Hold Check Valves ( T E17-10)
Make sure that inter-section seals 2R are located in their

grooves as shown.
Nuts 1A must be tightened evenly while the valve is lying

Follow the correct tie rod assembly procedure. K Tie
Rods ( T E17-8)
E17-7 9803/3760-07 (E-06-09) E17-7

C087480-C1
Fig 6.
Dismantle and Assemble 1 Remove the end cap retaining screws D.
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.
E17-9 9803/3760-07 (E-06-09) E17-9

Solenoid Valve Caps
The solenoid valve caps G (auxiliary and extend/retract

valve slices) are not serviceable parts. If the solenoid is
defective replace the end cap assembly G.
The solenoids can be removed without separating the

valve sections
1 Put a mark on the solenoid end cap G and valve slice

E to help position the solenoid correctly when
replacing.
2 Remove the solenoid end cap retaining screws H.
3 Clean all parts with clean hydraulic fluid and do an

inspection for signs of wear or damage.
If the solenoid end cap G is worn or damaged the end

cap G must be replaced. The solenoid is not
serviceable.
4 Install the solenoid end cap G to the valve slice E.

Make sure the marks made in step 1 are aligned.
5 Torque tighten screws H. K Table 4. Torque

Settings ( T E17-10)
Tie rod must be removed to release load hold check valve

plugs F. The load hold check valve can be pulled out from
the valve slice. Do not remove back-up ring J as this
cannot be renewed in service.

D 9 - 12 0.9 - 1.2 7-9
H 9 - 12 0.9 - 1.2 7-9
E17-10 9803/3760-07 (E-06-09) E17-10

Auxiliary Relief Valves and Main Relief

Valve
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.
3 Discard the seals B, C, E and F.
4 Clean all parts with clean hydraulic fluid and inspect

for signs of wear or damage.
If the ARV or MRV is worn or damaged the valve

assembly must be replaced. The valve cartridge D is
not serviceable.
5 Replace the valve D into the valve block A and torque

tighten. K Table 5. Torque Settings ( T E17-11)

ARV 20-24 2 - 2.4 14.7 - 17.7
MRV 20-24 2 - 2.4 14.7 - 17.7
E17-11 9803/3760-07 (E-06-09) E17-11

Inloader Valve
Introduction
applications table.
relevant topics.

K Pump P2 Directed to Tank ( T E18-4)
K Pump P2 In Circuit (Inloader Operation) ( T E18-5)
K Inloader Operation Override ( T E18-5)
E18-1 9803/3760-07 (E-28-00) E18-1

Inloader Valve
Related Topics
Related Topics

1 Applications ALL
C Harness SYSTEM ALL
E18-2 9803/3760-07 (E-28-00) E18-2

Inloader Valve
Operation Overview
Operation Overview
The output flow from the secondary hydraulic pump is

automatically controlled by an inloader valve. The valve
responds to the hydraulic load sense pressure and main
system pressure connecting the flow from pump C into the
main hydraulic system only when it is required. The
hydraulic operation of the inloader valve is overridden
electrically by energising inloader valve solenoid. The
solenoid is energised by a signal from the IFT ECU.
The IFT ECU is programmed to energise the inloader

valve solenoid dependant on engine speed (rpm). When
the solenoid is energised the flow from pump section is
diverted to tank.
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.
The valve automatically connects the flow from the pump

secondary section P2 through port P into the main
hydraulic circuit to supplement the flow from the pump
main section P1 when there are large demands on the
hydraulic system. Such as when operating multiple
hydraulic service simultaneously or when a high flow is
required by a single service.
The valve incorporates a solenoid X to enable it to be

actuated electrically by the inloader control IFT ECU
(Electronic Control Unit). When the solenoid is energised 772940-C1
Fig 1.
the valve dumps the flow from the pump secondary section
P2 to tank through port T, thereby reducing the load on the
engine.
E18-3 9803/3760-07 (E-28-00) E18-3

Inloader Valve
The inloader valve operates in 1 of 3 possible modes:
K Pump P2 Directed to Tank ( T E18-4)
K Pump P2 In Circuit (Inloader Operation) ( T E18-5)
K Inloader Operation Override ( T E18-5)
Pump P2 Directed to Tank

For most of the time during the machines work cycle, it is
the flow from the main pump section P1 which is available
within the main circuit. The flow from the secondary pump
section P2 is dumped to the hydraulic tank by the inloader
valve, reducing the load on the engine.
Normally, the flow available from the main pump section

P1 is more than sufficient to satisfy the flow demanded,
and the main pump circuit P1 pressure is always 15 bar
above the load sense circuit LS pressure. Pressure from
the main circuit holds the inloader valve spool 1a open and
flow from pump P2 is directed back to tank.
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
E18-4 9803/3760-07 (E-28-00) E18-4

Inloader Valve
Pump P2 In Circuit (Inloader Operation) Inloader Operation Override

If the flow demanded by a service or multiple services, The hydraulic operation of the inloader can be overridden
begins to exceed the flow available, the main circuit electrically via solenoid 1c. The solenoid 1c is energised
pressure will start to fall off. The pressure difference by a signal from the inloader control IFT ECU. The
between the main pump circuit P1 and the load sense solenoid valve spool isolates the inloader valve spool 1a
circuit LS will therefore reduce. When the pressure from the load sense pressure and directs trapped pressure
difference reduces from the normal 15 bar to back to tank. The inloader valve spool 1a is now always
approximately 12 bar, inloader valve spring 1b causes the held in the open position by pressure from the main circuit.
spool 1a to close, connecting the additional flow from the In this way the output from pump P2 is always directed to
secondary pump section P2 into the main hydraulic circuit. tank.
This ensures a surplus of flow in the main hydraulic circuit.
Note: The IFT ECU also functions to control other systems
in addition to inloader valve control.
747500B
Fig 3.
747500C
K Graph of System Pressures ( T E18-6) Fig 4.
The graph shows typical hydraulic pressures for inloader

valve operation when a service is operated fully.
E18-5 9803/3760-07 (E-28-00) E18-5

Graph of System Pressures
E18-6
K Fig 5. ( T E18-7)
The graph shows the typical P1, P2 and load sense

pressures when a service is operated fully.
At point X, the differential between the P1 working

pressure and the load sense pressure has reduced to
approximately 10 bar (145 lbf/in2). The inloader valve
activates to connect the flow from the pump
secondary section (P2) into the main hydraulic circuit,
supplementing the flow from the pump main section
(P1).
At point Y, the service ram reaches the end of its

stroke. The differential between the P1 working
pressure and the load sense pressure returns to 15
bar (215 lbf/in2). The additional flow from the pump
secondary section (P2) is not required and is dumped
to tank, consequently the P2 working pressure falls to
minimum.
Table 2. Key to Oil Flow and Pressure

P1 working pressure
9803/3760-07 (E-28-00)
P2 working pressure
Load sense pressure
E18-6

Inloader Valve
300
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

Inloader Valve
Inloader Valve
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
E18-8 9803/3760-07 (E-28-00) E18-8

Inloader Valve
K Fig 7. ( T E18-10) After replacement check the valve operation.
!MWARNING Important: The extent of permissible servicing is the

renewal of the solenoid coil. Further dismantling of the
You will be working close into the machine for these valve is not recommended. If the valve is suspected as
jobs. Lower the attachments if possible. Remove the being faulty it must be renewed as a complete assembly.
starter key and disconnect the battery. This will
prevent the engine being started. Make sure the park
brake is engaged.
Block all four wheels before getting under the

machine.
2-3-2-1
!MWARNING
Hydraulic Pressure
the hoses are open.
INT-3-1-11_2
Removal
2 Uncouple the harness electrical connector at the

solenoid 7-A. Label the connector to ensure correct
replacement.
3 Disconnect all hydraulic hoses 7-B from the valve

block and plug the ports to prevent ingress of dirt.
Label each hose before disconnecting to ensure
correct replacement. Plug hose ends to prevent
ingress of dirt.
4 Take hold of the valve assembly, loosen and remove

the fixing bolts 7-C securing the valve to the chassis.
Lift the valve assembly from the machine.
Replacement
E18-9 9803/3760-07 (E-28-00) E18-9

Inloader Valve
772970-2
Fig 7. Typical Inloader Valve
E18-10 9803/3760-07 (E-28-00) E18-10

Servo Pilot Valve

Introduction
applications table.
relevant topics.

K Renewing the Solenoid Coils ( T E19-4)
E19-1 9803/3760-07 (E-27-00) E19-1

Servo Pilot Valve
Related Topics
Related Topics

1 Applications ALL
1 Service Tools ALL
1 Fuses and Relays ALL
E19-2 9803/3760-07 (E-27-00) E19-2

Servo Pilot Valve
Operation Overview
Operation Overview
K Fig 1. ( T E19-3) pressure to enable the service spools to be operated for a

limited period with a stopped engine. This allows the
The servo pilot pressure supply valve incorporates a attachments to be lowered safely to the ground should the
pressure regulating valve 1 and four proportional solenoid engine stop.
valves 2a - 2d for control of the boom extend and retract
service and the auxiliary service. The proportional solenoid valves are energised via the
PWM controller electronic control units (ECU's) from the
The servo pilot system is supplied from a single line tapped thumbwheel switches on the control lever. When a
into the fan pump feed to the cooling fan hydraulic motor. thumbwheel switch is moved by the operator, the ECU
The pressure regulating valve 1 maintains servo pilot sends a proportional PWM (Pulse Width Modulated) signal
pressure by regulating the incoming supply pressure. to the relevant solenoid. When the solenoid is signalled,
Servo pilot pressure can be measured at the hydraulic test servo pilot oil is directed through the applicable port to
point 3. operate the main control valve service spool. The
proportional solenoid valve supplies pilot oil at a pressure
Down stream of the pressure regulating valve is located relative to the amount of thumbwheel movement, thus
the servo accumulator 4 with its associated non-return controlling how far the applicable service spool is
valve. The accumulator traps and stores servo pilot displaced.
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 èxtend'
2b Proportional solenoid valve - Auxiliary service
2c Proportional solenoid valve - Auxiliary service
2d Proportional solenoid valve - Boom `retract'
E19-3 9803/3760-07 (E-27-00) E19-3

Servo Pilot Valve
A372530-1
Fig 2.
Removal – Ensure that the hoses are reconnected to the correct

ports. Refer to the Hydraulic Schematic if in doubt.
1 Position the boom and fit the safety strut, see Section – After replacement, check servo pressures.
2 - Boom Safety Strut. K Related
Topics ( T E19-2) Table 2. Torque Settings
2 Make sure that all residual hydraulic pressure has
been vented, see Section 2 - General Procedures. 2-A 28 2.9 21
Renewing the Solenoid Coils
3 Disconnect and plug all hydraulic hoses, label each to
ensure correct position on replacement. Solenoids 2-B are individually replaceable. Disconnect the
electrical connection and remove the solenoid. Replace
4 Support valve block, undo and remove screws 2-A, lift
with one of the same part number.
out servo diverter valve.
Replacement
E19-4 9803/3760-07 (E-27-00) E19-4


Introduction
applications table.
relevant topics.

E20-1 9803/3760-07 (E-27-01) E20-1

Related Topics
Related Topics

1 Applications ALL
1 Service Tools ALL
(S1) ( T E5-1)
E20-2 9803/3760-07 (E-27-01) E20-2

Operation Overview
Operation Overview
K Fig 1. ( T E20-3)
The servo pilot pressure supply valve 1 is supplied from a

single line tapped into the gear pump feed line to the
cooling fan hydraulic motor.
The pressure regulating valve maintains servo pilot

pressure by regulating the incoming supply pressure. Oil at
servo pilot pressure is supplied to the main control valve
inlet section.
The pressure regulating valve incorporates accumulator 3

The accumulator traps and stores servo pilot pressure to
enable the service spools to be operated for a limited
period with a stopped engine. This allows for attachments
to be lowered safely to the ground should the engine stop.
Supply of pilot oil can be isolated from the main control

valve by de-energising solenoid 2. The solenoid is
controlled by switch in the cab. When the valve is de-
energised trapped pilot oil in the main control valve is
diverted to tank. The service spools are `locked' and
services cannot be operated with or without the engine
running.
Note: Oil stored in the accumulator 3 is isolated from the

servo pilot system when solenoid 2 is de-energised
C047940-C2
Fig 1.
E20-3 9803/3760-07 (E-27-01) E20-3

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)
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.
E20-4 9803/3760-07 (E-27-01) E20-4


Introduction
applications table.
relevant topics.

E21-1 9803/3760-07 (E-10-07) E21-1

Related Topics
Related Topics

1 Applications ALL
1 Service Tools ALL
(S2) ( T E6-1)
E21-2 9803/3760-07 (E-10-07) E21-2

Operation Overview
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.
E21-3 9803/3760-07 (E-10-07) E21-3

5 Support the valve D.

A B
C 6 Remove the bolts and washers E and remove the
valve D from the bracket F.
Replacement
A – Ensure that the hoses are reconnected to the correct

A ports.
– After replacement, check the servo pressure.

D renewal of the solenoid coil B and accumulator C. Further
dismantling of the valve is not recommended. If the valve
is suspected as being faulty it must be renewed as a
complete assembly.
F
C106950-C1
Fig 2.
Removal
- Boom Safety Strut. K Related Topics ( T E21-2)

been vented, see Section 2 - General Procedures.
3 Disconnect electrical harness at the solenoid

electrical connector B.
4 Label the hoses A to ensure correct position on

replacement. Disconnect the hoses. Cap all open
hoses and ports.
E21-4 9803/3760-07 (E-10-07) E21-4


Introduction
applications table.
relevant topics.

K Renewing the Solenoid Coils ( T E22-5)
K Renewing the Pressure Transducer/Switches ( T E22-5)
E22-1 9803/3760-07 (E-10-03) E22-1

Related Topics
Related Topics

1 Applications ALL
C Battery Removal and Replacement
E22-2 9803/3760-07 (E-10-03) E22-2

Operation Overview
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.
ACC PS LoI PR LiI PR CI PR DI

BI SW SW SW
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
E22-3 9803/3760-07 (E-10-03) E22-3

C085250-C3
Fig 2.
Removal 6 Put a label on the electrical connectors to help

Obey the General Safety procedures, see Section 2 7 Disconnect all electrical connectors to the valve block
- General Procedures. K Related solenoids and pressure switches.
Topics ( T E22-2)
8 Support the manifold A, undo and remove screws B.
2 Vent the hydraulic pressure, see Section 2 - General Remove manifold.
Replacement
3 Working below the cab, remove the battery.
K Related Topics ( T E22-2) Replacement is the opposite of the removal procedure.
4 Put a label on each hose before disconnecting to help During the replacement procedure do this work also:
E22-4 9803/3760-07 (E-10-03) E22-4

– Make sure that the hoses are reconnected to the
correct ports. Refer to the machine hydraulic
schematic if in doubt.
– After replacement, check pilot pressures.
Renewing the Solenoid Coils

K Fig 3. ( T E22-5) Solenoids C are individually
replaceable. Disconnect the electrical connection and
remove the nut D. Remove the solenoid.
Renewing the Pressure Transducer/

Switches
K Fig 3. ( T E22-5) The pressure transducer/switches F,
G and H are individually replaceable. Disconnect the
electrical connection and remove the switch from the pilot
manifold block E.
When replacing, put the switch in its original position, the

switches look the same but have different pressure
settings. Make sure replacement switches are the correct
part number. Torque tighten the switch. K Table 2. Torque
Settings ( T E22-5)
C087200-C2
Fig 3.

G 18-20 1.83-2.03 13.2-14.7
F, H 35-39 3.57-3-97 25.8-28.7
E22-5 9803/3760-07 (E-10-03) E22-5

E22-6 9803/3760-07 (E-10-03) E22-6


Introduction
applications table.
relevant topics.

E23-1 9803/3760-07 (E-11-03) E23-1

Related Topics
Related Topics

1 Applications ALL
1 Service Tools ALL
(S1) ( T E5-1)
H Priority Valve ALL
E23-2 9803/3760-07 (E-11-03) E23-2

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.
!MWARNING
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.
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.
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.
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 Disconnect the outlet hose 1-A at the fan pump 1-B.
E23-3 9803/3760-07 (E-11-03) E23-3

2 Fit new O ring seals to the pump to gearbox casing
mating face and inlet and outlet hose flanges.
Lubricate the O rings with clean hydraulic fluid.
3 Apply JCB threadlocker and sealer to the flange bolts

1-J and tighten to the correct torque.
4 Remove cap 1-K and fill the pump case with clean
hydraulic fluid. Refit the cap
5 Reconnect the hydraulic hoses and suction hose at

the pump.
6 Connect the electrical connectors at the hydraulic

fluid temperature switch and the pump control
solenoid.
7 Refill the hydraulic tank to the correct level with clean

hydraulic fluid.
8 Loosen cap 1-K and allow any trapped air to escape

from the pump body and drain hose 1-H. Tighten the
cap.

Item Nm Kgf. m Ibf. ft
1J 97 9.9 71.5
1K 84-92 8.5-9.4 62-68
E23-4 9803/3760-07 (E-11-03) E23-4

C051580
Fig 1.
E23-5 9803/3760-07 (E-11-03) E23-5

Do not attempt to dismantle the variflow pump. If the pump

is defective it must be renewed.
E23-6 9803/3760-07 (E-11-03) E23-6


Introduction
applications table.
relevant topics.

K Steering Priority Valve ( T E24-15)
E24-1 9803/3760-07 (E-11-02) E24-1

Related Topics
Related Topics

1 Applications ALL
1 Service Tools ALL
H Priority Valve ALL
E24-2 9803/3760-07 (E-11-02) E24-2

Operation Overview
9808_6163-1
Fig 2. Typical Gear Pump Section
Table 3. Key to Oil Flow and Pressure

Full Pressure
Exhaust
E24-4 9803/3760-07 (E-11-02) E24-4

K Fig 3. ( T E24-5) Item

E Steering Load Sense Line
Item
F Pump Main Output
A Main Services Pump Section
G Control Valve Block Secondary Feed
B Steering Service Pump Section
H Fan and Pilot Valve Feed
C Fan and Pilot Services Pump Section
J Test Point
D Priority Steer Valve
K Hydraulic Tank
C065900
Fig 3.
E24-5 9803/3760-07 (E-11-02) E24-5

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
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.
1 Park the machine on firm level ground, engage the

parking brake and set the transmission to neutral.
!MWARNING
Lower the boom to the ground. Stop the engine and This component is heavy. It must only be removed or
remove the starter key, see Section 2 - General handled using a suitable lifting method and device.
Procedures. K Related Topics ( T E24-2) BF-4-1_1
7 Secure the pump using a sling around the pump body.

!MWARNING With the pump suitably supported, undo the mounting
Make the machine safe before working underneath it. bolts E and carefully withdraw the pump clear of the
Park the machine on level ground, lower the gearbox.
the transmission in neutral and stop the engine. Block 8 Retain the drive coupling.

GEN-4-1_1
!MWARNING
Hydraulic Pressure
the hoses are open.
INT-3-1-11_2
2 Vent the hydraulic pressure, see Section 2 - General 416111-C7

Procedures. K Related Topics ( T E24-2) Fig 4. Typical Double Pump
E24-6 9803/3760-07 (E-11-02) E24-6

A 46 4.7 34
C 46 4.7 34
E 96 9.7 70
A313800-C5
Replacement
– Ensure the pump flange and gearbox mating face are

clean and free from oil and grease prior to assembly.
– Use new Ò' ring seals.
– Fit drive coupling, engage pump drive into coupling,
support the pump until bolts E have been torque
tightened. K Table 4. Torque Settings ( T E24-7).
Note: Mounting bolts E should be 10.9 grade M12 tuff lok,

make sure the correct bolts are fitted.
– Ensure the hoses are correctly installed, and phased

in the same position as removal to prevent chafing.
– Refill the hydraulic tank to the correct level with clean
hydraulic fluid.
– After fitting a new or serviced pump and before
starting the engine screw the Main Relief Valve
(MRV) out 4 full turns. Adjust the MRV, refer to the
applicable system topic. K Related
Topics ( T E24-2).
– Check the fan motor speed, refer to Parallel
SYSTEM Specifications. K Related
Topics ( T E24-2)
E24-7 9803/3760-07 (E-11-02) E24-7

Dismantle, Inspection and Assemble
Double Pump 10 Remove capscrews 6-20 and nuts 6-21 holding

mounting flange 6-22 to pump body 6-3.
Before removing or dismantling the pump, check that its
performance is as stated in Specifications. If the 11 Use a soft hammer to separate mounting flange 6-22
performance is below that specified, the pump should be from pump body 6-3.
renewed. Renewal of individual components such as
gears, bearings and housings will not effect a permanent 12 Remove circlip 6-23 and shaft seal 6-24.
cure. If a pump's output is satisfactory but there is
evidence of external leakage, it should be dismantled for 13 Remove driveshaft 6-25 from pump body 6-3.
re-sealing only. Removal will also remove balance plate 6-26
complete with seal 6-27 and seal energiser 6-28.
Prior to dismantling the unit, ensure that the exterior of the Discard the seal and seal energiser.
pump and the working area are thoroughly cleaned and
free of possible sources of contamination. 14 Remove driven gear 6-29 followed by balance plate
6-30, seal 6-31 and seal energiser 6-32. Discard the
Mark all sections to ensure correct assembly and keep seal and seal energiser.
pump components with their relative pump section.
15 Discard O-ring 6-33.
Dismantle
16 Remove all sealant from the contact faces of the
1 Remove the three capscrews 6-1 which attach the mounting flange/pump body and end cover/pump
priority valve 6-2 to the pump body 6-3. body interfaces.
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.
9 Discard O-ring 6-19. c There is a noticeable wear groove on driveshaft 6-

25 where shaft seal 6-24 runs.
E24-8 9803/3760-07 (E-11-02) E24-8

d The balance plate faces are scored, particularly in 9 Support the pump assembly on the mounting flange
the area adjacent to the gear root diameter. 6-22 (but not the driveshaft). Fit O-rings 6-9 into the
grooves on the face of pump body 6-3. Install splined
e The driveshaft splines are worn or severely coupling 6-8.
fretted.
10 Fit pump body 6-7 onto pump body 6-3 in its original
f The gear "cut-in" area in the low pressure side of position, as marked earlier, ensuring that it locates on
the pump body is deeper than 0.15 mm (0.006 in) the dowels and that the clamping bolt holes line up.
or has a torn or pitted appearance.
11 Fit seal 6-17 and seal energiser 6-18 into balance
Assemble plate 6-16. Ensuring that the seals do not fall out,
carefully feed the balance plate into pump body 6-7
When carrying out the following procedure, renew all seals with the two small holes through the balance plate to
and O-rings. Lubricate using JCB Special Hydraulic Fluid. the low pressure side (i.e. side with a port blank).
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 Ò' 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).
7 Carefully feed mounting flange 6-22 over driveshaft

6-25 in its original position, as marked earlier. Use a
soft faced hammer to tap the flange onto its location
spigot.
8 Attach mounting flange 6-22 to pump body 6-3 with

capscrews 6-20 and nuts 6-21.
E24-9 9803/3760-07 (E-11-02) E24-9

Triple Pump 11 Discard O-ring 7-23.
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.
8 Use a soft faced hammer to separate end cover 7-5 Inspection

from pump body 7-7.
1 Generally check all pump parts for damage and/or
9 Remove drive gear 7-15 from its bore. Pushing it out wear. The O-ring grooves, the seal recess in the
of the rear body will also remove balance plate 7-16 mounting flange and all sealing faces must be free of
complete with seal 7-17 and seal energiser 7-18. burrs and scores which could result in seal damage
Discard the seal and seal energiser. Note the position and hence hydraulic oil leakage.
of the driveshaft and the balance plate to ensure
correct re-assembly. 2 Renew the pump if any of the following symptoms
exist:
10 Remove driven gear 7-19, followed by balance plate
7-20 complete with seal 7-21 and seal energiser 7-22.
Discard the seal and seal energiser.
E24-11 9803/3760-07 (E-11-02) E24-11

a The PTFE coated bearings in the pump bodies, 6 Fit O-ring 7-43 into the groove on mounting flange 7-
the mounting flange and the end cover are worn 33.
through to reveal the bronze backing.
7 Apply a small amount of JCB Threadlocker and
b The gear side faces are scored. Often Sealer to the face of pump body 7-12 which seals with
contaminated fluid results in a distinct wear step mounting flange 7-33 (i.e. the face containing the
coincident with the gear root diameter. This can clamping bolt holes).
normally be felt by drawing a sharp point across
the gear side face from the journal towards the tip 8 Carefully feed mounting flange 7-33 over driveshaft
of the gear. 7-35 in its original position, as marked earlier. Use a
soft faced hammer to tap the flange onto its location
c There is a noticeable wear groove on driveshaft 7- spigot.
35 where shaft seal 7-34 runs.
9 Support the pump assembly on the mounting flange
d The balance plate faces are scored, particularly in 7-33 (but not the driveshaft). Fit O-rings 7-14 into the
the area adjacent to the gear root diameter. grooves on the face of pump body 7-12. Install
splined coupling 7-13.
e The driveshaft splines are worn or severely
fretted. 10 Fit pump body 7-11 onto pump body 7-12 in its
original position, as marked earlier, ensuring that it
f The gear "cut-in" area in the low pressure side of locates on the dowels and that the clamping bolt
the pump body is deeper than 0.15 mm (0.006 in) holes line up.
or has a torn or pitted appearance.
Assemble plate 7-29. Ensuring that the seals do not fall out,
When carrying out the following procedure, renew all seals with the two small holes through the balance plate to
and O-rings. Lubricate using JCB Special Hydraulic Fluid. the low pressure side (i.e. side with a port blank).
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
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.
E24-12 9803/3760-07 (E-11-02) E24-12

plate 7-22. Ensuring that the seals do not fall out,
with the two small holes through the balance plate to
the low pressure side (i.e. side with a port blank).
20 Fit drive gear 7-15 so that it locates with splined

coupling 7-9. Fit driven gear 7-19.
21 Fit balance plate 7-16 in its original position (i.e. with

7-17 and seal energiser 7-18 into the balance plate.
Fit O-ring 7-23 into end cover 7-5.Apply a small
amount of JCB Threadlocker and Sealer to the
exposed face of pump body 7-7 (i.e. the face
containing the clamping bolt holes).
22 Fit end cover 7-5 in its original position, as marked

earlier.
23 Install the four bolts 7-2, each with a serrated washer

7-3, and tighten evenly and progressively.
24 Refit the priority valve 7-B to the pump body 7-11. Be

sure to fit new Ò' rings 7-C. Tighten the three
capscrews 7-A evenly and progressively.
25 Pour a small amount of clean JCB Special Hydraulic

Fluid into the ports. Check that driveshaft 7-35 rotates
without undue force. If excessive force is required it is
possible that one or more of the balance plate seals
are trapped, in which case it will be necessary to
dismantle and assemble the pump again.

7-2 100 10 74
E24-13 9803/3760-07 (E-11-02) E24-13

C
A
11 B
14
C024880-C1
E24-14 9803/3760-07 (E-11-02) E24-14

Steering Priority Valve

For more information on the priority valve See Section H -

For more information on the priority valve See Section H -
E24-15 9803/3760-07 (E-11-02) E24-15

E24-16 9803/3760-07 (E-11-02) E24-16

Cooling Fan Motor

Introduction
applications table.
relevant topics.

K Dismantle, Inspection and Assemble ( T E25-8)
K Inspection ( T E25-8)
E25-1 9803/3760-07 (E-12-01) E25-1

Cooling Fan Motor
Related Topics
Related Topics

1 Applications ALL
E Hydraulic SYSTEM(2) ALL
K Engine Cooling Pack
(2) Refer to the relevant hydraulic system topic for fan motor location and specifications.
E25-2 9803/3760-07 (E-12-01) E25-2

Cooling Fan Motor
Specifications
Specifications
Refer to the relevant hydraulic system topic for fan motor

specifications.
E25-3 9803/3760-07 (E-12-01) E25-3

Cooling Fan Motor
Operation Overview
Operation Overview
K Fig 1. ( T E25-5)
The cooling fan motor is hydraulically driven. The motor

turns the cooling fan and air is drawn through the radiators
in the machine cooling pack.
Hydraulic oil from pump section B, supplies the fan motor

6 and pilot pressure supply valve.
Pressure relief valve 5 prevents component damage.
E25-4 9803/3760-07 (E-12-01) E25-4

Cooling Fan Motor
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

Full Pressure
Neutral
Exhaust
C066320
Fig 1.
E25-5 9803/3760-07 (E-12-01) E25-5

Cooling Fan Motor
Before removing and dismantling the fan motor, check that

its performance is as stated in the applicable SYSTEM
If the performance is below that specified, the motor

should be renewed. Renewal of individual components
such as gears, bearings and housings will not effect a
permanent cure. If the motor performance is satisfactory
but there is external leakage, it should be dismantled for
re-sealing only.
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.
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.
4 Remove the fan guard.
5 Undo 4 bolts 4-D and lift away the fan and motor
assembly.
6 Prevent the fan from turning, release the tab washer

and then undo nut 2-A.
764210-1
Fig 3.
Replacement
E25-6 9803/3760-07 (E-12-01) E25-6

Cooling Fan Motor
– Make sure all hoses are attached to the correct ports.

The case drain hose 4-C (reversible fan option only)
must be fed in to a tank line otherwise damage to the
motor will occur.
– Check the hydraulic fluid level. K Related
Topics ( T E25-2)

3-A 28 2.9 20.6
4-A 47 4.8 34.5
C025090-C4
Fig 4.
E25-7 9803/3760-07 (E-12-01) E25-7

Cooling Fan Motor
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.
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.
E25-8 9803/3760-07 (E-12-01) E25-8

Cooling Fan Motor
8 Fit relief valve 5-23.
9 Put a small amount of clean hydraulic oil in the inlet

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

5-22 (1) 47 4.8 36
(1) All four bolts must be torque tightened as above.
E25-9 9803/3760-07 (E-12-01) E25-9

Cooling Fan Motor
710370-1
Fig 5.
E25-10 9803/3760-07 (E-12-01) E25-10


Introduction
applications table.
relevant topics.

E26-1 9803/3760-07 (E-09-01) E26-1

Related Topics
Related Topics

1 Applications ALL
(S1) ( T E5-1)
(S1) ( T E20-1)
E26-2 9803/3760-07 (E-09-01) E26-2

Removal
K Fig 1. ( T E26-3)
Note: The control lever and attached powerbase 1-F is a

non serviceable part. If it is faulty it must be renewed.
1 Prise the screw cover from the armrest 1-A and

remove the screws and washers 1-B. Lift away the
armrest.
2 Remove rear screws and washers 1-C.
3 Remove front screws and washers 1-D.
4 Remove the gaiter collar 1-E.
5 Remove the pod top cover 1-G until access can be

gained to the switch 1-H electrical connectors. label
and disconnect the switch connectors.
6 Disconnect the electrical connectors 1-J, 1-K, and 1-

L and remove control lever from pod.
7 Undo screws 1-M and remove the control lever and

powerbase assembly 1-F.
Replacement
C048470-C1
Fig 1.
E26-3 9803/3760-07 (E-09-01) E26-3

E26-4 9803/3760-07 (E-09-01) E26-4


Introduction
applications table.
relevant topics.

E27-1 9803/3760-07 (E-09-09) E27-1

Related Topics
Related Topics

1 Applications ALL
(S2) ( T E6-1)
E27-2 9803/3760-07 (E-09-09) E27-2

Removal
Note: The control lever D and attached powerbase is a
non serviceable part. If it is faulty it must be renewed.
1 Prise the screw cover B from the armrest A and

remove the screws and washers J. Lift away the
armrest A and trim assembly C.
2 Remove screws E.
3 Remove the gaiter collar H.
4 Remove screws G and lift the control lever and

powerbase assembly D to get access to the electrical
connectors.
5 Disconnect the electrical connectors and remove

control lever D from housing F.
Replacement
A B
J C
H D
G E
F
C106940
Fig 1.
E27-3 9803/3760-07 (E-09-09) E27-3

E27-4 9803/3760-07 (E-09-09) E27-4


Introduction
applications table.
relevant topics.

K Valve Port Identification ( T E28-4)
E28-1 9803/3760-07 (E-09-02) E28-1

Related Topics
Related Topics

1 Applications ALL
1 Service Tools ALL
E28-2 9803/3760-07 (E-09-02) E28-2

Operation Overview
Operation Overview
The servo pilot control lever assembly operates as direct

acting pressure regulating valve, which consist of the
control lever and four integral proportional pilot control
valve capsules. Each pilot valve capsule consists of a
spool 1-1 with a control spring, a plunger 1-2 and plunger
return spring 1-3.
In neutral, the control lever is kept central by the force of

the plunger return springs 1-3. In this position the control
lever service ports are connected to the tank port ‘T’ via the
drillings 1 -X in the spools.
When the control lever is operated, the relevant plunger 1-

2 pushes on the return spring 1-3 and the spool control
spring. The spool control spring in turn moves the spool 1-
1 down which connects the selected service port to the
pressure port ‘P’.
The spool 1-1 regulates the incoming hydraulic servo

pressure to balance the pressure in the service port with
the force of the control spring. The interaction of the spool
and control spring in this way means that the control lever
will produce a pilot pressure in the selected service port
which is proportional to the position of the control lever.
C052030-C1
Fig 1.

Servo
Exhaust
E28-3 9803/3760-07 (E-09-02) E28-3

Operation Overview
Valve Port Identification
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
E28-4 9803/3760-07 (E-09-02) E28-4

Removal
Topics ( T E28-2)
!MWARNING
Hydraulic Pressure
the hoses are open.
INT-3-1-11_2

3 Remove gaiter screws A.
4 Remove the gaiter collar B.
5 Undo screws E and lift the control lever assembly F

away from the housing C to get access to the hoses
D and connectors G.


9 Disconnect the electrical connectors G and remove

control lever from housing C.
Replacement
C087210
Fig 3.
E28-5 9803/3760-07 (E-09-02) E28-5

E28-6 9803/3760-07 (E-09-02) E28-6

Extension Ram
Introduction
applications table.
relevant topics.

K Removal and Replacement - 2 Stage Boom ( T E29-3)
K Outer Ram ( T E29-5)
K Inner Ram ( T E29-7)
E29-1 9803/3760-07 (E-17-02) E29-1

Extension Ram
Related Topics
Related Topics

1 Applications ALL
3 Fluids, Lubricants and Capacities ALL
B Boom ALL
E K Displacement Ram ( T E32-1) ALL
E29-2 9803/3760-07 (E-17-02) E29-2

Extension Ram
Removal and Replacement - 2 Stage Boom
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.
Removal
!MWARNING
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.

Topics ( T E29-2)
!MWARNING
Hydraulic Pressure
the hoses are open.
INT-3-1-11_2

6 Remove cap screw 1-B, lock plate 1-C and withdraw

pivot pin 1-A.
A294030-1
7 Disconnect and plug extension ram hydraulic hoses
Fig 1.
2-D. Label each hose before disconnecting to ensure
Note: On 531-70 and 541-70 machines only. To gain

access to the extension ram, remove the displacement
ram. K Related Topics ( T E29-2)
8 Remove nut and bolt 2-E and withdraw main pivot pin
2-F sufficiently to allow the extension ram to be
removed.
Note: Remember that the extension ram pivot pin 2-F is

also the main pivot for the boom. Use a dummy pivot pin to
E29-3 9803/3760-07 (E-17-02) E29-3

Extension Ram
711210-1
Fig 2.
Replacement
– Grease the pivot pins, see Section 3 - Service

Schedules. K Related Topics ( T E29-2)
E29-4 9803/3760-07 (E-17-02) E29-4

Extension Ram
Outer Ram During the replacement procedure do this work also:
Removal – Grease the pivot pins, see Section 3 - Service

Schedules. K Related Topics ( T E29-2)
1 Fully retract and lower the boom to the ground. – Bleed the boom extension hydraulic circuit.
Topics ( T E29-2)
!MWARNING
Hydraulic Pressure
the hoses are open.
INT-3-1-11_2

4 Disconnect and plug feed hoses 3-A, 3-B and carry

over hoses 3-C, 3-D. Label each hose before
disconnecting to ensure correct replacement.
5 Remove restraining strap 3-E.
6 Support the extension ram.
!MWARNING
BF-4-1_1
7 Remove nut and bolt 3-G and withdraw pivot 3-F from
cylinder end.
8 Remove snap ring 3-J and withdraw pivot 3-H, from

rod end, remove ram from the machine.
Replacement
E29-5 9803/3760-07 (E-17-02) E29-5

Extension Ram
345790-1
Fig 3. Machines with 3 Stage Boom - Outer Ram
E29-6 9803/3760-07 (E-17-02) E29-6

Extension 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.
E29-7 9803/3760-07 (E-17-02) E29-7

Extension Ram
7 Stop the engine and remove the starter key. Remove
the hydraulic tank filler cap and operate the boom
extend and retract controls to vent residual pressure.
8 Open the cover at the rear of the boom to gain access

to the hose guides and roller assembly. Release
hydraulic breather tube 4-D from the chassis and tie
it clear of the rear of the boom.
9 Undo bolts 5-E and remove the boom roller assembly.
10 Undo bolts 5-F and remove hose guide 5-G.
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.
5 Grease front pivot pin 4-A. See Section 3 -

Lubricants & Capacities. K Related
Topics ( T E29-2)
E29-8 9803/3760-07 (E-17-02) E29-8

Extension Ram
6 Align the bush on the rod end of the cylinder with the
boom. Fit the pin and secure in place with bolt 4-B.
7 Connect hoses 4-D at the rear of the extension

cylinder. Refit the guide to the hose tray, roller
assembly and hose guide 5-G.
8 Tension the hoses equally by pivoting the roller

assembly. Ensure the boom hoses fit over the rollers
without being stretched. Use JCB Threadlocker and
Sealer and tighten bolts 5-E to 98 Nm (72 lbf ft).
9 Secure breather tube 4-D and replenish the hydraulic

tank as required.
10 Bleed the boom extension hydraulic circuit.

E29-9 9803/3760-07 (E-17-02) E29-9

Extension Ram
E29-10 9803/3760-07 (E-17-02) E29-10

Lift Rams
Introduction
applications table.
relevant topics.

E30 - 1 9803/3760-07 (E-18-01) E30 - 1

Lift Rams
Related Topics
Related Topics

1 Applications ALL
3 Greasing Every 50 Hours
B Boom ALL
E K Ram Maintenance ( T E35-1) ALL
E30 - 2 9803/3760-07 (E-18-01) E30 - 2

Lift Rams
Removal !MWARNING
K Fig 2. ( T E30-4) Hydraulic Pressure
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
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.
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.
6 Support the lift ram 2-A. Remove nut and bolt 2-B and
withdraw the pivot pin 2-C from rod end.
7 At this point it is advisable to remove the boom in

order to provide access for lifting out the ram, see
Section - Body and Framework. K Related
Topics ( T E30-2)
8 Attach suitable lifting equipment to the ram rod eye

end. Support the ram.
!MWARNING
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.
Topics ( T E30-2)
E30 - 3 9803/3760-07 (E-18-01) E30 - 3

Lift Rams
Replacement – Grease the ram pivot pins. K Related

Topics ( T E30-2)
Replacement is the opposite of the removal procedure. – Check the hydraulic fluid level. K Related
Topics ( T E30-2)
Fig 2. Typical Lift Ram
E30 - 4 9803/3760-07 (E-18-01) E30 - 4

Tilt Ram
Introduction
Tilt Ram
Introduction
applications table.
relevant topics.

K Removal and Replacement - 2 Stage Boom (P1) ( T E31-3)(1)
K Removal and Replacement - 2 Stage Boom (P2) ( T E31-5)(1)

Procedures(1) Machine Model Application
531-70, 536-60, 541-70, 536-70, 526-56
531-T70 536-T60 541-T70 536-T70
K Removal and Replacement - 2 Stage Boom (P1) ( T E31-3) z z z z
K Removal and Replacement - 2 Stage Boom (P2) ( T E31-5) z
E31-1 9803/3760-07 (E-19-02) E31-1

Tilt Ram
Related Topics
Related Topics

1 Applications ALL
E K Parallel Hydraulic SYSTEM ( T E2-1) (2) K Bleed Procedures ( T E2-53)
E K LSP Gearpump Hydraulic SYSTEM ( T E3-1)(2) K Bleed Procedures ( T E3-50)
E K LSP Variflow Hydraulic SYSTEM ( T E4-1)(2) K Bleed Procedures ( T E4-64)
E K LSP Electro Servo Hydraulic SYSTEM K Bleed Procedures ( T E5-70)
(S1) ( T E5-1)(2)
(2) Refer to the correct machine hydraulic system.
E31-2 9803/3760-07 (E-19-02) E31-2

Tilt Ram
Removal and Replacement - 2 Stage Boom (P1)
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)
Removal
1 Remove attachments from the carriage.
– Grease the ram pivot pins. K Related
2 Extend the tilt ram fully. Topics ( T E31-2)
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
the hoses are open.
INT-3-1-11_2
5 Park the machine and make it safe. Obey the care

and safety procedures. Vent the hydraulic pressure.

7 Disconnect and plug tilt ram hydraulic hoses 1-B.
8 Support the tilt ram 1-E.
!MWARNING
BF-4-1_1
9 Remove the bolt 1-C and remove the pivot pin 1-D
from rod end.
10 Remove the cap screw 1-A, lock plate 1-F and

remove the pivot pin 1-G from cylinder end.
E31-3 9803/3760-07 (E-19-02) E31-3

Tilt Ram
C043950
C043950
Fig 1. Tilt Ram - 2 Stage Boom (P1)
E31-4 9803/3760-07 (E-19-02) E31-4

Tilt Ram
IMPORTANT: This procedure is only applicable to some

for the applicable machine models. K Table 1. Procedure
Variants ( T E31-1)
Removal
1 Remove all attachments fitted on the tool carrier, tilt
back and lower the boom to the ground.
2 Park the machine and make it safe. Obey the care

and safety procedures. Vent the hydraulic pressure.
!MWARNING
Hydraulic Pressure
the hoses are open.
INT-3-1-11_2
3 Disconnect and plug hydraulic hoses to the ram.

!MWARNING
BF-4-1_1
4 Undo screw(s) 2-A and withdraw pivot pin 2-B from

rod end.
5 Support the ram, undo bolt 2-C and withdraw pivot pin
2-D from cylinder end, remove ram from machine.
Replacement

Topics ( T E31-2)
Topics ( T E31-2)
– Using the bleed procedures bleed the ram.
E31-5 9803/3760-07 (E-19-02) E31-5

Tilt Ram
Fig 2. Tilt Ram - 2 Stage Boom (P2)
E31-6 9803/3760-07 (E-19-02) E31-6

Tilt Ram
Removal – Grease the ram pivot pins. K Related

Topics ( T E31-2)
1 Remove any attachments from the carriage. – Check the hydraulic fluid level. K Related
Topics ( T E31-2)
2 Extend the boom approximately 600mm. – Using the bleed procedures bleed the ram.
K Related Topics ( T E31-2).
3 K Fig 3. ( T E31-8). Lower the boom onto a suitable
support so that the carriage is clear of the ground as
shown.

pressure. Obey the care and safety procedures.
!MWARNING
Hydraulic Pressure
the hoses are open.
INT-3-1-11_2
5 Disconnect and plug tilt ram hydraulic hoses 3-C.

6 Support the tilt ram.
!MWARNING
BF-4-1_1
7 Remove the recessed cap screw 3-A and withdraw

pivot pin 3-B from rod end.
8 Remove nut and bolt 3-D and withdraw pivot pin 3-E
from cylinder end, remove the ram from the machine.
Replacement
E31-7 9803/3760-07 (E-19-02) E31-7

Tilt Ram
A293270-1
Fig 3. Tilt Ram - 3 Stage Boom
E31-8 9803/3760-07 (E-19-02) E31-8

Displacement Ram
Introduction
Displacement Ram
Introduction
applications table.
relevant topics.

K Removal and Replacement - Single Ram (P1) ( T E32-3)(1)
K Removal and Replacement - Single Ram (P2) ( T E32-5)(1)
K Removal and Replacement - Twin Rams, 2 Stage Boom ( T E32-7)
K Removal and Replacement - Twin Rams, 3 Stage Boom ( T E32-8)

Procedures (1) Machine Model Application
531-70, 536-60, 541-70, 536-70, 526-56
531-T70 536-T60 541-T70 536-T70
K Removal and Replacement - Single Ram (P1) ( T E32-3) z z z z
K Removal and Replacement - Single Ram (P2) ( T E32-5) z
E32-1 9803/3760-07 (E-20-02) E32-1

Displacement Ram
Related Topics
Related Topics

1 Applications ALL
B Boom ALL
E32-2 9803/3760-07 (E-20-02) E32-2

Displacement Ram
Removal and Replacement - Single Ram (P1)
IMPORTANT: This procedure is only applicable to some 10 Remove the ram from the machine.
for the applicable machine models. K Table 1. Procedure Replacement
Variants ( T E32-1)
Replacement is opposite of the removal procedure.
Removal
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)
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
the hoses are open.
INT-3-1-11_2
4 Vent the hydraulic pressure. Obey the care and safety


6 Disconnect and plug displacement ram hydraulic

hoses 1-A.
7 Support the displacement ram 1-F.
!MWARNING
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.
E32-3 9803/3760-07 (E-20-02) E32-3

Displacement Ram
S293640-1
Fig 1. Single Displacement Ram (P1)
E32-4 9803/3760-07 (E-20-02) E32-4

Displacement Ram
IMPORTANT: This procedure is only applicable to some Replacement

for the applicable machine models. K Table 1. Procedure Replacement is opposite of the removal procedure.
Variants ( T E32-1)
Removal
1 Park the machine and make it safe. Vent the hydraulic Topics ( T E32-2)
pressure. Obey the care and safety procedures. – Check the hydraulic fluid level. K Related
K Related Topics ( T E32-2) Topics ( T E32-2)
2 Remove the lift ram. K Lift Rams ( T E30-1).
!MWARNING
Hydraulic Pressure
the hoses are open.
INT-3-1-11_2
3 Support the boom.
4 Lift the boom using the correct lifting equipment to get

access to the displacement ram top pivot.

6 Disconnect and plug displacement ram hydraulic

hoses 2-A.
7 Support the displacement ram 2-F.
!MWARNING
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.
E32-5 9803/3760-07 (E-20-02) E32-5

Displacement Ram
C075750
Fig 2. Single Displacement Ram (P2)
E32-6 9803/3760-07 (E-20-02) E32-6

Displacement Ram
Removal and Replacement - Twin Rams, 2 Stage Boom
Removal
1 Remove any attachments from the carriage.
2 Lower the boom onto a suitable support as shown.

K Fig 3. ( T E32-7)
A711140-1
Fig 4.
7 Attach suitable lifting equipment to the cylinder end of

the displacement rams. Support the rams.
!MWARNING
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
the hoses are open.
716910-1
INT-3-1-11_2 Fig 5.
4 Disconnect and plug hydraulic hoses to the rams.

Replacement
5 Support the displacement rams 4-A.
6 Remove nut and bolt 4-B and withdraw the pivot pin
4-C from the displacement rams. Use the slide
Topics ( T E32-2)
hammer kit, see Section 1 - Service Tools.
K Related Topics ( T E32-2) – Check the hydraulic fluid level. K Related
Topics ( T E32-2)
E32-7 9803/3760-07 (E-20-02) E32-7

Displacement Ram
Removal
Note: The illustration and procedure describes removal of
one displacement ram. The procedure for the second ram
is identical.

!MWARNING
Hydraulic Pressure
the hoses are open.
INT-3-1-11_2
2 Disconnect and plug the displacement ram hydraulic

hoses 6-A. Label each hose before disconnecting to
ensure correct replacement.
3 Support the displacement ram 6-D. Remove nut and

bolt 6-B and withdraw pivot pin 6-C from rod end.
4 Attach suitable lifting equipment to the ram rod eye

end. Support the ram.
!MWARNING
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

Topics ( T E32-2)
Topics ( T E32-2)
E32-8 9803/3760-07 (E-20-02) E32-8

Sway Ram
Introduction
applications table.
relevant topics.

E33-1 9803/3760-07 (E-21-01) E33-1

Sway Ram
Related Topics
Related Topics

1 Applications ALL
E K Parallel Hydraulic SYSTEM ( T E2-1) K Bleed Procedures ( T E2-53)
E33-2 9803/3760-07 (E-21-01) E33-2

Sway Ram
Removal 9 Remove nut and bolt 1-E and withdraw pivot pin 1-F
from rod end, remove the ram from the machine.

Topics ( T E33-2)
!MWARNING
Hydraulic Pressure
the hoses are open.
INT-3-1-11_2

There will still be residual pressure in the ram. This

should be borne in mind if the ram is to be dismantled.
K Ram Maintenance ( T E35-1)
5 Support the chassis on both sides of the machine.
6 Disconnect and plug sway ram hydraulic hoses 1-A.

S293690-2
7 Support the sway ram 1-B. Remove nut and bolt 1-C Fig 1.
and withdraw pivot pin 1-D from cylinder end.
8 Attach suitable lifting equipment to the cylinder end of

the ram. Support the ram.
!MWARNING
BF-4-1_1
E33-3 9803/3760-07 (E-21-01) E33-3

Sway Ram
Replacement

Topics ( T E33-2)
Topics ( T E33-2)
– Bleed the sway hydraulic circuit. K Related
Topics ( T E33-2).
E33-4 9803/3760-07 (E-21-01) E33-4

Stabiliser Rams
Introduction
applications table.
relevant topics.

K Checking Pressure Switch Operation ( T E34-3)
E34-1 9803/3760-07 (E-22-01) E34-1

Stabiliser Rams
Related Topics
Related Topics

1 Applications ALL
B Stabilisers Removal and Replacement
E34-2 9803/3760-07 (E-22-01) E34-2

Stabiliser Rams
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
pressure. Obey the care and safety procedures. Replacement is the opposite of the removal procedure.
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.
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.

5 Disconnect the electrical connector 1-A from the

pressure switch (if fitted).
6 Disconnect and plug stabiliser ram hydraulic hoses 1-

B. Label each hose before disconnecting to ensure
7 Support the stabiliser ram.
E34-3 9803/3760-07 (E-22-01) E34-3

Stabiliser Rams
S293700-1
Fig 1. Stabiliser Ram (if fitted)
E34-4 9803/3760-07 (E-22-01) E34-4

Ram Maintenance
Introduction
Ram Maintenance
Introduction
applications table.
relevant topics.

K Ram End Damping ( T E35-3)(1)
K JCB Ram Sealing Procedure ( T E35-9)
K Piston Head Retention ( T E35-11)
K Extension Ram Make-Up Valve (if fitted) ( T E35-12)
Table 1. Procedure and Specification Variants

531-70, 536-60, 541-70, 536-70,
531-T70 536-T60 541-T70 536-T70
K Ram End Damping ( T E35-3) Electro Servo Variants
E35-1 9803/3760-07 (E-24-01) E35-1

Ram Maintenance
Related Topics
Related Topics

1 Applications ALL
1 Service Tools ALL
E K Extension Ram ( T E29-1) ALL
E K Lift Rams ( T E30-1) ALL
E K Tilt Ram ( T E31-1) ALL
E K Displacement Ram ( T E32-1) ALL
E K Stabiliser Rams ( T E34-1) ALL
E K Sway Ram ( T E33-1) ALL

892/00334 (1) Ram Seal Fitting Tool
892/01027 (1) Piston Seal Assembly Tool
(2) Ram Protection Sleeve
(2) Hexagon Spanner
(2) For the applicable JCB part number refer to Section 1 - Service Tools
E35-2 9803/3760-07 (E-24-01) E35-2

Ram Maintenance
Operation Overview
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.
Ram - Cylinder End
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
E35-3 9803/3760-07 (E-24-01) E35-3

Ram Maintenance
Operation Overview
C078940
Fig 2. Ram Extending (Cylinder End of Ram)
Ram - Rod End
The damping effect is caused by a tapered collar on the

piston rod which engages with the end cap to decrease the
flow of oil.
E35-4 9803/3760-07 (E-24-01) E35-4

Ram Maintenance
Operation Overview
C078950
Fig 3.
As the ram opens to full extend the tapered collar 3-E on

the piston rod 3-B engages with the end cap 3-A, the oil
flows through the four holes 3-H in the end cap 3-A through
the cylinder port. The ‘o’ ring 4-A compresses on the anti
extrusion ring 4-B which closes the four oil galleries on the
front of the end cap 3-G.The damping effect is caused by
the tapered collar 3-E gradually decreasing the area
between the piston rod 3-B and end cap 3-A restricting the
flow of oil.
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.
E35-5 9803/3760-07 (E-24-01) E35-5

Ram Maintenance
Dismantle
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 Ò' 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 Ò' 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.
2 Use the correct size spanner to release end cap 6-8

and remove the piston rod assembly (items 6-1 to 6-
12) from the cylinder 6-19.
!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
3 Position piston rod assembly on bench in place of ram

cylinder. Discard seals (items 6-2, 6-3) and wear rings
(items 6-1 and 6-4) from piston head 6-6.
E35-6 9803/3760-07 (E-24-01) E35-6

Ram Maintenance
Dismantle
S314091-1
Fig 6. Typical Ram
E35-7 9803/3760-07 (E-24-01) E35-7

Ram Maintenance
Assemble
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).
Important: Ensure that seals or Ò' rings do not come into

contact with JCB Activator or anaerobic sealing and
retaining compounds such as JCB Threadlocker and
Sealer.
2 Fit new seals, Ò' rings and wear rings.
For the correct method of fitting seals to the end cap

and piston head. K JCB Ram Sealing
Procedure ( T E35-9)
Important: Ensure that lubricants used during assembly

do not come into contact with de-greased components or
sealing/retaining compounds.
3 Fit locking dowel 6-5 to piston 6-6. K Piston Head

Retention ( T E35-11)
4 Position cylinder 6-19 on the bench and install the

piston rod assembly into the cylinder.
5 Apply JCB Activator to threads of end cap and

cylinder. Allow JCB Activator to dry for 15 minutes
before bringing into contact with JCB Threadlocker.
6 Apply JCB Threadlocker to threads of cylinder and

torque tighten end cap 6-8. K Table 4. Torque
Settings ( T E35-8)
Note: If hydraulic oil contacts uncured locking fluid a

weakening of the bond will result. Cure times vary
according to the ambient temperature. The following
approximate cure time applies at 20ªC and is the minimum
period between assembly and filling the ram with oil.
JCB Threadlocker & Sealer (High Strength) or JCB

Threadlocker with JCB Activator - 1 hour.
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.
E35-8 9803/3760-07 (E-24-01) E35-8

Ram Maintenance
Assemble
JCB Ram Sealing Procedure

TE-005_2
1 Fit new rod seals.
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.
b Close the tool. K Fig 10. ( T E35-9). The seal

must form a reniform (kidney shape).
S216250-1
Fig 7. Seal Fitting Tool
The pins are screwed into threaded holes in the tool

body, the spacing of the holes is designed to suit
small or large diameter rod seals.
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.
d Locate the seal in the end cap groove.

K Fig 11. ( T E35-9). When the seal is in position,
open the tool to release the seal. Make sure the
seal is correctly installed in its grooved and
remove the tool.
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.
E35-9 9803/3760-07 (E-24-01) E35-9

Ram Maintenance
Assemble
Note: Some rod wipers, i.e. power track rod, may use a b Fit outer seal 13-C using the same procedure as
metal encased seal which is pressed into the housing. stated for seal 13-B. Check the external grooves
Care must be taken to ensure the seal is square before it are visible.
is pressed in.
c Ensure the O-ring is fitted into the internal seal
f Sleeve 12-A must be used to protect the rod seals groove on the piston head. Screw the piston head
from damage when fitting end cap onto the piston onto the thread of the piston rod, refer to the
rod. There are various sizes of sleeve, see relevant section for torque figure and completion
Service Tools, Section 1. Make sure the of ram assembly.
hexagon on the end cap is towards the eye end of
the rod. d Fit the piston head retaining dowel, refer to the
relevant section for torque figure and completion
of ram assembly.
e Fit wear rings 14-A and 14-B. Rotate the wear

rings so that the piston retention dowel is covered
by the wear ring, Not as shown at 14-C.
187361-1
Fig 12.
2 Fit new head piston seals.
a Use a blunt instrument 13-A (Part no. 892/01027)

to lever the inner seal 13-B into the piston head
seal groove. Do not let the seal twist. There are
identification marks on the outer diameter of the
seal, make sure the marks are visible and the seal
is free to rotate, if not remove the seal and refit.
338490-1
Fig 14.
3 Fit the piston rod and head assembly into the cylinder.
a Insert the piston/rod assembly into the cylinder.

Align the rod and head assembly until parallel with
the cylinder then push the assembly into the
cylinder.
b Fit the end cap, refer to the relevant section for

torque figure and completion of ram assembly.
338480-1
Fig 13.
E35-10 9803/3760-07 (E-24-01) E35-10

Ram Maintenance
Piston Head Retention
Piston Head Retention
Fit locking dowel to piston as follows: Drilling Dimensions

Existing piston head and rod
Align holes so that dowel can be fitted with tapped
extractor hole showing.
New piston head and rod

Drill and ream piston head and rod to the diameter and
depth indicated. K Drilling Dimensions ( T E35-11)
Remove all swarf and contamination and insert dowel with
tapped extractor hole showing.
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.
Existing piston head and new rod

A335740
Fig 15.
Drill through existing hole in piston head to the diameter
and depth indicated. K Drilling Dimensions ( T E35-11) Table 5. Drilling Dimensions
Remove all swarf and contamination and insert dowel with
Ram Size Diameter X Depth Y
tapped extractor hole showing.
50 x 25 6.02mm - 6.10mm 23mm
Note: Ensure that the top of the dowel is below the level of 90 x 50 8.10mm - 8.02mm 28mm
the bearing ring groove and use an undersized pilot drill
100 x 60 12.10mm - 12.02mm 33mm
before drilling to the final size shown in the table.
110 x 60 12.10mm - 12.02mm 33mm
New piston head and existing rod 120 x 60 12.10mm - 12.02mm 38mm
130 x 70 12.10mm - 12.02mm 38mm
Same as Existing piston head and new rod but at 90
degrees to existing hole in rod. 130 x 75 12.10mm - 12.02mm 38mm
140 x 75 12.10mm - 12.02mm 48mm
160 x 80 12.10mm - 12.02mm 48mm
E35-11 9803/3760-07 (E-24-01) E35-11

Ram Maintenance
Extension Ram Make-Up Valve (if fitted)
Extension Ram Make-Up Valve (if fitted)

Note: This valve is fitted to 3 stage boom machines only,
and is assembled to the piston rod using locking fluid.
With the valve removed check for freedom of movement of

the plunger and ball. Renew 'O' ring seal.
Thoroughly remove all oil, grease and dirt from threads of

valve and piston rod. Apply JCB Activator and allow to dry
for 15 minutes.
Coat three central threads of the valve with JCB

Threadlocker & Sealer (High Strength) ensuring that it
does not contact 'O' ring seal.
Re-assemble to piston rod ensuring that the end face is

flush to 0.5 mm (0.02 in) below the end face of the piston
rod as at X. Add washer 1410/0003 beneath valve if
necessary.
After assembly, plunger when pulled out, should protrude

a minimum of 4 mm (0.16 in) from end face of piston rod 159190-1
as at Y. Fig 16.
Note: Approximately 60 minutes should elapse from fitting

the valve before allowing contact with hydraulic oil.
E35-12 9803/3760-07 (E-24-01) E35-12


Introduction
applications table.
relevant topics.

K Electrical Connectors ( T E36-7)
E36-1 9803/3760-07 (E-32-01) E36-1

Related Topics
Related Topics

1 Applications ALL
(S1) ( T E5-1)
E36-2 9803/3760-07 (E-32-01) E36-2

Component Location
Component Location
Key: K Fig 1. ( T E36-4)

A Sway Valve
B Sway Direction Solenoid
C Sway/Fan Selection Solenoid
D Sway Switch
E Boom Proximity Switch
F Proximity Switch Trigger Plate
E36-3 9803/3760-07 (E-32-01) E36-3

Component Location
C084990-C1
Fig 1.
E36-4 9803/3760-07 (E-32-01) E36-4

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)
Full Pressure
Neutral
Exhaust
C084970-C1
Fig 3. Right Sway Switch Operated
C084970
Fig 2. Sway Switch Not Operated
E36-5

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.
E36-6 9803/3760-07 (E-32-01) E36-6

ECU connector pins.
M10
M10
1046 Sway Switch Located on the instrument panel. Remove the
1069 Sway Proximity Switch TBA

3056 Sway/Fan Changeover K Component Location ( T E36-3)
Solenoid
3057 Sway Direction Control K Component Location ( T E36-3)

Solenoid
3058 Sway Direction Control K Component Location ( T E36-3)

Solenoid

E36-7 9803/3760-07 (E-32-01) E36-7


E36-8 9803/3760-07 (E-32-01) E36-8

Removal 4 Disconnect the electrical connectors from the sway

direction control solenoids C.
5 Make a note of the route of the harness G.
6 Remove the harness retaining clips F.
7 Support the sway/fan valve D.
8 Undo bolts E and remove the sway/fan valve D and

from the bracket A.
G
F
C110660
Fig 7. Typical Sway Valve Harness
C085000 Replacement
Fig 6.
!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 Ò' 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.
2 Disconnect and plug the hydraulic hoses. Put a label

on each hose before disconnecting to aid
replacement.
3 Disconnect the electrical connector from the stabiliser

sway/fan selector solenoid B.
E36-9 9803/3760-07 (E-32-01) E36-9

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 Ò' ring seals. If damage to any 2 Remove the surface mounted Ò' 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
Any of the above may result in possible problems with the

operation of the valve.
Dismantle
C085020
Fig 9.
C085010
Fig 8.
5 Inspect the spool 9-4 for signs of wear, nicks
scratches etc.
E36-10 9803/3760-07 (E-32-01) E36-10

Assemble
– Renew all O-rings.

– Lightly lubricate all parts with clean hydraulic fluid
before assembling.
– Apply a small quantity of JCB Threadlocker and
Sealer to the threads in the knurled nut 1 before
fitting.
E36-11 9803/3760-07 (E-32-01) E36-11

E36-12 9803/3760-07 (E-32-01) E36-12

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Section E

E-0 9803/3760-07 E-0

Contents Page No.

Systems and Schematics

Parallel Hydraulic SYSTEM

LSP Gearpump Hydraulic SYSTEM

LSP Variflow Hydraulic SYSTEM

LSP Electro Servo Hydraulic SYSTEM (S1)

Contents Page No.

LSP Electro Servo Hydraulic SYSTEM (S2)

Servo Parallel Hydraulic SYSTEM

Smooth Ride SYSTEM (SRS) - Parallel

Smooth Ride SYSTEM (SRS) - LSP

Smooth Ride SYSTEM (SRS) (S1) - Electro Servo

Contents Page No.

Smooth Ride SYSTEM (SRS) - Servo Parallel

Parallel Control Valve - 4 Section

Parallel Control Valve - 6 Section

Flowshare (LSP) Control Valve

Electro Servo (LSP) Control Valve (S1)

Servo Parallel Control Valve

Contents Page No.

Servo Pilot Valve

Servo Pilot Pressure Supply Valve (S1)

Servo Pilot Pressure Supply Valve (S2)

Pilot Manifold Block

Main Pump - Variflow

Main Pump - Gearpump

Cooling Fan Motor

Contents Page No.

Control Lever - Electro Servo (S1)

Control Lever - Electro Servo (S2)

Control Lever - Servo Parallel

Contents Page No.

Sway/Fan Changeover Valve

Page left intentionally blank

E0-4 9803/3760-07 (AE-00-00) E0-4

Systems and Schematics

E1-1 9803/3760-07 (E-00-01) E1-1

Table 1. System Variants - Identification References - Hydraulics

E1-2 9803/3760-07 (E-00-01) E1-2

E1-3 9803/3760-07 (E-00-01) E1-3

E1-4 9803/3760-07 (E-00-01) E1-4

E1-5 9803/3760-07 (E-00-01) E1-5

Table 3. Specification Variants - Hydraulic Schematics

2H Auxiliary relief valve (ARV) 13 Second Auxiliary (option) - if fitted

K Table 4. Component Key: ( T E1-8) K Applications ( T E1-6)

K Table 4. Component Key: ( T E1-8) K Applications ( T E1-6)

K Table 4. Component Key: ( T E1-8) K Applications ( T E1-6)

K Table 4. Component Key: ( T E1-8) K Applications ( T E1-6)

E1-14 9803/3760-07 (E-00-01) E1-14

2E Extension spool 13 Auxiliary 1 with Sway (option) - if fitted

2G Auxiliary spool 13B Sway ram check valve - if fitted

K Table 5. Component Key: ( T E1-15) K Applications ( T E1-6)

K Table 5. Component Key: ( T E1-15) K Applications ( T E1-6)

K Table 5. Component Key: ( T E1-15) K Applications ( T E1-6)

K Table 5. Component Key: ( T E1-15) K Applications ( T E1-6)

K Table 5. Component Key: ( T E1-15) K Applications ( T E1-6)

K Table 6. Component Key: ( T E1-22) K Applications ( T E1-6)

K Table 6. Component Key: ( T E1-22) K Applications ( T E1-6)

K Table 6. Component Key: ( T E1-22) K Applications ( T E1-6)

K Table 6. Component Key: ( T E1-22) K Applications ( T E1-6)

K Table 7. Component Key: ( T E1-28) K Applications ( T E1-6)