JCB JS175W Service Manual PDF

General Information 1
Care & Safety 2

R
Routine Maintenance 3
Attachments A
Body & Framework
B
Service
Manual Electrics C
JS130W
Controls D
JS145W
JS160W Hydraulics E
JS175W
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
Transmission F
OF JCB SERVICE: ©
UTTOXETER, STAFFORDSHIRE, ST14 7BS,
ENGLAND
Tel. ROCESTER (01889) 590312
PRINTED IN ENGLAND
Brakes G
Publication No. 9803/6310
Issue 5
Engine K
Section E Hydraulics Section E
i i
Contents Page No.

Technical Data 1-1
Schematic Diagram
Component Key 2-1
* Schematic Circuit Diagram JS130W/JS145W/JS160W 2-2
JS160W/JS175W Boom Circuit (TAB Option) 2-3
* JS130W JS145W/JS160W revised circuit 2-4
* Schematic Circuit Diagram JS175W 2-5
* JS175W revised circuit 2-7
Fault Finding 3-1
Pressure Testing
Pressure Measuring Points 4-1
Pressure Relief Valves 4-1
Main Relief Valve 4-3
Servo Accumulator 4-4
Pilot Relief Valve 4-5
Auxiliary Relief Valves 4-6
Stabilisers/Blade Auxiliary Relief Pressure 4 - 14
Slew Motor Relief Valve 4 - 15
Brake Service Pressure 4 - 16
Steer Stall System Pressure 4 - 16
Clutch Pressure 4 - 17
Park Brake Pressure 4 - 17
Circuit Descriptions
Pump Circuits 15 - 1
* Drive Circuit (CAPS II only 15 - 2
* Drive Circuit (AMS only) 15 - 3A
Park Brake/Gearchange Circuit 15 - 5
Steering and Brake Circuit 15 - 7
Grab Rotate Circuit 15 - 9
Stabiliser Circuit 15 - 11
Dozer Blade Circuit 15 - 13
Axle Lock Rams 15 - 15
Axle Lock Circuit 15 - 16
Hammer Circuit 15 - 17
* Hydraulic Pump/Regulator - JS130W/JS145W/JS160W
Introduction/Specifications 17 - 1
Hydraulic Pump Circuit Diagram 17 - 2
Operation 17 - 3
Dismantling and Assembly 17 - 7
Checks after Installation 17 - 17
* Hydraulic Pump/Regulator - JS175W
Introduction/Specifications 18 - 1
Hydraulic Pump Circuit Diagram 18 - 2
Operation 18 - 5
* Proportional Reducing Valve
Valves
Control Valve
Introduction/Technical Data 20 - 1
Precautions Before Use 20 - 2
Spool Location 20 - 3
Hydraulic Circuit Diagram 20 - 4
Removal and Replacement 20 - 5
Shuttle Valve
Introduction 21 - 1
Service Valves
General Information/Technical Data 22 - 1
Gear Change Valve 24 - 1
Axle Lock Valve 25 - 1
9803/6310 Issue 4*
ii ii
Contents Page No.

Remote Control Valve (Services) 26 - 1
Cushion Valve - Early Machines 27 - 1
- Later Machines 27 - 6
Slew Brake Valve (CAPS II) 28 - 1
Slew Brake Valve (All later wheeled machines) 28 - 7
Steering Control Unit
Steering Priority Valve
Rotary Coupling
Drive Motor - JS130W/JS160W
* Drive Motor - JS145W/JS175W 34 - 1
Operation
Slew Motor
Hydraulic Motor Components- JS130W/JS145W 35 - 1
Hydraulic Circuit - JS130W/JS145W/JS160W/JS175W 35 - 2
Operation 35 - 3
Specification - JS130W/JS145W 35 - 4
Dismantling - JS130W/JS145W 35 - 5
Maintenance Specifications - JS130W/JS145W 35 - 10
Assembly - JS130W/JS145W 35 - 11
Relief Valves - JS130W/JS145W
Dismantling 35 - 17
Assembly 35 - 18
Fault Finding - JS130W/JS145W 35 - 19
Specifications - JS160W/JS175W 36 - 1
Hydraulic Motor Components - JS160W/JS175W 36 - 2
Dismantling - JS160W/JS175W 36 - 3
Maintenance Specifications - JS160W/JS175W 36 - 4
Assembly - JS160W/JS175W 36 - 5
Relief Valve - JS160W/JS175W 36 - 6
Hydraulic Rams
Specifications 40 - 1
Bucket Ram
Removal 42 - 1
Replacement 42 - 3
Dipper Ram
Removal 42 - 5
Replacement 42 - 7
Boom Rams (General)
Removal 42 - 10
Replacement 42 - 12
Boom Ram (TAB)
Removal 42 - 15
Replacement 42 - 17
Boom, Dipper, bucket and TAB Rams
Torque Settings 43 - 4
Stabiliser/Dozer Rams
Axle Lock Rams
9803/6310 Issue 5*
iii iii
Contents Page No.

Power Track Rod
Ram Piston Head Nut
Removal and Fitting 44 - 1
Reconditioning 45 - 1
Fault Finding 46 - 1
Maintenance Specifications 47 - 1
* Hydraulic Rams - from various serial numbers (see page 48-1)

Dismantling the piston rod from cylinder tube 48 - 1
Dismantling of piston rod 48 - 2
Removing of piston seals 48 - 4
Removing of cylinder head seals 48 - 4
Assembling the piston seals 48 - 7
Assembling the cylinder head seals 48 - 9
Assembling the piston rod with cushion ring on piston rod side 48 - 11
Assembling the piston rod with cushion ring on the piston 48 - 14
Rod & cylinder bottom side
Assembling the piston rod in cylinder tube 48 - 17
9803/8000 Issue 1
1-1 Technical Data 1-1
Pump
Type Variable displacement, two element piston pumps in

tandem. Integral gear servo pumps.
Control Valve
Manufactured in two halves and bolted together.
Left Hand Valve (3 spool) Servo actuation of bucket, boom options/dozer.
Right Hand Valve (4 spool) Servo actuation of dipper, swing, options and travel.
* Rams (JS130W/JS145W)
Bore Rod Diameter Stroke
Boom (2 off) (mono boom only) 110 mm (4.3 in) 70 mm (2.8 in) 1055 mm (41.5 in)
Dipper 120 mm (4.7 in) 80 mm (3.1 in) 1282 mm (50.5 in)
Bucket 105 mm (4.1 in) 65 mm (2.6 in) 890 mm (35.0 in)
Dozer (2 off) (optional) 110 mm (4.3 in) 60 mm (2.4 in) 192 mm (7.5 in)
Stabilisers (optional) 120 mm (4.7 in) 65 mm (2.6 in) 476 mm (18.7 in)
Axle Lock (2 off) 85 mm (3.3 in) 85 mm (3.3 in) 160 mm (6.3 in)
Triple Articulated Boom (if fitted)
Boom Raise/Lower 110 mm (4.3 in) 70 mm (2.8 in) 835 mm (32.9 in)
Boom Position 110 mm (4.3 in) 70 mm (2.8 in) 815 mm (32.1 in)
* Rams (JS160W/JS175W)
Boom (2 off ) (mono boom only 120 mm (4.7 in) 80 mm (3.1 in) 1184 mm (46.6 in)
Dipper 125 mm (4.9 in) 85 mm (3.3 in) 1448 mm (57.0 in)
Bucket 110 mm (4.3 in) 70 mm (2.8 in) 997 mm (39.3 in)
Dozer (2 off) (optional) 110 mm (4.3 in) 60 mm (2.4 in) 192 mm (7.5 in)
Stabilisers (optional) 120 mm (4.7 in) 65 mm (2.6 in) 476 mm (18.7 in)
Axle Lock (2 off) 85 mm (3.3 in) 85 mm (3.3 in) 160 mm (6.3 in)
Triple Articulated Boom (if fitted)
Boom Raise/Lower 120 mm (4.7 in) 80 mm (3.1 in) 927 mm (36.5 in)
Boom Position 120 mm (4.7 in) 80 mm (3.1 in) 927 mm (36.5 in)
Motors
Drive Variable displacement, axial piston motor.

Swing Fixed displacement, axial piston motor.
9803/6310 Issue 2*
1-2 Technical Data 1-2
Service Max Engine Speed, ‘S’ Mode JS 130W/145W JS 160W JS175W Tolerance
Bar (lbf/in2) Bar (lbf/in2) Bar (lbf/in2) Bar (lbf/in2)
2 Stage Main Relief

Boom Raise ARV
Arm in/out ARV
Bucket open/close ARV
Standard 312 (4524) 315 (4568) 315 (4568) ± 5 (72)
Boost/’F’ Mode 340 (4930) 340 (4930) 340 (4930) ± 5 (72)
Boom Service Relief - Boom Lower Stall 295 (4227) 285 (4132) 295 (4227) ± 5 (72)
* TAB 363 (5264) 363 (5264) 363 (5264) ± 5 (72)
TAB Machine Only - Dipper in 280 (4060) 280 (4060) 280 (4060) ± 5 (72)
Swing Crossline Relief (x 2) - Left/Right Stall 295 (4227) 285 (4132) 295 (4227) ± 5 (72)
Overload Relief - Boom/Arm/Bucket 365 (5292) 365 (5292) 365 (5292) ± 5 (72)
Hammer Service Relief (x 2) - Hammer/Auxiliary Stall 180 (2610) 180 (2610) 180 (2610) ± 10 (145)
Boom Position Ram Service Relief - TAB Stall 365 (5292) 365 (5292) 365 (5292) ± 5 (72)
Blade/Stabiliser Service Relief (x 2) - Service Stall 250 (3625) 250 (3625) 250 (3625) ± 5 (72)
Steer/Brakes Service Relief - Steer Stall 175 (2538) 175 (2538) 175 (2538) ± 5 (72)
Hand Steer Valve Overload - Steer Stall 185 (2682) 185 (2682) 185 (2682) ± 5 (72)
Grab Rotate Cross-line Relief (x 2) - Rotate Stall 150 (2175) 150 (2175) 150 (2175) ± 10 (145)
Negative Control - ‘S’ Mode, Neutral, Maximum RPM 40 (580) 40 (580) 40 (580) +5 (72)/ -0(0)
Servo Pressure - Continuous 40 (580) 40 (580) 40 (580) ± 2 (29)
Clutch Pilot Pressure - Continuous 32 (464) 32 (464) 32 (464) ± 2 (29)
Service Brake Pressure - On Latch 48 (696) 48 (696) 48 (696) ± 2 (29)
Park Brake Pressure - Clutch Residual15 (218) 15 (218) 15 (218) ± 1 (14.5)
Service Brake Charge - Cut In on Falling Pressure 130 (1885) 130 (1885) 130 (1885) ± 5 (72)
Service Brake Charge - Cut Out on Rising Pressure 150 (2175) 150 (2175) 150 (2175) ± 5 (72)
Hose Burst Check Valve Relief - Boom Ram Head Side 365 (5292) 365 (5292) 365 (5292) ± 5 (72)
Hose Burst Check Valve Relief - Position Ram Head Side 365 (5292) 365 (5292) 365 (5292) ± 5 (72)
Hose Burst Check Valve Relief - Arm Ram Rod Side 365 (5292) 365 (5292) 365 (5292) ± 5 (72)
100% Swing Brake - Normal Residual Pressure 13 (188) 15 (218) 15 (218) ± 1 (14.5)
Service Brake Accumulators (x 4) - Nitrogen Pre-charge 37 (536) 37 (536) 37 (536) ± 2 (29)
Park Brake Accumulator - Nitrogen Pre-charge 6 (87) 6 (87) 6 (87) ± 1 (14.5)
Service Brake Warning Lamp - Pressure Switch Falling 105 (1522) 105 (1522) 105 (1522) ± 10 (145)
Rear Brake Lights - Pressure Switch Rising 5 (72) 5 (72) 5 (72) ± 1 (14.5)
Reverse Lights - Pressure Switch Rising 5 (72) 5 (72) 5 (72) ± 1 (14.5)
Park Brake (Drive Inhibit and Alarm) - Press. Switch Falling 26 (377) 26 (377) 26 (377) ± 3 (43)
P22 Pump Signal - Drive at 90% Flow 28 (406) 28 (406) 28 (406) ±2 (29)
Pressure Sequence Valve - Clutch Priority 28 (406) 28 (406) 28 (406) ±2 (29)
Clutch Priority Accumulator - Nitrogen Pre-charge 8 (16) 8 (16) 8 (16) ±1 (14.5)
9803/6310 Issue 3*
2-1 Schematic Diagram 2-1
JS130W/JS145W/JS160W ‡48 Servo Control (Foot Operated, TAB)

49 Transmission Control Valve
Component Key 50 Spool Valve (Servo Controls)
52 Solenoid Valves:
1 Swing Motor A Drive Isolate
2 Swing Brake Control: B Axle Lock
A Swing Lock Solenoid Valve 53 Solenoid Valves (Dozer/Stabiliser):
B Swing Brake Solenoid Valve A Stabiliser LHS
3 Arm Cylinder B Stabiliser RHS
4 Arm Cylinder Hose Burst Check Valve (HBCV) C Stabiliser Down
* D Stabiliser Up
5 Bucket Cylinder
6 Boom Cylinder (Left) 54 Rotary Coupling
7 Boom Cylinder (Right) 55 Stabiliser Rams
8 Hose Burst Check Valve - Boom 56 Shuttle Valve
9 Steering Control Valve and Steering Priority Valve Unit 57 Logic Valve
10 Brake Valve 58 Front Axle
11 Accumulators 59 Axle Lock Rams
12 Pressure Switch (Charge Warning) 60 Drive Motor
13 Pressure switch (Brake Light Warning) 61 Transmission
14 In-line Filter 62 Left Hand Dozer Ram
15 Manifold 63 Right Hand Dozer Ram
16 Hydraulic Pump #64 Remote Control Valve (Hammer)
17 Test Point #65 Control Valve (Hammer)
18 Main Control Valve 66 Rear Axle
19 Solenoid Valves: ‡67 Boom Position Ram (TAB)
A Drive ‡68 Hose Burst Check Valve (TAB)
B Swing Shut-off ‡69 Boom Lift Rams
C 2 Stage Relief 71 In-line Filter
D Cushion Control 72 Shuttle Valve
E Boom Speed Control 73 Dozer/Arm Control Solenoid Valve
F Boom Down Delay 74 Pressure Switch
G Maximum Flow Control 75 Manifold (JS 16OW)
H Servo Isolator 76 Pilot Shuttle Valve
20 Accumulator
21 Accumulator ‡‡ Overload Warnings
22 Transmission Control Valve: † Grab Rotate Option
A Pl Flow limiter ‡ Triple Articulated Boom Option
B P2 Flow limiter # Hammer Option
C Gear Change †† Stabiliser Option
D Park Brake
23 In-line Filter * Note: The diagram on page 2-2 is for JS13OW/145W
‡‡24 Pressure Switch (Overload Warning) machines. The circuit for JS16OW/175W machines is identical
25 Pressure Switch except for the TAB boom option (see page 2-3).
26 Relief Valve
27 Test Point
28 Oil Cooler
29 Return Manifold
30 In-line Filter
31 Nephron Group
32 Air breather
33 Sump Tank
34 Suction Strainer
35 Relief Valve
36 Return Line Filter
37 In-line Filter
38 Check Valve
†39 Solenoid Valves:
A Grab Left
B Grab Right
42 Servo Control Valve (Bucket/Boom)
43 Pressure Switch (Boom/Swing Control)
44 Shuttle Valve
45 Servo Control Valve (Swing/Arm)
46 Pressure Switch (Transmission control)
47 Accumulator
9803/6310 Issue 3*
Section E Electrics Section E
67 6 10
1 4 7 13
8
8 9
68
11
11
12
3 15
2
69
69 26
24 14 17
5
68 68
17
25
16
17
18 56
29
39
28
30 31
32
38
33
20 21
34
17
A
D H
71 19
C G 17
35 36 37 B
23
65 22
45 B F
27
C D
42 49
64 52 A E
74 46
47
48 76
53
72 A B D A B C
73
43 43 13
44 59 54
57
58
62 63
61 55
55
60
50 66
9803/6310 Issue 1
2-3 Schematic Diagram 2- 3
J160W/JS175W Boom Circuit (TAB Option)

for key see page E/2-1
9803/6310 Issue 2*
J130W/JS145W/ J160W
For complete circuit from machine No.TBA see E/2-2
97.8KW/1900rpm
(133PS) Dr 1 Dr 2 P1
A4
a4
B4 B3 A3
S
PRE CHARGE 0.8MPa

2
(8.2Kgf/cm )1000cc
PRE CHARGE 1.5MPa

2
20 21
(15.2Kgf/cm ) 300cc
17
C6 C5 C4 C3 C2 C1
B1 T1
OUT 10um
CUSHION SERVO ISOLATOR
IN
k
L-1
C4 C8 0.05MPa
2
1 (0.5Kgf/cm )
D H 3.3MPa
19 P P1 (33.6Kgf/cm 2 )
2-STAGE RELIEF MAX FLOW CONTROL P

C3 C7 0.103MPa
P2 2
(1.05Kgf/cm )
C G 17
2.8MPa
23
2
SWING SHUT OFF BOOM DOWN DELAY T 2
(28.5Kgf/cm )
C2 C6 22
B1
B F B
27
A
DRIVE BOOM SPEED REG.
A1
C1 C5 10 11
Aa 1.5MPa
C-7 2
(15.2Kgf/cm )
A E
52 46
DS SP 1.0
PRE CHARGE 0.8MPa
B2 T2 47 2
(8.2Kgf/cm )1000cc
T2 T1 T2 T1
P2 P1 P2 P1
53
4 5 C1 D A B C C6
C2 C1 w x
E-9 E-9
C2 C0 C3 C4 C5
z y
I-1 J-1
1A 3A 2B 3B 2A 4A 7B 1B 8B 5A 6A 6B
JS10622
9803/6310 Issue 2*
JS175W 49 Remote Valve

50 Spool Valve (Servo Controls)
Component Key 52 Solenoid Valves:
A Drive Isolate
1 Swing Motor B Axle Lock
2 Swing Brake Control: 53 Solenoid Valves (Dozer/Stabiliser):
A Swing Lock Solenoid Valve A Stabiliser LHS
B Swing Brake Solenoid Valve B Stabiliser RHS
3 Arm Cylinder C Stabiliser Down
4 Arm Cylinder Hose Burst Check Valve (HBCV) D Stabiliser Up
5 Bucket Cylinder 54 Rotary Coupling
6 Boom Cylinder (Left) (non HBCV) 55 Stabiliser Rams
7 Boom Cylinder (Right) (HBCV) 56 Shuttle Valve
8 Hose Burst Check Valve - Boom 57 Logic Valve
9 Steer and Priority Valve Unit 58 Front Axle
10 Brake Valve 59 Axle Lock Rams
11 Accumulators 60 Drive Motor
12 Pressure Switch (Charge Warning) 61 Transmission
13 Pressure switch (Brake Light Warning) 62 Left Hand Dozer Ram
14 In-line Filter 63 Right Hand Dozer Ram
15 Manifold #64 Remote Control Valve (Hammer)
16 Hydraulic Pump #65 Control Valve (Hammer)
17 Test Point 66 Rear Axle
18 Main Control Valve ‡67 Boom Position Ram (TAB)
19 Solenoid Valves: ‡68 Hose Burst Check Valve (TAB)
A Drive ‡69 Boom Lift Rams
B Swing Shut-off 71 In-line Filter
C 2 Stage Relief 72 Shuttle Valve
D Cushion Control 73 Dozer/Arm Control Solenoid Valve
E Boom Speed Control 74 Pressure Switch
F Boom Down Delay 75 Manifold (HBCV)
G Maximum Flow Control 76 Pilot Shuttle Valve
H Servo Isolator
20 Accumulator ‡‡ Overload Warnings
21 Accumulator † Grab Rotate Option
22 Transmission Control Valve: ‡ Triple Articulated Boom Option
A Pl Flow limiter # Hammer Option
B P2 Flow limiter †† Stabiliser Option
C Gear Change
D Park Brake Note: The diagram on page 2-2 is for JS175 machines. See
23 In-line Filter the TAB boom option (see page 2-7).
‡‡24 Pressure Switch (Overload Warning)
25 Pressure Switch
26 Relief Valve
27 Test Point
28 Oil Cooler
29 Return Manifold
30 In-line Filter
31 Nephron Group
32 Air breather
33 Sump Tank
34 Suction Strainer
35 Relief Valve
36 Return Line Filter
37 In-line Filter
38 Check Valve
†39 Solenoid Valves:
* A Grab Left
B Grab Right
42 Servo Control Valve (Bucket/Boom)
43 Pressure Switch (Boom/Swing Control)
44 Shuttle Valve
45 Servo Control Valve (Swing/Arm)
46 Pressure Switch (Transmission control)
47 Accumulator
9803/6310 Issue 2*
9803/6310 Issue 1*
2-7 Circuit Descriptions 2-7
J175W
For complete circuit from machine No.TBA see E/2-2
97.8KW/1900rpm
(133PS) Dr 1 Dr 2 P1
A4
a4
B4 B3 A3
S
PRE CHARGE 0.8MPa

2
(8.2Kgf/cm )1000cc
PRE CHARGE 1.5MPa

2
20 21
(15.2Kgf/cm ) 300cc
17
C6 C5 C4 C3 C2 C1
B1 T1
OUT 10um
CUSHION SERVO ISOLATOR
IN
k
L-1
C4 C8 0.05MPa
2
1 (0.5Kgf/cm )
3.0MPa
D H 2
(30.6Kgf/cm )
3.3MPa
19 P P1 (33.6Kgf/cm 2 )
2-STAGE RELIEF MAX FLOW CONTROL P

C3 C7 0.103MPa
P2 2
(1.05Kgf/cm )
C G 17
23
2
SWING SHUT OFF BOOM DOWN DELAY T
C2 C6
22
B1
B F B
27
A
DRIVE BOOM SPEED REG.
A1
C1 C5 10 11
Aa 1.5MPa
C-7 2
(15.2Kgf/cm )
A E
52 46
DS SP 1.0
PRE CHARGE 0.8MPa
B2 T2 47 2
(8.2Kgf/cm )1000cc
T2 T1 T2 T1
P2 P1 P2 P1
53
4 5 C1 D A B C C6
C2 C1 w x
E-9 E-9
C2 C0 C3 C4 C5
z y
I-1 J-1
1A 3A 2B 3B 2A 4A 7B 1B 8B 5A 6A 6B
JS10622
The above circuit is for JS175W only.
9803/6310 Issue 1
3-1 Fault Finding 3-1
Some problems which may occur in the hydraulic system are

listed below, either for the system as a whole or for
individual components
Symptom Possible Cause Action
1 Hydraulic System
a The hydraulic system is 1 The pump is defective. Check pump pressure and renew if
defective or does not defective.
operate at all.
2 Dirt is clogging the inside of the relief Dismantle and clean the relief valve.
valve.
3 The relief valve is defective. Strip and check the relief valve.
4 A ram is worn. Repair or renew the ram.
5 Negative pressure is low. Check circuit pressure.
6 A valve is cracked. Renew the valve.
7 A spool is not operating over its full Check the movement of the spool or the
stroke. operational linkage.
8 The oil level in the tank is too low. Replenish the oil.
9 Circuit filters are clogged. Clean or renew filters.
10 The circuit pipes are restricted. Check the piping.
2 Hydraulic Pump
a Oil is not discharged from 1 The tank strainer or intake pipe is Clean the strainer and clean the intake
the pump. blocked. pipe.
2 The end of the inlet pipe is above Replenish the oil tank.
the tank oil level.
3 One or more of the pump major Dismantle and inspect pump. Renew
components is damaged or the damaged components and reassemble
input shaft or coupling are defective. the pump. Renew shaft or coupling.
b Pump output is low. 1 The pressure does not increase Check hydraulic pump and control valve.
Hydraulic pressure because of problems with the Renew as required.
does not increase. hydraulic pump or control valve.
2 Internal leakage within the hydraulic Strip and inspect the hydraulic pump,
pump with excessive fluid drain from paying particular attention to sliding
pump drain port. surfaces. Repair or renew as necessary.
Reassemble the pump.
3 Air is being drawn into the pump Check tank oil level and strainer for
from the inlet side. clogging. Correct as necessary. If OK,
check tightness of pump inlet connection.
4 Inlet resistance causing cavitation. Check correct oil . Check pump low
pressure inlet pipe for collapse. Renew
as required.
c The pump makes an 1 Oil level is low and the pump is drawing Check and replenish oil level. Run the
abnormal noise. in air. pump under no load to bleed air from the
hydraulic system.
9803/6310 Issue 1
2 Hydraulic Pump (cont'd)
2 Clogging of the tank strainer. Clean strainer. If strainer is severely

clogged, drain and flush hydraulic
system.
3 Oil temperature is too low or wrong Check correct oil for ambient
oil specification. temperature, see Lubrication Chart,
Section 3.
4 Coupling defective. Check shaft run out.
5 The pump is resonating with Check pump mounting bolts for tightness.
external equipment. Tighten as required.
6 Internal damage to pump. Dismantle and inspect pump, paying

particular attention to bearings and
sliding surfaces.
d Engine overload 1 Regulator torque set too high. Adjust as necessary.

(engine speed very low
or engine stalled). 2 The servo flow within the regulator Remove the regulator from the pump and
is blocked or internal components check filter for blockage. Clean as
are seized. necessary. If filter OK, dismantle and
inspect regulator.
3 Pump is seized or worn. Dismantle and inspect pump, paying

particular attention to sliding surfaces.
Repair or renew as necessary.
Reassemble the pump.
e Oil leakage. 1 Internal leakage within the pump Dismantle and inspect pump, paying
causing oil seal damage and oil particular attention to oil seals and
leakage. sliding surfaces. Renew as
necessary, ensuring that lips of oil
seals are not damaged when installed.
2 Damaged or blocked drain pipe. Inspect and renew as necessary.
3 Control Valve
a A spool is sticking. 1 Oil temperature abnormally high. Check correct oil, see Lubrication Chart,
Section 3. Check oil cooler and grille
for blockage.
2 The hydraulic oil is dirty. Clean the tank strainer. If strainer badly
clogged, drain and flush hydraulic
system.
3 The service pipe connection Check tightening torque.

is overtightened.
4 The valve housing was twisted Loosen retaining bolts and tighten to
during installation. correct torque figures.
5 Pressure too high. Check system pressure.
6 A spool is bent. Renew the control valve section.
7 A return spring is broken. Renew as necessary.
9803/6310 Issue 1
3 Control Valve (cont'd)
8 A return spring or cap is out of Remove the cap, check that the spring is
alignment. in the correct position. Refit cap and
torque tighten bolts.
9 Temperature distribution within Warm the entire system up before

control valve not uniform. using service.
b A spool does not move 1 Dirt is clogging the inside of the Remove the dirt (flush out the valve).
over its full stroke. valve.
c The dipper/boom falls 1 Oil is leaking past the ram/ boom Renew piston seals.
under load with the spool piston seals.
in neutral.
2 Oil is bypassing dipper/boom spool. Renew control valve section.
3 Oil is leaking past dipper/boom ARV. Remove ARV and clean housing seat
and relief valve seat. Refit ARV.
d The dipper/boom falls 1 Dirt is clogging the load hold check Dismantle and clean the load hold check
under load when the valve. valve.
spool is moved to a
position higher than 2 The load hold check valve seat is Renew the poppet or smooth the poppet
neutral. scratched or damaged. and seat with very fine emery cloth.
4 Main Relief Valve
a System pressure does 1 The main poppet, check valve poppet Remove MRV and dismantle as detailed
not rise at all. or pilot poppet is sticking open, or dirt on page 20-19. Inspect and clean all
is caught in the valve seat. parts. Assemble MRV, ensuring that
all parts slide freely. Refit the MRV.
b Relief pressure is unstable. 1 The pilot poppet seat is scratched or Remove MRV and dismantle as detailed
the pilot piston is sticking with the on page 20-19. Inspect and clean all
main poppet. Parts worn. parts. Renew damaged parts or remove
scratches with very fine emery cloth. Assemble MRV,
ensuring that all parts
slide freely. Refit MRV.
2 The lock nut and adjusting screw Tighten the lock nut and reset MRV
are loose. pressure.
c Oil leak 1 Worn 'O' rings. Remove MRV and renew 'O' rings.
5 Slew Motor
a Motor does not turn. 1 Internal damage to the motor. Measure the oil drain volume. If the supply
volume approaches drain volume, dismantle
and inspect as detailed on page 35-1
(JS130W) or 36-1 (JS160W). Repair or
renew as necessary.
2 Internal damage to the motor. Disconnect motor inlet and outlet ports
and apply servo pressure of 19.6 bar
(284 lb. in2) to the brake release port. Try
to rotate shaft with a torque of
approximately 4.8 - 9.8 Nm (3.6 - 7.2 lbf
ft.). If the shaft does not rotate
smoothly, dismantle and inspect as
detailed on page 35-1 (JS130W) or 36-1
(JS160W). Repair or renew as
necessary.
9803/6310 Issue 1
5 Slew Motor (cont'd)
a Motor does not turn. 3 Relief valve in the circuit not Fit a pressure gauge and measure load
(cont’d) correctly set. pressure, as detailed on page 10-1.
Reset as necessary.
4 The pressure does not rise because Set the relief valve to the correct setting.
the relief valve is incorrectly set.
5 The relief valve plunger sticks. Dismantle and inspect the relief valve.
6 The relief valve plunger choke is Dismantle and inspect the relief valve.
blocked. Clean or renew as necessary.
7 The relief valve plunger seat is defective. Dismantle and inspect the relief valve,
paying particular attention to the valve
seat. Renew the seat if abrasions or
damage is found.
8 The motor is thermally seized. Dismantle and inspect the motor, as

necessary.
9 The brake piston is stuck. Dismantle and check the brake, as

necessary.
10 The brake friction plate is thermally Dismantle and check the brake, as
seized. detailed on page 35-1 (JS130W) or 36-1
(JS160W). Renew as necessary.
b The direction of rotation 1 Motor assembled incorrectly. Dismantle and assemble as detailed
is reversed. on page 35-1 (JS130W) or 36-1
(JS160W).
2 The inlet and outlet pipe connections Fit pipes to correct positions.
are reversed.
c Motor speed low. 1 The oil flow rate is insufficient. Check the hydraulic pump delivery rate
and the circuit up to the motor.
2 The oil temperature is high and Check the oil cooler and grille for
leakage abnormally high. damage and blockage.
3 The motor sliding surfaces are Dismantle and inspect the motor, as
worn or damaged. detailed on page 35-1 (JS130W) or 36-1
necessary.
d The superstructure over 1 High drainage rate within the motor. Check the motor drain flow. If the flow
swings when neutral is exceeds 500 cc/min., dismantle and
selected. inspect the motor, as detailed on page
35-1 (JS130W) or 36-1 (JS160W) paying
particular attention to the sliding
surfaces.
9803/6310 Issue 1
d The superstructure over 2 The A.R.V. is incorrectly set. Set the relief valve to the correct setting.
swings when neutral is
selected. (cont’d)
3 The relief valve plunger seat is defective. Dismantle and inspect the relief valve,
paying particular attention to the
valve seat. Renew the seat if damage is
found.
e Large slip. 1 Wear or damage to the motor sliding Measure the oil drain volume. If the
surfaces or high pressure seal. volume exceeds 5 litres/min, dismantle
(JS130W) or 36-1 (JS160W). Repair or
renew as necessary.
2 Oil hot and large leakage in the motor. Reduce oil temperature.
f Insufficient torque. 1 Wear or burning of the motor sliding Disconnect motor inlet and outlet ports
surfaces. and apply servo pressure of 19.6 bar
(284 lb. in2) to the brake release port. Try
to rotate shaft with a torque of
approximately 4.8 - 9.8 Nm (3.6 - 7.2 lbf
ft). If the shaft does not rotate
necessary.
2 ARV in the circuit not Fit a pressure gauge and measure load
correctly set. pressure, as detailed on page 10-1.
Reset as necessary.
g Abnormal noise. 1 Internal damage to the motor. Check for metallic particles in the motor
drain oil or drain filter. If particles found,
dismantle and inspect as detailed on
page 35-1 (JS130W) or 36-1 (JS160W).
2 Large amounts of air in the oil. Check the oil in the tank and motor
casing. Bleed the system.
3 Loosening of bolts or connections. Check pipe connections, mounting bolts

for tightness. Retighten to specified
torque.
h Abnormal heating. 1 Burning of the motor sliding or Check for metallic particles in the motor
turning parts. drain oil or drain filter. Also apply servo
pressure of 19.6 bar (284 lb. in2) to the
brake release port. Try to rotate the
shaft with a torque of approximately 4.8 -
9.8 Nm (3.6 - 7.2 lbf ft). If particles
found or the shaft does not rotate
necessary.
9803/6310 Issue 1
j Leaks from the oil seal. 1 Damage or wear to oil seal lip. Renew the oil seal, as detailed on page
35-1 (JS130W) and 36-1 (JS160W).
2 Damage or wear to shaft seal. Repair the problem or renew the motor
assembly.
3 Abnormal pressure in the casing. Set the pressure in the casing to below
2.9 bar (43 lb in2) and check drain
volume. If drain volume large, dismantle
(JS130W) and 36-1 (JS160W). Renew
the oil seal and, if possible, repair or
renew other damaged parts.
k Oil leaks from mating 1 An 'O' ring is damaged. Renew 'O' ring.
surface.
2 The seal face is damaged. Repair seal face or renew.
3 Bolts are loose. Check bolts and tighten to the specified

torque.
6 Remote Control Valves
a Low secondary pressure 1 Servo pressure is low. Check servo pressure as detailed on
page 10-1 and adjust as necessary.
2 Spring 14 is damaged. Renew spring.
3 The clearance between the spools Renew spool and casing assembly.
and casing is too large.
4 The handle unit is loose. Renew the handle unit.
b Unstable secondary 1 Sliding parts are sticking. Dismantle and inspect as detailed on
pressure. page 26-2. Repair or renew as
necessary.
2 Air is trapped in the pipes. Operate the valve several times to

remove the air.
c High secondary pressure. 1 Sliding parts are sticking. Dismantle and inspect as detailed on
page 26-2. Repair or renew as
necessary.
9803/6310 Issue 1
4-1 Pressure Testing 4-1
A Pressure Measuring Points
G1
G2
G3
G4
G5
G6
G7
A302840
G1 Steering Test Point

G2 Servo Test Point
G3 Drive Control Signal
G4 P1 Test Point (Main Pump 1)
G5 P2 Test Point (Main Pump 2)
G8
G6 B1 Test Point (Low Gear)
A302870
G7 A1 Test Point (High Gear)
G8 Brake Service Pressure Test point
B Pressure Relief Valves
J
G H
F
E D
K L
C B
Key
A Main relief valve G Dipper in relief valve
B Boom raise relief valve H Dozer/Stabilizer down relief valve
A J A302880
Dozer/Stabilizer up relief valve
C Boom lower relief valve
D Bucket open relief valve K T.A.B. or hammer
E Bucket close relief valve L T.A.B. or hammer
F Dipper out relief valve
302880
9803/6310 Issue 1
Pressure settings
Service Max Engine Speed, `S´ Mode JS130W JS160W Tolerance

Bar (lbf/in2) Bar (lbf/in2) Bar (lbf/in2)
2 Stage Main Relief
Boom Raise
Arm in/out
Bucket open/close
Standard 312 (4524) 315 (4568) ±5 (72)
Boost/ F mode 340 (4930) 340 (4930) ±5 (72)
Boom Service Relief - Boom Lower Stall 295 (4227) 295 (4227) ±5 (72)
Swing Service Relief (x2) -Left/Right Stall 295 (4227) 285 (4132) ±5 (72)
Overload Relief - Boom/Arm/Bucket 365 (5292) 365 (5292) ±5 (72)
Hammer Service Relief (x2) - Hammer/Auxiliary Stall 180 (2610) 180 (2610) ±10 (145)
Boom Position Ram Service Relief - TAB Stall (if Fitted) 365 (5292) 365 (5292) ±5 (72)
Blade/Stabilizer Service Relief (x2) - Service Stall 250 (3625) 250 (3625) ±5 (72)
Steer/Brakes Service Relief - Steer Stall 175 (2538) 175 (2538) ±5 (72)
Hand Steer Valve Overload - Steer Stall - Orbital 195 (2828) 195 (2828) ±5 (72)
Grab Rotate Cross-line Relief (X2) - Rotate Stall 150 (2175) 150 (2175) ±10 (145)
Negative Control - `S´ Mode, Neutral, Maximum RPM 40 (580) 40 (580) ±2 (29)
Servo Pressure 40 (580) 40 (580) ±5 (72)
0 (0)
Clutch Pilot Pressure - Continuous 32 (464) 32 (464) ±2 (29)
Service Brake Pressure - On Latch 48 (696) 48 (696) ±2 (29)
Park Brake Pressure - Clutch Residual 15 (218) 15 (218) ±1 (14.5)
Service Brake Charge - Cut In on Falling Pressure 130 (1885) 130 (1885) ±5 (72)
Service Brake Charge - Cut Out on Rising Pressure 150 (2175) 150 (2175) ±5 (72)
Hose Burst Check Valve Relief - Boom Ram Head Side 365 (5292) 365 (5292) ±5 (72)
Hose Burst Check Valve Relief - Position Ram Head Side 365 (5292) 365 (5292) ±5 (72)
Hose Burst Check Valve Relief - Arm Ram Rod Side 365 (5292) 365 (5292) ±5 (72)
100% Swing Brake - Normal Residual Pressure 13 (188) 15 (218) ±1 (14.5)
Service Brake Accumulators (x4) - Nitrogen Pre-charge 37 (536) 37 (536) ±2 (29)
Park Brake Accumulator - Nitrogen Pre-charge 6 (87) 6 (87) ±1 (14.5)
Service Brake Warning Lamp - Pressure Switch Falling 105 (1522) 105 (1522) ±10 (145)
Rear Brake Lights - Pressure Switch Rising 5 (72) 5 (72) ±1 (14.5)
Reverse Lights - Pressure Switch Rising 5 (72) 5(72) ±1 (14.5)
Park Brake (Drive Inhibit and Alarm) -Pressure Switch Falling 26 (377) 26 (377) ±3 (43)
P22 Pump Signal - Drive at 90% Flow 312 (4524) 315 (4568) ±5 (72)
Pressure Sequence Valve - Clutch Priority 28 (406) 28 (406) ±2 (29)
Clutch Priority Accumulator - Nitrogen Pre-charge 8 (16) 8 (16) ±1 (14.5)
9803/6310 Issue 1
Main Relief Valve (MRV)

1 Prepare the Machine
a Put the operator levers into neutral and lower the
gate lock lever. Start the engine and park the
machine on level ground. Operate the dipper out
and lower the boom to set the bucket on the
ground. Lower the blade onto the ground. Stop the
engine. Release the hydraulic oil tank pressure. (See
Releasing Tank Pressure).
b Install an adaptor and 0 - 600 bar (0 - 8700 lb/in2)

pressure gauge at test point G4 or G5 (see view A
on page 4 - 1).
c Start the engine, and confirm that the engine is at its

maximum no-load speed and it is in the S mode.
2 Pressure Setting
Raise the boom and then operate the dipper out
A
control. Read the pressure gauge with the dipper ram
stalled at the end of its stroke. (It may be necessary to 302880
reposition the power boost servo hose A during
adjustment).
2a High Pressure Setting (with Power Boost) A

a. Release lock nut B and tighten the adjusting screw (*) E B
C until the piston E touches the inner face marked *,
make sure, when locking screw C with lock nut B,
that nut F does not turn.
b. Release lock nut F and tighten plug D and adjust the
pressure (while watching the pressure gauge and
gradually tightening plug D). After setting the
pressure, 338 bar ± 19 bar(4977 lb/in 2 ± 284.4
lb/in2), lock with nut F. F D C
2b Low pressure setting 312450

a. Adjust the pressure as in the high pressure setting
above by loosening Locknut D. If the plug C is also
loosened, the piston E moves to the plug C the 5 Stop the engine and relieve the pressure in the
spring loading is reduced. hydraulic oil tank (see Releasing Tank Pressure) .
Remove the pressure gauge and adaptor from test
b. Pressure is therefore reduced. The setting pressure point G4 or G5 and refit the seal cap.
is 314 bar ± 19 bar (4621 lb/in2 ± 284.4 lb/in2).
Note: The pressure is adjusted 209 bar (3086 lb/in2) per
revolution.
c. Lock with the plug B.
3 Stop the engine
4 Confirmation of the rated pressure

a Start the engine, raise the r.p.m to maximum in the
S mode. Check for leakage at the adjusted points.
b Operate the dipper in control to bring the ram to the

end of its stroke. Continue to hold the lever with the
ram stalled in this position. Check the pressure at
the low pressure setting (no power boost) if this is
not correct repeat step 2b.
c Operate the dipper in control and bring the ram to

the end of its stroke. Continue to hold the lever with
the ram in the stalled position and press the F mode
button. Check the pressure this should be the high
pressure setting (with Power Boost) if this is not
correct repeat step 2a.
9803/6310 Issue 1
Servo Accumulator
1 Accumulator Pressure
2 With the servo isolator lever lowered, start the engine.
3 Raise the boom to its full height and stop the engine.
switch the ignition ON.
4 Move the boom operating lever fully from neutral to

lower and back to neutral and check the boom begins
to lower and then stops. Repeat six times, checking A
that the boom lowers after each time.
5 If the boom lowers three or more times, the gas pressure

in the accumulator is satisfactory.
6 If the boom lowers twice or less, investigate for internal

leakage.
A306500
9803/6310 Issue 1
Pilot Relief Valve

Put the operator levers into neutral and lower the gate
lock lever. Start the engine and park the machine on
level ground. Operate the dipper out and lower the
boom to set the bucket on the ground. Lower the blade
onto the ground. Stop the engine. Release the hydraulic
oil tank pressure. (See Releasing Tank Pressure).
2 Before testing the Pilot Relief valve (S), connect a 0-100

bar (0-1500 lb/in2) pressure gauge to test point G2 (see
view A on page 4-1).
3 Start the engine and confirm that the engine is at its

maximum no-load speed and it is in the S mode. The P12
pressure gauge reading should be compared to the S
technical data at the start of this section. If it is outside
the limits adjust the pilot relief valve as below.
4 Adjust at the servo pump Relief valve S, one turn of the

screw equals 39.2 bar. P22
5 After locking, check the relief pressure again.

If it is not within the limits above, perform steps 3 to 5
again.
6 Stop the engine, release the tank pressure (see

Releasing Tank Pressure) and then remove the
pressure gauge.
JS06711
9803/6310 Issue 1
Auxiliary Relief Valves
General
Some auxiliary relief valves (ARV’s) are set to a higher

pressure than the main relief valve (MRV). To permit pressure
testing of the ARV’s it is necessary to temporarily adjust the
MRV to a higher setting (refer to view B on page 4 - 1).
Proceed as follows:
JS03911
1 Prepare the machine
ground. Lower the blade onto the ground.
b Run the engine at maximum no-load speed in B

the S mode.
2 Increase MRV pressure

Loosen MRV lock nut B and turn pressure adjusting
screw C 180° clockwise. Tighten lock nut B.
3 Restore Original MRV pressure

After completion of all ARV pressure testing, loosen C
lock nut B and turn adjusting screw C, 180° anti-
312450
clockwise and restore the original MRV setting
pressure.
4 Stop the engine
9803/6310 Issue 1
Auxiliary Relief Valves (continued)

Boom Ram

and lower the boom to set the bucket on the JS03911

b Connect a 0 - 600 bar (0 - 8700 lb/in2) pressure

gauge to Test point G4 (see view A on page 4 - 1).
2 If not already done, temporarily increase the pressure

setting of the MRV (see Auxiliary Relief Valves,
General, step 2).
3 Start the engine, lower the gate lock lever and run the
engine at maximum no-load speed in the S mode.
4 Pressure Adjustment
C B
Boom up
Note: For accurate setting, the pressure should be adjusted

up to the required level. Release lock nut X. Adjust setting
screw Y to indicate a pressure below the required level and
then bring the pressure back up for final setting. Tighten lock
nut X.
302880
a Fully raise the boom and then continue to operate
the right control lever as at A.
b The pressure gauge reading should be compared to

the technical data at the start of the section. If it is
outside the limits, adjust ARV B.
JS04121
Y
312460
9803/6310 Issue 1

Boom Ram (continued)
Boom Down

boom to set the bucket on the ground. Lower the blade JS03911
onto the ground. Stop the engine. Release the hydraulic
oil tank pressure. (See Releasing Tank Pressure).
6 It is not physically possible to fully close the boom ram,

without lifting the undercarriage of the ground.
Therefore the ARV’s B and C must be swapped over.
a Fully raise the boom and then continue to operate

the right control lever as at A.
b The pressure gauge reading (Boom down) should be

compared to the technical data at the start of the
section. If it is outside the limits, adjust ARV.
7 Stop the engine and release the hydraulic pressure,

C B
(see Releasing Tank Pressure). Remove the pressure
gauge and adaptor. The Relief Valves for Boom up and
Boom down must be swapped and returned to the
correct ports.
8 If further ARV tests are necessary carry out the relevant

procedures detailed in this section. If no further ARV
tests are required restore the MRV pressure setting to 302880
its original value (see Auxiliary Relief Valve, General,
step 3).
9 Stop the engine and release the hydraulic pressure,

(see Releasing Tank Pressure). Remove the pressure
gauge and adaptor.
JS04121
Y
312460
9803/6310 Issue 1

Dipper Ram
1 Prepare the Machine.

JS03911

gauge to test point G5 (see view A on page 4 - 1).

General, step 2).
F
3 Start the engine, lower the gate lock lever and run the G

then bring the pressure back up for final setting. Tighten lock A
nut X.
a Raise the boom to its full height.

302880
b Move the dipper fully out and then continue to

operate the control lever, as at A.
c The pressure gauge reading (Dipper out) should be A

compared to the technical data at the start of the
section. If it is outside the limits, adjust ARV F.
d Move the dipper fully in and then continue to

operate the control lever, as at B.
e Compare the pressure gauge reading to that stated

in the technical data section at the start of the
section. If it is outside the limits, adjust Auxiliary
Relief Valve G. B
5 If further ARV tests are necessary carry out the relevant JS04121
tests are required, restore the MRV pressure setting to
step 3).
6 Stop the engine and release the hydraulic pressure (see

Releasing Tank Pressure). Remove the pressure gauge X
and adaptor.
Y
312460
9803/6310 Issue 1
4 - 10 Pressure Testing 4 - 10

Bucket Ram

JS03911


General, step 2).
E D

A
nut X.
a Raise the boom.

302880
b Open the bucket fully and then continue to operate

the control lever at A.
c The pressure gauge reading should be compared to

outside the limits, adjust ARV D.
B A
d Close the bucket fully and then continue to operate
the control lever, as at B.
e Repeat step 4c and, if necessary, adjust ARV E.
5 If further ARV tests are necessary, carry out the relevant

its original value (see Auxiliary Relief Valve, General, JS04121
step 3).

Releasing Tank Pressure). Remove the pressure
gauge and adaptor.
X
312460
9803/6310 Issue 1

T.A.B Ram (if fitted)

engine. Release the hydraulic oil tank pressure. (See 305500


General, step 2).
K L
nut X.
a Raise the boom to its full height. 302880
b Move the T.A.B. fully out and then continue to

operate the pedal, as at A.
c The pressure gauge reading (T.A.B. out) should be

compared to the technical data at the start of the A
section. If it is outside the limits, adjust ARV K.
d Move the T.A.B. fully in and then continue to

operate the pedal, as at B.
e Compare the pressure gauge reading to that stated

in the technical data section at the start of the
section. If it is outside the limits, adjust Auxiliary
Relief Valve L.
5 If further ARV tests are necessary carry out the relevant

B JS04121
step 3).

Releasing Tank Pressure). Remove the pressure gauge X
and adaptor.
Y
312460
9803/6310 Issue 1

Rockbreaker ARV (Monoboom)

and lower the boom to set the hammer on the
JS05821
b Fit two caps B to the hammer pipes on the dipper.
c Connect a 0 - 400 bar (0-6000 lbf/in 2) pressure

B
3 Operate the hammer by pressing the button C on the

front of the L.H. control lever. Check the pressure on JS 06720
the gauge, adjust ARV L.

C
nut X.

Releasing Tank Pressure). Remove the pressure gauge
and adaptor.
JS 04121
302880
Y
312460
9803/6310 Issue 1

Rockbreaker ARV (TAB)

and lower the boom to set the hammer on the
JS05821
b Fit a cap B to the hammer feed pipe on the dipper.
c Connect a 0 - 400 bar (0-6000 lbf/in 2) pressure

3 Operate the hammer by pressing the button C on the

front of the L.H. control lever. Check the pressure on B
the gauge, adjust ARV T.
JS06720
nut X.
5 Stop the engine and release the hydraulic pressure (see C

Releasing Tank Pressure). Remove the pressure gauge
and adaptor.
JS04121
A306940
Y
312460
9803/6310 Issue 1
Stabilisers/Blade Auxiliary Relief Pressure

Releasing Tank Pressure). JS03911

gauge and adaptor to port G4 on the hydraulic
pump (see view A on page 4 - 1).
J H
nut X.
a Press the dozer blade switch C to the right to select

dozer operation. 302880
b Raise the blade, and then continue to operate the

control D lever at A.
B
c The pressure gauge reading should be compared to
outside the limits, adjust ARV J.
C
d Lower the blade fully and then continue to operate D

the control lever, as at B.
e Repeat step 4c and, if necessary, adjust ARV H.
4 If further ARV tests are necessary, carry out the relevant

procedures detailed in this section. If no further ARV A
step 3).
JS04121
5 Press the dozer blade switch to the left to return the

control to the excavator. Check that the dozer lamp
goes out.

Releasing Tank Pressure). Remove the pressure
gauge and adaptor.
X
Y
289910
9803/6310 Issue 1
Slew Motor Relief Valve

boom to set the bucket on the ground. Stop the engine.
Release the hydraulic oil tank pressure. (See Releasing
Tank Pressure). JS03911
2 Connect a 0-400 bar (0-6000 lb/in2) pressure gauge and

adaptor to pressure test point G5 (see view A on page
4 - 1).
Note: Pressure can also be measured on the upper section

of the slew motor.
3 Initiate slew lock procedures. B A

a Remove the water-proof connector (dark green wire)
from swing shut off solenoid valve V, which is
mounted at the side of the hydraulic pump.
JS04121
b Press the slew lock switch ON (on the cab left

console) and confirm that the slew lock symbol
appears on the monitor.
c Start the engine, and operate the engine at around V

1000 r.p.m, and operate the slew lever slowly. Listen
to confirm that the relief valve is heard to operate
and check that the machine does not slew.
Note: If the water-proof connector of the slew lock solenoid

valve is not removed (step 3a), slew lock status can be
obtained with the slew lock switch ON (step 3b), but the
slew relief valve does not operate.
312470
d Run the engine at maximum no-load speed in the S
mode.
e Operate the slew lever.
4 The pressure gauge reading should be 279 ± 10 bar

(4045 ± 145 lb/in2). W
5 If the pressure is within the limits, stop engine, release
tank pressure and remove the gauge and adaptor. If the
readings are outside the limits, continue as below.
X
Repeat step 3 above and confirm pressure setting.
302880
Adjust the appropriate slew motor relief valve (W for
right slew, X for left slew
a Remove screw cap Y.
b Adjust the pressure by altering the thickness of shim
Z (increasing the thickness increases the pressure,
decreasing the thickness decreases the pressure).
Z
c Refit screw cap Y.
d After locking, check the relief pressure again. If it is
not within the specified limits (see step 4 above) Y
repeat steps 6a to 6d.
e Repeat step 5 above. 312480
9803/6310 Issue 1
1 Brake Service Pressure

a Connect a 0-70 bar (0-1000 lbf/in2) pressure gauge to
the test point on the rear axle. With the engine running A
at maximum rpm in the S mode, lock the service pedal
fully down. The gauge should read 48 bar (696 lbf/in2). If
incorrect, adjust the linkage from the brake valve to the P
brake pedal (See A). Slacken the locknut N and increase
the linkage length by turning rod P to increase pressure,
decrease length to lower pressure. Ensure the pressure
returns to 0 bar when the pedal is released. Tighten the N
locknut N and recheck.
2 Steer Stall System Pressure

a Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge to
the test point G1 (see view A on page 4 - 1).).
b Disconnect hose X (see B) Plug the hose and fit a * BSP

cap onto the open port of the relief valve.
c With the engine running at a maximum rpm in the S B

mode, the gauge should read 195 bar (2828 lbf/in2). If
incorrect, adjust the steering circuit relief valve R,
mounted on the steering circuit filter (see B).
d Repeat operation until the reading is correct.
e With the engine running at a maximum rpm in the S

mode, turn the steering wheel to its limit and hold in this
position. The gauge should read 185 bar (2683 lbf/in2)
±10%. No adjustment is possible.
R
f Repeat operation until the reading is correct.
A306950
9803/6310 Issue 1
3 Clutch Pressure 5 Drive Control Signal

a Connect a 0-70 bar (0-1000 lbf/in2) pressure gauge to the a Connect a 0-70 bar (0-1000 lbf/in2) pressure gauge to the
test point B1 on the Transmission valve (see C). With the test point 3 (see A). With the engine running apply foot
engine running in high gear (Hare symbol illuminated), the brake and lock.
gauge should read 32 bar (464 lbf/in2). b Stall out the drive against brakes in high or medium gear
b If incorrect, adjust, CT3 (see C) cartridge in the ensuring dozer mode is not selected.
transmission valve. Screw in to raise the pressure, screw c The drive control signal should be 28 bar (406 lbf/in2). If
out to lower the pressure. incorrect, adjust CT7 in the transmission valve (see C).
Screw in to raise pressure, screw out to lower pressure.
4 Park Brake Pressure
a Connect a 0-70 bar (0-1000 lbf/in2) pressure gauge to the
test point B1 on the Transmission valve (see C). With the
engine running in high gear (Hare symbol illuminated),
select drive park brake switch on the control panel.
b The pressure reading should decay to 15 bar (217 lbf/in2)
when the park brake is selected. The pressure should
return to 32 bar (4640 lbf/in2) when deselected.
c If incorrect, adjust, CT10 (see C) cartridge in the
transmission valve. Screw in to raise pressure, screw out
to lower pressure.
Note: After each adjustment, deselect and reselect park brake
control to allow the system to recharge.
JS130W/JS145W/JS160W only
Key
C 1 - A1 Test Point - Low Gear

2 - B1 Test Point - High Gear
3 - C3 Servo Pressure Connection
4 - PB Parking Brake Override
5 - CT1 Sequence Valve
6 - CT3 Clutch Feed Pressure Reducer
7 - CT7 90% Pump Signal (P22)
8 - CT10 Park Brake
3
6
1 2
5
4 7
8 312490
9803/6310 Issue 3*
15 - 1 Circuit Descriptions 15 - 1
Pump Circuits Key
1 Drive
2 Hammer (TAB Option)
3 Low-flow Circuit
1 4 Priority Valve
Drive 5 Logic Valve
5 6 Dozer
2 Logic Valve 7 Stabilisers
Hammer 8 Steering Priority Control Valve and Steering Unit
(TAB opt) Dozer Stabs 9 Steer Ram
3 4 10 Grab Rotate Solenoids
Low-flow circuit Priority Valve 6 7 11 Brake Valve
12 Front and Rear Brakes
Pump 13 Accumulators
P1 14 Transmission Control Valve
15 8-Spool Solenoid Block
16 Assemble Valve
17 Remote Control Levers and TAB/ Hammer Control
1 18 Park Brake Solenoid
Drive
2
TAB or Hammer
Pump
P2
8 9
Pump Steering priority control
Steer ram
Pb valve & steering unit
0 @
!
Grab rotate Front &
Brake valve
solenoids Rear brakes
£
Accumulators
$ %
Transmission 8-Spool
Pump
Control Valve solenoid block
Pp
^
Assemble &
Valve Remote control
£ levers &
Accumulators TAB/hammer
* control
Park brake
solenoid
JS08110
9803/6310 Issue 1
* Drive CIrcuit (CAPS II only)

There are 3 speeds available on the JS130 and JS160 High speed and medium speed work by the same system
wheeled machines - high, medium and creep. On starting except that selecting high speed by the gearbox ratio
the machine, the system will always be in medium speed change switch, energises gear change solenoid 22C,
and on pressing the gearbox ratio change switch located on switching the ports through which oil is sent to the drive
the cab floor at the front left hand side, it is possible to gear box and thus changing gear.
switch between high and medium speeds.
Selecting Creep Speed
Note: Creep speed selection is not available via the gearbox
ratio change switch as on tracked machines. Creep speed is 1 Energises P1 flow limiter solenoid 22A allowing pressure
available by first selecting medium speed via the gearbox from port P12 on the main pump to vent to tank and
ratio change switch and then pressing the button on the therefore through the negative control system allows the
sub-monitor indicated by a tortoise. The CAPS controller will pump, if required, to be at 100% capacity.
not permit creep to be selected in High mode.
2 Energises maximum flow control solenoid 19G and
Travel allows oil to:-
Once the engine is running, pressurised oil from pump Pp 3 Pump 2 flow control solenoid, which is de-energised,
flows into the transmission control valve and via the de- allowing 40 bar from solenoid 19G to port P22 on the
energised gear change solenoid 22C to the clutch (see E/2-2 main pump keeping this pump at 60% capacity.
Schematic Diagram). Once the clutch pack and
accumulator are fully charged, the pressure switch on the 4 De-energises drive solenoid 19A preventing either the
transmission valve signals the drive isolator relay, which will straight line travel spool or Arm II spool being selected
in turn energise the drive isolator solenoid 52A. When the and thus preventing any flow from one pump combining
servo isolator lever is lowered, oil at servo pressure flows to with the other inside the main control valve.
the transmission control valve 49.
Selecting creep speed also prevents the signal from
Selecting the travel pedal sends the servo signal to shuttle
drive shuttle valve pressure switch 43 being acted on by
valve 72 which sends the oil down 3 paths simultaneously:-
the computer and re-energising any solenoids.
1 Oil flows to the relevant end of the drive spool in the
main control valve and selects drive. This allows oil from Selecting dozer via the rocker switch on top of the left
the main pumps to flow down to and operate the drive hand joystick:-
motor.
1 De-energises drive solenoid 19A preventing the Arm II
2 The servo signal reaching the pressure switch 43 on the spool or straight line tracking spool being selected
shuttle valve causes it to signal the controller and thereby keeping pump flows separate inside the main
energise 3 solenoids. valve block.
a Drive solenoid 19A which sends oil at servo pressure 2 Prevents the signal from the drive shuttle valve pressure
to the drive II spool in the main control valve and switch 43 being acted on and re-energising any
also to switch the pilot valve 76. solenoids, therefore, because maximum flow control
solenoid 19G is not energised, any pressure to ports
b The maximum flow control solenoid 19G which P12 and P22 is vented to tank allowing both pumps to
sends oil at servo pressure onto the transmission be available at 100% flow if requested.
control valve and to:
Selecting dozer in high or medium travel would,
c Pump flow control solenoid 22B. Oil from solenoid
therefore, cut the available pump flow to the drive spool
19G can now flow:
from 150% to 100% thus slowing the machine.
i Through the pressure reducing valve at 28 bar However, if dozer is selected whilst in creep speed,
and through solenoid 22B onto port P22 on pump flow to the drive spool is maintained at 60%
pump 2 keeping this pump at 90% flow rate. capacity from pump 2 and the dozer spool has 100%
pump flow from pump 1, therefore a constant travel
ii Through solenoid 22A at 40 bar onto port P12 speed is maintained whilst dozing in creep mode.
on pump 1 keeping this pump at 60% flow rate.
Reverse
3 The third signal flows through pilot valve 76 (now open,
see 2a above) via the shuttle valves and onto the Arm II By selecting reverse drive using the foot operated control
spool thus selecting it. pedal 49, the system operates in the same way as for
forward drive except for the operation of the reverse light
This, together with the drive II spool which has already pressure switch 74.
been operated (see 2a above), allows the two pump
flows at 90% and 60% to combine and give 1.5 pump
flow rate to the drive system.
9803/6310 Issue 2*
* Drive Circuit (CAPS II only) (cont’d)
Electrical Selecting Creep Speed
On starting the machine, the drive system will default to Select creep speed by pressing the creep switch on the
medium speed with oil from pump Pp flowing to the monitor panel, this signals the wheel controller through pin 2
transmission control valve 22. Inside the transmission of PL5. The wheel controller will then inform the main
control valve the oil flows through the de-energised controller by passing a signal from pin 2, SK4 (wheel
gearchange solenoid 22C to the clutch pack. controller) to pin 1, CN5 (main controller).
Once the pressure at the clutch pack and associated The main controller then energises pump 1 flow control
accumulator reaches 28 bar (406 lbf/in2), pressure switch 74 solenoid 22A through pin 5 of CN6. This vents pressure from
on the transmission control valve will close and energise port P12 to tank, allowing pump 1 if required, to be at 100%
drive isolator solenoid 52A via the drive isolator relay as capacity.
follows:
The energised max flow control solenoid 19G (pin 15, CN6)
The drive isolator relay has 24 V supplied to one-side, allows oil flow to:
through fuse 4 of the fusebox via pin 5 of BC4.
Pressure switch 74 closing, earths the other side of the 1 De-energised pump 2 flow control solenoid 22B (pin 9,
relay through pin 4 of BC4, energising the relay and CN6), allowing oil at 40 bar from solenoid 19G to port
supplying 24 V to drive isolator solenoid 52A through P22, holding pump 2 at 60% capacity.
pin 3 of BC4. Providing none of the servo isolate
controls have been operated, solenoid 52A will now 2 De-energised drive solenoid 19A (pin 7, CN7), which
energise and allow oil flow to reach the pedal control prevents either the drive II or arm II spools from being
valve of the travel pedal. selected and thus preventing the oil flow from one
pump combining with the other inside the main control
Pressing the travel pedal sends servo pressure to shuttle valve.
valve 72 and closes pressure switch 43 which signals the
main controller through pin 6 of CN5. The main controller will Selecting creep speed also prevents the signal from shuttle
then energise the following 3 solenoids: valve pressure switch 43 (pin 6, CN5) being acted upon by
the main controller and re-energising any other drive
1 Drive solenoid 19A through pin 7 of CN7. solenoids.
2 Max flow control solenoid 19G through pin 15 of CN6. Selecting Dozer
3 Pump 2 flow control solenoid 22B through pin 9 of CN6 When dozer mode is selected, the wheel controller informs
the main controller by passing a signal from pin 4, SK4
Pressing the gearbox ratio change switch will signal the (wheel controller) to pin 1, CN2 (main controller).
main controller through pin 4 of CN4. The main controller will
then energise the gearchange solenoid 22C through pin 1 of The main controller then de-energises drive solenoid 19A
CN6, switching the ports through which oil is sent to the through pin 7, CN7 which prevents either the drive II or arm
drive gearbox and thus changing gear. II spools being selected and thus preventing the flow from
one pump combining with the other inside the main control
valve.
Therefore, if dozer mode is selected in either medium or high

speed, the machine will slow down. If dozer mode is
selected in creep speed, the machine will not slow down, as
the pump flows are already separated.
9803/6310 Issue 2*
15 - 3A Circuit Descriptions 15 - 3A
* Drive Circuit (AMS only) This, together with the drive II spool which has already
been operated (see 2a above), allows the two pump
There are 3 speeds available on the JS130, JS145, JS160 flows at 100% and 60% to combine and give 1.6 pump
and JS175 wheeled machines - high, medium and creep. flow rate to the drive system.
On starting the machine, the system will always be in the
last selected mode and on pressing the gearbox ratio High speed and medium speed work by the same system
change switch located on the cab floor at the front left hand except that selecting high speed by the gearbox ratio
side, it is possible to switch between high and medium change switch, energises gear change solenoid 53,
speeds. switching the ports through which oil is sent to the drive
gear box and thus changing gear.
Note: Creep speed selection is not available via the gearbox
ratio change switch as on tracked machines. Creep speed is Selecting Creep Speed
available by first selecting medium speed via the gearbox
ratio change switch and then pressing the button on the 1 Energises P1 flow limiter solenoid 55 allowing pressure
facia switch panel (FSP) indicated by a tortoise. The AMS from port P12 on the main pump to vent to tank and
system will not permit creep to be selected in High mode. therefore through the negative control system allows the
pump, if required, to be at 100% capacity.
Note: The numbers in bold refer to AMS Service Manual
Supplement 9803/6450 Section C page 5-2. 2 Energises maximum flow control solenoid 43 and allows
oil to:
Travel
3 Pump 2 flow control solenoid, which is de-energised,
Once the engine is running, pressurised oil from pump Pp allowing 40 bar from solenoid 43 to port P22 on the
flows into the transmission control valve and via the de- main pump keeping this pump at 60% capacity.
energised gear change solenoid 53 to the clutch. Once the
clutch pack and accumulator are fully charged, the pressure 4 De-energises drive solenoid 41 preventing either the
switch on the transmission valve signals the drive isolator straight line travel spool or Arm II spool being selected
relay, which will in turn energise the drive isolator solenoid and thus preventing any flow from one pump combining
58. When the servo isolator lever is lowered, oil at servo with the other inside the main control valve.
pressure flows to the transmission control valve 49.
Selecting creep speed also prevents the signal from
Selecting the travel pedal sends the servo signal to shuttle
drive shuttle valve pressure switch 37 being acted on by
valve 72 which sends the oil down 3 paths simultaneously:
the computer and re-energising any solenoids.
1 Oil flows to the relevant end of the drive spool in the
main control valve and selects drive. This allows oil from Selecting dozer via the rocker switch on top of the left
the main pumps to flow down to and operate the drive hand joystick:
motor.
1 De-energises drive solenoid 41 preventing the Arm II
2 The servo signal reaching the pressure switch 37 on the spool or straight line tracking spool being selected
shuttle valve causes it to signal the controller and thereby keeping pump flows separate inside the main
energise 3 solenoids. valve block.
a Drive solenoid 41 which sends oil at servo pressure 2 Prevents the signal from the drive shuttle valve pressure
to the drive II spool in the main control valve and switch 37 being acted on and re-energising any
also to switch the pilot valve 76. solenoids, therefore, because maximum flow control
solenoid 43 is not energised, any pressure to ports P12
b The maximum flow control solenoid 43 which sends and P22 is vented to tank allowing both pumps to be
oil at servo pressure onto the transmission control available at 100% flow if requested.
valve and to:
Selecting dozer in high or medium travel would,
c Pump flow control solenoid 56. Oil from solenoid 43
therefore, cut the available pump flow to the drive spool
can now flow:
from 150% to 100% thus slowing the machine.
i Through the pressure reducing valve at 0 bar However, if dozer is selected whilst in creep speed,
and through solenoid 56 onto port P22 on pump pump flow to the drive spool is maintained at 60%
2 keeping this pump at 100% flow rate. capacity from pump 2 and the dozer spool has 100%
pump flow from pump 1, therefore a constant travel
ii Through solenoid 55 at 40 bar onto port P12 on speed is maintained whilst dozing in creep mode.
pump 1 keeping this pump at 60% flow rate.
Reverse
3 The third signal flows through pilot valve 76 (now open,
see 2a above) via the shuttle valves and onto the Arm II By selecting reverse drive using the foot operated control
spool thus selecting it. pedal 49, the system operates in the same way as for
forward drive except for the operation of the reverse light
pressure switch 77.
9803/6310 Issue 1*
15 - 3B Circuit Descriptions 15 - 3B
* Drive Circuit (AMS only) (cont’d)
Electrical
Refer to AMS Service Manual Supplement 9803/6450

Section C Page 4-36 for details on Drive Circuits.
9803/6310 Issue 1*
Drive Circuit (cont’d)
* Electrical Circuit (CAPS II)
Hydraulic Circuit (CAPS II)
* Key
Key
10 Creep Mode Signal
1 Pressure switch 46
P1 Hydraulic Pump 1 11 Pressure Switch 43
16 2 Fuse 4 - Wheeled Fusebox
{ P2 Hydraulic Pump 2
3 Drive Isolator Solenoid 52A
12 Pump 1 Flow Control Solenoid 22A
18 Main Control Valve 13 Pump 2 Flow Control Solenoid 22B
4 Drive Isolator Relay
19 8 Spool Solenoid Valve 14 Gearchange Solenoid 22C
5 Creep Switch
22 Gearchange Valve 15 Max Flow Control Solenoid 19G
6 Wheel Controller
43 Pressure Switch 16 Drive Solenoid 19A
7 Main Controller
8 Dozer Mode Signal
4
52 Drive Isolator Valve
9 Gearbox Ratio Change Switch
54 Rotary Coupling 85 86
60 Drive Motor BC4

2 5 87
61 Drive Gearbox 30 PL5
1 4 5 6
72 Shuttle Valve 5 1
3 87A
74 Pressure Switch
3 3 2
76 Pilot Shuttle Valve
Note: Key references correspond with references on the main schematic diagram.
CN1
5
7
16
18 Px SK4
P1 P2
ARM II a1
CN2
1 4
P12 P22 8
CN4
19 22 4 9
A
C7 P1 CN5
P
1 10 2
G
6
P2
16
C1 11
PL
B
A
49
CN6 BC2
5 1
C
9 2 12
74 52 1 3
1 P 2 P2 A
15
B2 A2 13
72 76
C2 14
B1 S1
IN 15
CN7
60 43 C 7
B
A
61 Pp
16
JS08061
JS10890
9803/6310 Issue 2*
Park Brake/Gearchange Circuit

Hydraulic Gearchange Circuit
Servo pressure at 40 bar from pump Pp is delivered to the IN

port of the transmission valve 22 via the pilot filter 23. The
servo pressure charges the accumulator 21 and crosses the
pressure maintaining valve b to energised solenoid valve
22D which directs oil to release one of the clutch packs 61.
When clutch oil pressure reaches 31 bar, the pressure
maintaining valve b operates and holds 31 bar in the line
available to operate a clutch pack. Oil flows from port A in
the gearchange valve 22, through port 3B in the rotary
coupling to port P1 of the gearbox, engaging the lower drive
speed.
When high speed travel is selected, solenoid valve 22C is

energised and oil pressure from the operating clutch pack 61
is vented to tank. Pressure available to solenoid valve 22C is
re-directed from port B in the gearchange valve 22, through
port 2B in the rotary coupling to port P2 in the gearbox and
engages the high speed drive. Providing the pressure is high
enough at solenoid valve 22C, the pressure switch 46 will
close and solenoid valve 52A in the drive isolator 52 is
energised allowing servo pressure to flow to port P on the
directional drive pedal control valve 49.
Park Brake Circuit
When the park brake circuit control is selected on the sub-

monitor, solenoid valve 22D is de-energised allowing any
residual clutch oil pressure to vent to tank via the pressure
maintaining valve c. As clutch oil pressure drops to 15 bar,
the pressure maintaining valve c disengages, maintaining 15
bar at one of the clutch packs. The drop in clutch oil
pressure causes pressure switch 46 to open and de-
energises the drive isolator solenoid valve 52A allowing oil
pressure at the drive transmission control valve 49 to vent to
tank. If the park brake is selected whilst driving, the machine
would not come to a sudden stop, but would gradually slow
down. This is achieved by metering the oil exiting the clutch
accumulator through a 1 mm diameter orifice in port C4 of
valve 22.
*
Electrical (CAPS II only - refer to 9803/6450 for AMS)
Gearchange Circuit
See Drive Circuit - Electrical.
Park Brake Circuit
Pressing the park brake switch on the right hand switch

panel, signals the wheel controller through pin 15 of plug 3.
The wheel controller then switches channel 2 of switch box
1 through pin 3 of plug 1. Channel 2 then de-energises
solenoid 22D, engaging the parking brake.
Note: When the park brake switch is not selected, the park
brake solenoid is energised. This is a fail-safe system, if the
electrical circuit or solenoid fails, the park brake would be
engaged.
9803/6310 Issue 2*
Park Brake/Gearchange Circuit (cont’d)

Hydraulic Circuit
Key
Pp Servo Pump
21 Accumulator Pp
22 Gearchange valve 21
23 Pilot Filter
46 Pressure Switch 22 23
52 Drive Isolator Valve OUT IN
61 Clutch Pack
b
Note: Key references correspond
with references on the main
schematic diagram. 49 T
B c
A
C D
P
A 52 46
61 2B 3B
P2 P1
JS08011
Park Brake Electrical Circuit

* (CAPS II only - refer to 9803/6450 for AMS 2 3
A A
1 1
Key B B
2 CH1
1 Wheel Controller C
2 Plug 1 4
3 Switch Box 1 C D 2
4 Channel 2 3 CH2
5
E 1
5 Solenoid 22D
6 Fuse 3 - Wheeled Fusebox
D F
7 Plug 3
4 CH3
8 Right Hand Switch Panel
G
9 Park Brake Switch
T
6
U
8
V
7
7
15
9
1
3
JS10040
9803/6310 Issue 2*
Steering and Brake Circuits

Steering Circuit
The steer and brake circuits are supplied with oil by a

dedicated gear pump Pb mounted between the main
hydraulic pumps and the servo pump Pp. Oil from pump Pb
flows to port P on the steer priority valve after passing
through relief valve 26 and the steer circuit pressure line filter
14. The steer priority valve 9 is integral with the steering
control unit and when the steering wheel is turned, oil is
demanded from the priority valve and is fed to the steering
control unit. From the steering control unit, it is directed to
the RH and LH side of the axle mounted steer ram. Steering
circuit pressure is limited by a relief valve S mounted within
the steering control unit. The unit also contains two smaller
relief valves for the right and let hand steer circuits to protect
them against shock loading. When the steering unit is not
demanding oil flow (i.e. the steering wheel is not turned), oil
flows through the priority valve 9 to port EF and then to port
P on the brake valve 10.
Brake Circuit
Oil enters the brake valve 10 through port P and flows

around the charging spool by lifting a sequence of check
valves to charge the front and rear brake accumulators 11.
When the charging pressure reaches 150 bar, the charging
spool moves to the left and allows oil to pass directly from
port P to the outlet port N. Accumulator pressure is held by
the check valves. When the brake pedal is operated, oil is
metered from the accumulators to the front and rear brake
circuits through ports B1 and B2. The maximum pressure
available to the brakes is 48 bar. As the brake pressure rises
above 5 bar, the brake light switch 13 is closed giving a
‘brake-on’ signal to the wheeled excavator controller. When
the brakes are operated repeatedly, the accumulators
discharge and accumulator pressure falls until a pressure of
120 bar is reached. At this pressure, the charging spool
moves back to the right, closing port N allowing the
accumulators to recharge. If for any reason there is a sudden
drop in the charging pressure, the pressure change warning
switch 12 operates and gives a visible warning on the
monitor in the cab.
9803/6310 Issue 1
Steering and Brake Circuit (cont’d)

Hydraulic Circuit
Key
Pb Servo Pump
9 Steer Priority Valve
10 Brake Valve
11 Accumulator
12 Pressure Switch
13 Brake Light Switch
14 Line Filter
26 Relief Valve
Note: Key references correspond with references on

the main schematic diagram.
B1 B2 10
13
11 11
12
EF P
14 26
P
Pb
JS08080
9803/6310 Issue 1
Grab Rotate Circuit

Hydraulic
Servo oil from pump Pb up to 25 l/min depending on engine

speed, flows via relief valve 26 and line filter 14 through the
priority valve 9 to port P in the brake valve 10 located
beneath the cab, and leaves through port N. Oil enters the
grab rotate valve 39 through port P. By operating the
auxiliary switch on the R.H. console joystick, solenoid valves
39A or 39B are energised, providing clockwise or counter-
clockwise rotation of the grab. Oil enters the solenoid valve
39A/39B through port P and operates the grab through port
A or port B depending on direction of rotation, then
exhausts to tank via port T.
* Electrical (CAPS II only - refer to 9803/6450 for AMS)
When the grab rotate switch on the right hand controller is

operated, the wheel controller is signalled through socket 3;
pins 9 and 21 for rotate clockwise, pins 8 and 20 for rotate
counter-clockwise.
The wheel controller will then switch either channel 5, D or

channel 6, E of switch box C through pins 6 and 7 of plug B.
Channel 5, D or 6, E will energise solenoids 39B, F or 39A, G
respectively.
9803/6310 Issue 2*
Grab Rotate Circuit (cont’d)
Hydraulic Circuit 10
Key N
Pb Servo Pump 9
9 Steer and Priority Valve
10 Brake Valve P
14 Line Filter
26 Relief Valve
39 Grab Rotate Valve 14 26
Solenoid Energised
Note: Key references

correspond with references on
the main schematic diagram.
P
T 39
Pb
39A 39B
A B JS08001
Electrical Circuit
* (CAPS II only - refer to 9803/6450
for AMS C
A B
Component Key
A Wheel Controller F D L 2
B Plug 3 6 CH5
F
M 1
C Switch Box 3
D Channel 5 G E N 2
7 CH6 G
E Channel 6 P 1
F Solenoid 39B
G Solenoid 39A
H Fuse 2 - Wheeled Fusebox T
J Grab CCW Switch H
K Grab CW Switch U
L Socket 3 V
1
8
J 2
20
3
9
K 4
21
JS10070
9803/6310 Issue 2*
Stabiliser Circuit
The stabilisers are operated by pressing control buttons
located on the left console (see Operation, Other Controls
in Operator Handbook).
Left Hand Stabiliser Down Operation Key

Hydraulic P1 Hydraulic Pump 1
Pp Servo Pump
Pressing the left hand down control button energises Ssd Shuttle Valve
solenoid 53A (left hand stabiliser) and solenoid 9 (stabiliser 18 Main Control Valve Dozer/Stabiliser Spool
down) in the stabiliser solenoid block 53. Oil at servo 22 Transmission Control Valve
pressure can now pass through solenoid 53C and via an 23 Line Filter
internal shuttle from port C6 to port br3, on the main control 28 Oil Cooler
valve, pushing the dozer/stabiliser spool to the left, closing 29 Return Manifold
the neutral circuit and directing oil from pump 1 through port 33 Sump Tank
4A in the rotary coupling and onto port P of the chassis logic 53 Solenoid Valve
valve 57. 54 Rotary Coupling
55 Stabiliser Ram(s)
Solenoid 53A sends servo pressure oil via port C3 on the
57 Logic Valve
stabiliser solenoid block 53 and port 1B in the rotary
Solenoid Energised
coupling to port X2 of the chassis logic valve 57, opening
the left hand stabiliser check valve, allowing oil from port P Note: Key references correspond with references on the
to flow, via port Z2, to the left hand stabiliser ram piston main schematic diagram.
side. Returning oil has a direct path, through the rotary
coupling port 2A and main control valve to tank.
All stabiliser operations are controlled by the four solenoids Pp

53A, 53B, 53C and 53D in the stabiliser solenoid block,
solenoids 53A and 53B selecting left hand or right hand and
solenoids 53C and 53D selecting down or up. 22 23
Note: If four stabilisers are fitted then the left hand control
switch operates the front stabilisers and the right hand
switch the rear. If required, by pressing both control buttons
the stabilisers can be operated simultaneously. 53
A C
Ssd C6
9 x
B D
4A 2A
54
1B
29
28 X2
18 x
57
br3
P
P
33
Z2
P1
55
JS07071
9803/6310 Issue 1
Stabiliser Circuit (cont’d)
When the left hand stabiliser down button (located in the left
hand console) is pressed, a signal is passed to the wheel
controller through pin 24 of socket 1.
The wheel controller then switches channels 5 and 7 of

switch box 1 through pins 6 and 8 of plug 1. When channels
5 and 7 are on, the channel LED’s on the switch box are
illuminated and the 28V supply, from fuse 3 of the wheeled
fusebox, energises solenoid 53C (stabiliser down) and
solenoid 53A (left hand stabiliser).
1 2 3 H 2
1 8
* Electrical Circuit (CAPS II only)
E
4 J
5 CH4
K
Component Key
F
5 L 2
6 CH5 9
1 Wheel Controller M 1
2 Plug 1
G
6 N 2
3 Switch Box 1 7 CH6
P 10
1
4 Channel 4
5 Channel 5
7 R
H 2
8 CH7
6 Channel 6 S 1 11
7 Channel 7
T
8 Solenoid 53D (Stabiliser Up)
9 Solenoid 53C (Stabiliser Down) U 12
10 Solenoid 53B (Right Hand Stabiliser) V
11 Solenoid 53A (Left Hand Stabiliser)
13 Socket 1 14
14 Left Hand Console 13 5
12
15 LH Stabiliser Up Button 15
2
16 LH Stabiliser Down Button 10
3
13
17 RH Stabiliser Up Button 9
25
18 RH Stabiliser Down Button
1
24
16
4
11
17
23 6
18
1
18
2
5
3
19
4
6
JS10060
9803/6310 Issue 2*
Dozer Blade Circuit

Hydraulic Circuit * Electrical (CAPS II only - refer to 9803/6450 for AMS)
Dozer operation is selected by pressing the two way switch Dozer Operation is selected by pressing the switch on top of
on the top of the Left Hand Control Lever. When dozer mode the left hand controller to the right.
is selected, an orange light (with blade symbol) will appear
on the warning light panel. This signals the wheel controller through pins 19 and 6 of
socket 1. The wheel controller then illuminates the dozer
To deselect dozer, the two way switch should be pressed in select lamp on the status monitor through pin 10 of plug 5.
the opposite direction. The wheel controller also switches channel 6 of switch box 2
through pin 7 of plug 2 to energise solenoid 3.
The dozer blade is raised and lowered by moving the control
lever forward and backwards (see Operation, Other The wheel controller also informs the main controller by
Controls, Operator Handbook). passing a signal from pin 4, SK4 (wheel controller) to pin 1,
CN2 (main controller).
Dozer Blade Operation
The main controller then de-energises drive solenoid 19A
Hydraulic through pin 7, CN7 which prevents either the drive II or arm
II spools from being selected and thus preventing the flow
Dozer operation is selected by pressing the rocker switch on from one pump combining with the other inside the main
the top of the left hand controller. control valve.
Note: This is a momentary connection switch and does not Therefore, if dozer mode is selected in either medium or high
therefore need to be pressed continuously. speed, the machine will slow down. If dozer mode is
selected in creep speed, the machine will not slow down, as
Dozer operation is achieved by moving the left hand control the pump flows are already separated.
lever forwards or backwards.
Dozer operation is de-selected by pressing the switch on
Operating the dozer selection switch energises the top of the left hand controller to the left.
dozer/arm solenoid 3, on the diverter valve 73, allowing
servo oil to flow from the hand control valve through the This signals the wheel controller through pins 18 and 5 of
diverter valve port A2 and onto port C2 on the stabiliser socket 1. The wheel controller then turns off the dozer select
solenoid block. lamp and de-energises solenoid 3 by switching channel 6.
Note: If stabilisers are not fitted, the oil passes directly from
port A2 on the diverter valve 73 to the spool port on the
main control valve 18.
From here, it is directed via internal shuttles to both:
a The pilot port ar3 on the main control valve 18 via port
C1 on the stabiliser solenoid block 53, moving
dozer/stabiliser spool, closing off the neutral circuit and
directing oil from pump 1, via the rotary coupling port 2A
to port P0 on the chassis logic valve.
and...
b Ports X1 and X0 on the chassis logic valve 57 via port

C0 in the stabiliser solenoid block 53 and port 7B in the
rotary coupling which opens the check valves and
allows main circuit oil to flow from port P0 through port
Z0 and onto the dozer rams, returning via port Z1 and
port P through rotary coupling port 4A to the main
control valve and back to tank.
9803/6310 Issue 2*
Dozer Blade Circuit (cont’d)

45 Pp
Hydraulic Circuit P
19
Key
19A
P1 Hydraulic Pump 2 22
23
Pp Servo Pump
Sdd Shuttle Valve z
19H
18 Main Control valve Spool 3 73
53
19 Servo Isolator Sdd
P A2
22 Transmission Control Valve w
C2
23 Line Filter q Z C0
28 Oil Cooler 2A 7B
29 Return Manifold 54
w
33 Sump Tank 4A
28 29 X0 X1
18
45 Remote Control Valve ar3
x
57
53 Solenoid Valve
54 Rotary Coupling
q
57 Logic Valve P
33 P Po
62 Dozer Ram (LH) Z0 Z1
63 Dozer Ram (RH)
73 Solenoid Valve
Solenoid Energised 62 63
Note: Key references correspond with references on

the main schematic diagram. P1
JS07080
Electrical Circuit
(CAPS II only - refer to
9803/6450 for AMS) 1 3
7
24
6
25
Component Key
5
12
1 Status Monitor 4 4
2 Dozer Select Lamp 3
13
3 Plug 5 11 5
4 Wheel controller
2
5 Plug 2 23
6 Channel 6
2 1
7 Switch Box 2 10
6 7
N
8 Solenoid 3 G 2 8
7 CH6
9 Fuse 1 - Wheeled Fusebox P 1
10 Socket 1
11 Dozer De-select Switch
T
12 Dozer Select Switch 9
U
10
1
18 11
2
5
3
19 12
4
6
JS10050
9803/6310 Issue 2*
Axle Lock Rams
Hydraulic
When axle lock is not selected, solenoid valve 52B is

energised allowing servo pressure from port B2 in the 8
spool solenoid assembly 19 to enter port P2 in the solenoid
valve assembly 52. Oil flow crosses solenoid valve 52B
leaving via port C1 to the rotary coupling 54 port 6B and to
both axle lock rams 59 through a tee connection. With the
circuit open, oil is transferred from one ram to the other
allowing free movement of the axle.
When axle lock is selected, solenoid valve 52B is de-

energised and servo pressure crosses solenoid valve 52B
and vents to tank through port T2 at the same time closing
the oil transfer circuit. The oil trapped in each axle lock ram
cannot vent due to the action of the non-return valve in each
ram, thus locking the axle.
When axle lock with brakes is selected, solenoid valve 52B

will be energised until the controller receives a signal from
the brake light pressure switch at which point the solenoid
valve will de-energise, locking the axle.
When axle lock is not selected, solenoid 52B is energised

and hydraulic oil flows between the pair of axle lock rams,
allowing free movement of the front axle.
When manual axle lock (located on the right hand switch

panel) is selected, a signal is passed to the wheel controller
through pin 16, plug 5. The wheel controller then switches
channel 5 of switch box 2 through pin 6 of plug 2. Channel 5
then de-energises solenoid 52B, trapping the hydraulic oil in
each ram, thus locking the axle.
When auto axle lock is selected, operation of the circuit is as

above except that the wheel controller will only switch
channel 5 when a signal from the brake light switch is also
present at pin 5, plug 4.
Note: Due to the arrangement of this circuit, when axle lock

is engaged, the channel 5 LED on switch box 2 will be OFF.
When axle lock is disengaged, the LED will be ON.
9803/6310 Issue 2*
Axle Lock Circuit

Hydraulic Circuit
Pp
Key
Pp Servo Pump B1 23
19 22
19 8 Spool Solenoid Assembly
OUT IN
23 Line Filter
52 Solenoid Valve
54 Rotary Coupling
58 Axle Lock Assembly
59 Axle Lock Rams 6B 54
Solenoid Energised
Note: Key references correspond

with references on the main 52 58
schematic diagram.
59 59
P2
C1
B
T2
JS08031
* Electrical Circuit
(CAPS II only - refer to 9803/6450 for AMS)
Component Key
1 Wheel Controller 1
2 Plug 4
3 Plug 2 2
4 Switch Box 2 1
5 Channel 5
3
6 Solenoid 52B
5
7 Brake Light Switch
10 Plug 5
11 Right Hand Switch Panel 3
12 Auto Axle Lock
13 Manual Axle Lock
4 5
F L 2
6 CH5
M 1
6
8
11 7
10 T
2 9
17 U
V
12
4
4
8
16
13
6
5
JS10030
9803/6310 Issue 2*
Hammer Circuit
TAB Option
Hydraulic
Operating the Hammer switch located on the front of the left

hand joystick (see Operation, Other Controls, Operator
Handbook) energises solenoid valve 64 allowing pressurised
oil from the servo pump Pp to flow from port 2 in two
directions:
1 Through shuttle of valve 76 selecting ARM II spool and

closing off neutral circuit. Pressurised oil from pump P1
enters the main control valve 18 by port PR and is sent
via port PO to port P of the hammer control valve 65.
2 To port a of hammer control valve selecting hammer

spool and allowing oil delivered from pump P1 (see
above) to flow to the hammer.
Return oil from the hammer passes through the in-line return
filter 71 and then flows directly to tank via the normal tank
return line.
No TAB
Operating the Hammer switch on the front of the left hand

joystick energises solenoid valve 64 allowing pressurised oil
from the servo pump Pp to flow from port 2 to port b12 on
the main control valve 18, selecting the option spool, closing
off the negative control circuit allowing pump P2 to come up
to full flow and send pressurised oil via port BL2 to the
hammer.
Return oil from the hammer passes through the in-line return
filter 71 and then flows directly to tank via the normal tank
return line.
*
Electrical (CAPS II only - refer to 9803/6450 for AMS)
Hammer relays 1 and 2 are earthed on one-side, through pin

2 of BC4. Pressing the hammer switch on the front of the left
hand joystick, energises both relays by supplying 28V from
fuse 6 of the wheeled fusebox through pin 1 of BC4.
Relay 1 energising, switches 28V to hammer solenoid 64

through pin 6 of BC4.
Relay 2 energising, earths pin 7 of CN5, signalling the main

controller to cut engine rpm to a pre-set level for the
hammer in use. The main controller is also signalled by
pressure switch 19A in the hammer pilot line closing.
9803/6310 Issue 2*
Hammer Circuit (cont’d)

Pp
71
19 23
Av 22
64 76
T
IN A
V
C
Ac
ARM II
a1
a 2 PP B
Ac v
65
P Av
Hydraulic Circuit Ab
33
Key 18
P1 Hydraulic Pump
Pp Servo Pump
18 Main Control Valve PR
19 Servo Isolator
22 Transmission Control Valve Po
23 Line Filter Ab
33 Sump Tank P1
64 Solenoid Valve
65 Hammer Control Valve JS07091
71 In-line Return Filter
76 Shuttle Valve
Solenoid Energised
Note: Key references correspond with references on the main schematic diagram.
Electrical Circuit
* (CAPS II only - refer to 9803/6450 for AMS)
2
1
CN5
Key 7
8
1 Main Controller
16
2 Pressure Switch 19A
3 Hammer Relay 2 3
4 Hammer Relay 1
5 Hammer Select Switch 86 85

7 Hammer Solenoid 64 30
87
87A
86 85
5 2
87
1
30
87A
BC4
1
6
6
7 2
JS10900
9803/6310 Issue 2*
17 - 1 * Hydraulic Pump/Regulator JS130W/145W/160W 17 - 1
Introduction
The pump/regulator consists of two variable displacement

type axial piston pumps (P1 and P2) supplying pressurised
oil to operate machine functions, plus two gear type pilot
pumps, one (Pp) to provide pilot circuit pressure for operator
control of machine functions. The other (Pb) to provide
pressure for brake and steering functions.
Pumps P1 and P2 each incorporate a regulator which

adjusts the output flow rate according to system demand.
Specifications
Axial Piston Pumps JS130W JS 145W/JS160W
Maximum displacement cc (in3)/rev 55 (3.36) x 2 60 (3.66) x 2
set 319 bar (4551 lbf/in2, 320 kgf/cm2) 319 bar (4551 lbf/in2, 320 kgf/cm2)
Working pressure (travel)
maximum 343 bar (4978 lbf/in2, 350 kgf/cm2) 343 bar (4978 lbf/in2, 350 kgf/cm2)
Speed rpm 2230 2330
Maximum flow l (gal)/min 122.7 (32.4) 139.8 (36.9)
Maximum input torque Nm (lbf ft) 278.5 (205.4) 278.5 (205.4)
Weight kg (lb) 83 (183) 83 (183)
Gear pump JS130W JS160W
Front 11.9 (0.73) 11.9 (0.73)

Displacement
cc (in3)/ rev
Rear 9.08 (0.55) 9.08 (0.55)
Working pressure 42 bar (612 lbf/in2, 43 kgf/cm2) 42 bar (612 lbf/in2, 43 kgf/cm2)
Front 26.53 (5.84) 27.3 (6.10)

Maximum flow
l (gal)/min
Rear 20.2 (5.34) 21.2 (5.60)
9803/6310 Issue 2*
Hydraulic Pump Circuit Diagram
JS06970
Pump Configuration
JS06980
Key
A Negative control signal J Pump outputs
B Maximum flow signal L Swash plate angle
C Mode change - electrical signal P1 Front pump
E Solenoid proportional pressure control (SPPC) valve P2 Rear pump
F Total horsepower control electrical signal Pp Pilot pump
G Pilot pressure relief valve Pb Pilot pump
H Pump input
9803/6310 Issue 2*
Operation
In the following descriptions the bold figures (e.g. 4) relate to The fixed valve plate 9 contains two crescent shaped ports
the items on the sectional and exploded views on pages X. The valve plate is located so that when a piston reaches
17 - 7 to 17 - 9 and the component list on page 17 - 10. its nearest point to the plate it comes into line with the pump
inlet port H. During the next 180° of cylinder block rotation
Main Pumps (P1 and P2) the piston draws oil into the cylinder bore. When the piston
reaches its furthest point from the plate it ceases to be in
Each pump consists of a cylinder block 4, containing nine line with the inlet port and comes into line with pump outlet
piston/shoe assemblies 6. Driven by shaft 5, the block port J. The next 180° of cylinder block rotation causes the
rotates between a variable angle, non-rotating swash plate piston to force oil from the cylinder bore through the outlet
(7 on P1, 8 on P2) and a fixed valve plate (9 on P1, 10 on port.
P2).
The process is carried out sequentially by the nine pistons to
Retainer plate 11 holds the piston shoes against the swash provide a continuous smooth pump output.
plate. Due to the angle of the swash plate, as the cylinder
block rotates the pistons are forced to move back and forth
in their cylinders. The piston stroke, and therefore the pump
displacement, varies according to the swash plate angle,
which is controlled by machine demand.
JS00060
9803/6310 Issue 2*
Operation
Pilot Pump (Pp) / Brake Pump (Pb)
JS07000
Regulator
Key
A Negative control signal

B Maximum flow signal
K Horsepower control signal (from pump proportional solenoid control valve)
L Swash plate angle
P1 Front pump
P2 Rear pump
Pp Pilot pump
Pb Brake pump
9803/6310 Issue 2*
Operation (cont’d)
Pilot Pump (Pp) and Steer and Brake Pump

(Pb)
As the pump gears revolve, oil from the common inlet port Y Horsepower Control
is trapped between the gears and the housing and carried to
the outlet ports Z1 and Z2. The operation of the pump is based on the principle that at a
given horsepower setting:
Regulator
“pressure x output flow rate = constant”
The function of each regulator is to maximise the efficiency
The setting can be varied using the signal K as described
of its associated pump circuit by making it respond to
under Flow Control. Signal K is controlled by the Solenoid
system demand i.e. adjusting the output flow to satisfy the
Proportional Pressure Control valve (SPPC), the output of
changing requirements of the machine services. This is
which is determined by electric signals according to the
achieved by varying the angle of the pump swash plate.
working mode selected.
The following description refers to pump P1. The circuit for
Maximum Flow Cut
pump P2 functions in exactly the same way.
When the maximum flow cut signal B is present, it acts on
Flow Control
piston 54 to operate spool 40 via piston 38, as described
under Flow Control. Due to the diameter of piston 54 being
Pump P1 pressure is routed to piston 32, regulator piston 24
smaller than that of piston 38, maximum flow is 65% of that
(small diameter chamber ‘a’) and spool 40. Pump P2
obtainable under normal flow control conditions.
pressure is also routed to piston 32. Pilot pump Pp pressure
and horsepower control signal K (which is derived from Pp
pressure and related to the operating mode selected)
produce control pressure Pc which is equal to 5% of total
pump pressure (P1 + P2).
Pressure Pc, routed to piston 38, increases with pump

pressure. The piston moves spool 40 to the left to direct
pump P1 pressure to the large diameter chamber ‘A’ of
regulator piston 24. This causes piston 24 to move to the
right to reduce the swash plate angle and decrease oil flow.
Bridging piece 29, connected to piston 24, compresses
springs 43/44 to act against Pc pressure through piston 38.
When Pc pressure and the pressure of springs 43/44 are
equal the regulator piston stops moving.
Pressure Pc decreases as pump pressure falls and springs

43/44 cause spool 40 to move to the right, connecting
chamber ‘A’ of regulator piston 24 to the case drain. P1
pressure at chamber ‘a’ causes regulator piston 24 to move
to the left to increase the swash plate angle and increase oil
flow. When pressure Pc and the pressure of springs 43/44
are equal the regulator piston stops moving.
Negative Control
When the pump output is not being used (or is at a very low
rate) pressure signal A, derived from the main control valve,
acts on piston 38 in the same way as pressure signal Pc,
described under Flow Control, to minimise oil flow.
9803/6310 Issue 2*
Pilot Relief Valve
Pilot pressure is controlled by the pilot relief valve setting.

Pressure can be varied using adjuster 56-6 which holds
poppet 56-2 against seat 56-3 by means of spring 56-5. If
the pressure exceeds the set value, the poppet lifts to vent
excess Pp pressure to tank.
Solenoid Proportional Pressure Control (SPPC) Valve
The function of the SPPC valve is to provide a means of

varying the horsepower settings of the two pumps according
to the operating mode selected. Each mode selection
causes an electrical signal F to be applied to the valve
solenoid. The signal current level is dependent on the mode
selected. The solenoid converts the electrical signal into a
thrust from plunger E.
When solenoid 58 is energised, the thrust of plunger E

moves spool 103 to the left to connect input port B (at pilot
pump Pp pressure) to output port C. The output pressure at
port C is routed to chamber A where it acts as a back
pressure to oppose the thrust of plunger E. High back
pressure causes spool 103 to move so that output port C
connects to drain port D lowering the output pressure and
hence the back pressure. The result is a level output
(horsepower signal) pressure which is proportional to
solenoid plunger thrust and determined by the proportion of
input pressure (at port B) connected to port C via spool 103.
9803/6310 Issue 2*
Dismantling and Assembly
JS07010
9803/6310 Issue 2*
Dismantling and Assembly (cont’d)
JS07020
9803/6310 Issue 2*
JS00020
9803/6310 Issue 2*
Component List
No Description Qty. No. Description Qty.
1 Pump housing 1 61 Mounting flange 1

2 Flange 1 62 Pin 2
3 Rear cover 1 63 Pin 2
4 Cylinder block assembly 2 64 Pin 4
5 Shaft 1 65 Plug 1
6 Piston assembly 18 66 Plug 1
7 Swash plate (front) 1 67 Plug 2
8 Swash plate (rear) 1 68 Plug 1
9 Valve plate (front) 1 69 Plug 2
10 Valve plate (rear) 1 70 Plug 4
11 Retainer plate 2 71 Socket head bolt 4
12 Retainer plate holder 2 72 Socket head bolt 6
13 Bearing 2 73 Socket head bolt 18
14 Bearing 4 74 Socket head bolt 4
15 Oil seal 1 75 Socket head bolt 4
16 Oil seal case 1 76 Plug 8
17 Shim 1 77 Bolt 2
18 Shim 1 78 ‘O’-ring 2
19 Conical spring assembly 2 79 ‘O’-ring 1
20 Spring seat 2 80 ‘O’-ring 1
21 Guide assembly 4 81 ‘O’-ring 1
22 Slide metal 2 82 ‘O’-ring 2
23 Regulator piston 2 83 ‘O’-ring 4
24 Stopper 2 84 ‘O’-ring 1
25 Stopper 2 85 ‘O’-ring 2
26 Set screw 2 86 ‘O’-ring 1
27 Set screw 2 87 ‘O’-ring 3
28 Nut 4 88 ‘O’-ring 3
29 Bridging piece 2 89 ‘O’-ring 1
30 Cover (R) 2 90 ‘O’-ring 2
31 Plug 1 91 ‘O’-ring 1
32 Piston 1 92 ‘O’-ring 2
33 Sleeve 1 93 ‘O’-ring 2
34 Spool 1 94 Back-up ring 2
35 Plug 1 95 Back-up ring 2
36 Spring 1 96 Back-up ring 2
37 Sleeve 2 97 Back-up ring 2
38 Piston 6 98 Back-up ring 3
39 Sleeve 2 99 Name plate 1
40 Spool 2 100 Drive screw 2
41 Spring seat 2 101 Eyebolt 1
42 Spring seat 2 102 Sleeve 1
43 Spring 2 103 Spool 1
44 Spring 2 104 Spring 1
45 Plug 2 107 Plug 1
46 Spring seat 2 108 ‘O’-ring 1
47 Spring 2 109 Washer 2
48 Nut 2 110 Orifice 1
49 Nut 2 111 ‘O’-ring 1
50 Sub-block 1
51 Disc filter 2
52 Cover (LF) 1
53 Cover (LR) 1
54 Piston 2
55 Steel ball 2
56 Relief valve assembly 1
57 Pilot gear pumps 1
58 Solenoid valve 1
59 Hose 1
60 Adjustable elbow 2
9803/6310 Issue 2*
Dismantling
Refer to the illustrations on pages 17 - 3 to 17 - 9 and the 8 Unscrew the four socket head bolts 75 and take out oil
component list on page 17 - 10. In the following procedures, seal case 16.
the part numbers in bold type (e.g. 71) correspond with the
numbers on the illustrations. Note: Take care not to damage the oil seal lip with the shaft
spline.
Before attempting to dismantle the hydraulic pump, drain all
oil, blank all inlet and outlet ports and wash the outer 9 Unscrew the six socket head bolts 73 and remove
surfaces with a suitable solvent to remove all dirt and dust. flange 2. Then remove the bearings 14 from the swash
Dry using compressed air. plate.
Make different alignment marks across each sub-assembly Note: It may be necessary to lightly tap the flange with a
joint face as an aid to assembly. plastic hammer to assist removal.
The cylinder block assemblies, servo pump, relief valve and 10 Remove bearing 13 on the front side, using the bearing
proportional pressure reduction valve must be replaced as removal tool and the front shaft protection tool (see
complete assemblies. Service Tools, Section 1).
The following procedures show a complete strip down, but,
unless absolutely necessary, avoid disturbing or dismantling 11 Remove front swash plate 7 and the assembly
the control elements of the pump, i.e. those retained by comprising cylinder block 4, piston assembly 6, retainer
covers 30, 52 and 53 and by plugs 31 and 35. Any plate 11, retainer holder 12, spring 19, spring seat 20
interference with setting screws will affect pump output and valve plate 9.
control, necessitating precision re-setting on the bench.
Note: Take care not to mix these parts with those removed
The pump/regulator unit contains two pressure pumps, P1 from the rear end at step 7.
and P2. Take care not to get the parts from one mixed in
with parts from the other. 12 Unscrew the three socket head bolts 72 on the rear side
and remove cover ‘LR’ 53.
During dismantling, record the number and dimensions of
shims. Take care to reassemble in the same manner. At this point, sleeve 37 may come out with the cover.
Take care not to allow the pistons 38 and 54 to fall out.
Note: Protect the clamping faces when supporting the pump
housing in the vice. 13 If necessary, remove sleeve 37 complete with pistons
38 and 54. Remove the three pistons 38 and piston 54
1 Support pump housing 1 in a vice, clamped across the from the sleeve.
inlet and outlet port flanges. Unscrew the four socket
head bolts 71 and remove mounting flange 61. 14 Remove spool 40, spring seats 41 and 42 and springs
43 and 44 in the same direction as sleeve 37.
2 Remove hose 59.
15 Unscrew the three socket head bolts 73 on the rear side
3 Unscrew the two bolts 77 and remove gear pumps 57. and remove cover ‘R’ 30.
4 Unscrew the four socket head bolts 74. Remove sub- 16 Unscrew the three socket head bolts 72 on the front
block assembly 50 and put to one side. side and remove cover ‘LF’ 52.
5 Unscrew the six socket head bolts 73 and remove rear Remove sleeve 37 and spool 40 assembly.
cover 3. Then remove bearings 14 from the swash plate.
Note: Take care not to mix these parts with those removed
Note: It may be necessary to lightly tap the rear cover with a at step 12.
plastic hammer to assist removal.
17 Remove the stoppers 24 and 25 on the rear side using
6 Remove bearing 13 on the rear side, using the bearing an M6 bolt screwed into the threaded hole in the end of
removal tool and the rear shaft protection tool (see each one.
Service Tools, Section 1).
Take out regulator piston 23 and bridging piece 29.
7 Remove rear swash plate 8 and the assembly
comprising cylinder block 4, piston assembly 6, retainer Repeat for front side, removing stoppers 24 and 25,
plate 11, retainer holder 12, spring 19, spring seat 20 regulator piston 23 and bridging piece 29.
and valve plate 10.
Note: Take care not to mix rear and front side components.
18 Remove plug 31 complete with piston 32.
9803/6310 Issue 2*
Dismantling (cont'd)
19 Loosen plug 35 and remove it along with spring 36. By
hooking it with a wire, take out spool 34 together with
sleeve 33.
20 Return to sub-block assembly 50 removed at step 4.

Remove the ‘O’-rings 89 (1 off), 91 (1 off), 93 (2 off) and
111 (1 off), plus disc filter 51.
21 Unscrew the four securing bolts and remove solenoid

58 from sub-block 50. Remove sleeve 102 and spool
103.
22 Remove relief valve assembly 56 and adjustable elbow

60 from sub-block 50. Remove plug 107 and take out
spring 104 and disc filter 51.
23 Using a screwdriver remove oil seal 15 from oil seal

case 16 and discard the seal.
9803/6310 Issue 2*
Inspection
All parts should be checked for signs of damage or wear,

paying particular attention to the parts detailed below.
Part Renew if these conditions exist
Piston assembly 6 a Any sliding part is deeply scratched or has a rough surface.
b The clearance between any piston and its cylinder is 0.050 mm (0.002 in) or
more.
c The shoe/ball clearance X is 0.39 mm (0.0157 in) or more.

X
Cylinder block assembly 4 a Any sliding part is deeply scratched or has a rough surface.
b The spline is excessively worn or damaged.
Valve plates 9, 10 a The cylinder block sliding contact surface is deeply scratched or has a
rough surface.
Swash plates 7, 8 a The piston shoe sliding contact surface is deeply scratched or has a rough
surface.
b Flaking or peeling on the roller bearing 14 contact surface.
Retainer plate 11 a The sliding surface is deeply scratched, thermally seized or unevenly worn
Retainer holder 12 or has a rough surface.
Shaft 5 a The oil seal 15 contact surface is deeply scratched or has a rough surface.
b The spline is excessively worn or damaged.
Bearings 13, 14 a Flaking or peeling on the rolling surface.
b The bearing does not operate smoothly and freely.
Oil seal 15 a The lip has been damaged, excessively worn or hardened.
Body 1 a The piston and/or its bore is deeply scratched or has a rough surface.
Regulator piston 23
Relief valve assembly 56 a Any problem occurs, e.g. the set pressure has been lowered
Servo regulator parts (spool, sleeve, a Any sliding part is deeply scratched or has a rough surface.
piston)
9803/6310 Issue 2*
Assembly
Clean each part in a suitable solvent and dry using
compressed air. 4 Pass shaft 5 through cylinder block assembly 4 from
the rear, double splined end first.
Inspect all parts and renew as required.
5 Insert pin 63 into the front side of the pump housing.
Care must be taken not to let dust or dirt adhere to parts Install valve plate 9, stepped face outermost, so that
after cleaning and that parts do not become dented, the slot on its rear face locates the pin.
scratched or damaged.
6 Install cylinder block 4/shaft 5 assembly into pump
Fit new ‘O’-rings, plugs, packing, oil seals and fastener housing 1 with the piston shoes outermost.
seals.
7 Using suitable blocks to allow the shaft to clear the
Apply Lithium grease to all new oil seals (particularly the lip work surface, position the pump housing on the bench,
areas) and ‘O’-rings, and clean hydraulic fluid to all sliding front end uppermost.
parts before installation.
8 a Fit the two guide assemblies 21 and slide metal 22
to swash plate 7.
All tapped holes and gasket faces should be thoroughly
degreased by washing, as liquid packing and adhesive is Note: The hole in slide metal 22 is not central. Install with the
used on all gasket surfaces and threads. hole furthest from the pistons.
Apply adhesive to the final few threads of a bolt or screw. Do b Assemble swash plate 7 into the pump housing.
not apply excessive amounts of adhesive. Wipe off any
surplus. Note: Position regulator piston 23 with the groove for slide
metal 22 in the centre and locate the two during assembly.
Leave the pump for at least twelve hours after assembly to
allow the adhesive to dry fully. 9 Using a suitable tool (see Service Tools, Section 1) and
a press, fit bearing 3 onto shaft 5.
Ensure that all components are re-fitted to the positions from
which they were removed, paying particular attention not to Note: This job can be carried out by drifting the bearing into
intermix components from identical sets front and rear. place, taking care not to scratch or damage the bearing, the
shaft or any other parts.
1 Install regulator piston 23 and bridging piece 29 into the
front of pump housing 1. 10 Fit bearing cage/rollers 14 on swash plate 7. Set guide
assembly 21 in the cut-out of the bearing cage,
Note: Make sure the bridging piece is orientated as shown standing upright.
on page 17 - 9.
11 Using a swash plate levelling jig (see Service Tools,
2 Fit ‘O’-ring 82 and back-up ring 94 to stopper 24. Insert Section 1), adjust swash plate 7 so that it is parallel with
the stopper into pump housing 1. the outer face of pump housing 1, by ensuring the same
height A on the left and the right
Fit ‘O’-ring 85 and back-up ring 95 to stopper 25. Insert
the stopper into pump housing 1.
Note 1: Install stoppers 24 and 25 with the tapped centre

holes facing outwards.
Note 2: The back-up ring is fitted to the end of the stopper

nearest the tapped hole, with the ‘O’-ring innermost.
Note 3: The stoppers must be fitted flush with the housing to

prevent damage to the ‘O’-rings.
7
3 Assemble the front piston/cylinder block assembly as
follows: 1
a Mount spring seat 20 on cylinder block assembly 4
JS00110
followed by conical spring assembly 19 and retainer
holder 12.
12 Install two guide rods (see Special Tools, Section 1)
b Install piston assembly 6 into retainer plate 11 and into opposite threaded holes in the pump housing
insert the pistons in cylinder block assembly 4. flange.
9803/6310 Issue 2*
Assembly (cont’d)
13 a Insert two pins 64 into flange 2, then fit the outer 20 Install assembled cover ‘R’ 30 into the pump housing,
race of bearing 13 into the flange. first aligning the slot in bridging piece 29 (by means of a
piece of wire from the opposite side) to accommodate
b Fit ‘O’-ring 78 into the flange. sleeve 39. Install the three socket head bolts 73 and
tighten to a torque of 129 Nm (95 lbf ft, 13.1 kgf m).
c Insert pin 62 into pump housing 1 and then
assemble flange 2 onto the housing along the guide Note: Having been dismantled it will be necessary to make
rods fitted at step 12. adjustments on the bench to the variable components
secured by locking nuts 28, 48 and 49. On completion of the
d Install four socket head bolts 73 into the vacant adjustments torque tighten as follows:
mounting holes. Remove the two guide rods and
insert the remaining two bolts 73. Tighten the bolts 28 73 Nm (54 lbf ft, 7.5 kgf m)
evenly to a torque of 129 Nm (95 lbf ft, 13.1 kgf m). 48 182 Nm (134 lbf ft, 18.5 kgf m)
49 45 Nm (33 lbf ft, 4.5 kgf m)
14 Lay the pump housing on its side and repeat steps 1, 2
and 3 at the rear end of the housing. Fit the cylinder Repeat steps 19 and 20 for cover ‘F’ 30.
block assembly on the spline of shaft 5.
21 Install spring seat 41, springs 43 and 44 and spring
Using suitable blocks to allow the shaft to clear the seat 42 onto spool 40.
work surface, position the pump housing on the bench,
rear end uppermost. Note: The larger diameter side of spring seat 42 should be
against springs 43 and 44.
15 Repeat step 8 to assemble and fit rear swash plate 8.
22 Fit ‘O’-ring 83 onto sleeve 37. Insert the three pistons
Fit bearing 13 into swash plate 8, using a bearing 38 and piston 54 into the sleeve.
insertion tool (see Service Tools, Section 1) and fit
bearing cage/rollers 14 with guide assembly 21 in the Fit set screw 27 and locking nut 28 into front cover 52.
cut-out of the bearing cage, standing upright (see step Install spool 40 assembly, followed by sleeve 37
10). assembly into the pump housing, making sure spool 40
moves freely and that pistons 38 (3 off) and 54 do not
Repeat step 11. fall out. Secure cover 52 with the three socket head
bolts 72 tightened to a torque of 129 Nm (95 lbf ft, 13.1
Repeat steps 12 and 13 referring to rear cover 3 instead kgf m).
of flange 2.
Repeat steps 22 and 23 for rear cover 53.
16 Fit ‘O’-rings 81, 86, 87 and 88 and back-up rings 96, 97
and 98 onto plug 31. Insert piston 32 into the end of 23 Using a suitable tool (see Service Tools, Section 1) and
plug 31. a press, fit oil seal 15 squarely into oil seal case 16 with
the open side of the seal facing flange 2. Fit ‘O’-ring 79
With plug 31 horizontal to prevent the piston falling out, onto the oil seal case.
fit it into the pump housing and tighten to a torque of
229 Nm (169 lbf ft, 23.4 kgf m).
17 Insert spool 34 into sleeve 33 and, after verifying that

piston 32 is installed in plug 31, fit the sleeve into pump
housing 1.
18 Insert spring 36. Fit ‘O’-ring 84 onto plug 35 and then

screw the plug into the pump housing and tighten to a
torque of 157 Nm (116 lbf ft, 16 kgf m).
19 Fit ‘O’-ring 88 and back-up ring 98 onto sleeve 39,

taking care not to damage the wire mesh filter around
the outside. Install the sleeve into cover ‘R’ 30 and
temporarily tighten with nut 48. JS01840
In order, install spring seat 46, spring 47 and plug 45 24 Fit shims 17 and 18 (if used) and oil seal case 16
with ‘O’-ring 92 fitted into sleeve 39 and fit locking nut assembly onto flange 2. Install the four socket head
49. bolts 75 and torque tighten to 33 Nm (24 lbf ft, 3.3 kgf
m).
Install set screw 26 complete with locking nut 28 into
cover ‘R’ 30. Note: Shims 17 and 18 provide clearance adjustment, if
required. Always re-fit the shims removed during
dismantling.
9803/6310 Issue 2*
Assembly (cont’d)
25 Fit ‘O’-ring 80 into rear cover 3. Install gear pumps 57
and secure with washer 109 and the two bolts 77
tightened to a torque of 45 Nm (33 lbf ft, 4.5 kgf m).
26 Assemble sub-block 50 as follows:
a Fit relief valve 56.
b Fit adjustable elbow 60, making sure the elbow

faces away from the relief valve.
c Insert disc filter 51 followed by spring 104 and plug

107 complete with ‘O’-ring 108.
d Insert spool 103 into sleeve 102 with the drilled end
of the spool corresponding to the stepped end of
the sleeve. Insert the assembly, stepped end of
sleeve first, into the block. Mount solenoid 58.
e Into the mounting face of the block, insert ‘O’-rings

89, 91, 93 (2 off), and 111, the second disc filter 51
and orifice 110.
Note: Check that the orifice and its mounting position are
not clogged.
27 Fit sub-block 50 assembly onto the pump housing and

secure with the four socket head bolts 74, tightened to
a torque of 33 Nm (24 lbf ft, 3.3 kgf m).
Tighten the following parts of the sub-block assembly to

the specified torque:
Relief valve 56 - 83 Nm (61 lbf ft, 8.5 kgf m)

Plug 107 - 52 Nm (38 lbf ft, 5.2 kgf m)
Solenoid 58 retaining screws (x 4) - 4.2 Nm (3.1 lbf ft,
0.43 kgf m).
28 Connect hose 59 to the two adjustable elbows 60 and

tighten to a torque of 52 Nm (38 lbf ft, 5.2 kgf m).
29 Tighten plugs 65 and 66 to a torque of 71 Nm (52 lbf ft,

7.2 kgf m) and plug 67 to 30 Nm (22 lbf ft, 3.0 kgf m).
Fit mounting flange 61 to flange 2 and secure with the
four socket head bolts 73 tightened to a torque of
275 Nm (203 lbf ft, 28 kgf m).
9803/6310 Issue 2*
17 - 17 Hydraulic Pump/Regulator 17 - 17
Checks After Installation

After the pump has been fitted to the engine, the following
procedure must be carried out.
1 Remove pump drain port A and loosen air bleed plug B.
2 Fill the pump casing with clean hydraulic fluid

(approximately 2 litres).
3 Bleed air from hydraulic piping.
4 Fit and tighten the drain and air bleed plugs A and B.
5 Start the engine and run at a slow speed. Check the

pump for abnormal noises which could signify air
trapped in the pump. If the pump is noisy, stop the
engine, vent the hydraulic pressure and loosen the air
bleed plug B. When satisfactory, tighten the plug,
restart the engine and check for abnormal noises.
6 When satisfactory, gradually increase engine speed

until the machine operating range is reached. B
7 Operate each service several times with a light load.
Check for leaks. If satisfactory, operate each service
with a greater load. If satisfactory, operate each service
under normal working loads.
8 For stable control of the Solenoid Proportional Pressure

Control valve, it is necessary to bleed air from the valve
by loosening bleed screw C. When all air has vented,
torque tighten the screw to 0.15- 0.245 Nm (0.11-1.8
lbf. ft.). A
JS06711
JS06790
9803/6310 Issue 2*
17 - 18 Hydraulic Pump/Regulator 17 - 18
Torque Tightening Table - JS 130W
BOLT PLUG NUT TIGHTENING TORQUE
P69, R47 P75, R34 14.6 Nm (10.8 lbf ft)
P67, P68, P85, R29, R30, R46 R49 32.4 Nm (23.9 lbf ft)
P51 39.2 Nm (28.9 lbf ft)
P64, P65, P66 P50, P70, R7, R38 R39 63.7 Nm (47.0 lbf ft)
P32 98.0 Nm (72.3 lbf ft)
P63 176.5 Nm (130.2 lbf ft)
A6 274.6 Nm (202.5 lbf ft)
Torque Tightening Table - JS 160W
BOLT PLUG NUT TIGHTENING TORQUE
P69, R47 12.2 Nm (9.0 lbf ft)
P75, P86, R34 17.2 Nm (12.7 lbf ft)
R49 27.0 Nm (19.9 lbf ft)
P67, P68, P85, R29, R30, R46 32.4 Nm (23.9 lbf ft)
P51 36.7 Nm (27.1 lbf ft)
P64, P65, P66 P50, R7, R 38 R39 63.7 Nm (47.0 lbf ft)
P70 83.3 Nm (61.4 lbf ft)
P32 108.0 Nm (79.6 lbf ft)
P63 191.2 Nm (141.0 lbf ft)
A6 274.6 Nm (202.5 lbf ft)
9803/6310 Issue 1
18 - 1 Hydraulic Pump/Regulator JS175W 18 - 1
Introduction
The pump/regulator consists of two variable displacement

type axial piston pumps (P1 and P2) supplying pressurised
oil to operate machine functions, plus two gear type pilot
pumps, one (Pp) to provide pilot circuit pressure for operator
control of machine functions. The other (Pb) to provide
pressure for brake and steering functions.
Pumps P1 and P2 each incorporate a regulator which

adjusts the output flow rate according to system demand.
Specifications
Axial Piston Pumps JS175W

Maximum displacement cc (in3)/rev 80 (3.05) x 2
Working pressure (travel) set 315
maximum 343
Speed rpm 1950
Maximum flow l (gal)/min 156 x 2 (34.2 x 2)
Maximum input torque Nm (lbf ft) 87 (64.16)
Weight kg (lb) 93 (205.01)
Gear Pump JS175W
Displacement cc (in3)/rev Front Steering Pump 13.9 (0.84)
Rear Servo Pump 10.00 (0.61)
Working pressure Front 195
Rear 39 (+0.3/-0)
Maximum flow I (gal/min Front 27.1 (5.96)
Rear 19.5 (4.28)
9803/6310 Issue 1*
Pump Hydraulic Circuit Diagram
A1 A2
(FRONT) (REAR)
a1 a2
Pm1 Pm2
Pi1 Pi2
a3
B1
Dr1 Dr2
A4
a4
B4 B3 A3
A357760
Key
A1,2 Delivery port
B1 Suction port
Dr1 Drain port
Dr2 Drain port
Pi1,2 Pilot port
P1 Proportional pressure reducing valve
Pm1,2 Q max cut port
a1-3 Gauge port
a4 Gauge port
A3 Gear pump delivery port
B3 Gear pump suction port
A4 Gear pump delivery port
B4 Gear pump suction port
9803/6310 Issue 1*
18 - 3 Hydraulic Pump/Regulator JS175W 18- 3
Hydraulic Pump/Regulator JS175W
a4
a2
B1
B3
A3
P1
a4
Pi2
Pm2
a3
A2
Pm2
Dr1
A1
Pm1
Dr2
Dr2
Pi1
B4
A4
Pm2
Dr2
a1
CLOCKWISE
A1
Pi1
a3
B4
A4
Dr1
9803/6310 Issue 1*
Operation
Main Pumps (P1 and P2) The fixed valve plate contains two crescent shaped ports.
The valve plate is located so that when a piston reaches its
Each pump consists of two cylinder blocks, each containing nearest point to the plate it comes into line with the pump
nine piston/shoe assemblies. Driven by shaft, the block inlet port. During the next 180° of cylinder block rotation the
rotates between a variable angle, non-rotating swash plate piston draws oil into the cylinder bore. When the piston
and a fixed valve plate. reaches its furthest point from the plate it ceases to be in
line with the inlet port and comes into line with pump outlet
A retainer plate holds the piston shoes against the swash port. The next 180° of cylinder block rotation causes the
plate. Due to the angle of the swash plate, as the cylinder piston to force oil from the cylinder bore through the outlet
block rotates the pistons are forced to move back and forth port.
in their cylinders. The piston stroke, and therefore the pump
displacement, varies according to the swash plate angle, The process is carried out sequentially by all the pistons to
which is controlled by machine demand. provide a continuous smooth pump output.
PISTON ASSEMBLY
SWASH PLATE
PUMP 1 PUMP 2
JS00060
9803/6310 Issue 2*
Proportional Reducing Valve
9803/6310 Issue 2*
Hydraulic Pump
J374321
9803/6310 Issue 2*
Hydraulic Pump
The working environment must be clean and the workbench

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

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

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

correspond with those in the exploded view.
Dismantling
Before dismantling, the pump ports should be plugged and

the external surfaces thoroughly cleaned to prevent the
ingress of dirt into the pump mechanism.
1 Remove drain plug 1 and let the oil drain into a suitable
receptacle.
2 As an aid to re-assembly, match mark the mating

3
flanges of regulator 4 and pump casing 5. Remove
socket head screws 2 and 3 (2 off each) and lift off the
regulator. Put the regulator to one side in readiness for 2
dismantling if required (see Regulator, Dismantling).
3 Remove the gear pump assembly 6.
379380
9803/6310 Issue 1*
Hydraulic Pump (cont’d)

Dismantling (cont’d)
4 Remove the four socket head screws 7.
5 Place the pump on the workbench with its regulator 7

mounting face downwards. Match mark the mating
flanges of pump casing 5 and valve block 8. Separate
the pump casing from the valve block.
8
5 379540
6 Remove the piston/cylinder assembly Z comprising

cylinder 9, piston assemblies 10, set plate 11, spherical 5
bush 12 and cylinder springs 13 from pump casing 5.
Take care not to damage the sliding surfaces of the
components.
379550
7 Remove socket head screws 14 and then remove seal

cover 15 (Pump 1) or 15A (Pump 2), taking care not to
damage the oil seal 16. This task can be simplified by 14
inserting a pull-out bolt into the tapped hole in the cover.
15A
(15)
379560
9803/6310 Issue 1*

8 Match mark the mating flanges of swash plate support

17 and pump casing 5. Separate the swash plate 5A (5)
support from the pump casing by lightly tapping the
support around its flange using a plastic hammer.
17A (17)
379570
9 Remove shoe plate 18 and swash plate 19 from pump

casing 5.
18
19
379580
10 Pump 1
32A
Remove snap ring 20 and bearing spacer 21. Using a
plastic hammer, gently tap shaft 22 out of its support
bearing 32 to remove it from swash plate support 17.
22A
Pump 2 (right)
Gently tap shaft 22A, at the end nearest the mating
flange of valve block 8, to separate it from swash plate
support bearing 32A.
17A
379590
9803/6310 Issue 1*

11 Remove valve plate 23 from valve block 8.
23 379600
12 If necessary, remove plugs 24 and 25, servo piston 26

and tilting pin 27 from pump casing 5.
Note 2: When removing the tilting pin use a protector to

prevent damage to the pin head. Also take care not to
damage the servo piston as a result of the Loctite used to
secure it.
13 Remove needle bearings 28 (see Note 3) and splined

coupling 29 from valve block 8.
Note 3: Do not remove the needle bearing assembly unless

it needs renewing.
Note 4: To avoid the risk of changing the flow settings, do

not loosen nut 30 in valve block 8 or nut 31 in swash plate
support 17.
9803/6310 Issue 1*

Assembly
Before assembling:
a Thoroughly clean all components with clean hydraulic oil

and dry with compressed air.
b Apply clean hydraulic oil to all sliding surfaces, bearings,

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

pin 27 and servo piston 26. Use a protector to prevent
damage to the tilting pin head and feedback pin.
2 Take care to align the flange match marks and then fit
swash plate support 17 to pump casing 5 by gently
tapping it with a plastic hammer.
5
17A
(17)
379610
3 Place the pump casing on the workbench with its

regulator mounting face downwards. Attach swash plate
5
tilting bush 31 to tilting pin 27. Smear the sliding
surfaces of swash plate support 17 and swash plate 19 17
with grease. Install the swash plate against the support
and manually check that the swash plate slides
smoothly.
19
379620
9803/6310 Issue 1*

Assembly
4 Pump 1
From inside pump casing 5 install shaft 22 through its
support bearing 32 and secure with bearing spacer 21
and snap ring 20. 5A
Pump 2 (right)
From outside pump casing 5A, install shaft 22A, small
splined end first, through its support bearing 32A as far 32A
as it will go.
22A 379630
5 Grease oil seal 16 and fit seal cover 15 (15A) to swash

plate support 17. Secure it with socket head screws 14
tightened to a torque of 11.5 Nm (8.5 lbf ft). 5A (5)
17A
(17)
15A
(15)
14
379640
6 Assemble the piston/cylinder sub-assembly Z 9

comprising cylinder 9, piston assemblies 10, set plate
11 12
11, spherical bush 12 and cylinder springer 13. Make
sure the internal splines of the cylinder and the spherical 10
bearing are aligned.
Insert the piston/cylinder sub-assembly into pump

casing 5.
13
379650
9803/6310 Issue 1*

Assembly (cont’d)
7 Attach valve plate 23 to valve block 8, engaging the

location pin in the process. Check that the suction and 23
delivery ports of the plate are not transposed.
8 Insert splined coupling 29 into valve block 8. Fit the

valve block to pump casing 5, taking care to align the
match marks. Engage the spline on shaft 22 with the
splined coupling. Secure with the four socket head
screws 7, tightened to a torque of 130 Nm (94 lbf ft).
29
379660
9 Refit regulator 4 to pump casing 5 taking care to locate 3

the feedback pin of tilting lever 27 with the lever of the
regulator. Secure the regulator with socket head screws
2 and 3, tightened to a torque of 29.4 Nm (25.8 lbf ft). 2
379380
10 Refit gear pump assembly 6. Tighten the securing

screws to a torque of 33.3 Nm (29.2 lbf ft).
11 Refit drain plug 1.
9803/6310 Issue 1*
14
18 - 14
9803/6310
13 Regulator
15
Section E
12
42
D
41 B 36
40
F 35
34 16
32 17 5
37A 18
39 A 11
26 G
10
22 E 6
24 C
25 33A
23 10
7
8
38 3 2
9
Hydraulics
E
Hydraulic Pump/Regulator JS175W
37
3
F 29
G
28A
20 A
B 28
C
31
19
4 30A
21 30
379670
Issue 1*
18 - 14
Section E
Regulator
The working environment must be clean and the workbench

covered with a cloth or rubber sheet to prevent damage to
the components.
The item numbers called up in the following procedures

correspond with those in the exploded view opposite.
Dismantling
Before dismantling, remove dust, rust, etc. using clean

hydraulic oil.
Retain all washers, snap rings etc. for later re-use. O-rings
should be renewed.
1 If not already done, separate the regulator 1 from the

3
pump casing by removing socket head screws 2 and 3
(2 off each). Do not lose the large O-ring 4.
379380
2 Remove the four socket head screws 5 and lift off cover 5
6 complete with adjusters 7/8, adjusting screw 9, two 6
locking nuts 10, mounting nut 11 and adjusting ring 12.
Do not interfere with the settings of any of these
components as this could alter the pre-set flow settings.
379390
9803/6310 Issue 1*
Regulator (cont’d)
3 From regulator body 1, withdraw outer spring 13, inner

spring 14 and spring seat 15. Also withdraw adjusting 13
ring 16 (see Note 1), pilot spring 17 and spring seat 18. 14
15
Note 1: Use an M4 screw Z attached to the end of adjusting 16
ring 16 to facilitate its easy removal. 1
18 17
Z
379400
4 Remove socket head screws 19 and 20 and lift off pilot

cover 21. Take out set spring 22.
22
20
21
19
379410
5 Remove snap ring 23 taking care not to allow the

components behind it to spring out. Take out spring seat
24, return spring 25 and sleeve 26 (complete with snap
ring 27).
25
23
26
24
379420
9803/6310 Issue 1*
6 Remove snap ring 28 and take out fulcrum plug 29,

complete with pin 33. Remove snap ring 30 and take out 1
adjusting plug 31.
Note 2: Use an M6 screw Y attached to the ends of fulcrum

plug 29 and adjusting plug 31 to facilitate their easy removal.
33
29
28
31
30
379430
7 Remove lever 32 leaving pin 33A in position on the lever.
32
33A
8 Knock out pin 34 (4 mm dia.) using a suitable metal rod

X and a plastic hammer.
379450
9803/6310 Issue 1*
9 Withdraw feedback lever 25.
35
379460
10 Remove lever 36 from pin 37 (in the regulator body)

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

compensating rod 42.
Note 3: Piston case 40 can be removed by pressing

compensating rod 42 from the opposite side of regulator
body 1.
9803/6310 Issue 1*
Assembly
Before assembling:
a Thoroughly clean all components with clean hydraulic oil

and dry with compressed air.
b Apply clean hydraulic oil to all sliding surfaces, bearings,

etc.
c Renew any damaged components.
d Renew all O-rings and other seals.
1 Insert compensating rod 42 into hole B of regulator

body 1.
2 Locate pin 37A in lever 36 in the groove of

compensating rod 42. Locate lever 36 on pin 37 in
regulator body 1.
3 Fit spool 39 and sleeve 26 into hole A of regulator body

1. Check that the spool and the sleeve slide smoothly in
the body without binding. Check the orientation of the
spool with respect to feedback lever 35 (see right).
Spool 35
Feedback Leve
39
379470
4 Install feedback lever 35, orientating it as shown right

and aligning its pin hole with that of spool 39. Insert pin
34.
36
Lever(1)side 32
Lever(2)side
(Fulcrum plug of
adjusting plug si
35
379480
5 Insert pilot piston 38 into hole C of regulator body 1.

Check that the piston slides freely without binding.
9803/6310 Issue 1*
Assembly (cont’d)
6 Locate pin 33A in lever 32 in the groove of pilot piston

38. Position lever 32 in regulator body 1.
7 Fit fulcrum plug 29 so that integral pin 33 locates with

lever 32. Fit a new seal 28A and install snap ring 28.
29
379490
8 Insert adjusting plug 31. Fit a new seal 30A and install
snap ring 30.
Check that feedback lever 35 moves freely but does not

have excessive play.
9 Insert return spring 25 and spring seat 24 into hole A of

regulator body 1. Compress the spring and secure with
snap ring 23.
23
24
25
379500
9803/6310 Issue 1*
Assembly (cont’d)
10 Insert set spring 22 into hole A of regulator body.

1
Insert compensating piston 41 and piston case 40 into
hole B of regulator body 1.
22
Fit pilot cover 21 and secure with socket head screws
19 and 20 tightened to a torque of 11.8 Nm (10.3 lbf ft).
41
40
379510
11 Insert spring seat 18 (flat face first), pilot spring 17 and

13
adjusting ring 16 into hole E of regulator body 1.
14
15
Insert spring seat 15 (flat face first) inner spring 14 and 1
outer spring 13 into hole D of regulator body 1.
16
17
18
379520
12 Install the cover 6 assembly comprising adjusting 5

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

to a torque of 11.8 Nm (10.3 lbf/ft).
379530
9803/6310 Issue 1*
20 - 1 Control Valve 20 - 1
Introduction
The control valve is located on the mainframe to the rear of the boom mounting. Its function is to direct pressurised oil by
means of the operator’s controls to the rams and motors which supply power for the machine’s operation.
The valve is designed to perform the following functions:
a Controlling oil flow direction.
b Operating the hydraulic system smoothly, accurately and safely.
c Maintaining the hydraulic circuit pressure within specified ranges.
Integrated control valves operate a tandem circuit to provide maximum pressure when simultaneous operations are required.
Check valves are incorporated to provide load hold functions.
Identification of spool functions, as marked on the valve body, is as follows:
TR = Travel
AM = Dipper ram
OPT = Auxiliary supply to attachment (if fitted)/Dozer, Stabiliser
SW = Slew motor supply
BKT = Bucket ram
BM = Boom rams
TAB = Triple articulated boom
Technical Data
Rated flow - JS130W 123 l/min (27 gal/min)
- JS145W, JS160W 139.8 l/min (30.75 gal/min)
*
- JS175W 155.6 l/min (34.23 gal/min)
Maximum pressure for normal use 350 kgf/cm2 (4978 lbf/in2)

Oil temperature range - 20 ~ 95 °C (-4.4 ~ 203 °F)
Maximum oil temperature 100 °C (212 °F)
Pilot maximum allowable pressure 40 kgf/cm2 (569 lbf/in2)
Pilot operation pressure 2.8 ~ 24 kgf/cm2 (40 ~ 341 lbf/in2)
Spool stroke 8 mm (0.315 in)
Control method Hydraulic pilot operation
Main relief valve 2-step pressure switching type relief valve
Standard pressure setting 320 kgf/cm2 (4550 lbf/in2) @ 91 l/min (20.02 gal/min)
Maximum pressure setting 350 kgf/cm2 (4977 lbf/in2) @ 83 l/min (18.26 gal/min)
Overload relief valve Pilot operated type relief valve plus make-up valve
Standard pressure setting (boom raise, dipper, bucket) 365 kgf/cm2 (5190 lbf/in2) @ 30 l/min (6.6 gal/min)
Maximum pressure setting (boom lower) 300 kgf/cm2 (4266 lbf/in2) @ 30 l/min (6.6 gal/min)
Options/dozer/stabiliser 255 kgf/cm2 (3626 lbf/in2)
Spool Solid type
Weight 104 kg (229.3 lb)
Function Travel priority, slew priority, boom/dipper with load holding,

bucket, auxiliary
9803/6310 Issue 2*
* Precautions Before Use

Installation
Ensure that excessive force is not put on the valve by the

piping.
Tighten the installation bolts to the specified torque.
Take care when welding work is done near the valve,

excessive heat can damage the seals.
To prevent foreign matter from entering the ports, do not

remove the plugs from the ports until installation.
Running
Operate only after confirming that the hydraulic circuit and

hydraulic oil are clean.
Use the hydraulic oil specified in this manual.
Do not raise the pressure of the main relief valve or port

relief valve set pressures.
The difference between the main relief valve and port relief
valve set pressures should be more than 20 kgf/cm2 (285
lbf/in2).
Carry out warming up sufficiently before beginning actual

operations. Because of the low temperature of the oil and
valve, note the following points in particular, to prevent
seizure of the main spools due to heat shock:
1 Do not operate the main relief valve or port relief valve

continuously on a cold machine, but operate so that the
hydraulic oil in each ram can circulate, thereby warming
up each part uniformly.
2 Fine and combined operations cause heat build-up, do

not perform sudden operations at low temperatures.
9803/6310 Issue 2*
Spool Location
Key
TR = Travel
AM = Dipper ram
OPT = Auxiliary supply to attachment (if fitted)/Dozer, Stabiliser rams
SW = Slew motor supply
BKT = Bucket ram
BM = Boom rams
TAB = Triple articulated boom ram
9803/6310 Issue 1
Hydraulic Circuit Diagram
A373640
9803/6310 Issue 2*
Removal and Replacement
Removal
! WARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses or
couplings, vent the pressure trapped in the hoses in
accordance with the instructions given in this
publication.
HYD 1-5
Before working on the hydraulic system, ensure that the

engine is switched off and the starter key removed.
Disconnect all hydraulic hoses from valve ports A. Seal JS01780

exposed connections to prevent the ingress of dirt. Mark the
hoses to ensure correct re-connection.
Disconnect all pilot hoses from spool housing B. Seal ports

to prevent ingress of dirt. Mark the hoses to ensure correct
reconnection.
Remove securing screws C (3 off) and lift the valve block

from the machine.
Replacement
Replacement is the reverse of the removal procedure.
Ensure all hoses and ports are clean and free from dirt.
Torque Settings
JS01790
C 267 - 312 Nm (197 - 230 lbf ft)
9803/6310 Issue 1
9803/6310 Issue 1
Sub-assembly Location
Headings identified on sub-assembly location layout

opposite.
Item Page
1 Valve block 20 - 9
2 Spool assemblies 20 - 10
3 Centre bypass valve (4-spool section) 20 - 12
4 Centre bypass valve (3-spool section) 20 - 13
5 Foot relief valve 20 - 14
6 Load holding valve 20 - 15
7 Logic check valve 20 - 17
8 Linear travel switching valve 20 - 18
9 Main relief valve 20 - 19
10 Overload relief valve 20 - 21
11 Dipper load diverter valve 20 - 22
12 Boom (lower) stroke limit valve 20 - 23
13 Load check valve (BM, SW) 20 - 24
14 Load check valve (AM, BKT, TAB, TR) 20 - 25
15 Pilot valve 20 - 26
16 Check valve (4-spool section) 20 - 27
17 Bucket flow check valve 20 - 28
18 Diverter valve 20 - 29
19 Inner parallel check valve 20 - 30
20 ‘O’-rings -
9803/6310 Issue 1

Note:
1 Ensure all work surfaces are clean.
2 Discard and renew all seals, ‘O’-rings and back-up

rings.
3 Lubricate all new seals and ‘O’-rings on assembly,

using a suitable grease or clean hydraulic oil and
ensure seals are firmly and correctly seated.
4 During dismantling, ensure all components are clearly

identified to assist assembly.
JS01510
5 Handle components and sub-assemblies with care,
they are precision made and are easily damaged.
6 Prior to assembly, all components should be liberally

coated with hydraulic oil to ensure full movement
between moving parts.
7 Ensure screws and bolts are tightened to the correct Key

torque figures to prevent distortion of parts.
A 70 - 100 mm (2.7 - 3.9 in)
8 After dismantling, use a suitable solvent to clean all
components, dry using compressed air. B 3 - 6 mm (0.12 - 0.24 in)
9 Torque tightening values in assembly procedures are for C 30 - 40 mm (1.18 - 1.57 in)
threads lubricated with hydraulic oil.
D 22 mm (0.87 in)
11 To prevent surface damage when working on spools,
ensure they are encased in protective wooden blocks
as detailed opposite.
9803/6310 Issue 1
Valve Block
Dismantling
1 Remove socket screw 1 from 4 spool section.
2 Remove socket screws 2 and 3 from 3 spool section.
3 Carefully separate the two halves of the valve body.
Note: Ensure that ‘O’-rings and check valve assembly are

retained in the 4 spool section of the body and the check
valve and spring are retained in the 3 spool section.
4 Remove ‘O’-rings and discard.
Assembly
1 Clean surfaces of valve block sections.
2 Renew ‘O’-rings.
3 Rejoin the two halves of the valve body and insert

socket screws 1, 2 and 3. Tighten to a torque of 97 Nm
(72 lbf ft).
9803/6310 Issue 1
Spool Assemblies
Dismantling
1 Remove socket screws 1 from the valve body.
2 Remove cover 2.
3 Remove ‘O’-ring and discard.
4 Withdraw spool 3.
Note: Identify spools during removal to ensure correct

JS01000
replacement.
5 Encase spool in holder blocks 4 and clamp into a vice.
Note: See page 20 - 8 for details of holder.
6 Remove locating screw 5 holding spring guides 6.
7 Remove spring guides 6 and spring 7.
Cleaning and Inspection

JS01010
1 Clean all parts with clean oil and dry with compressed
air. Inspect all parts.
2 Ensure spool 3 moves smoothly.
3 Check spring 7 has no defects, deformation or wear.
4 Remove slight defects by lapping.
5 Renew damaged or badly worn parts.
JS01020
Assembly
Assembly is the reverse of the dismantling procedure.
Torque Settings
1 30 Nm (22 lbf ft)
5 60 Nm (44 lbf ft)
JS01030
9803/6310 Issue 1
Spool Assemblies (cont’d)
Dismantling
Dipper Spool with Check Valve
1 See Spool Assemblies, Dismantling items 1 - 7.
2 Remove sealing plug 8.
3 Remove ‘O’-ring and backing ring 9 and discard.
4 Withdraw spring 10 and check valve 11.

JS01040
Cleaning, Inspection
2 Ensure check valve 11 moves smoothly.
Assembly
Torque Setting
8 30 Nm (22 lbf ft)
9803/6310 Issue 1
Centre Bypass Valve (4 Spool Section)
Dismantling
1 Remove end cap 1.
2 Remove ‘O’-ring 2 and discard.
3 Remove piston 3.
4 Unscrew and remove sleeve 4.
5 Withdraw spool 5.
JS01050
6 Encase spool in holder and clamp into a vice.
7 Slacken and remove locknuts 6, spring seating washers

7 and spring 8.
2 Ensure spool 5 and piston 3 move smoothly.

JS01060
Assembly
Torque Settings
1 60 Nm (44 lbf ft) JS01070
4 60 Nm (44 lbf ft)
6 25 Nm (18 lbf ft)
9803/6310 Issue 1
Centre Bypass Valve (3 Spool Section)
Dismantling
1 Remove end cap 1.
3 Withdraw spool 3.

JS01080
5 and spring 6.
3 Check the spring has no defects, deformation or wear.

JS01090
Assembly
Torque Settings
1 60 Nm (44 lbf ft)
4 25 Nm (18 lbf ft)

JS01100
9803/6310 Issue 1
Foot Relief Valve
Dismantling
1 Remove relief valve sub-assembly 1.
Note: Pressure setting is critical - do not dismantle the valve

sub-assembly.
3 Remove screwed plug 3.
5 Remove socket screws 5. JS01100
6 Remove cover 6.
8 Withdraw bushing 8, sleeve 9, spring 10, spool 11,

outer sleeve 12 and spacer 13.
JS01120
3 Check spring has no defects, deformation or wear.
Assembly
Torque Settings
1 48 Nm (36 lbf ft) JS01130
3 30 Nm (22 lbf ft)
5 48 Nm (36 lbf ft)
9803/6310 Issue 1
Load Holding Valve
JS01170
JS01140
JS01150 JS01190
JS01160
JS01200
9803/6310 Issue 1
Load Holding Valve (cont’d)
Dismantling Torque Settings
1 Remove socket screws 1. 1 98 Nm (72 lbf ft)
2 Remove cover assembly 2. 6 30 Nm (22 lbf ft)
3 Remove ‘O’-ring 3 and discard. 10 49 Nm (36 lbf ft)
4 Remove spring 4. 14 58 Nm (43 lbf ft)
5 Withdraw check valve 5. 17 49 Nm (36 lbf ft)
6 Remove plug 6 and discard ‘O’-ring 7.
7 Withdraw piston 8.
8 Remove spring 9.
9 Remove plug 10.
11 Remove spring 12 and check valve 13.
12 Remove cap 14.
13 Remove ‘O’- ring 15 and discard.
15 Remove cap 17.
17 Remove spring 19.
18 Withdraw poppet valve 20.
19 Tilt and tap cover to remove sleeve 21.
Note: Ensure the sliding surface of the sleeve is protected.
Cleaning and Inspection
2 Ensure check valve 5, pistons 8 and 16 and poppet 20

move smoothly.
3 Check springs 4, 9, 12 and 19 have no defects,

deformation or wear.
Assembly
9803/6310 Issue 1
Logic Check Valve
Dismantling
1 Remove screwed cap 1.
4 Remove spring 4.
5 Insert a small puller into the transverse hole and

withdraw sleeve 5.

JS01210
7 Remove spring 7.
8 Remove check valve 8.
Note: Ensure internal surfaces of the sleeve are protected.
9 Screw a rod (having one end threaded M5 x 0.8), into

sleeve 9 and withdraw.
10 Remove spring 10.
JS01220
2 Ensure piston 3, sleeve 5, check valve 8, sleeve 9 and

check valve 11 move smoothly.
3 Check springs 4, 7 and 10 have no defects,

JS01230
Assembly
Torque Setting
1 98 Nm (72 lbf ft)
9803/6310 Issue 1
Linear Travel Switching Valve
Dismantling
1 Unscrew and remove cover 1.
2 Remove 'O’-ring 2 and discard.
3 Withdraw spool 3.
Note: See page 20 - 8 for details of holders. JS01240

5 and spring 6.

JS01250
Assembly
Torque Setting
1 98 Nm (72 lbf ft)
4 25 Nm (18 lbf ft) JS01260
9803/6310 Issue 1
Main Relief Valve
Dismantling
1 Secure adjusting screw 1 and housing 10.
2 Slacken locknut 2.
3 Secure relief valve body 4.
4 Slacken locknut 3.
5 Slacken relief valve body 4 and remove assembly from

main control valve housing. JS01270
6 Remove O’-ring 5 and discard.
7 Withdraw outer sleeve 6 from main control valve

housing.
8 Remove sleeve 7.
9 Remove spring 8.
Note: Pilot seat 9 is press fitted into the relief valve body 4.
Do not attempt to remove it.
10 Remove adjusting screw 1 with locknut 2 from housing

10.
12 Remove adjustment screw housing 10 with locknut 3

from relief valve body 4.
13 Remove spring seat 12, spring 13 and poppet 14 from JS01280

housing 10.
1 Clean all components in clean oil and dry with

compressed air.
2 Check that the seat surfaces on the end of the poppet

14 and seating 9 are defect free and contact surfaces
are uniform.
3 Check that the poppet sleeve 7 and outer sleeve 6

move smoothly and freely.
4 Check springs 8 and 13 have no defects, deformation

or wear.
5 Check that there is no foreign matter blocking orifices in

the main poppet or pilot seat.
6 Remove any minor defects by lapping.
7 Renew the relief valve if any damaged or badly worn

parts are found.
9803/6310 Issue 1
Main Relief Valve (cont’d)
Assembly
High Pressure Setting
1 Insert relief valve assembly into control valve housing

and tighten relief valve body 4.
2 Tighten down adjusting screw 1 until piston 12 seats

onto internal surface Z.
3 Adjust housing 10 until high pressure setting is correct

(see Pressure Testing). JS01290
4 Tighten locknut 3.
Low Pressure Setting
1 Slacken adjusting screw 1 and adjust until low pressure

setting is correct (see Pressure Testing).
2 Tighten locknut 2.
Torque Settings
2 58 Nm (43 lbf ft)
3 58 Nm (43 lbf ft)
4 58 Nm (43 lbf ft)
9803/6310 Issue 1
Overload Relief Valve
Dismantling
1 Slacken the valve housing 1 and remove complete from

the control valve body.
Note: Because pressure adjustment is difficult, do not

dismantle the adjusting screw 2 and poppet assembly.
3 Slacken relief valve seat 4 and remove as a sub

assembly. JS01300
5 Remove poppet housing sleeve 6, piston 7, poppet 8

and spring 9.
6 Remove ‘O’-rings and seals 10 and 11 and discard.
1 Clean all parts in clean oil and dry with compressed air.
Inspect all parts.
2 Ensure piston 7 and poppet sleeve 6 move smoothly.

JS01310
Assembly
Torque Settings
1 39 Nm (29 lbf ft)
4 58 Nm (43 lbf ft)
JS01320
9803/6310 Issue 1
Dipper Load Diverter Valve
Dismantling
1 Remove cover plug 1.
3 Remove spring seating washer 3 and spring 4.
4 Remove housing 5.
6 Withdraw spool 7. JS01330
7 Remove sleeve 8 and piston 9.
Inspect all parts.
2 Ensure spool 7, piston 9 and check valve 11 move

smoothly.
3 Check that springs 4 and 10 have no defects,

Assembly
JS01340
Torque Settings
1 58 Nm (43 lbf ft)
5 58 Nm (43 lbf ft)
9803/6310 Issue 1
Boom (Lower) Stroke Limit Valve
Dismantling
3 Remove socket screws 3 and housing 4.
Inspect all parts.
JS01350
2 Ensure piston 5 moves smoothly.
Assembly
Torque Settings
1 58.3 Nm (43 lbf ft) JS01360
3 29.8 Nm (22 lbf ft)
9803/6310 Issue 1
Load Check Valve (Boom and Slew)
Dismantling
1 Remove housing 1.
2 Remove ‘O’-ring 2, back-up ring 3 and discard.
4 Remove nylon plug 6.
Inspect all parts.
3 Check that spring 4 has no defects, deformation or

wear.
Assembly
JS01370
Note: Renew nylon plug 6.
Torque Settings
1 97.63 Nm (72 lbf ft)
JS01380
9803/6310 Issue 1
Load Check Valve (Dipper, Bucket, T.A.B.,

Travel)
Dismantling
1 Remove housing 1.
2 Remove ‘O’-ring 2 and back-up ring 3 and discard.
5 Remove nylon plug 7.
Inspect all parts.
2 Ensure check valves 4 and 6 move smoothly.

wear.
5 Renew damaged or badly worn parts. JS01390
Assembly
Note: Renew nylon plug 7.
Torque Settings
1 97.63 Nm (72 lbf ft)
JS01400
9803/6310 Issue 1
Pilot Valve
Dismantling
1 Remove housing 1.
2 Remove ‘O’-ring 2 and back-up ring 3 and discard.
Inspect all parts.
2 Ensure pilot holes are clean and free from sediment and
foreign matter.
Assembly
Torque Settings
1 97.63 Nm (72 lbf ft) JS01410
9803/6310 Issue 1
Check Valve (4 Spool Section)
Dismantling
1 Remove housing 1.
3 Withdraw check valve 3 and spring 4.
Inspect all parts.

wear.
4 Remove slight damage by lapping.
Assembly
Torque Settings
1 39.32 Nm (29 lbf ft)
JS01420
9803/6310 Issue 1
Bucket Flow Check Valve
Dismantling
3 Withdraw spring 3 and check valve 4.
Inspect all parts. JS01430

wear.
5 Ensure pilot holes in check valve 4 are clean and free

from sediment and foreign matter.
Assembly
JS01440
Torque Settings
1 97.63 Nm (72 lbf ft)
9803/6310 Issue 1
Diverter Valve
Dismantling
3 Using a steel rod X with one end threaded M5 x 0.8,

screw into sleeve 3 and withdraw from control valve
body.
2 Ensure sleeve 3 moves smoothly.
JS01450
Assembly
Torque Settings
1 29.8 Nm (22 lbf ft)
9803/6310 Issue 1
Inner Parallel Check Valve
Dismantling

wear.

JS01460
Assembly
Torque Settings
1 29.8 Nm (22 lbf ft)
9803/6310 Issue 1
21 - 1 Shuttle Valve 21 - 1
Introduction
* The shuttle valve A is incorporated into the main control

circuit to act as a pilot signal diverter valve. Pressurised
hydraulic oil, directed by the operator’s controls from the
remote control valves to the main control valve is redirected
by the shuttle valve to perform additional pilot control
functions. The valve is mounted in front of the battery
assembly.
JS07371
9803/6310 Issue 2*
General Information
Key to illustrations:
X Front
A1 Right slew
A2 Left slew
A3 Boom up
A4 Boom down
A5 Bucket open
A6 Bucket close
A7 Dipper open
A8 Dipper close
B1 Right slew
B2 Left slew
B3 Boom up
B4 Boom down
B5 Bucket close
B6 Bucket open
B7 Dipper open
B8 Dipper close
C1 Slew pressure switch
C2 Boom up
C3 Boom up, down
S1 Slew brake valve
S2 Boom lowering pressure switch
S3 Bucket open
S4 Dipper close
S5 Slew shut-off
JS01970
9803/6310 Issue 1
General Information (cont’d)
Key
Y = Steel ball
Z = Valve seats
9803/6310 Issue 1
Operation
Note: The following description is for the slew operation.
Other operations are similar. (c)
B2 B1
When right slew operation is selected by the control lever,
pressurised oil from the remote control valve enters port A1
in the shuttle block. The oil moves steel ball a to the left and
continues through port B1 to operate the right slew control
valve spool.
Pressurised oil entering port A1 passes through hole d into

chamber e and moves steel ball b to the left, allowing oil to
pass through port C1 to the slew pressure switch, and (a)
through port S1 to the slew brake valve.
Return oil from the slew spool pilot control enters port B2 A2 A1
and moves steel ball c to the right, and returns to the remote
control valve via port A2.
d
S1
(b)
C1
JS06740
B1 B2 B3
S5
S1
A1 A2 A3
C1
JS07350
9803/6310 Issue 1
22 - 1 Service Valves 22 - 1
General
A C
B D
9803/6310 Issue 1
22 - 2 Service Valves 22 - 2
General (cont’d)
6 Replace all seals and 'O' rings. Dip the cartridge in clean
Note: It is not usually necessary to remove an entire valve hydraulic oil.
from the circuit piping. The cartridges themselves are basic
service items and are usually easy to remove from their 7 Re-install the cartridge and torque tighten to the figure
mounting for cleaning or replacement. However, seals and given in the table.
'O' rings must always be discarded and replaced with new
ones. 8 When all cartridges are cleaned and re-installed,
pressure test the system.
The valves shown in the illustrations opposite are typical of
the types of valve fitted in the hydraulic system. The ! WARNING
procedures for fitting, removing and servicing the cartridges Hydraulic Fluid
are similar in each case. The torque figures for replacing the Fine jets of hydraulic fluid at high pressure can penetrate
cartridges are detailed in the table below right. the skin. Do not use your fingers to check for hydraulic
fluid leaks. Do not put your face close to suspected
Key leaks. Hold a piece of cardboard close to suspected
leaks and then inspect the cardboard for signs of
A Two cartridge valve, e.g. flow regulators and direct acting hydraulic fluid. If hydraulic fluid penetrates your skin, get
relief valves with check valves. medical help immediately.
INT-3-1-10/1
B Single cartridge valve, e.g. pressure reducing valves and

sequence valves. 9 If a cartridge does not function correctly, replace it with a
new factory tested unit.
C Cross port relief valve.
D Multi cartridge valve, e.g. dual sequence valve with relief

and check valves. Service Torque into Body
! WARNING Nm lbf ft
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before Cross Port Relief 40 - 50 30 - 37
disconnecting or connecting hydraulic hoses, stop the
engine and operate the controls to release pressure Dual Sequence with relief 60 - 65 44 - 48
trapped in the hoses. Make sure the engine cannot be Dual Sequence with relief
started while the hoses are open. and Check 45 - 50 33 - 37
INT-3-1-11/1
Direct Acting Relief with
1 Stop the engine and operate the service controls to Check 40 - 50 30 - 37
relieve system pressure.
Flow Regulator 45 - 50 33 - 37
! WARNING Flow Regulator with
Gear Change Circuit Accumulators Bypass Orifice 200 - 215 148 - 150
The gear change circuit accumulators remain charged
even when the main servo circuit has been vented. Do Pressure Reducer 45 - 50 33 - 37
NOT remove the gear change/pilot circuit sequence
valve or its components until these accumulators have Sequence Valve 45 - 50 33 - 37
been discharged as described under Gear Change Valve.
HYD 6-8
2 Remove the cartridge from the body, catching any

excess fluid in a suitable container. Plug the port and/or
hoses as necessary.
3 Inspect the cartridge for visible signs of contaminants,

carefully removing any obvious particles.
4 With the cartridge submerged in a suitable cleaning

agent, operate the inner working parts with a piece of
stiff plastic tubing. Do not use sharp objects.
5 After cleaning, blow dry with clean filtered air.
9803/6310 Issue 1
24 - 1 Gear Change Valve 24 - 1
Venting Accumulator Pressure

1 Using the controls on the right console switch panel,
reduce engine speed by adjusting the rotary throttle
control to its slowest setting. Stop the engine by
pressing the red Engine Shutdown push-button.
2 Use the excavator hand controls to vent the main servo

circuit.
3 Switch off the ignition and remove the starter key.
4 Carefully remove the hose from port B on the

transmission control valve and in its place install a small
bore hose (JCB Part No. 892/00137). Put the free end
of the small bore hose into a suitable receptacle.
5 Insert the starter key. Switch the ignition ON but do not

start the engine.
6 Using the relevant controls, operate the gear change

and park brake circuits repeatedly until oil ceases to
flow into the receptacle. When oil ceases to flow, the
accumulators are fully discharged.
9803/6310 Issue 1
25 - 1 Axle Lock Valve 25 - 1
JS10960
9803/6310 Issue 2*
25 - 2 Axle Lock Valve 25 - 2
* The valve consists of housing 1 and two cartridges 4 with

three seals 3 per cartridge. The cartridge’s are operated by
solenoids 2 which are held in place by locknut 5.
* Dismantling and Assembly

Servicing of this valve consists of cleaning the components
in a suitable solvent and replacing the seals 3. New seals
must always be used whenever a cartridge is removed.
9803/6310 Issue 2*
26 - 1 Remote Control Valve (Services) 26 - 1
Introduction
This section deals with the Remote Control Valve which provides pilot pressure for the hydraulic control valve and electrical
switching to flow-control solenoids.
The remote control valve is a pressure reduction valve used to control the pilot pressure operated system. Four pressure
reduction valves used to control the pilot pressure are located in the main housing. Direction of the output pilot pressure is
controlled by selective movement of the control lever. The valves and control levers are mounted in the arm rests on both sides
of the operator’s seat.
Specification
Control operation angles Single handle ± 19°
Weight Single handle 2.8 kg
9803/6310 Issue 1
1 T P
E A
F GB C
P
6,7
H D 1 2 3 4
JS06780 JS03240
21
Key
26
RH Control
A Power Boost
*B Grab Rotate (anti-clockwise) 18
*C Grab Rotate (clockwise)
D Idle 8
19
LH Control
* E Hammer Select 9
* F Dozer Select
* G Dozer De-select 10
H Horn
2 11
12
20
3
23
13
4
5
14
22 1
15
24
16
25 7
17
6
JS07970
Item Description Qty. Item Description Qty. Item Description Qty.
1 Lower body 1 10 Seal 4 19 Gaiter 1

2 Upper body 1 11 Plunger 4 20 Roll pin 1
3 ‘O’-ring 1 12 Split washer 4 21 Control handle 1
4 ‘O’-ring 1 13 Spring seat 4 22 Locknut 1
5 Dowel pin 2 14 Compression spring 4 23 Mounting knuckle 1
6 Body assembly screw 1 15 Return spring 4 24 Joint nut 1
7 ‘O’-ring 1 16 Shims - 25 Rocker plate 1
8 Plunger guide 4 17 Spool 4 26 Knuckle joint 1
9 Seal 4 18 Retaining plate 1
9803/6310 Issue 2*
Operation
The assembly of the pilot pressure control valve is shown on

facing page.
The pressure reduction unit is comprised of spools 17,

pressure control springs 14, return springs 15, spring seats
13 and split washers 12. The spools 17 are held against the
plungers 11 by the return springs 15. When the control
handle is tilted, the plungers 11 move down, depressing the
return spring seats 13, simultaneously compressing the
pressure control springs 14, moving the spool, allowing
hydraulic oil to flow to the designated pilot port.
The lower end of the main body 1 contains the main inlet
port P, outlet port T to tank and the pilot pressure outlet
ports 1, 2, 3 and 4.
The pilot pressure controls the stroke and direction of the

main control valve spools. This is achieved by providing a
spring at one end of the main control valve spools and
applying pilot pressure to the opposite end. (In some cases,
pilot pressure is applied to both ends of the control valve
spool.)
Function
Oil supplied by the hydraulic pilot pump enters at port P and

the function of the spools 17 is to direct oil from the inlet
port P to the output ports 1, 2, 3 and 4 or alternatively, to the
exhaust port T to tank. The pressure control springs 14 act
on the spools 17 to determine pressure at each port.
Plungers 11 slide in the guides 8 to vary the compression in
the springs 14. The control handle, fixed to the adjusting nut
24 and circular rocker plate 25 is operated to move the
plungers 11. The control handle is able to rotate 360° around
the knuckle joint 26.
The return springs 15 operate between the casing 1 and the

seats 13, regardless of the outlet pilot pressure, returning the
plungers 11 to their outer positions, ensuring the spools 17
return to their neutral (closed) positions. The springs 15 also
provide a resistive force, giving the operator a ‘tactile feel’ of
the controls.
The control handles contain electrical push button and

rocker switches which are used to operate auxiliary services
(see facing page).
9803/6310 Issue 1

Notes:
1 All parts are precision made and require the utmost

care when being handled.
2 During dismantling, do not use excessive force to

separate components which could cause scratches or
burrs on bearing surfaces. Failure to observe this
instruction will cause oil leaks leading to poor
performance.
3 Label all parts during dismantling, to ensure correct

assembly.
4 Storing the valve when dismantled could cause rusting

of parts. Ensure they are suitably protected by anti-rust
treatment.
5 During assembly, ensure all parts are clean and free

from burrs and scratches. Remove minor damage by
lapping.
6 Renew all ‘O’-rings, seals and back-up rings. Take care

to install seals the correct way around.
7 During assembly apply hydraulic oil to ‘O’-rings and

seals.
8 Ensure all screws and bolts are tightened to the torque

settings given.
Dismantling
Details of the service tools used in the dismantling and

assembly procedures are given in Service Tools, Section 1.
Note: For part number identification for the main valve

assembly, see illustration in Remote Control Valve
(Services).
1 Push down upper section of gaiter 19 and remove roll

pin 20.
2 Remove control handle from mounting knuckle 23.
Note: Take care when removing handle to avoid damage to

wiring loom and switches. These should be removed by
separating the line connectors in the control handle and
below the valve body.
3 Remove gaiter 19 from valve housing.
4 Slacken locknut 22 and remove mounting knuckle 23.
5 Slacken and remove joint nut 24 and rocker plate 25.
6 Using a jig, slacken and unscrew knuckle joint 26,

releasing retaining plate 18.
Note: Ensure retaining plate moves freely to prevent sudden

release due to spring pressure beneath.
9803/6310 Issue 1
7 Remove mounting screws (4 off) and lift out control

valve.
8 Clean the valve exterior using approved solvent and

using soft metal pads for protection, clamp the valve
body into a vice.
9 If the return springs 15 are weak, the sliding resistance

of the seal 9 will cause the guides 8 to stick in the
casing. Using a screw driver, carefully ease out the
guides 8 and plungers 11.
Note: Care must be taken to prevent damage to the guides

when removing. Ensure the guides do not fly out due to the
force of the return springs.
10 Remove spring seats 13, split washers 12, return

springs 15, pressure control springs 14 and spools 17.
Note: Identify each set of parts and their locations for

assembly.
11 Slacken and remove body assembly screw 6. Remove

and discard ‘O’-ring 7.
12 Separate upper and lower body sections 1 and 2 and

remove dowel pins 5.
13 Remove and discard ‘O’-rings 3 and 4.
14 Hold spools 17 firmly on the work bench and depress

spring seat 13 and remove split washers 12.
Note: Avoid scratching the surface of the spools. Do not

depress the spring seats more than 6 mm (0.24 in).
15 Separate spools 17, spring seats 13, springs 14 and 15

and shims 16.
16 Remove plungers 11 from guides 8.
17 Remove seals 9 and 10 from guide 8 and discard.
Note: Leave all parts to soak in suitable solvent until dirt is

loosened. Using clean solvent wash all parts and allow to air
dry. Apply rust inhibitor to all parts.
9803/6310 Issue 1
Assembly
The numerical sequence given previously is a guide to

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

using the jig, screw knuckle joint into position. Torque
tighten to 30 Nm (3 kgf m, 22 lbf ft).
2 Locate rocker plate 25 and torque tighten to 30 Nm (3

kgf m, 22 lbf ft), until it makes contact with the plungers
11. Ensure the plungers are not depressed at this stage. 24
3 Holding the rocker plate 25 in its position, screw down

joint nut 24. Torque tighten to 30 Nm (3 kgf m, 22 lbf ft). 25
4 When fitting the body assembly screw 6 torque tighten

to 40 Nm (4 kgf m, 29.5 lbf ft).
5 Ensure the switch cable is free from obstruction and the 26

line connectors are securely fastened.
18
6,7
JS03250
9803/6310 Issue 1
Fault finding
Symptom Possible cause Remedy
1 Low secondary pressure. a Primary pressure is low. Apply the correct primary pressure.
b Spring 14 is damaged. Renew the spring.
c Clearance between the spool Renew the remote control valve

and seating is too large. assembly.
d The handle unit is loose. Dismantle, reassemble or renew the

handle unit.
2 Unstable secondary pressure. a Sliding parts are sticking. Release the sticking part.
b Fluctuations in the tank line Check return line and filter for
pressure. blockage.
c Air is trapped in the piping. Operate the valve several times to

remove the air.
3 High secondary pressure. a The tank line pressure is too Check retur n line and filter for
high. blockage.
b Sliding parts are sticking. Release the sticking part.
9803/6310 Issue 1
Maintenance Specification
Maintenance Item Standard Note
Leakage Amount Replace if the leakage exceeds 1.0 Condition:

litre/min (0.22 gal/min) with the handle in Primary pressure 29 bar
the neutral position or 2.0 litre/min (0.44 (30 kgf/cm2 426.5 lbf/in2).
gal/min) during operation. Oil viscosity 23 cSt.
Spool Replace when the sliding contact faces The conditions are approximately
are worn more than 0.01 mm (0.0004 in) or the same as for the leakage
more than the non-sliding contact faces. above.
Plunger Replace if the

tip is wor n
more than 1
mm (0.039 in).
JS02060
Loose movement in the Replace the parts if the wear in the pin
operating controls. and joint lead to loose movement of more
than 2 mm (0.079 in).
Investigate if abnormal noises, jerky

Actuation stability. operation or drops in primary pressure are
experienced during operation. Replace the
valve if the problem cannot be solved.
Note: Ensure that ‘O’-rings and other seals are renewed during reassembly. If the body assembly screw 6 is loosened, always
replace the ‘O’-ring 7.
9803/6310 Issue 1
27 - 1 Cushion Valves 27 - 1
* Cushion Valve Schematic - Early JS Machines
Key
1 Dipper Control Valve
2 Boom Control Valve
3 Hydraulic Oil Tank
4 Line Filter
5 Cushion Valve
6 Cushion Valve Solenoid Valve
7 Cushion Switch
8 Dipper Remote Control Valve
9 Boom Remote Control Valve
10 Pilot Gear Pump
JS02010
9803/6310 Issue 2*
Operation
* Cushion Valve - Early JS Machines
Whenever the machine ignition is first switched on, the
dipper and boom circuits default to the cushioned mode i.e.
solenoid valve 6 is de-energised.
The following descriptions deal only with the ‘dipper in’

function, but the ‘dipper out’, ‘boom in’ and ‘boom out’
circuits operate in exactly the same way.
1 Cushioned Mode - Remote Control Lever in Neutral
When the remote control lever is in neutral the hot oil

taken from the oil cooler line enters port R of cushion
valve 5 and flows through the centre of spool Y to
oilways e and f.
From oilways e and f, oil flows via the outer surface of

the cushion spools and returns to the hydraulic oil tank
via port T.
JS02020
9803/6310 Issue 2*
2 Cushioned Mode - Remote Control Lever to ‘Dipper

In’
a Pilot pressure enters port A of cushion valve 5 from

dipper remote control valve 8. The left hand cushion
spool Z and spool Y both move to the right.
b The pilot pressure to the cushion spool enters

oilway g through the centre of the spool. It passes
spool Y outer surface and enters the dipper control
valve via port C.
c The pilot return oil from the dipper control valve

enters oilway f via port D and the outer surface of
spool Y. From oilway f it passes the cushion spool
outer surface and returns to the hydraulic oil tank
port T.
d Oilways e and f are shut off by the movement to the

right of spool Y. This causes hot oil to flow from
port R through oilway h to orifice c. Thence it flows
via port B to the dipper control valve which warms
up.
JS02030
9803/6310 Issue 2*
3 Cushioned Mode - Remote Control Lever Moved
From ‘Dipper In’ to ‘Neutral’
a When dipper control lever 8 is set to neutral there is

no pilot pressure from the dipper remote control
valve. Spool Y returns to neutral.
b Left hand cushion spool Z also returns to neutral,

allowing pilot oil returning from the control valve via
port C to pass through orifice b. The cushion spool
moves further to the left side due to the pressure
differential across orifice b so that the pilot return oil
flows through and is restricted by orifice a.
c Due to this restrictive effect, the spool of dipper

control valve 1 only slowly returns to the neutral
(stop) position.
JS02040
9803/6310 Issue 2*
4 Non-Cushioned Mode
When cushion switch 7 is switched ON, solenoid valve

6 is energised and pilot pressure 39.2 bar (40 kgf/cm2)
is fed to port S of cushion valve 5.
The two cushion spools Z are forced into the centre by

pilot pressure so that the unrestricted oilways of the
cushion valve spools are open to the pilot outputs from
dipper remote control valve 8.
The hot oil from port R returns to the hydraulic oil tank
via port T when dipper remote control lever 8 is at
neutral.
When the dipper remote control is operated, pilot

pressure from the lever to port A is fed via the left hand
cushion valve and port C directly to dipper control valve
1. At the conclusion of lever operation the returning
pilot oil goes straight back to the lever, i.e. there is no
cushioning.
JS02050
9803/6310 Issue 2*
Cushion Valves for later JS machines
F B
H D
R
G C
S
E1 A1
HG E1 D C A1
E A
S
T
F E B A
377970
9803/6310 Issue 1*
Cushion Valves for later JS machines 4. Cushion Control off (Fig 4)
Information When the cushion switch is illuminated, the cushion solenoid

is energised and pilot pressure is fed to port S on the
There has been a changeover to a new cushion valve. The cushion valve. The two inner left and right cushion spools
operation has also changed, compared to that of the original are both pushed into the centre of the outer spool, so that
valve fitted to the early JS range. the unrestricted galleries X and the cushion valve spools are
The new valve has internal porting for the HBCV facility and open to allow the pilot outputs from the hand controller to
does not require T adapters on two hoses. pass through the valve unrestricted, to the main control
valve. When the dipper hand controller is operated, pilot
Operation pressure from the lever to port A, moves the outer spool to
The machine defaults to cushioned mode on start up. The the right and pilot pressure is fed to the dipper spool in the
following describes only the “Dipper in” function but, Dipper control valve, via port C. At the conclusion of the hand
out, Boom in and Boom out circuits all operate in the same controller operation, the returning pilot oil, goes straight
way. back to the lever, with no restriction. There is no cushioning
effect. Hot oil from port R returns to tank via the dipper hand
1. Cushioned Mode - Hand controller in neutral (Fig 1) controller, as it does in the warming circuit in the neutral
When the Hand control is in Neutral, hot oil is taken from the position.
pressurised oil cooler line, entering port R of the cushion
valve, through the outer spool and around the inner spool,
via the galleries E and F, around the middle of the outer, via
galleries G and H, returning to the tank via port T.
2. Cushioned Mode - Hand controller at Dipper in (Fig 2)
Pilot pressure enters port A of cushion valve from the left
hand controller. The left-hand inner and outer spools move
over to the right. Oil passes from A to C via gallery I and
flows on to the dipper spool in the main control valve.
Returning oil from the main control valve enters port D and
passes through gallery J to tank via port T. The movement
to the right, of the left hand inner and outer spool cuts off
galleries E, G and H. This allows hot oil from port R, to pass
through gallery F, through the central orifice Z, via port B to
the dipper hand controller, which then warms up.
3. Cushioned Mode - Hand controller moved from dipper
in to neutral (Fig 3)
When the hand controller is released, the left hand inner and
the outer spools move over to the left, back into the neutral
position. Pilot return oil from the control valve enters via port
C, then passes through the restricted orifice Z through the
centre of the inner spool. Due to this restrictive effect, the
dipper control spool in the main control valve returns slower
than normal to the neutral/stop position.
Anticavitation
Anticavitation oil is supplied from the T port on the hand
controller, through port B, through the centre of the right
hand spool and gallery K, via port D to the main control
valve.
9803/6310 Issue 1*

1. Cushion valve - No Pressure applied
2. Cushion valve -Pressure applied to A port (A to C and D to T)
9803/6310 Issue 1*

3. Cushion valve - Pressure applied to S port (Piloted Open)
4. Cushion valve - No Pressure applied
9803/6310 Issue 1*
28 - 1 Slew Brake Valve 28 - 1
Introduction
The valve is used to control the application and release of the slew brake at either 50% or 100% pressure. The valve is
operated by pilot pressure selected by the operator’s control lever.
Specification
JS130W (CAPS II)
Working pressure 40 kgf/cm2 (569 lbf/in2)

Rated flow 16 l/min (3.52 gal/min)
+0
Pressure reducing valve setting 12.5 -1 kgf/cm2 (177.7 +- 14.2
0
lbf/in2)
Oil temperature range 20 °C ~ +95 °C (-4.4 °F ~ +203 °F)
Weight TBA
Voltage 24 V DC
Power rating 12 W
JS160W (CAPS II)
Working pressure 40 kgf/cm2 (569 lbf/in2)

Rated flow 5 l/min (1.1 gal/min)
Pressure reducing valve setting 16 kgf/cm2 (228 lbf/in2)
Oil temperature range 20 °C ~ + 95 °C (-4.4 °F ~+ 203 °F)
Weight 4.3 kg (9.5 lb)
Voltage 24 V DC
Power rating 14.5 W
9803/6310 Issue 2*
Technical Data - JS130W (CAPS II)
Key
6 Solenoid control valve (slew lock)

7 Solenoid control valve (slew brake)
8 Pressure reducing valve
Key
1 Waterproof, 2-pin electrical contact housing

2 Power source (pink)
3 Ground (grey)
4 Low voltage cable 0.85 mm (.00132 in2)
5 Mounting holes, 2 - M10 x 1.5, 15 (0.591 in) deep
6 Solenoid control valve slew lock
7 Solenoid control valve slew brake
JS02080
9803/6310 Issue 2*
Technical Data - JS160W (CAPS II)

Key
6 Solenoid control valve (slew lock)

7 Solenoid control valve (slew brake)
Key
1 Waterproof, 2 pin electrical contact housing

2 Power source
3 Ground
4 Protective tube (yellow)
5 Protective tube (black)
9803/6310 Issue 2*
Operation - JS130W (CAPS II)

Slew Brake Release
Pilot pressure at 40 kgf/cm2 (569 lbf/in2), selected by the

operator’s control lever, enters port P, passes over the outer
surface of solenoid spool 1 and enters passageway a. The
oil then passes over the lower end of the pressure reducing
valve spool 2 and enters chamber b, which is connected to
passageway C. As oil enters passageway C, the steel ball 3
is lifted and allows oil to pass over the outer surface of
solenoid spool 4 to outlet port B. Pilot pressure at 40
kgf/cm2 (569 lbf/in2) leaving port B enters the brake port of
the slew motor and releases the brake.
JS02100
9803/6310 Issue 2*
Operation - JS130W (CAPS II) (cont’d)

Slew Brake (50% Application)
Five seconds after the control lever has been returned to

neutral, an electric signal from the controller operates
solenoid valve 7 and spool 1 moves down.
Oil in the pressure reducing valve spring chamber d is

connected to tank passageway T.
Pilot pressure entering port P flows to passageway a and

chamber b and tries to lift the reducing valve spool 2. Oil in
chamber b is throttled into passageway e and spring
chamber d and continues to tank.
Simultaneously, part of the flow from chamber b flows

through passageway c to the solenoid control valve 6,
through port B and to the brake port of the slew motor. Oil at
the spring release pressure of the reducing valve 8 enters
the brake area of the slew motor and 50% brake force is
applied.
JS02110
9803/6310 Issue 2*
Operation - JS130W (CAPS II) (cont’d)

Slew Brake (100% Application)
When the solenoid valve 6 for slew lock is energised, the

spool 1 moves down, stopping oil from passageway C.
Return oil from the slew motor enters port B and flows
through spool passage 2 to tank port T. Simultaneously,
brake release pressure oil enters port B and flows to tank T,
allowing 100% brake force to be applied.
JS02120
9803/6310 Issue 2*
Slew Brake Valve - All Later Wheeled Machines
T A
B
1 3 5
C
A Swing Brake Spool
B Pressure Reducing Valve

2 4
C Swing Lock Spool
All Ports 1/4in.BSPP

Max. Flow 16 l/min.
Max Pressure 40 bar
Voltage 24 V
Operation - All wheeled machines it is dead-ended, but is still available at reducing spool
50% Brake. Ignition On. Engine On. end on the right hand side. As the same pressure is being
1 Oil enters at port P. It is available to swing brake spool felt at both ends of the spool, the spool does not move.
where it is dead-ended. It is also available at the Oil is still available across the reducing spool and up to
pressure reducing valve spool, which it can cross. the slew motor.
After crossing this spool, oil is available to the spool Swing Released. Ignition On Engine On.
end and also via the shuttle valve to the swing lock 4 After 5 seconds, the brake solenoid is energised and
spool, which it can also cross. On crossing the lock moves to the left. Oil from P is dead-ended at the brake
spool, the oil is available to partially lift the swing spool. Oil is still available at and across the reducing
brake in the slew motor (50% Brake). spool. It is also available on the left-hand side of the
2 Once the pressure acting on the reducing spool end reducing spool. Oil is vented to tank from the right hand
overcomes 15 bar (the pressure that the spool is set side of the reducing spool, across the brake spool. Oil
at), the spool will move to the right, cutting off oil from from P is still available to swing brake to give 50 %
P and at the same time oil from the slew motor brake brake.
to tank. As the pressure acting against the spring on Swing Brake. Ignition On. Engine On.
the spool drops off, the spring effect on the spool,
moves the spool over to the left and allows the flow 5 With the slew brake button not selected, the slew brake
from P to cross the spool, where it is available to the is at 50%. When the slew brake button is pressed, the
spool end again and the slew motor. This shuttle effect swing lock solenoid is energised. The oil supply from P is
is ongoing whilst the machine is running. cut off and so does not reach the slew brake. Oil from the
slew brake is then vented to tank, through the lock
Swing Engaged. Ignition On. Engine On. solenoid. This gives 100% brake effect.
3 The same situation as above but, swing brake
solenoid is selected from a controller signal. Activated
by the swing pressure switch. Oil enters at P, is
available through the reducing spool, also available at
the reducing spool end. The oil also passes over the
swing brake spool and up to the reducing spool where
9803/6310 Issue 1*
29 - 1 Steering Control Unit 29 - 1
B C
D D
9803/6310 Issue 1
Dismantling and Assembly (cont'd)

Note: The valves listed below are non-serviceable. Should
they be suspected of malfunction or damage the complete 11 Remove set screw 22. This will enable the check valve
steering control unit should be changed. (23, 24 and 25) to be removed. Discard 'O' rings 26 and
27.
1 Inlet Check Valve A
12 Clean all parts in a suitable solvent and blow dry.
Prevents oil from returning through the steering unit Examine all parts for wear and/or damage. Replace as
when pressure on the cylinder side is greater than the necessary.
pressure on the inlet side, thus eliminating steering
wheel kick. Assembly
2 Inlet Load Sensing Relief Valve B Assembly is a reversal of the dismantling procedure. Use
new seals, 'O' rings and retaining rings.
Limits maximum pressure to the steering unit, protecting
the steering circuit. After assembling the steering control unit (SCU), deflect the
input shaft approximately 10° and then release it. The shaft
3 Cylinder Port Shock Valves C (Right and Left) should recentre without hesitation. Repeat this procedure in
the opposite direction. Rotate the SCU in both directions to
Protects hoses against pressure surge created by ensure freedom of movement and proper action.
ground forces on the steered axle.
If the centring springs 15 are to be changed they must be
4 Anti Cavitation Valves for Cylinder Ports D (Right and changed as a set (see Spring Installation).
Left)
Protects steering circuit against vacuum (cavitation)

conditions.
Dismantling
Before commencing dismantling, separate the steering unit

and the steering priority valve (see Steering Priority Valve,
Removal and Replacement).
The numerical sequence shown is a guide to dismantling.
1 Hold the Steering Control Unit (SCU) in a suitable jig or

soft jawed vice.
2 Remove the capscrews 1 (7 off) and their washers 2.
3 Remove cast end cap 3 and spacer 4.
4 Remove and discard 'O ' ring 5.
5 Remove the geroter 6 and drive shaft 7 together with

spacer plate 8, remove and discard 'O' rings 9 and 10.
6 Remove the control sleeve 11/control spool 12 assembly

from the housing 13. Drive out centring pin 14. Pull
control spool 12 up and out of control sleeve 11, taking
care to restrain the centring springs 15.
7 Remove the centring springs 15 from control spool 12.
8 Remove and discard seal 16. Remove retaining ring 17.

Carefully remove and discard seal gland bushing 18.
9 Remove 'O' ring 19 and seal 20, discard.
10 Do not remove bearing 21 unless it is damaged.
9803/6310 Issue 1
Dismantling and Assembly (cont'd)

Assembly (cont'd)
Spring Installation
A
The arrangement of the centring springs is as shown in Fig a
A. c
d
Align the spring slots of sleeve 11 and spool 12 as shown in f
Fig. B, and then proceed as follows, referring to Fig. A for e
identification of individual springs. Make sure that the b
extended edges X of the springs are downwards.
1 Insert spring a in spring slot of spool 12. (Raise spool

slightly from sleeve 11 for more spring clearance).
2 Insert spring b. Make sure the bowed centre sections of

X
both springs are together.
JS07980
3 Push springs c and d between the two springs a and b.
Push springs e and f between springs b and d.
4 Push spool 12 into sleeve 11 until the springs seat flush

with the top and sides of the sleeve.
B
B 12
11
A234470
9803/6310 Issue 1
30 - 1 Steering Priority Valve 30 - 1

1 Remove the two socket head screws A.
2 Separate steering priority valve B from steering control

unit C, noting their relative positions.
3 Check O-rings D and E and renew if damaged.
4 Replacement is the reverse of removal.

The numerical sequence on the illustration is a guide to
dismantling.
Clean all parts in a suitable solvent and blow dry with clean
filtered air.
Assembly is the reverse of dismantling.
When Assembling
Renew O-rings 2 and 6, lightly smearing with clean hydraulic

oil before fitting.
A
Torque Settings
Item Nm kgf m lbf ft

A 56 - 64 5.7 - 6.5 41 - 47
1 33.9 - 54.2 3.5 - 5.5 25 - 40
5 33.9 - 54.2 3.5 - 5.5 25 - 40
B 5
6
4 D D
3
E C
D
2
JS07600
9803/6310 Issue 1
31 - 1 Rotary Coupling 31 - 1
JS06770
9803/6310 Issue 1
Removal and Replacement (cont’d)

Removal
1 Position the machine on level ground. Extend the

dipper fully and then lower the boom fully. Switch off
the engine and remove the starter key.
2 Release hydraulic tank pressure (see Releasing Tank

Pressure, Hydraulics, in Routine Maintenance,
Section 3).
3 Drain the hydraulic tank by means of the drain plug (see

Draining Tank Impurities, Hydraulics in Routine
Maintenance, Section 3).
4 Taking steps to contain any oil spillage, disconnect the

hydraulic hoses from both the top and bottom of the
coupling. Make a note of where the hoses fit as an aid
to re-assembly. Plug the ports of the coupling and cap
the ends of the hoses.
To facilitate the following procedures, tie the hoses

back, clear of the rotary coupling.
5 Remove the two screws 1 and washers 2. Lift locating

bracket 3 clear of its mounting on the superstructure.
* Note: The locking bracket has been re-located on later

machines.
6 Remove the three screws 4, and spring washers 5

which secure the rotary coupling to the chassis.
7 As an aid to re-assembly, note the orientation of the

rotary coupling assembly relative to bracket 3.
Using suitable lifting gear, lift the rotary coupling

assembly clear of the machine.
Replacement
Coat the threads of screws 1 with JCB Threadlocker and

Sealer.
Replacement is the reverse of removal.
Refill the hydraulic tank (see Topping-Up Fluid Level,

Hydraulics, in Routine Maintenance, Section 3).
Torque Settings

1 137 14 101
4 260-280 26 - 28 192-206
9803/6310 Issue 2*
C
B
A A
14
16
4,5
6
Z Z
JS06390
9803/6310 Issue 1
Dismantling and Assembly (con t’d)

Dismantling and assembly should only be carried out in a Assembly
clean environment. Before starting, the outer casings should
be thoroughly cleaned to remove all traces of dirt and oil. Assembly is the reverse of dismantling. Note the following
points:
Once dismantled, all seals should be discarded.
1 Smear 13 (including extension tube 14) and 16 with
Dismantling
JCB Special MPL Grease.
The numerical sequence on the illustration is a guide to
dismantling. Note the following points: 2 After mating the two halves of the rotary coupling
assembly, check that location pin 7 is fitted to 6. Then
1 Position the rotary coupling assembly in a vertical locate 6 with extension tube 14, taking care that the
attitude, supported on flange A, with access to the bottom of tube 14 and the bottom of 6 are flush Z.
hose couplings at the lower end.
To secure 6 to 14 and to seal the ports, fit new seals to
2 When removing all adapters 4 and 5, make a note of 4 and 5, refit them to their original positions and tighten
where each one fits. Discard the flange seals. firmly.
3 When removing item 6 do not lose pin 7 which locates
it with extension tube 14. Torque Settings
4 Replace screws 9 with M8 eye bolts. To separate the
Item Nm lbf ft
two halves of the coupling, attach suitable lifting gear to
1 38-43 28-32
the eye bolts. Raise upper coupling 10 to withdraw
8, 9, 18 20-25 15-18
extension tube 14 from the centre bore of lower
coupling 11. It may be necessary to hold down coupling
11 when lifting coupling 10.
Port Services
Place upper coupling 10 on the bench. Remove the eye
bolts and cover 12. Items 16 (Distributor A bottom) and 17 (Distributor A top).
5 Use gentle pressure on 13 to force it downwards out of

15. Port No. Service
6 Use gentle pressure on 16 to force it downwards out of 0 Tank Return

17. 1 Drive - reverse
2 Dozer - up
Cleaning
3 Drive - forward
1 Remove and discard all the rubber sealing rings and the 4 Dozer - down
plastic back-up rings from inside the bores of 15 and 17. 5 Steer - right
6 Steer - left
2 Thoroughly clean 13 and 16 and the bores of 15 and 17,
taking particular care with the sealing ring grooves.
Replacing the Oil Seals Items 6 (Distributor B bottom) and 15 (Distributor B top).
Obtain the relevant sealing kits and proceed as follows:

Port No. Service
1 a Smear the rubber sealing rings with JCB Special
MPL Grease, in readiness for insertion into 15 and 1 Dozer/stabiliser select
17. 2 1st gear select
3 2nd gear select
b To fit a rubber ring B, squeeze as shown X and
4 Brake - front
insert into the groove before releasing Y. Check that
5 Brake - rear
the sealing ring is sitting evenly in its groove.
6 Axle lock
c Repeat step b with the plastic back-up rings C. * 7 Dozer/Stabiliser select
8 Dozer/Stabiliser select
d Finally, make sure there are no kinks in any of the
sealing rings or back-up rings.
2 Remove nuts 18 and take off cover 19. Replace seals

20.
3 Lubricate and renew all other seals during assembly.
9803/6310 Issue 2*
33 - 1 *Drive Motor - JS130W/160W 33 - 1
Removal and Replacement and Dismantling and Assembly
31
29
28 25 26
33 30
29
27
23 15
16
22
38
24
32
14
13 33
7
6
9
5 8
12
10 11
36
35
34
4
3
2
1
37
JS07380
9803/6310 Issue 2*
33 - 2 *Drive Motor - JS130W/160W 33 - 2
Removal and Replacement and

The permitted level of servicing is limited to the replacement
of the seals, O-rings and gaskets. These comprise the Assembly
individual items shown collectively on the illustration as seal
kit 38. Assembly is the reverse of dismantling.
The unit must be removed from the machine for servicing.
Removal
1 Switch off the engine and operate the drive controls to

relieve system pressure.
2 Taking steps to catch any oil spillage, disconnect the

hoses to the drive motor. Identify the hoses with their
ports to assist in replacement. Cap the hose ends and
plug the motor ports.
3 Remove the four bolts securing the drive motor to the

drive gearbox and lift clear.
Note: The drive motor is heavy. Using suitable lifting tackle,

make sure it is supported when the bolts are removed.
! WARNING
Lifting Equipment
You can be injured if you use faulty lifting equipment.
Make sure that lifting equipment is in good condition.
Make sure that lifting tackle complies with all local
regulations and is suitable for the job. Make sure that
lifting equipment is strong enough for the job.
INT-1-3-7
Replacement
Replacement is the reverse of removal.
Dismantling
Each individual seal, O-ring or gasket can be accessed by

following the specific numerical sequence which includes it.
The numerical sequences itemised below can be carried out
individually and independently of one another:
1 - 4; 5 - 9; 10 - 12; 13 - 14; 15 - 16; 22 - 31; 32 - 34;
35 - 37.
Note: To prevent the pistons and associated parts becoming

displaced, during the relevant sequences proceed as
follows:
a When carrying out sequence 32 - 34, position the unit as

shown in the illustration, i.e. with cover 33 uppermost.
b When carrying out sequence 35 - 37, position the unit at

180° to the position shown in the illustration, i.e. with
cover 36 uppermost.
9803/6310 Issue 2*
34 - 1 Drive Motor - JS145W/JS175W 34 - 1
Drive Motor - JS145W/JS175W
9 10
11 12
1 2 3 4 13
14 15
6
5
Key
1 Gauge port X4 Servo supply pressure
2 Gauge port X1 Servo piston pressure (max. displacement side)
3 Construction plug X2
4 Gauge port X2 Servo piston pressure (min. displacement side)
5 Pressure port (A)
6 Pressure port (B)
7 Make up port (S)
8 Safety valve (port B)
9 Plug X2
10 Plug X1
11 Drain port
12 Safety valve
13 Plug X2
14 Threshold pressure (57 bar)
15 Gauge port X5 pilot pressure
9803/6310 Issue 1
34 - 2 Drive Motor - JS145W/JS175W 34 - 2
Drive Motor Circuit schematic (JS 145W/JS175W)
X5
X4
E
BRAKE
SPOOL
A
MIN
SPEED
CV2
MAX CV1
THRESHOLD
SPEED SPOOL B
X2 X1
Operation
Under normal non-inclined road conditions, oil enters at When the machine travels down hill, the motor operation acts
ports A and B (depending on the drive direction). At port A, as a pump, the oil supply is insufficient to prevent cavitation
oil pressure moves the shuttle and oil flows at system within the motor. Negative pressure can lift the check valve
pressure to act on the threshold piston. The oil is allowed to and allow oil from tank to make up and prevent cavitation.
pass through the motor and back to tank The restrictions within the brake spool give the motor its
braking effect by slowing the oil as it returns to tank.
Oil is available to the brake spool section. The flow is dead-
ended at a check valve, but is available at the spool end, Ports on Motor Body.
where it selects a spool. Oil passes through the other check
X1 Gauge Port. Servo Piston Pressure (Max displacement
valve, where it is dead-ended by the selected spool.
side)
When the machine encounters an incline however, the
X2 Gauge Port. Servo piston Pressure (Min displacement
operation changes. Oil still flows through the motor but, as
side)
the pressure starts to build up from the effect of the incline,
this pressure starts to be felt at CV1 which allows oil to pass, X4 Gauge Port. Servo supply Pressure (Before Orifice)
at CV2, which closes off, the supply to the filter, through the
X5 Gauge Port. System Pressure.
orifice, across the spool to the Max speed /Min Flow side of
the piston. The piston holds Max speed. Ports A and B Main drive pressure hoses from valve block.
The pressure is felt at the spool end, but the spool does not The threshold pressure can be adjusted to alter the point at
select as the spring pressure holds it stationary. Oil from the which maximum and minimum displacement takes place.
other side of the piston is open to tank. As the pressure rises The adjustment screw gives a 57 Bar increase/reduction per
to match and overcome the spring pressure (threshold one complete turn. Altering the threshold pressure will give
pressure), the spool will start to select. varying amounts of torque and speed that will effect the
machines road speed and also the machines ability to climb
The oil flow across the spool changes direction to feed the
hills.
Min speed/Max flow side of the piston, this moving the
piston in the opposite direction altering the swash angle to There is no external adjustment on the displacement limiter
give maximum torque. The max side of the piston is then screw as on 130/160W machines. Although adjustment is still
open to tank. The spool shuttles to match torque with road possible, it is done by the addition/removal of shims,
conditions. internally.
9803/6310 Issue 1
35 - 1 Slew Motor 35 - 1
Hydraulic Motor Components - JS130W/JS145W
Key
a Drain port
a1
Pilot port
b1
a2
Pilot hole
a3
b
c
Flow paths
d
e
f Piston bore
g
h Flow paths
i
j By pass valve
A Inlet port
B Outlet port
C Anti-cavitation check valve
D Mechanical brake
J Cross-line relief valve
K A side cavity
L B side cavity
M Intermediate cavity
N A side seat
P B side seat
R Anti-pendulum valve
S Anti-pendulum valve
T Pilot hole
U Spring chamber
V Make-up port
W Oil transfer port
X Mechanical brake release
port
Y Motor output shaft
Z Slipper foot
JS00960
Note: Item numbers are referred to on the following pages.
9803/6310 Issue 2*
35 - 2 Slew Motor 35 - 2
Hydraulic Circuit - JS130W/JS145W/JS160W/JS175W
Key
A Hydraulic motor D D
B Bypass/Anti-pendulum valve
C Anti-cavitation check valve
D Relief valve
E Mechanical brake
C C
F Tank line F
G Drain line
JS02680
9803/6310 Issue 2*
35 - 3 Slew Motor 35 - 3
Operation
Slew Motor Configuration - JS130W/JS145W/JS160W/JS175W
Slew Unit
Planetary 2-stage Reduction Gear Swash Plate Type Axial Piston Hydraulic Motor
Mechanical Brake
By-pass Valve Relief Valve
Make-up Valve
The above diagram indicates the relationships between the main components of the slew motor.
9803/6310 Issue 2*
35 - 4 Slew Motor 35 - 4
Specification
JS130W/JS145W
Motor type Fixed displacement piston motor

Reduction gear type Planetary gear with 2 gear reduction
Slew parking brake type Mechanical lock (slew lever and slew lock switch interlocked
system)
Suction capacity 65 cm3/rev (3.97 in3/rev)
Working pressure 285 kgf/cm2 (4052.7 lbf/in2)
Normal flow 121 l/min (26.62 gal/min)
Relief pressure 285 kgf/cm2 (4052.7 lbf/in2) at 107 l/min (23.54 gal/min)
278 kgf/cm2 (3953.2 lbf/in2) at 40 l/min (8.8 gal/min)
Gear reduction - deceleration ratio 17.03
Slew brake torque (excluding reduction gear) More than 30 kgf m (217 lbf ft)
Brake release pressure Min. 30 kgf/cm2 (426.6 lbf/in2)
Weight 99 kg (218 lb)
9803/6310 Issue 2*
35 - 5 Slew Motor 35 - 5
Dismantling - JS130W/JS145W
Refer to the sectional drawing on page E/35-1 of this section
as a guide to dismantling and assembly.
Before attempting to dismantle the slew motor assembly, the

inlet and outlet ports should be blanked and the outer
surfaces washed down with a suitable solvent to remove all
dirt and dust. Dry using compressed air.
1 Remove the level gauge with a pipe wrench.
JS06100
2 Remove plug 26 with an 8 mm Allen key and drain the

gear oil.
26
JS06110
9803/6310 Issue 2*
35 - 6 Slew Motor 35 - 6
Dismantling - JS130W/145W (cont’d)

3 Remove screws with a 19 mm socket wrench and
remove the motor.
Note: Before removing the motor from the reduction gear, it

is advisable to make an alignment mark on the mating faces
to facilitate reassembly.
JS06120
4 Remove the caps 37 with 14 mm A/F hexagonal key 30

and remove relief valves 34 from the motor.
17
31
Note: Record the position of relief valves 34 to ensure
29
correct reassembly.
28
5 Remove the caps 30 with a 14 mm A/F hexagonal key
and take out the springs 31 and check valves 29.
Remove by-pass valve assembly by unscrewing cap 28
using a 10 mm A/F hexagonal key.
29 34
Note: Record the relative positions of the parts to ensure
correct reassembly.
6 It is advisable to make alignment marks on cover 17

and housing 25 with white paint, etc. to facilitate
reassembly. 34 37
31
30 25
JS06130
7 Remove screws 27 attaching cover 17 to housing 25

with a 12 mm hexagonal key. 7
8 Place the motor with the main shaft downwards and lift
off cover 17.
17
25
JS05670
9803/6310 Issue 2*
35 - 7 Slew Motor 35 - 7
Dismantling - JS130W/JS145W (cont’d)

9 Remove snap ring 23 and remove the inner ring of
needle bearing 22. 23
10 Remove 'O'-ring 13.
11 Remove balance plate 21. Remove the pins 15 from the 22

balance plate.
13
Note: The balance plate 21 must be reinstalled correctly on
cover 17. (The alignment of the hair groove and round
groove which select high and low pressure is very important. 21
Before removing the balance plate, note the correct 15
relationship with cover 17.) 20
15
12 Remove the bushings 20 with Teflon rings 19 and the 19
plate springs 18.
18
JS05680
13 Remove the springs 14 from brake piston 12.

14
Note: Keep the springs in the order in which they are to be
reinserted. 13
14 It may be difficult to remove brake piston 12 from 12
housing 25 due to resistance caused by ‘O’-rings 11
and 13. Therefore remove brake piston 12 using the
tapped M6 holes X as shown in the illustration. 11
15 Remove ‘O’-ring 11 from housing 25 and ‘O’-ring 13 25
from brake piston 12.
25
12
JS05700
9803/6310 Issue 2*
35 - 8 Slew Motor 35 - 8

16 Remove friction plate 9 and mating plate 10. 9
17 Hold the end of cylinder 24 by hand and pull out the
cylinder assembly from housing 25. 10
9
Note: The oil seal 2 and the outer ring of taper roller bearing 10
3 remain in the housing. 9
The end face of the cylinder should be protected by clean 10
cloth to prevent it from being damaged.
Make alignment marks or write numbers on the piston bores
and the piston assemblies so that the piston assemblies can
be replaced in the same bores during reassembly. 24
18 Remove the outer ring of taper roller bearing 3 from the

housing.
25
3
JS05710
19 Tap oil seal 2 with a screwdriver and hammer to remove

it from housing 25.
Note: The oil seal cannot be reused.
JS06170
9803/6310 Issue 2*
35 - 9 Slew Motor 35 - 9

20 Attach a puller to the inner ring of taper roller bearing 3
at two places and on the end of cylinder 24 spline, then 1
extract bearing inner ring 1. Take out collar 53.
53
21 Remove swash plate 6, piston assemblies 8 and 6
retainer plate 7 together from cylinder 24.
24
JS06160
22 Slide swash plate 6 from the sliding faces of the piston

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

handling.
6
JS06150
23 Remove spring 5 from cylinder 24.

5
24
JS06140
9803/6310 Issue 2*
35 - 10 Slew Motor 35 - 10
Maintenance Specifications - JS130W/JS145W

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

following table.
3 Discard all used seals and ‘O’ rings and fit new ones
during assembly.
! CAUTION
If the machine is operated at full load, before its initial
run-in procedure is complete, it may cause scuffing and
seizing which can adversely effect the service life of the
machine.
8-3-1-5
Item Inspection and Maintenance Standards

The crescent-shaped ports in the balance plate, which are in sliding contact with
the end face of the cylinder assembly shaft, act to switch between high and low oil
pressure. Any damage to the sliding contact face will increase leakage, causing a
decrease in volumetric efficiency and an increase in slip.
Balance Plate 21 Any seizure of the sliding contact face causes a reduction in mechanical efficiency
and can lead to further damage.
If the grooves or marks depths are less than 0.03 mm (.001 in), the plate can be
corrected using fine emery cloth.
If the wear is greater than 0.03 mm (.001 in), the plate should be renewed. The
plate should be renewed if it shows any sign of seizure.
Correct any damage to the sliding contact face of the slipper feet by using fine
Piston assembly 8 slipper feet emery cloth.
Renew the motor if the depth of any slipper foot oil groove is less than 0.45 mm
(.018 in) or if the slipper foot surfaces are seriously damaged.
Piston assembly 8 pistons The external surfaces of the piston assemblies should be practically unworn. The
motor should be renewed if a piston assembly shows any sign of seizure.
Cylinder assembly 24 piston bores The piston bores should be practically unworn. The motor should be renewed if the
bores show any sign of seizure or are badly damaged.
Taper roller bearing 3 The bearings should be renewed if any slight damage is noticed on the contact
Needle bearing 22 surfaces of the rollers or needles.
It is recommended that all bearings be renewed on reassembly of the motor
because bearings can be damaged when the motor is dismantled.
Oil seal 2 Renew any oil seal if damage to the lip is apparent.
New seals must be used when reassembling the motor.
O-rings 11, 13, 33, 36, 41, 45, 52 Renew any 'O'-ring that appears to be damaged.
New 'O'-rings must be used when reassembling the motor.
Back-up ring 32, 35, 46 The back-up rings must be renewed when reassembling the motor.
9803/6310 Issue 2*
35 - 11 Slew Motor 35 - 11
Assembly - JS130W/JS145W
Refer to the sectional drawing on page E/35-1 as a guide to ! CAUTION
dismantling and assembly.
Cleaning
Cleaning metal parts with incorrect solvents can cause
Check all parts before assembly and remove any scratches
corrosion. Use only recommended cleaning agents and
with a fine oil stone or carborundum paper. Wash with a
solvents.
suitable solvent and blow dry. INT-3-2-11
! CAUTION
Replace all seals with new ones.
‘O’-rings, Seals and Gaskets
Badly fitted, damaged or rotted ‘O’-rings, seals and
Apply clean hydraulic oil to all sliding faces during assembly.
gaskets can cause leakages and possible accidents.
Renew whenever disturbed unless otherwise instructed.
Do not use Trichloroethane or paint thinners near ‘O’-
rings and seals.
INT-3-2-12
1 Lap the sliding contact faces of piston assemblies 8,

balance plate 21 and swash plate 6 with very fine paste
on a flat surface.
JS06180
JS06190
JS06200
9803/6310 Issue 2*
35 - 12 Slew Motor 35 - 12
Assembly - JS130W/JS145W (cont’d)

2 Apply grease to the curved part of cylinder 24 (contact
1
face with spring 5) and mount spring 5. 53
3 Position the piston assemblies 8 into the holes of 6

retainer plate 7.
4 Mount the piston assemblies 8 together with retainer

plate 7 into cylinder 24.
Note: Insert the piston assemblies into the same bores from 8
which they were removed.
Apply clean hydraulic oil to all cylinder 24 bores before 7
reassembling.
5 Apply clean hydraulic oil to piston assembly 8 shoe 5

sliding surface and mount the swash plate 6.
6 Mount collar 53 and inner ring of taper roller bearing 1

on motor output shaft.
7 Apply a thin coat of JCB Retainer where the inner ring is

mounted on motor output shaft.
24
JS05720
8 Using a jig, (see Special Tools, Section 1) press inner

ring 1 on output shaft.
24
JS05730
9 Apply grease to the lip of seal 2 and use a press and jig
(see Special Tools, Section 1) to force fit the seal into
position.
JS05740
9803/6310 Issue 3*
35 - 13 Slew Motor 35 - 13

10 Mount the outer ring of the taper roller bearing into
housing 25. 14
11 Hold the end of cylinder 24 by hand and carefully insert
the cylinder assembly into housing 25. Use the seal
protector on the splines. 13
Note: The splines of the cylinder assembly protrude beyond 12

the housing, so use a guide of 30-50 mm (1.2-1.9 in) on the
lower part of the housing. Verify that spring 5 is inserted
correctly into the back face of retainer plate 7.
9
12 Mount friction plate 9 and mating plate 10.
10
Note: Apply hydraulic oil to both faces before mounting the 9
plates. 10
9
13 Mount 'O'-ring 11 in housing 25 and 'O'-ring 13 on
piston 12. 10
Note: Grease the 'O'-rings before mounting. 11
14 Apply hydraulic oil to the sliding surface around piston

12 and slide it into housing 25.
Note: It is difficult to insert piston 12 into the housing due to 24

O'-rings 11 and 13. Hold the piston horizontally and push it
into the housing with one movement.
15 Insert the brake unit springs 14 back into brake piston 7, 5

12.
Note: Insert the springs 14 in the same order as they were

found during dismantling.
25
JS05690
9803/6310 Issue 2*
35 - 14 Slew Motor 35 - 14

16 Mount the bushings 20 with Teflon rings 19 and the
23
plate springs 18 into the bushing holes in cover 17.
Note: Apply a coating of grease to the end faces and

peripheries of the bushings 20 and to the Teflon rings 19 22
before mounting them, as this helps prevent them from
falling out when the cover is mounted onto the housing. 13
17 Generously grease the pins 15 and insert into cover 17. 21

15
18 Mount balance plate 21 onto cover 17.
20
15
19 Press needle bearing 22 inner ring into cover 17 and
19
attach snap ring 23.
18
20 Apply grease to the 'O'-ring and install 'O'-ring 13 to
cover 17. 17
JS05680
21 To prevent oil leakage from the cover bolt holes apply

JCB Multi-gasket to the surface.
JS05650
22 Lift cover 17 and balance plate 21 by hand and mount

them carefully on housing 25. 27
Take care that balance plate 21 and bushings 20 do not
fall out while mounting cover 17. Align housing 25 and
cover 17 alignment marks which were made before
dismantling. 17
23 Tighten the cap screws 27 (with a 12 mm A/F hexagonal

key) which attach cover 17 to housing 25 to a torque of
157 Nm (116 lbf ft). 25
JS05660
9803/6310 Issue 2*
35 - 15 Slew Motor 35 - 15

24 Assembling the Make-up and by-pass valves.
30
Assemble the check valves 29 and springs 31 in cover 17
17 and tighten the caps 30 (14 mm A/F hexagonal
31
sockets) to a torque of 137 Nm (101 lbf ft). 29
Assemble by-pass valve assembly 28 to cover 17 and 28

tighten the caps (10 mm A/F hexagonal sockets) to a
torque of 78.65 Nm (58 lbf ft).
29 34
25 Insert the relief valve assemblies 34 into cover 17 and
tighten the caps 37 (14 mm A/F hexagonal sockets) to a
torque of 78.65 Nm (58 lbf ft).
Note: Ensure that the relief valves are replaced in their

original positions.
34 37
31
30 25
JS06130
26 Final checks after assembling.
Open the inlet and outlet ports and apply 30 kgf/cm2

(427 lbf/in2) pilot pressure to the brake release port.
(Take care as oil will be discharged from the drain port).
Check that the drive shaft can be rotated smoothly for
at least one full revolution by applying a torque of
approx. 39.32 Nm (29 lbf ft).
Note: If the shaft does not turn, the unit has not been
assembled correctly so dismantle again and inspect.
27 Degrease the mating faces of the gear unit ring gear 64

and motor housing 25 and apply Multi-gasket to the
ring gear.
25
64
JS06220
9803/6310 Issue 2*
35 - 16 Slew Motor 35 - 16

28 Attach the motor with hexagonal bolts and spring
washers.
Size: 19 mm
Tightening torque: 103 Nm (76 lbf ft).
JS06120
29 Attach the level gauge A with a pipe wrench, setting the

height as shown.
JS06210
30 Fill with gear oil through the filler port.
Insert plug 26 with an 8 mm Allen key and tighten to

torque of 39.32 Nm (29 lbf ft). 26
Note: Fill the hydraulic motor case with hydraulic oil before
connecting the piping to the drain port.
See Fluids and Lubricants, Section 3, for type and quantity
of oil.
JS06110
31 Apply grease (type and capacity is given in Fluids and

Lubricants).
Note: Bleed air in the chamber from the air bleed port before
filling with grease, as a build-up of internal pressure can
damage the oil seal.
After the unit is filled, run it for around 10-15 minutes at zero
load, and at low speed and verify that there is no abnormal
noise or vibration. Gradually bring the system into high
speed and loaded operation.
9803/6310 Issue 2*
35 - 17 Slew Motor 35 - 17
Relief Valves - JS130W/JS145W

Dismantling
Refer to the sectional drawing on page E/35-1 as a guide to
dismantling and assembling.
Take steps during dismantling to ensure that all the parts are
returned to their original positions.
Clean the parts with a suitable solvent and blow them dry.
Replace all used 'O'-rings.
1 If not already done, remove cap 37 (with a 14 mm A/F

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

using a soft object, taking care not to scratch the seat
face.
9803/6310 Issue 2*
35 - 18 Slew Motor 35 - 18
Relief Valves - JS130W/145W (cont’d)

Assembly
1 Press fit seat 44 into sleeve 39 which has an 'O'-ring 41.
2 Mount poppet 43, spring 42, shim 40, piston 38, liner 51
onto sleeve 39.
3 Screw cap 37 (with a 14 mm A/F hexagonal key) with

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

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

approximately.
9803/6310 Issue 2*
35 - 19 Slew Motor 35 - 19
Fault Finding - JS130W/145W

Table 1.
Symptom Cause External Inspection Countermeasure Repair

Internal damage to the Measure the oil drain High possibility of Refer to Table 2.
motor. volume. damage to the sliding
surfaces if the supply
volume is approximately
equal to the drain
volume. Dismantle and
inspect.
Internal damage to the Open the motor inlet and High possibility of Renew damaged parts
motor. outlet ports and apply internal damage to the or renew the motor
20 kgf/cm2 (284 lbf/in2 ) motor if the supply shaft assembly.
pilot pressure to the does not rotate smoothly
brake release port. Try when this torque is
to rotate the shaft with applied. Dismantle and
a torque of approx. inspect.
39.32 Nm (29 lbf ft).
Relief valve in circuit not Measure pressure. Reset to the prescribed
set correctly. setting.
Wear or damage to the Measure the oil drain Leakage is too high if the Refer to table 2.
motor sliding surfaces or volume. oil drain volume exceeds
to the high-pressure seal. 5 l/min (1.1 gal/min).
Dismantle and inspect.
Oil hot and excessive Measure the oil Reduce the oil Refer to table 2.
leakage in the motor. temperature. temperature.
Seizure of motor sliding Check for any metallic If metallic matter is Repair or renew the
parts or circuit. matter deposited in discovered or the supply damaged parts. Renew
motor drain oil or drain shaft does not rotate the motor assembly.
filter. Apply a 30 kgf/cm2 smoothly when torque is
(427 lbf/in2) pilot pressure applied, there is a high
to the brake release port possibility of internal
and try to rotate the shaft damage to the motor.
with a torque of approx. Dismantle and inspect.
39.32 Nm (29 lbf ft).
Damage or wear to oil Renew the oil seals.
seal lip.
Damage or wear of the Repair the problem or
shaft seal. renew the motor
assembly.
Abnormal pressure in the Check the pressure in the Set the pressure in the Renew the oil seal.
casing. casing and measure the casing below 3 kg/cm2. Repair or renew the
drain volume. (43 lbf/in2) Dismantle damaged parts. Renew
and inspect if drain the motor assembly.
volume is excessive.
9803/6310 Issue 2*
35 - 20 Slew Motor 35 - 20
Fault Finding - JS130W/JS145W (cont’d)
Symptom Cause External Inspection Countermeasure Repair

Wear or seizure of the Open motor inlet and High possibility of Inspect the parts and
motor sliding surfaces. outlet ports and apply 20 internal damage to the bearing according to
kgf/cm2 (284 lbf/in2) pilot motor if the supply shaft Table 2 a-e and renew
pressure to the brake does not rotate smoothly any defective parts.
release port.Try to rotate when this torque is
the shaft with a torque of applied. Dismantle and
approx. 39.32 Nm inspect.
(29 lbf ft).
Relief valve in the circuit Measure relief pressure. Reset to the prescribed
is not set correctly. setting.
Internal damage to the Check if any metallic High possibility of Repair or renew
motor. matter is deposited in the internal damage to the damaged parts. Renew
motor drain oil or drain motor if metallic matter the motor assembly.
filter. is discovered.
Dismantle and inspect.
Large amount of air Check the oil in the tank Thoroughly bleed the air.
mixed in the oil. and motor casing.
Loosening of bolts or Check if the piping Tighten to the specified
pipes connections, attachment torque.
mounting bolts, motor
attachment bolts or other
bolts are loose.
O-ring is damaged Renew O-rings.
Seal face is damaged. Repair seal face or

renew.
Bolts are loose. Check the bolt tightness. Tighten the bolts to the
correct torque.
Table 2.
No. Part Inspected Repair

a Wear of the sliding surface of balance plate 21. Repair or renew the part
b Damage to sliding surface of cam plate 6. Repair the part or renew the motor.
c Damage to sliding surface of the piston assemblies 8. Repair the part or renew the motor.
d External wear to the piston assemblies 8. Repair the part or renew the motor.
e Wear to piston bores in cylinder assembly 24. Renew the motor.
f Damage to Teflon ring 19 or ‘O’-rings 52. Renew the part.
9803/6310 Issue 2*
36 - 1 Slew Motor 36 - 1
Specifications - JS160W/JS175W
Motor type Fixed displacement piston motor

Reduction gear type Planetary gear with 2 gear reduction
Slew parking brake type Mechanical lock (slew lever and slew lock switch interlocked
system)
Suction capacity 151 cm3/rev (9.21 in3/rev)
Working pressure 285 kgf/cm2 (4052.7 lbf/in2)
Normal flow 138 l/min (36.5 gal/min)
Relief pressure 285 kgf/cm2 (4052.7 lbf/in2) at 126 l/min (27.72 gal/min)
275 kgf/cm2 (3910.5 lbf/in2) at 40 l/min (8.8 gal/min)
Gear reduction - deceleration ratio 13.34
Slew brake torque (excluding reduction gear) More than 68.5 kgf m (495.3 lbf ft)
Brake release pressure Min. 32 kgf/cm2 (455 lbf/in 2 )
Weight 197 kg (434 lb)
9803/6310 Issue 2*
36 - 2 Slew Motor 36 - 2
Hydraulic Motor Components - JS160W/JS175W
Note: Item numbers are referred to on the following pages.
9803/6310 Issue 2*
36 - 3 Slew Motor 36 - 3
Dismantling - JS160W/JS175W
Refer to the section drawing Hydraulic Motor Components 11 Using special pliers, remove locking ring 25 and remove
- JS160W as a guide to dismantling and assembling. the front cover 26 from the casing 1. When removing the
front cover, care must be taken not to damage the
Before attempting to dismantle the slew motor assembly, sliding surface of oil seal 27.
blank inlet and outlet ports and wash the outer surfaces with
a suitable solvent to remove all dirt and dust. Dry using 12 Lightly tap the end of drive shaft 13 with a plastic
compressed air. hammer and withdraw the drive shaft from the casing 1.
Care must be taken not to damage the sliding surface in
1 With the slew motor assembly in the vertical position, contact with oil seal 27.
remove the drain plug and drain the gear oil from the
gearbox section into a clean container and check for 13 Using a drift of soft material passed in from the
metal particles caused by wear. cylindrical roller bearing side of casing 1, gently extract
shoe plate 22 from the casing.
2 Make some alignment marks across the mating faces to
assist assembly. Remove the bolts securing the motor 14 Remove snap ring 28 and spacer 29 from drive shaft 13.
section to the gearbox section and remove the motor Using a press, remove the inner race of cylindrical
section. For the Dismantling/Assembly of the gearbox bearing 30.
section, refer to Slew Gearbox, Dismantling and
Assembly, Section F. 15 Using a jig, remove oil seal 27 from front cover 26.
Discard the oil seal.
3 Remove the optional brake switch valve from casing 1
by removing the retaining bolts. 16 Using a slide hammer bearing puller, remove cylindrical
roller bearing 32 from valve casing 3. Discard the roller
4 Remove relief valves 2 from valve casing 3 . (For bearing.
dismantling and assembly of the relief valve, refer to
Relief Valve, Dismantling and Assembly, Slew Motor.)
5 Remove plug 4 from valve casing 3, and remove spring

5 and plunger 6.
6 Progressively slacken valve casing retaining socket head

screws 7 in turn. The pressure of the slew brake springs
8 will push the valve casing 3 from the casing 1. When
spring pressure is no longer felt, remove screws 7.
Carefully remove valve casing 3 as valve plate 9 may
stick to the cylinder side. Remove valve plate 9 from
valve casing 3, noting its position as an aid to assembly.
Remove pins 10 from valve plate.
7 Remove brake springs 8 from brake piston 11.
8 Using the brake piston extraction jig, remove the brake

piston 11 from the casing 1. Note the relative position of
the brake piston to assist assembly.
9 Turn the motor into the horizontal. Withdraw cylinder 12

from drive shaft 13. Remove locking ring 14, spring 15,
pressure ring 16 and push rods 17. Withdraw piston 18,
retaining plate 19, spherical bush 20, spacer 21 and
shoe plate 2 2. Care must be taken not to damage
sliding surfaces.
Note: If shoe plate 22 cannot be removed at this stage,

remove it after step 14.
10 Withdraw friction plates 23 and separator plates 24 from

* the casing 1, noting the positions of the friction plates
and separator plates to aid assembly.
9803/6310 Issue 2*
36 - 4 Slew Motor 36 - 4
Maintenance Specifications - JS160W/JS175W

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

tables.
3 Discard all used seals and 'O' rings and fit new ones during
assembly.
4 Wash, dry and inspect relief valve assembly 2 parts: piston,

plunger, spring and seat. If any part fails inspection the whole
relief valve assembly must be changed.
Part Replacement Criteria
ITEM STANDARD RECOMMENDED REMEDY

DIMENSIONS (mm) VALUE (mm)
Clearance between 0.028 (0.001 in.) 0.058 (0.002 in.) Renew the piston or cylinder
piston and cylinder bore
Play between the piston 0 0.3 (0.012 in.) Replace the piston assembly
and shoe (að)
Shoe thickness (t) 5.5 (0.217 in.) 5.3 (0.209 in.) Replace the piston assembly
Assembly height of Replace the retaining plate

retaining plate and 6.5 (0.256 in.) 6.0 (0.24 in.) and spherical bush as an
spherical bush assembly
Thickness of friction plate 4.0 (0.16 in.) 3.6 (0.142 in.) Renew
Play between piston and shoe (að) Assembly height (H-h) of retaining plate
Shoe thickness (t) and spherical bush
9803/6310 Issue 3*
36 - 5 Slew Motor 36 - 5
Assembly - JS160W/JS175W
1 Apply clean hydraulic fluid to all sliding contact faces 16 Apply a thin film of grease to 'O' rings 36 and 37 and fit
during assembly. to casing 1.
2 Place casing 1 on a suitable base with the valve casing 17 Fit brake piston 11 into casing 1 into the position from
side down. which it was removed. If difficulty is experienced when
fitting the brake piston due to the resistance of the 'O'
3 Fit snap ring 28 and spacer 29 to drive shaft 13. Shrink ring, fit an M8 bolt into the brake piston and tap with a
fit bearing 30 with the inner race flange marked 'R' plastic headed hammer.
towards the spacer 29.
18 Fit brake springs 8 into brake piston 11. Check that the
4 Turn drive shaft 1 3 so that the drive splines are springs are securely seated.
uppermost. Fit spacer 29 and snap ring 28 to other side
of bearing 30. 19 Fit outer race of roller bearing 32 into valve casing 3. Tap
into place using a drift of soft material until the bearing
5 Turn drive shaft 13 so that the drive shaft splines are is seated in the stepped area of the valve casing.
down. Shrink fit the inner race of roller bearing 32 to the
drive shaft. Fit snap ring 33. 20 Apply a thin coating of grease to the mating faces of
valve plate 9. Grease and fit pins 10 into casing 3. Fit
6 With the drive splines upward, fit the drive shaft 13 with valve plate 9 into the valve casing 3 in the position from
roller bearing 30 into casing 1. Using a hammer and a which it was removed. Fit 'O' ring 38.
drift of soft material, lightly tap the outer race of bearing
30 until it stops at the stepped area of the casing. 21 Fit valve casing 3 to casing 1, ensuring that casing
marks are aligned. Secure with socket head screws 7,
7 Using a jig (see Service Tools, Section 1), fit oil seal 27 partially tighten each screw in turn. Finally torque tighten
into front cover 26 until it stops at the stepped area. to 423 Nm ± 65 (312 lbf. ft. ± 48).
Care must be taken to fit the oil seal in the correct
orientation. Note: Care must be taken to prevent brake springs 8 and
valve plate 9 from falling out.
8 Fit 'O' ring 34 into casing 1.
22 Insert plunger 6 and spring 5 into valve casing 3. Check
9 Apply a thin film of grease to the lip of oil seal 27. Fit that the plunger moves smoothly. Fit 'O' ring 39 onto
front cover 26 to casing 1 by lightly tapping the front plug 4 and fit plug into valve casing 3. Torque tighten to
cover with a plastic hammer. To prevent damage to the 221 Nm ± 24.4 (163 lbf. ft. ± 18).
oil seal lip, use a seal protector or tape to cover the
drive shaft splines. 23 Fit relief valves 2 into valve housing 3. Torque tighten to
176.3 Nm ± 9.8 (130 lbf. ft. ± 7). For assembly of relief
10 Using pliers, fit lock ring 25 to casing 1. valves 2, refer to Relief Valve Assembly, Slew Motor.
11 Position casing 1 horizontally. Apply a thin coating of 24 Fit 'O' ring 40 onto plug 41. Fit 'O' rings 43 to the valve
grease to the mating faces of shoe plate 22 and casing casing 3 and plug 42 and install the assembly on casing
1. Fit the shoe plate 22 with the large chamfered side of 1.
the shoe plate towards the casing.
25 Fit the optional brake switch valve to the casing 1 using
12 Insert push rods 17 into cylinder 12 (two to each hole). the specified bolts.
Insert pressure ring 16, spring 15 and fit locking ring 14.
Fit spacer 2 1 and assembled spherical bush 20 to 26 Fit the stop ring onto motor drive shaft. With the
cylinder. Care must be taken not to damage the sliding gearbox section mounted horizontally, carefully lower
surface of the cylinder. the motor section and match the drive shaft splines.
Finally, lower the motor section while matching casing
13 Fit piston sub-assemblies 18 and 35 into retaining plate alignment marks. Secure motor section with screws 44.
19. Torque tighten to 235.4 Nm (173.6 lbf. ft.).
14 Insert piston sub-assemblies 18 and 35 into cylinder 12. 27 Wrap sealing tape around the drain plug and fit the plug.
Slide cylinder assembly onto drive shaft 13, aligning the Torque tighten to 64.7 Nm (47.7 lbf. ft.).
splines of the spherical bush 20, cylinder 12 and drive
shaft 13. 28 Fill the motor section with the recommended gear oil
(see Lubricants and Capacities, Section 3).
15 Reposition the casing with the front cover side
downward. Fit three separator plates 24 and two friction
plates 23 in the positions from which they were
removed.
9803/6310 Issue 2*
36 - 6 Slew Motor 36 - 6
Relief Valve - JS160W/JS175W
Dismantling
1 Hold relief valve plug 1 in a vise and unscrew body 2.
Remove piston 3, spring seat 4, spring 5, rod 6 and
plunger 7 from body 2.
2 Remove plug 1 from the vise and remove spring 8, and

spring seat 9.
Assembly
1 Fit seat 10, plunger 7, rod 6, spring 5, spring seat 4 and
spring 8 into body 2.
2 Fit spring seat 9 on rod 6.
3 Fit spring 8 onto bush 11 in plug 1. Fit 'O' ring 12 onto

plug 1. Bring body 2 and plug 1 together, introducing
rod 6 into bush 11. Screw the relief valve together and
tighten.
9803/6310 Issue 2*
40 - 1 Hydraulic Rams 40 - 1
Specifications
Ram JS130W JS160W
Boom Ram Cylinder Inside Diameter: 100 mm (3.94 in) Cylinder Inside Diameter: 115 mm (4.53 in)
Left & Right Rod Diameter: 75 mm (2.95 in) Rod Diameter: 80 mm (3.15 in)
Max. Contraction: 1561 mm (61.46 in) Max. Contraction: 1693 mm (66.65 in)
Stroke: 1081 mm (42.56 in) Stroke: 1184 mm (46.61 in)
Dry Weight: 116 kg (256 lb) Dry Weight: 157 kg (346 lb)
Dipper Cylinder Inside Diameter: 115 mm (4.53 in) Cylinder Inside Diameter: 125 mm (4.92 in)
Ram Rod Diameter: 80 mm (3.15 in) Rod Diameter: 90 mm (3.54 in)
Bucket Cylinder Inside Diameter: 95 mm (3.74 in) Cylinder Inside Diameter: 105 mm (4.13 in)
Ram Rod Diameter: 70 mm (2.76 in) Rod Diameter: 75 mm (2.95 in)
* TAB Cylinder Inside Diameter: 100 mm (3.94 in) Cylinder Inside Diameter: 115 mm (4.53 in)
Boom Lift Rod Diameter: 73 mm (2.95 in) Rod Diameter: 80 mm (3.15 in)
Ram Max. Contraction: 1478 mm (58.18 in) Max. Contraction: 1491 mm (58.70 in)
* TAB Cylinder Inside Diameter: 140 mm (5.52 in) Cylinder Inside Diameter: 160 mm (6.29 in)
Boom Rod Diameter: 95 mm (3.74 in) Rod Diameter: 80 mm (3.15 in)
Position Max. Contraction: 1170 mm (46.06 in) Max. Contraction: 1230 mm (48.42 in)
Ram Stroke: 555 mm (21.85 in) Stroke: 580 mm (22.83 in)
9803/6310 Issue 2*
Bucket Ram - General
! WARNING
Hydraulic Pressure
! WARNING
Lifting Equipment
Hydraulic fluid at system pressure can injure you. Before You can be injured if you use faulty lifting equipment.
disconnecting or connecting hydraulic hoses, stop the Make sure that lifting equipment is in good condition.
engine and operate the controls to release pressure
Make sure that lifting tackle complies with all local
trapped in the hoses. Make sure the engine cannot be regulations and is suitable for the job. Make sure that
started while the hoses are open.
lifting equipment is strong enough for the job.
INT-3-1-11/1
INT-1-3-7
Bucket Ram - Removal
1 Park the machine on level ground and, with the bucket

and dipper rams fully retracted, lower the attachment to
the ground.
2 Place a wooden block under the bucket ram.
3 Stop the engine, remove the key.
Release the tank pressure (see Releasing Tank

Pressure, Section 3).
9803/6310 Issue 1
Bucket Ram - Removal (cont’d)

4 Remove the nuts and bolt securing the tipping link pivot
pin.
5 Knock out the pivot pin using a bar and hammer.
! WARNING
Metal Splinters
You can be injured by flying metal splinters when driving
metal pins in or out. Use a soft faced hammer or drift to
remove and fit metal pins. Always wear safety glasses.
INT-3-1-3
6 Secure the eye end of the ram piston rod to the ram
cylinder to prevent the piston rod from extending.
7 Disconnect the ram hoses and install plugs and caps to

prevent contamination.
9803/6310 Issue 1
Bucket Ram - Removal (cont’d)

8 Attach a sling to support the ram.
9 Remove the nuts and bolt from the cylinder end of the
ram. Knock out the pivot pin using a bar and hammer.
Lift the ram clear.
! WARNING
Metal Splinters
INT-3-1-3
Bucket Ram - Replacement

1 Attach a sling to the ram and lift it into position on the
dipper.
2 Install the pivot pin, bolt and nuts to secure the cylinder
end of the ram to the dipper.
* Note: When checking or refitting JS machine pivot pins, the
retaining nuts and bolts should not be fastened up tight to
the pivot boss but must have approximately 3mm of play so
that the pin is free from tension.
3mm A409820
! WARNING
Metal Splinters
INT-3-1-3
9803/6310 Issue 3*
Bucket Ram - Replacement (cont’d)

3 Connect the hoses.
4 Manoeuvre the ram to align the piston rod eye with the
tipping link.
5 Install the pivot pin, bolt and nuts to secure the rod end
of the ram to the tipping link.
Note: When checking or refitting JS machine pivot pins, the
3mm A409820
6 Once the installation is complete, start the engine and

raise the boom fully. Under no load conditions, expel
any trapped air by operating the ram to full stroke in
both directions several times. Check for oil leaks.
9803/6310 Issue 2*
Dipper Ram - General

! WARNING ! WARNING
Hydraulic Pressure Lifting Equipment
engine and operate the controls to release pressure Make sure that lifting tackle complies with all local
started while the hoses are open. lifting equipment is strong enough for the job.
INT-3-1-11/1 INT-1-3-7
Dipper Ram - Removal
1 Park the machine on level ground and, with the dipper

and bucket rams fully retracted lower the attachment to
the ground.
2 Place a wooden block under the dipper ram.
3 Stop the engine, remove the key.

Release the tank pressure (see Releasing Tank
9803/6310 Issue 1
Dipper Ram - Removal (cont’d)
4 Remove the nuts and bolt securing the dipper pivot pin.
! WARNING
Metal Splinters
INT-3-1-3
7 Disconnect the ram hoses and install plugs and caps to

9803/6310 Issue 1
Dipper Ram - Removal (cont’d)
8 Disconnect the grease tube.
9 Attach a sling to support the ram.
10 Remove the nuts and bolt securing the boom pivot pin.
Knock out the pin using a bar and hammer.
! WARNING
Metal Splinters
INT-3-1-3
Lift the ram clear.
Dipper Ram - Replacement
1 Attach a sling and position the ram over the boom.
9803/6310 Issue 1
Dipper Ram - Replacement (cont’d)
2 Install the pivot pin, bolt and nuts to secure the cylinder
end of the ram to the boom.
3mm A409820
! WARNING
Metal Splinters
INT-3-1-3
3 Connect the grease tube to the dipper ram.
4 Connect the hoses to the ram.
5 Manoeuvre the ram to align the piston rod eye end with
the dipper pin position.
9803/6310 Issue 2*
Dipper Ram - Replacement (cont’d)
6 Install the pivot pin, bolt and nuts to secure the ram to
the dipper.
3mm A409820
! WARNING
Metal Splinters
INT-3-1-3

raise the boom fully. Under no load conditions expel
9803/6310 Issue 2*
Boom Rams - General

! WARNING ! WARNING
Hydraulic Pressure Lifting Equipment
engine and operate the controls to release pressure Make sure that lifting tackle complies with all local
started while the hoses are open. lifting equipment is strong enough for the job.
INT-3-1-11/1 INT-1-3-7
The following pages describe the procedures for a single

boom ram. The procedures for the other boom ram are
identical.
Boom Rams - Removal

1 Park the machine on level ground and, with the dipper
and bucket rams fully retracted, lower the attachment
to the ground.
Stop the engine, remove the key.
JS06360
2 Disconnect the grease tube.
3 Attach a sling to the boom ram.
9803/6310 Issue 1
Boom Rams - Removal (cont’d)
4 Remove the nuts, bolt and retaining collar on the side

of the ram being removed.
Knock out the pivot pin, using a bar and hammer, until it
just clears the eye of the ram.
! WARNING
Metal Splinters
INT-3-1-3 JS07500
5 Lower the ram and support the free end on a stand.
7. Release the tank pressure (see Releasing Tank

JS06370
9803/6310 Issue 1
Boom Rams - Removal (cont’d)
8 Disconnect the hoses, and install plugs and caps to

9 Remove the nut and bolt and knock out the body pivot
pin with a hammer and bar.
! WARNING
Metal Splinters
INT-3-1-3
10 Lift the ram clear.
Boom Ram - Replacement

1 Attach a sling to the boom ram.
Align the ram with its mounting position.
9803/6310 Issue 1
Boom Rams - Replacement (cont’d)
2 Install the body pivot pin and the securing bolt and
nuts.
3mm A409820
! WARNING
Metal Splinters
INT-3-1-3
3 Connect the hoses.
4 Raise the free end of the ram and align the rod eye with
the pivot pin.
5 Knock in the pivot pin as far as possible using a bar

and hammer.
! WARNING
Metal Splinters
INT-3-1-3
JS07550
9803/6310 Issue 2*
Boom Rams - Replacement (cont’d)
6 Install the retaining collar and secure with the bolt and
nuts.
3mm A409820
7 Connect the grease tube.
8 Once the installation is complete, start the engine, raise

the boom fully and extend the dipper ram. Under no
load conditions, expel any trapped air by operating the
ram to full stroke in both directions several times.
Check for oil leaks.
9803/6310 Issue 2*
Triple Articulated Boom (TAB) Ram -

General
! WARNING
Hydraulic Pressure ! WARNING
Hydraulic fluid at system pressure can injure you. Before Lifting Equipment
disconnecting or connecting hydraulic hoses, stop the You can be injured if you use faulty lifting equipment.
engine and operate the controls to release pressure Make sure that lifting equipment is in good condition.
trapped in the hoses. Make sure the engine cannot be Make sure that lifting tackle complies with all local
started while the hoses are open. regulations and is suitable for the job. Make sure that
INT-3-1-11/1 lifting equipment is strong enough for the job.
INT-1-3-7
Triple Articulated Boom Ram -

Removal
1 Park the machine on level ground and, with the bucket

and dipper rams fully retracted and the TAB ram
partially extended, lower the attachment to the ground.
Stop the engine and remove the key.
JS06380
2 Attach suitable lifting gear to the TAB ram and just take
take up the slack.
JS07240
3 Release the tank pressure (see Releasing Tank

Pressure, Section 3)
JS06370
9803/6310 Issue 1

Removal (cont’d)
4 Remove the pivot pin retaining nuts and bolt from the
rod end of the ram.
JS07250
! WARNING
Metal Splinters
INT-3-1-3
JS07260
6 Fully retract the ram and secure the eye end of the ram
piston rod to the ram cylinder to prevent the piston rod
from extending.
JS07270
7 Disconnect the hoses and install plugs and caps to

prevent contamination. Discard the ‘O’ ring seal.
JS07280
9803/6310 Issue 1

Removal (cont’d)
8 Remove the pivot pin retaining nuts and bolt from the
cylinder end of the ram. Knock out the pin using a bar
and hammer. Lower the ram clear.
! WARNING
Metal Splinters
INT-3-1-3
JS07290

Replacement
1 Attach suitable lifting gear and manoeuvre the TAB ram

to locate the cylinder end eye with its mounting.
JS07300
2 Install the cylinder eye retaining pin, bolt and nuts.

JS07290
3mm A409820
! WARNING
Metal Splinters
INT-3-1-3
3 Fit new ‘O’ ring seal to the connection flange. Connect

the hoses.
JS07280
9803/6310 Issue 2*

Replacement (cont’d)
4 Hoist the ram and extend the piston rod to align the
piston rod eye end with the boom mounting.
JS07310
5 Install the pivot pin and retaining bolt and nuts.

Note: When checking or refitting JS machine pivot pins, the
* retaining nuts and bolts should not be fastened up tight to
JS07320
3mm A409820
! WARNING
Metal Splinters
INT-3-1-3

raise the boom fully. Under no load conditions, expel
9803/6310 Issue 2*
Boom, Dipper, Bucket and Triple

Articulated Boom (TAB) Rams
5
14 8
15
9
4
6
7
10 12
3 13
11 13
1 25 22
16
2 21
19
20 23
17
24
2 18 17
16
JS07570
9803/6310 Issue 1

Articulated Boom (TAB) Rams (cont’d)

Dismantling 11 Remove wear ring 21 (JS160W only).
1 Drain all hydraulic fluid from the ram, disconnect and Note: Care must be taken not to damage any seal grooves.
remove the hydraulic pipes.
12 Remove gland external 'O' rings 22 and back-up rings
2 Place the ram horizontally on a dismantling/assembly 23.
fixture and secure firmly.
13 If it is necessary to remove bush 24 from end cap 1,
3 Remove end cap 1 by removing retaining screws 2 using remove snap ring 25. Push out the bush with a suitable
an Allen key. press and tube. Discard all 'O' rings, seals and back-up
rings.
4 Use slings to support the weight of the piston rod
assembly 3 and pull the assembly clear of the ram Assembly
cylinder 4. Use a suitable container to catch any residual
hydraulic fluid displaced. Before assembly, make sure all components are thoroughly
cleaned in a suitable solvent and then dried. Use new 'O'
Note: It may be necessary to apply air or hydraulic pressure rings, seals and back-up rings, lightly greased before use.
to the head side of the ram in order to extract the piston rod
assembly from the cylinder. 1 Fit a new bush 24, using a suitable tube and press. Fit
snap ring 25 into end cap 1.
! WARNING
If air or hydraulic pressure is used to force out the piston 2 Fit buffer seal ring 17 into end cap 1. Bend gland seal 16
assembly, ensure that the end cap is securely fitted. into a 'U' shape (bend radius greater than 6 mm (0.24 in)
Severe injury can be caused by a suddenly released to avoid kinking) and install into its groove. The open
piston rod. end of the 'U' shape must face towards the piston head.
HYD-1-2
! WARNING 3 Install a new back-up ring 18 and 'U' shaped seal 19 ('U'
You can be injured if you use faulty lifting equipment. shape facing piston head). Make sure there is no
Make sure that lifting equipment is in good condition. twisting and rolling of the ring 18 and seal 19.
Make sure that lifting tackle complies with all local 4 Fit wear ring 21 (JS160W only).
regulations and is suitable for the job. Make sure that
lifting equipment is strong enough for the job. 5 Fit new wiper seal 20.
INT-1-3-7
6 Install new gland external 'O' rings 22 and back-up rings
5 Position the piston rod assembly on the ram piston head 23 ('O' rings closest to the piston head).
dismantling/assembly rig (see Ram Piston Head Nut,
Removal and Fitting) with the piston rod resting on 7 Fit 'O' ring 15 into the middle groove of piston head 9,
support block J. making sure it is not twisted.
6 Remove grub screw 5, after drilling out the staking. 8 Fit piston head seal 14 as follows (refer to illustration on
Remove steel ball 6. following page):
7 Remove piston nut 7 as detailed in Ram Piston Head a Smear the surface of inner guide X with grease and
Nut, Removal and Fitting. fit seal 14 onto it in a horizontal position.
8 Remove shim 8, piston head 9, cushion ring 10 and end b Fit lower slide bearing rings 12 and 13 to the piston
cap assembly 1, in order, from piston rod 11. head by hand.
9 Hold piston head 9 in a soft jawed vice and proceed as c Fit the thin end of inner guide X over the upper
follows:- section of piston head 9.
a Remove upper and lower slide bearing rings 12 and d Position outer guide Y over inner guide X so that it
13 by hand. rests on seal 14.
b Cut and remove piston head main seal 14, taking e Use a hydraulic press to push seal 14 off inner guide
care not to damage the seal groove. X and into its groove on piston head 9.
c Remove 'O' ring 15 Note: Press carefully to ensure that the seal fits straight onto
the inner guide X and thence squarely into its groove. Once
10 Remove the end cap seals 16, 17, back-up rings 18, 'U' pressing starts do not stop in mid-travel or the seal will
shaped seal 19 and wiper seal 20. become deformed.
f Withdraw the press and remove guides X and Y.
9803/6310 Issue 1

Articulated Boom (TAB) Rams (cont’d)
Assembly (cont'd)
9 Use bedding jig Z as follows to ensure that piston head

seal 14 is resized:
a Smear the tapered section of jig Z with grease.
b Insert the piston head assembly into the jig Z and,

using the hydraulic press, push the piston head
assembly slowly into the jig. Stop the press for 3-5
seconds at the bedding point W.
c Continue to press the piston head through jig Z.
10 Fit the upper slide bearing rings 12 and 13 to the piston

head 9.
11 Install end cap assembly 1 over piston rod 11.
Note: It is advisable to tape the piston rod threads to

prevent damage to internal seals. Remove the tape after
installation.
12 Fit cushion ring 10, piston head assembly 9, new shim 8

and piston head retaining nut 7 to piston rod 11.
13 Position the piston rod assembly on the ram piston head

dismantling/assembly rig (see Ram Piston Nut,
Removal and Fitting) with the piston rod resting on a
support block.
14 Proceed as described in Ram Piston Nut, Removal and

Fitting, torque tightening the piston head nut 7 to the
torque specified in Torque Settings.
15 Insert steel ball 6 and grub screw 5. Tighten the grub

screw to the torque specified in Torque Settings. Stake
the grub screw using a punch.
16 Using slings remove the assembly from the rig and insert
into cylinder body 4. Ensure that slide rings do not move
out of place by keeping the piston rod assembly square
to the cylinder.
17 Fit end cap 1 to the cylinder and secure following the

sequence shown in Torque Settings, End Cover
Screws, Tightening Sequence, tighten retaining
screws 2 to the torque specified.
9803/6310 Issue 1
Boom, Dipper, Bucket and Triple Articulated Boom (TAB) Rams (cont’d)
Torque Settings
JS130W
Ram Dimensions Piston Piston Nut Grub Screw
Location Bore x Rod Nut A/F Torque Torque
(mm) (mm) Nm (lbf ft) Nm (lbf ft)
Boom 100 x 75 75 2430 (1792) 31.5 ± 5.9 (23.3 ± 4.4)

Dipper 115 x 80 85 5650 (4167) 56.9 ± 10.7 (42.1 ± 7.9)
Bucket 95 x 70 75 3270 (2412) 31.5 ± 5.9 (23.3 ± 4.4)
* TAB (Lift) 100 x 75 75 2430 (1792) 31.5 ± 5.9 (23.3 ± 4.4)
* TAB (Pos’n) 140 x 95 100 5590 (4123) 56.9 ± 10.7 (42.1 ± 7.9)
JS160W
Ram Dimensions Piston Piston Nut Grub Screw
Location Bore x Rod Nut A/F Torque Torque
(mm) (mm) Nm (lbf ft) Nm (lbf ft)
Boom 115 x 80 85 3770 (2780) 56.9 ± 10.7 (42.1 ± 7.9)

Dipper 125 x 90 95 7420 (5473) 56.9 ± 10.7 (42.1 ± 7.9)
Bucket 105 x 75 80 4310 (3179) 56.9 ± 10.7 (42.1 ± 7.9)

* TAB (Lift) 115 x 80 85 3770 (2780) 56.9 ± 10.7 (42.1 ± 7.9)
* TAB (Pos’n) 160 x 80 85 8000 (5900) 56.9 ± 10.7 (42.1 ± 7.9)
Note: For piston nut torque pressures see Ram Piston Head Nut, Removal and Replacement.
End Cover Screws - Tightening Sequence
7 1
3 5
6 4
2 8 JS06760
9803/6310 Issue 2*
Stabiliser/Dozer Rams
9803/6310 Issue 1
Stabiliser/Dozer Rams (cont’d)

Torque Settings
Dismantling
Item Nm lbf ft
The numerical sequence on the illustration is a guide to 1 678 500
dismantling. 5 405 299
19/20 40 29.5
1 Drain all hydraulic fluid from the ram.
2 Place the ram horizontally on a dismantling/assembly

fixture and secure firmly.
3 Remove end cap 1 and withdraw piston rod 2 complete

with its associated components 3 from cylinder 22.
Note: It may be necessary to apply air or hydraulic pressure

to the head side of the ram in order to extract the piston rod
assembly from the cylinder.
! WARNING
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
4 Discard all seals, ‘O’ rings, back-up rings and wear

rings.
Assembly
For assembly reverse the numerical sequence on the

illustration, bearing in mind the following points:
1 Clean all components thoroughly in a suitable solvent.

Use new seals, back-up rings and ‘O’ rings. Lightly
grease seals etc. before fitting.
2 Apply Loctite Activator ‘N’ to the threads of piston head

5 and cylinder 22. Allow to dry for 15 minutes before
applying JCB Lock and Seal.
3 Apply JCB Lock and Seal to threads of piston rod 2. Fit

and tighten piston head 5 to the torque shown opposite.
Adjust the position of the piston head so that its dowel
hole aligns with that of piston rod 2. Drive home dowel
4.
4 Apply JCB Lock and Seal to the threads of end cap 1.

Fit end cap 1 into cylinder 22 and tighten to the torque
shown opposite.
Note: JCB Lock and Seal and Loctite Activator N must not
contact seals, back-up rings or ‘O’ rings.
Note: If hydraulic oil contacts uncured Loctite a weakening

of the bond will result. When using Activator ‘N’ allow a
minimum curing time of 1 hour.
9803/6310 Issue 1
Axle Lock Rams

Dismantling
1 Drain hydraulic fluid from the ram, disconnect the

hydraulic pipes and plug the ports to prevent ingress of
dirt or water.
2 Remove mounting bolts A and place the ram on a

suitable workbench.
3 Remove capscrews B and remove the cover.

B
4 Remove the pilot piston, guide sleeve with check valve
ball and spring and discard the seals. A
5 Remove main piston C from the housing and discard the
seals.
6 Clean all the parts thoroughly in a suitable solvent and

inspect for damage. Remove all burrs and scratches
with a fine oil stone or carborundum paper. Re-clean in
solvent and blow dry.
C
Assembly JS09640
For assembly, reverse the sequence for dismantling.
1 Fit new seals and lightly oil parts before reassembly.
Note: Ensure new seals are fitted the correct way round.
2 Install capscrews B after coating the threads with JCB

Threadlocker and Sealer and torque tighten to 16 Nm
(1.7 lbf ft, 12 kgf m).
3 Refit the ram and connect the hydraulic pipes.
9803/6310 Issue 1
Power Track Rod
* Removal and Replacement 4 Remove screws C and washers D (4 off each) from the
cylinder mounting flange.
! WARNING
5 Using a soft faced hammer, tap the closed end of the
A raised and badly supported machine can fall on you.
cylinder and carefully withdraw the cylinder and track-
Position the machine on a firm, level surface before
rod from the housing.
raising one end. Ensure the other end is securely
chocked. Do not rely solely on the machine hydraulics or
Replacement
jacks to support the machine when working under it.
Replace the power track rod by reversing the removal
Disconnect the battery, to prevent the engine being
procedure.
started while you are beneath the machine.
GEN-1-1
Apply Anti-Seize Paste, Part No. 4003/0211 to pivot pins B
Removal to facilitate subsequent removal.
Note: Depending on accessibility, the steer cylinder can be After connecting hoses, check the hydraulic fluid level, and if
removed and replaced with the axle on the machine. Where necessary top-up.
accessibility is limited, the axle should be removed before
removal of the cylinder (see Front Axle, Removal and Bleed the Hydraulic System (see Steering System -
Replacement, Section F). Bleeding Procedure).
Note: Before removal, mark the cylinder flange and housing Torque Settings
for relocation.
1 Thoroughly clean external parts. A 56 5.6 41
C 166 16.8 122
2 Disconnect and cap hydraulic hoses to prevent loss of
fluid and ingress of dirt. Label hoses for identification
and correct refitting.
3 Remove locking screws A and pivot pins B. Swing the

track-rod clear of the steering joints.
CD
A
B
A275490
9803/6310 Issue 2*
* Power Track Rod (cont’d)

10
11
7
3
8
4
5
13
1 D
9
A
2 E
11 B
10
C
Z o
35 T
X X
V JS07951
Y
9803/6310 Issue 2*
Power Track Rod (cont’d)

The following procedures can only be carried out with the 3 Take out screws 1 (4 off) and remove the cylinder
axle removed from the machine (see Front Axle, Removal cover/piston guide 2. Remove and discard seals 9 and
and Replacement, Section F). 10 with back-up washer 11 and seal 13.
It will be necessary to provide a suitable stand on which to 4 Pull piston/rod assembly 5 out of the cylinder. Remove
support the axle once it has been removed from the machine. and discard guide rings 8 and seal 7 from the piston.
Dismantling Note: The piston is shrunk onto the piston rod. DO NOT
attempt to remove it.
1 Remove setscrew A, extract pivot pin B and disengage
the track rod ends from the steering knuckles.
5 Using a soft faced hammer, carefully tap the closed end
2 Remove ball joints D. of cylinder 3 and withdraw the cylinder from its housing
4. Remove and discard seals 9 and 10 with back-up
Note: The piston rod operates at full length and damage to washer 11.
the surface will cause fluid leaks. DO NOT attempt to grip the
rod with pipe grips etc.
Assembly
i Using two suitable open ended spanners located on
the flats at F and G, rotate against each other until 1 Fit new seal 7 and guide rings 8 to the piston. Ensure
one ball joint unscrews. they are seated correctly.
2 Grease piston rod seal 9, wiper ring 10 and back-up

washer 11 and fit them into the grooves in the closed
end of cylinder 3. Ensure they are seated correctly.
3 Grease the machined external shoulders on cylinder 3

and insert the closed end into housing 4. Using a soft
G faced hammer, carefully tap the flange until the cylinder
is fully seated in the housing. Align the flange marking
with the housing mark.
4 Apply grease to piston seal 7 and the surfaces of the

F piston rod. Insert piston/rod assembly 5 into the
cylinder, ensuring it is the correct way round, with the
A277050
piston sleeve towards the closed end of the cylinder,
carefully guiding the rod through the seals in the closed
ii Unscrew the ball joint until an open ended spanner end of cylinder 3.
can be fitted on rod 5. Screw the ball joint against
the spanner to secure the spanner and to prevent 5 Grease and fit seal 9, wiper ring 10, back-up washer 11
damage to the rod. and cover seal 13 to the cylinder cover/piston guide.
Ensure they are seated correctly.
6 Apply JCB Multi-Gasket to cylinder flange face 3.
Locate cover/piston guide 2 onto the piston rod and

slide into position against cylinder flange 3, aligning the
location mark made during dismantling.
G
7 Insert screws 1 (4 off) and torque tighten to 166 Nm
5 (122 lbf ft).
8 Coat the first three external threads of track rod end

ball joint D with JCB Threadlocker and Sealer and
A277060
screw into the end of the steering piston rod. Torque
tighten to 400 Nm (295 lbf ft).
iii Using the spanner at 5 to lock the rod, rotate the
spanner at G to undo the other ball joint. 9 Grease and fit new web seals C to the hub steering
knuckle. Ensure the seals are fitted correctly and are
Note: Mark cover 2 and cylinder flange 3 relative to housing fully seated in position.
flange 4 before removal.
9803/6310 Issue 1
Power Track Rod (cont’d)

10 Connect the track rod ends to the hub carrier steering

knuckles.
Coat the surface of pivot pin B with anti-seize paste

(see Sealing and Retaining Compounds, Section 1)
and insert the pin into the hub carrier and fit the
setscrew A. Apply JCB Threadlocker and Sealer to the
threads and torque tighten to 56 Nm (41 lbf ft).
11 Centralise the steering so that the distance T measured

from the end of the piston guide to the steering ball
joint face is 111 mm (4.37 in).
12 Attach a straight edge X to both hubs using a wheel

mounting nut.
Make a mark at position Y which corresponds to the

distance Z, wheel centre to rim flange on each straight
edge.
13 Measure the distance V between the two straight

edges. Rotate both hubs through 180° and measure the
distance W. The two measurements should be the
same. If not, carry out step 14.
14 Loosen the locknut E on each track rod end. To adjust

the tracking, use a spanner to rotate the inner ends of
the track rods.
Repeat steps 13 and 14 until the two measurements are

the same.
Check that a steering angle of 35° can be achieved in

both directions. If the steering angle is not the same in
both directions it is necessary to adjust both track rod
ends to compensate while still meeting the
requirements of step 13.
Finally torque tighten the locknut E on each track rod

end to 240/260 Nm (177/192 lbf ft).
9803/6310 Issue 1
Ram Piston Head Nut
Removal and Fitting
JS00980
9803/6310 Issue 1
Ram Piston Head Nut (cont’d)
Due to the high piston nut tightening torques used on the Nut Fitting
rams, it is necessary to use a special rig (consisting of the
special tools shown in the Tables) for ram piston head nut Before assembly ensure that all components have been
fitting and removal (see Service Tools - Section 1). thoroughly cleaned and all new seals, backing rings and ‘O’-
rings are available. Smear all seals, etc. with hydraulic fluid.
As shown in illustrations A and B, the rig uses a modified lift
ram C acting on a heavy-duty ring spanner D to loosen or 1 Assemble the piston rod components as detailed earlier
tighten the piston nut. Hydraulic power to operate the rig for individual rams.
may be obtained from a suitable hydraulic power pack
(maximum pressure required 150 bar (2175 lb/in2 ) or from 2 Install the piston rod assembly in the nut removal/fitting
the auxiliary circuit of a JCB machine equipped with quick- rig with the piston rod supported by block J.
release couplings. In either case, small bore hoses E (Part
No. 892/00137 - 2 off) must be used to connect the rig to 3 Secure the eye end of the piston rod to the rig at
the power source to limit the speed of operation of ram C. In position G, using a suitable pivot pin.
addition F, test point (Part No. 892/00262) and pressure
gauge (Part No. 892/00279) should be fitted in the line to the 4 Fit a ring spanner to the piston nut and connect it to the
piston side of the ram C to measure the tightening pressure eye end of ram C at position K.
being applied.
5 Using the rig, tighten the piston head nut H to the
See Table 1 on the following page for details of the pressure torque specified for individual rams by powering the
necessary to achieve the required tightening torques. The ram slowly downwards. The torque required is indicated
torque settings are given in Boom, Dipper, Bucket and by gauge F (see Table 1 on following page).
Triple Articulated Boom (TAB) Rams, Torque Settings.
6 Remove the piston rod assembly from the rig and insert
into the ram cylinder as detailed earlier for individual
Nut Removal rams.
It is assumed that the ram has been removed from the

machine, hydraulic piping removed and the piston rod
assembly separated from the cylinder.
Note: Before using the nut removal/fitting rig, operate the rig
cylinder over its full range for 5 or 6 strokes to remove all air
from the cylinder.
1 Install the piston rod assembly in the

dismantling/assembly rig with the piston rod supported
by block J.
2 Secure the eye end of the piston rod to the rig at

position G, using a suitable pivot pin.
3 Fit a ring spanner to the piston nut and connect it to the

eye end of ram C at position H.
4 Power the ram slowly downwards, noting the pressure

at which the piston nut first moves on the piston rod.
(The pressure should be 1.0 to 1.5 times the tightening
pressure for the particular size).
5 Remove the piston nut.
6 Remove the piston rod assembly from the rig and then
proceed with dismantling as detailed earlier for
individual rams.
9803/6310 Issue 1
Ram Piston Head Nut (cont’d)

Nut Fitting (cont’d)
Table 1
Required Tightening Necessary Gauge

Torques Pressure
Nm lbf ft bar lbf/in2
640 472 4.4 64
1400 1033 9.6 140
1470 1084 10.1 147
1790 1320 12.3 179
1840 1357 12.7 184
1900 1401 13.1 190
2230 1645 15.4 223
2300 1696 15.9 230
2430 1792 16.7 242
2620 1933 18.1 262
3270 2412 22.5 326
3480 2567 24.0 348
3580 2641 24.7 358
3590 2648 24.7 359
3770 2780 25.9 375
4310 3179 29.6 429
4590 3385 31.6 459
4820 3555 33.2 482
5140 3791 35.4 514
* 5590 4123 38.5 558
5650 4167 38.9 564
6220 4588 42.8 622
7420 5473 51.1 741
* 8000 5900 55.1 799
8700 6417 60.0 870
9100 6712 62.7 910
9330 6882 64.3 933
9425 6952 64.9 942
10700 7892 73.8 1070
10740 7922 74.0 1074
12700 9367 87.6 1270
12750 9404 87.9 1275
14000 10326 96.5 1400
16900 12465 116.5 1690
17700 13055 122.0 1770
19615 14468 135.2 1961
21000 15490 144.8 2100
21500 15858 148.3 2150
The torque is determined by reading the pressure on gauge

F in the rig circuit (with the spanner at 90° to the rig ram) and
converting it according to the table above.
Note: The pressures in the above table assume that the rig
is used with spanners having 500 mm centres.
9803/6310 Issue 2*
Reconditioning
Note: Jig details are in accordance with ram sizes. See Service Tools, Section 1.
This section should be used in conjunction with Boom, Dipper, Bucket and TAB Rams, Dismantling and Assembly.
Procedures for inserting and bedding the seal ring.
1 O-ring installation Stretch 'O'-ring A by hand and fit it into the piston
groove.
Be sure not to twist the 'O'-ring. A twisted 'O'-ring may

cause oil leakage.
2 Attaching the inner guide jig Carefully fit thinner end X of inner-guide jig B on the upper
section of piston C.
B
B
C X
JS07670
3 Seal ring installation Apply a thin coat of lubricant to inner guide jig B
periphery and then set seal ring D on the inner guide jig.
Make sure that any foreign matter like dust, chipped

metal and lint do not adhere to the outer surface of the
inner guide jig.
B D
9803/6310 Issue 1
Reconditioning (cont’d)
4 Outer guide jig fitting Mount outer guide jig E over inner guide jig B and using
plate F, continue pressing the plate by hand until outer
guide jig E touches seal ring D.
Be sure to set the seal ring squarely on the inner guide

F jig.
E
D
B
C
5 Press-fitting Continue to press plate F on outer guide jig E by hydraulic

press until seal ring D fits into the groove.
Be sure to press the plate carefully so that seal ring D will

fit squarely on the inner guide jig and into the groove.
F Carry out this operation smoothly.
E
D
B
6 Removal of jig After confirming that seal ring D is completely fitted into
the piston groove, remove the jigs in the following order.
F 1 Retract the press rod.

2 Remove plate F.
3 Remove outer guide jig E.
E 4 Remove inner guide jig B.
The fitting of the seal ring is completed at this stage.
B Next, correct the fitting of the seal ring using the bedding
jig.
C
D
9803/6310 Issue 1
7 Bedding jig preparation Set bedding jig G underneath the press.
Apply a thin coat of lubricant to the tapered section of

bedding jig G and place the jig with the tapered section
facing up.
Be careful that no dust, chipped metal and lint adheres to

the jig.
8 Inserting the piston Slowly and evenly insert piston C, with seal ring D fitted,
into bedding jig G.
C
D
9 Press fit Carefully press piston C into bedding jig G until seal D is
in full contact with bedding surface X.
G
D
X
C
9803/6310 Issue 1
10 Removal of bedding jig After completion of the bedding of seal ring D, remove
the jig in the following order.
1 Retract the press rod.

2 Remove bedding jig G.
This completes the fitting and bedding of the seal ring.
C
D
9803/6310 Issue 1
Bushing Removal
1 Cylinder head setting Place the cylinder head on the work bench with the
cylinder tube connecting surface facing up.
The work bench should be clean so that no dust or other

foreign matter can cause damage to the pipe joint .
2 Removing snap ring Remove the bushing securing snap ring.
Secure the cylinder head in a vice, etc. and using a

screwdriver blade, pull out the snap ring and remove.
9803/6310 Issue 1
Bushing Removal (cont’d)
3 Setting the chuck assembly Gradually insert chuck assembly A into cylinder head B
until its blade end reaches bushing end X.
1 Insert chuck assembly A into the cylinder head B,
taking care that parts of the blade do not damage
the inner circumferential surface.
2 Be careful that the blade does not jump out from
bushing end surface Y.
A B
Y
A A X
4 Temporary tightening 1 Fit the Allen wrench into chuck assembly adjuster
head J and at the same time insert lever C into the
chuck assembly rear hole.
2 Tighten enough so that when the cylinder head is
lifted, the jig will not fall off.
Note: Tightening torque less than 5 kgf m (36.16 lbf ft) is
sufficient.
J Move cylinder head B and chuck assembly to the press
C bench, gripping the assembly as shown.
9803/6310 Issue 1
5 Attaching the retainer Gently place retainer D on the stepped portion of wedge
F inside the chuck assembly A.
1 Place so that collar E is uppermost as shown.
2 Keep the press bench clean to prevent dust,

chipped metal and other foreign material causing
damage to the bottom of the chuck assembly.
D
E
D
F
A
6 Tightening Press the upper part of retainer D gradually so that the

blade part of chuck assembly A digs into the bushing
surface part of the retainer.
Note: Press load should be 2~3 tonnes.
If necessary use a retainer when pressing.
D
9803/6310 Issue 1
7 Block preparation Choose a block suitable in shape and size from the table
below. Position the cylinder head centrally on block G as
shown.
Rod Dia. d1 d2 h
mm mm mm mm
75 82 110 80
80 87 112 80
85 92 124 80
90 97 130 80
G 95 102 136 80
100 107 140 80
105 112 146 80
110 117 150 80
8 Removing bushing 1 Position block G and cylinder head B assembly

underneath the press.
2 Gradually press retainer D upper surface until the
bushing falls out from cylinder head B.
Note: Normally it falls out with a load of less than 3
tonnes.
The press ram stroke varies with the cylinder head size
D and is about 32~52 mm.
1 Use a retainer when pressing.
2 If the shaft centre of block G and cylinder head
assembly become misaligned, stop the press work
B and realign before proceeding.
9803/6310 Issue 1
9 Removing chuck assembly with bushing 1 After removing the cylinder head assembly B from
attached under the press, remove retainer D from cylinder
head B and, grasping both sides of the cylinder
head B, set aside.
2 Remove chuck assembly A with bushing H attached

B and move to the work bench.
Note: Keep the work bench clean so that no dust or

foreign matter adheres to, or damages the bottom
surface of the chuck or the outer periphery. Also ensure
D that the work bench is level.
H
A
10 Removing bush 1 Place chuck assembly A with bushing H on the work

bench horizontally and insert the Allen wrench into
chuck assembly A adjuster head section. At the
same time insert a lever into the round hole of chuck
assembly A rear section.
2 Use the lever and Allen wrench to loosen the
adjuster as shown.
3 Place the chuck assembly A vertically and turn the
adjuster with your finger until the wedge rises about
5 mm.
4 After confirming that bushing H is not touching the
chuck blade section, gently remove bushing H from
A chuck assembly A.
9803/6310 Issue 1
11 Retightening the adjuster With chuck assembly A and the bushing removed, turn
the adjuster with your fingers until there is no gap
between the adjuster and the wedge upper surface.
Note: Do not remove the adjuster J and wedge from the

chuck assembly .
9803/6310 Issue 1
Bushing Assembly
1 Cylinder head setting Set cylinder head B on the press bench with the tube
connecting surface facing up.
1 Keep the work bench clean so that dust or other
foreign matter does not damage the bottom surface
of the cylinder head. Also make sure that it is level.
2 Use compressed air to remove the foreign matter.
! CAUTION
When using compressed air, wear safety glasses and
B gloves. Do not direct compressed air at your skin.
8-3-4-2
2 Temporary setting of bushing Temporarily place bushing H evenly inside the cylinder
head B inner diameter.
Check that there is no foreign matter adhering to the inner

and outer peripheral surfaces.
3 Attaching chuck assembly Supporting chuck assembly A with your fingers, gradually
attach it to cylinder head B.
Check that there is no gap Z between chuck assembly

adjuster J and wedge M.
A J Z
A M
B
JS07820
9803/6310 Issue 1
Bushing Assembly (cont’d)
4 Attaching the retainer Gently place retainer D so that its end is aligned with
wedge stepped section Z of chuck assembly A.
Place retainer D so that the larger diameter part is facing

up as shown.
Z
A
5 Preparation for press-fitting Place cylinder head B with retainer D and chuck
assembly A attached underneath the press.
Adjust so that the shaft centre of the press is in line with

that of retainer D and chuck assembly A.
D
D
A
A
9803/6310 Issue 1
Bushing Assembly (cont’d)
6 Press-fitting the bushing At the press, push on adjuster head J and gradually
press-fit bushing H into the specified position in the
cylinder head.
The press load should be less than 5 tonnes.
Check that the bushing end surface is below snap ring
groove K.
K H
7 Removal of retainer and chuck assembly After the press-fitting of bushing H is completed, remove
the retainer and chuck assembly A from cylinder head B.
Continue attaching the seals and press-fitting the wiper
ring.
A
Check that bushing H is press-fitted correctly.
9803/6310 Issue 1
Wiper Ring Assembly
1 Setting the cylinder head Note: Keep the work bench clean so that no dust or other
foreign matter can damage the bottom surface of the
cylinder head.
Position cylinder head B on the work bench as shown.
2 Inserting the wiper ring Check that there is no foreign matter in the groove where
the wiper ring or the retainer is to be inserted.
Insert wiper ring L into the groove in retainer D, lip side first
L as shown.
3 Attaching the retainer Gently place retainer D on cylinder head B as shown.
9803/6310 Issue 1
Wiper Ring Assembly (cont’d)
4 Preparation for press-fitting Position cylinder head B and retainer D underneath the
press.
Adjust so that the shaft centre of the press and retainer D
are in line as shown.
D
D
B
B
5 Press-fitting wiper ring Press-fit wiper ring L into the specified position in cylinder
head B.
Press fit until the retainer's collar N contacts the cylinder
head.
The press load should be less than 1 tonne.
N
L
6 Removing the retainer After the wiper ring press-fitting is completed, remove
retainer D from cylinder head B.
Check that wiper ring L is correctly in position.
9803/6310 Issue 1
Cylinder Head Assembly
1 Fixing the piston rod Handle piston rod A with care to prevent damage to its
outer surface.
Position piston rod A so that the threaded part is facing

you.
2 Attaching guide Ensure that the piston rod thread and shaft A are free from
damage by dust or other foreign matter.
Locate guide B onto piston rod A, to the end of the shaft

as shown. Take care not to damage the piston thread.
A
JS02290
9803/6310 Issue 1
Cylinder Head Assembly (cont’d)
3 Inserting the cylinder head Locate cylinder head C onto piston rod A, wiper ring D
side first, to the specified position, sliding on the
peripheral surface of guide B.
1 Support the cylinder assembly with both hands,
C taking care not to drop it.
2 If oil is thinly coated on the peripheral surface of the
guide and piston rod, the cylinder assembly can be
inserted smoothly.
B
A
4 Removal of Guide After checking that cylinder head assembly C has been
completely located on piston rod A, remove guide B from
piston rod A. Next, assemble the piston, etc. on the piston
rod (see Boom, Dipper, Bucket and TAB Rams,
Dismantling and Assembly).
When removing the guide, be careful not to damage the

threaded part of the piston rod.
A C
9803/6310 Issue 1
Fault Finding
The chart below lists some possible problems and suggested remedies. The types of problems fall into four main categories as
follows:
Item Symptoms
1 Oil leakage from piston rod sliding part.
2 Oil leakage from cylinder head joint.
3 Oil leakage from pipe and cylinder tube welds.
4 Faulty operation
Item Symptoms Related Parts Trouble Treatment

On the sliding surface, there are 1 Use an oil stone and remove the scratch
scratches and rust that can be and make the sliding surface smooth.
felt by the fingernail. If oil leakage continues even though the
rod surface is made smooth, the scratch
may have damaged the U-ring and
other seals, so dismantle and inspect.
Piston rod
2 If the scratches and rust cover such a
wide area that they cannot be repaired
by an oil stone, renew the piston rod
and U-ring, wiper ring and seals and the
piston rod bearing member.
Piston rod The plating is peeling. Re-plate or renew the piston rod.
1 sliding part Also inspect the seal and piston rod
oil leakage bearing member and renew if damaged.
Foreign matter is biting into the Remove foreign matter.

inner and outer surfaces of If there is damage to packing, renew it.
the packing.
Rod packing There is a scratch on the inner Renew.
(Buffer ring surface.
U-ring) Possibly due to burning caused by
The lip and groove parts are adiabatic compression from air remaining
locally carbonized (burned). inside the ram. After renewing the
packing, first operate the ram at
low-pressure, low speed to sufficiently
bleed the air.
9803/6310 Issue 1
Fault Finding (cont’d)

Packing rubber is perished. The packing life or hydraulic oil
deterioration and high temperature are
possible reasons.
1 Renew hydraulic oil.
Rod packing 2. Check the hydraulic oil temperature.

(Buffer ring, (Below 80 °C is advisable).
U-ring)
3 Check if high temperature locally.
Lip is deficient all around. Renew.
It is possible that abnormally high pressure
is working on the packing.
1 Check the operation pressure, cushion

pressure.
2 Part which is attached to the buffer ring

may be abnormal. Inspect the buffer
ring.
The protrusion of the heel of the As a rule, renew the rod packing at the
packing is excessive. same time. (It is desirable to renew parts
1 Piston rod which are attached to the buffer ring at the
oil leakage Back up ring same time).
It is possible that abnormally high pressure

is the cause. Check the same as above
(heel of packing protruding).
Foreign matter is biting into the Remove the foreign matter.
Wiper ring lip. The lip is damaged.
There is also other abnormal Renew.
damage.
Wear is excessive and the clearance Renew.
with piston rod exceeds the
maximum permissible value.
Bushing (Refer to Maintenance
Specifications for maximum
permissible value.)
Large scratch on the sliding part. Renew.
Also inspect the piston rod.
Scratches, rust on the seal Remove scratch, rust with oil stone. If it
Cylinder head attachment parts. cannot be repaired, renew the cylinder
head.
9803/6310 Issue 1

Foreign matter on inner • Remove foreign matter.
and outer diameters. • Renew 'O'-ring if damaged.
• Inspect inside tube: if any scratches or
O-ring damaged. rust, make surface smooth with oil
stone.
‘O’-ring • Inspect cylinder head 'O'-ring groove: if
any scratches or rust, make surface
smooth with oil stone.
• Inspect back up ring: if any deformation
or protrusion, renew.
Confirm the above and renew 'O'-ring.
Back up ring Deformation, protrusion • Renew, with the 'O'-ring.
Oil leakage Looseness • Dismantle cylinder head and inspect
2 from cylinder 'O'-ring and back up ring.
head joint Cylinder head • Check tube and cylinder head thread for
damage. If any damage, renew.
• After inspection, tighten to specified
torque.
Bolt Looseness, stretching, broken Renew all bolts and tighten to specified
torque.
Abnormal bulge Replace with new parts.
Oil leakage from connecting parts

Cylinder tube may be caused by abnormal
pressure (including cushion
pressure). Inspect the tube for
bulges, deformation and check the
circuit pressure.
Crack in welding Replace with new parts.

Oil leakage • Cracks will develop into fractures.
from pipe Cylinder tube Fractures are very dangerous, so if any
3 and cylinder pipe (hollow cracks are found, stop work immediately
tube welded piston rod) and renew the parts.
seam • Welding on top of cracks will have no
effect.
9803/6310 Issue 1

Poor Bending to more than the • Replace with new part.
operation Piston rod specified limit. The seal and sliding part material may
be
cylinder tube (Bending distortion: damaged too, so inspect. If abnormal,
refer to Maintenance renew.
Specifications)
4-1 Tube scored • Replace with new part.
Movement Cylinder tube As above, inspect the seal and sliding
not smooth part material.
Abnormal wear, damage of sliding • Replace with new part.
Piston rod area As above, inspect the seal and sliding
* cylinder head part material.
sliding part Foreign matter intruding on piston • Remove foreign material.
and cylinder head sliding area As above, inspect the seal and sliding
part material.
4 4-2 Scratches, wear are present • Replace with new part.
Inner oil Piston seal Inspect the cylinder tube inner surface
leakage. also.
Piston rod
extends Scratches, rust on inside • Remove the scratches, rust by honing or
when work with an oil stone and make the surface
stops or smooth.
lowers Cylinder tube If the scratch is deep and cannot be
abnormally repaired, renew cylinder tube.
during work. • Renew piston seal.
Also,
specified Piston nut Loose nut • Tighten to specified torque.
operating
Valves Leak from valve • Inspect the valve leakage amount and
speed is not
service.
achieved.
Note: Hydraulic oil expands and contracts due to changes in temperature and pressure. Accordingly, the ram also
expands and this can be mistaken for internal leakage. When inspecting for internal leakage, do so at set conditions.
9803/6310 Issue 2*

4-3 Air remaining inside ram. • Bleed the air.
Operation is unsteady For rams that do not have an air
bleeder, operate back and forth several
times at low pressure and low speed to
bleed the air. For rams with an air
bleeder, remove the load to reduce the
Air pressure then loosen the air bleeder
and completely bleed the air.
Note: The ram may expand if it is
stopped suddenly. This is due to the
compression of the hydraulic oil. This
occurs especially with long stroke rams.
4
4-4 Pin bushing/pin Gap between mounting and Measure the pin and pin bushing and
Heavy shock pin bushing is too large. renew parts if measurements exceed
loading when the specifications.
changing from
extension to
retraction
and back
4-5
Noisy Oil supply Insufficient oil. • Add oil.
operation
Pin bushing/pin Scuffing at connecting part. • Replace with new part and add oil.
Note: If left in the state where operation is poor, the ram will no longer move and other parts will be affected
adversely. Inspect early and carry out appropriate measures.
9803/6310 Issue 1
Maintenance Specifications
Piston Rod Diameter Wear Limits
Nominal diameter Maximum wear limit

Treatment
mm (in) mm (in)
55~80 (2.17~3.15) -0.023 (-0 .001) Renew or replate
85~120 (3.35~4.73) -0.027 (-0 .001) Renew or replate
Rod Bushing Inner Diameter Wear Limits
Nominal diameter Nominal inner diameter limit Maximum wear limit Treatment
mm (in) mm (in) mm (in)

55~75 (2.17~2.96) +0.06~+0.195 (+0.002~+0.007) +0.30 (+0.012) Renew bushing
80~120 (3.15~4.73) +0.06~+0.195 (+0.002~+0.007) +0.30 (+0.012) Renew bushing
Piston Guide Ring Thickness Wear Limit Section
Nominal diameter Standard thickness Minimum thickness Treatment
mm (in) mm (in) mm (in)

95~160 (3.74~6.299) 2.42~2.48 (0.095~+0.098) 2.37 (0.093) Renew guide ring
165~250 (6.496~9.843) 2.92~2.98 (0.115~+0.177) 2.87 (0.113) Renew guide ring
9803/6310 Issue 1
The following information is for rams used on JS wheeled

machines:
Machine Ram Serial number

JS 130W Boom 717053
Arm 717050
Bucket 717049
JS 145W All 810000
Fig. 1
JS160W Boom 718920
Boom (HBCV) 718965
Arm 718966
Bucket 718966
JS 175W All 875000
Dismantling the piston rod from cylinder tube

Necessary equipment
Assembly bench
Overhead crane
Cleaning facilities
Socket wrench
Note: Disassembly should be done vertically.
Fig. 2
1 Clean the cylinder carefully. Use high-pressure cleaning
and solvent (Fig. 1). Empty the oil from the cylinder.
2 Unfasten the cylinder head screws. Keep screws in
place (Fig. 2).
3 Position the cylinder vertically (Fig. 3).
4 Release the end cover and pull out the piston rod pack.
Note: Handle the piston rod with care to avoid damage. Put
some soft material between piston rod and shims during
transport and at storage. Fasten the covers for the end
flange.
Fig. 3
9803/6310 Issue 1*
Dismantling the piston rod

Note: protect all the parts from dirt.
1 Secure the piston rod pack on the bench, brace the

piston rod head (Fig. 4).
Fig. 4
2 Unfasten and remove the stop screw X. Remove the
steel ball Y (Fig. 5).
X
Y
3 Unfasten the nut (Fig. 6). Fig. 5
Fig. 6
4 Dismantle the snap ring by carefully knocking on it with

a plastic hammer(Fig. 7).
Fig. 7
5 Press the cushion ring against the piston (Fig. 8).
Fig. 8
9803/6310 Issue 1*
Dismantling the piston rod (cont)

6 Dismantle the lock halves (Fig. 9).
Fig. 9
7 Remove the cushion ring (Fig. 10).
Fig. 10
8 Remove the seal (Fig. 11).
Fig. 11
9 Remove the shims A, the piston B, the cushion ring C
and disassemble the cushion ring seal D (Fig.12).
C D B A
Fig. 12
10 Dismantle the cylinder head.

Note: Protect the threads (Fig 13).
Fig. 13
9803/6310 Issue 1*
Removing the piston seals

Note: Never reuse seals
While dismantling, handle the piston very carefully.
1 Remove the four slotted guiding rings and the two back
up rings from the piston (Fig. 14).
Fig. 14
2 Turn the sharp edge of the scalpel against the slide ring
and press it down into the small gap between piston and
slide ring (Fig. 15). Lift the O-ring with a chisel and cut it
off.
Take care not to damage the surface.
Fig. 15
Removing the cylinder head seals
1 The cylinder head wiper is disassembled by deforming it
with a hammer and chisel according to (Fig. 16).
Fig. 16
2 Press a sharp object into the back up ring (Pos. 1) at its

slit, bend out and pull away the back up ring with pliers
(Fig. 17).
Fig. 17
3 The secondary seal (Pos. 2) is removed using a chisel.

Put the chisel into the small gap where the back up ring
was earlier, bend out (Fig. 18).
Note: Do not put the chisel in too far, the surfaces of the
head are galvanised.
Fig. 18
4 Cut the primary seal with a scalpel (Fig. 19). After that,
the chisel may be used to remove the back up ring.
Note: Do not cut through, the surfaces of the cylinder head
are easily damaged.
Fig. 19
9803/6310 Issue 1*
Removing the cylinder head seals (cont)

5 Remove the O-ring using a sharp tool. Press the tool
through the square ring and bend out (Fig. 20).
Fig. 20
6 Turn the cylinder head and remove the snap ring with a
chisel (Fig. 21).
Fig. 21
7 Remove the O-ring and back up ring for the external

seal. Use a chisel (Fig. 22).
Fig. 22
9803/6310 Issue 1*
Removing the cylinder head seals (cont)
D C A B
Fig. 23
8 To remove the bush in the cylinder head, an expander

tool is required. Fit the expander tool A in the cylinder
head B according to Fig. 23. Please note the direction!
Press the tool in far enough, so that the rifled part is
opposite the bush.
Assemble the guide jig C and the screw D.
Extend the flutes in the expander tool using the Allen
key.
9 Put the cylinder head on the press rod (Fig. 24). Press
out the expander tool which will then remove the bush.
Fig. 24
9803/6310 Issue 1*
Assembly of piston seals

Before assembly
1 To assemble the piston seals use a seal insertion tool.

Make sure the tool is free from defects. Burrs or marks
may damage the seals and cause leakage. Check the
outside of the tool carefully.
One part of the seal insertion tool is thin-walled, make
sure it is not damaged (Fig. 1).
Fig. 1
2 Carefully place seal insertion tool on the piston and roll on

the O-ring until it is placed in the middle groove of the
piston.
Make sure the O-ring is not twisted after assembly (Fig. 2)
Fig. 2
3 Assembly of slide ring
Set up according to Fig. 3.
A
B
Plate
Outer guide jig
A
C Slide ring.
D Inner guide jig,(heated to approximately 60ºC).
E Piston.
D
E
Fig. 3
9803/6310 Issue 1*
Assembling the piston seals (cont)

4 Pressing of slide ring
Use the press to press the slide ring down into the
middle groove of the piston (where the O-ring already
is). During pressing, the outer guide jig must be held
together with one hand (Fig. 4). The slide ring will open
out at this stage.
Fig. 4
5 Assembling the back up rings.
Attach the green back up rings, make sure that their slits
are not aligned (Fig. 5).
Fig. 5
6 Use the correction jig to clibrate the seals. Please note

the direction of the jig! (Fig. 6)
Fig. 6
7 Check the piston seal.
Press the piston through the correction jig (Fig. 7).
Fig. 7
9803/6310 Issue 1*
Assembling the piston seals (cont)

8 Fit slotted guiding rings. Note: Guiding ring slits must
not be aligned! (Fig. 8).
Fig. 8
Assembling the cylinder head seals

Before assembly
Check that assembly tools are free from defect. Clean
tools before starting the set. Pre-heat the U-ring to
approximately. 60ºC. Clean cylinder head before
assembly. Check that grooves are clean and not
damaged.
1 Fitting of bushing and snap ring.
Set up according to Fig. 9. Press in the bush using the
press rod. Attach snap ring.
Fig. 9
2 Fit O-ring and back up ring (Fig. 10).
Fig. 10
3 Fitting of primary seal and U-ring.
Turn the head to get the wiper end up and clean. Attach A
the square ring.
Note: Please check the correct direction!
A Back up Ring (green).
C
B Side Ring (black).
C Square ring. B
Turn with the
slotted side to the
pressure side
Fig. 11
9803/6310 Issue 1*
Assembling the cylinder head seals (cont)

Bend the slide ring to a loose curve before fitting,
(Fig.12). Please note the right direction!
Fit back up ring after putting the slide ring in place. Soft transition
4 Attach the back up ring first. No breaking
Bend the U-ring according to Fig. 12.
Fig. 12
BACK
BACKUP
UPRING
RING
Insert the U-ring under the back up ring.
U-RING
U-RING
Fig. 13
5 Fitting of wiper. Plate for

mounting
Use the plate to press in the wiper (Fig. 14).
wiper
WIPER
Fig. 14
B
6 Complete pre-assembled head (Fig. 15).
C
A WIPER
B SQUARE RING D
C BACK UP RING (green)
D SLIDE RING (black)
E BACK UP RING A
F SECONDARY SEAL TURN WITH
G BUSHING E THE SLOTTED
H SNAP RING SIDE TO
J BACK UP RING F PRESSURE
SIDE
K O-RING
G
H
J
K
Fig. 15
9803/6310 Issue 1*
Assembly of piston rod with cushion ring

on the piston rod side
The cylinder components must be cleaned before
assembly. The piston and cylinder head must be
cleaned before seal assembly and be kept clean up until
this stage. Do not clean piston or cylinder head with
seals fitted.
2 5
1 3 4 6
Fig. 16
Piston rod (Fig.16)
Fig. 16
Fig. 17
9803/6310 Issue 1*
Assembly of the piston rod with cushion

ring on the piston rod side (cont) 1
1 Fit the cylinder head on (Fig. 19).
Fig. 19
2 Fit the seal under the cushion ring (Fig. 20).

Please note the direction!
Fig. 20
3 Put the cushion ring on (Fig. 21).
Please note the direction! Turn the arrow point towards
the piston.
Fig. 21
4 Put the piston on. Please note the direction! (Fig. 22).
5 Fit shims (reduction of friction) (Fig. 23). Fig. 22
Fig. 23
9803/6310 Issue 1*
Assembly of piston rod with cushion ring on

the piston rod side (cont)
6 Assemble and tighten the nut to torque value according
(Fig. 24).
Ram Part No. Torque

Boom non HBCV 331/17710 3770 Nm (2780 lbf ft) (384 kgf m)
Bucket 331/17711 4310 Nm (3178 lbf ft) (439 kgf m)
Arm 331/17712 7090 Nm (5229 lbf ft) (723 kgf m)
Boom with HBCV 331/17731 3770 Nm (2780 lbf ft) (384 kgf m) Fig. 24
7 Fit the steel ball 7 (Fig. 25).
Fig. 25
8 Fit the stop screw (Fig. 26). Tighten to 46.9 to 66.9 Nm

(34.6 to 49.3 lbf ft) (4.8 to 6.8 kgf m).
Fig. 26
Make two punch marks by the stop screw so that the

material is clearly indented (Fig. 27).
Fig. 27
9803/6310 Issue 2*

on the piston rod & cylinder bottom side
Cylinder components must be cleaned before assembly.
Piston and cylinder head must be cleaned before seal
assembly and be kept clean up until this stage. Do not
clean piston or cylinder head with seals fitted.
Fully assembled piston rod
7 6
8
9
2
5 10 11 12
Turn the notch

and arrows
towards the
piston
Turn the notch and arrows

towards the piston
Fig. 28 1 3 4
Piston rod (Fig.29)
Fig. 29
Put the guide jig on 683035 (Fig. 30)
Fig. 30
9803/6400 Issue 1*

on the piston rod & cylinder bottom side 1
1 Put the cylinder head on (Fig. 31).
Fig. 31
2 Fit the seal for the front cushion ring (Fig. 32).
2
Please note the direction!
Fig. 32
3 Put the front cushion ring on. Please note the direction!
3
Warning! Turn arrow point towards the piston (Fig. 33)
Fig. 33
4 Fit the piston (Fig. 34). Please note the direction!

4
Fig. 34
5 Fit shims (Fig. 35).

5
Fig. 35
6 Fit the seal for the rear cushion ring (Fig. 36).
Please note the direction! 6
Fig. 36
9803/6310 Issue 1*
Assembly of piston rod with cushion ring on

the piston rod & cylinder bottom side
(cont)
7 Fit the rear cushion ring. Please note the direction! (Fig. 37)
Note: Turn arrow point towards the piston
Fig. 37
8 Press in the rear cushion ring as far as possible (Fig. 38).
Fig. 38
Assemble the two lock halves and hold them with your
fingers. Use the other hand to put the rear cushion ring
over the two halves (Fig. 39).
Fig. 39
The rear cushion ring keeps the lock halves in place (Fig.
40).
9 Carefully knock the snap ring in place. Fig. 40
Use a plastic hammer (Fig. 41).
10 Fit and tighten the nut to stated torque value as follows: Fig. 41
(Fig. 42).
Note: Do not use oil!
Ram Part No. Torque
Boom non HBCV 331/17710 3770 Nm (2780 lbf ft) (384 kgf m)
* Bucket 331/17711 4310 Nm (3178 lbf ft) (439 kgf m)
Arm 331/17712 7090 Nm (5229 lbf ft) (723 kgf m)
Boom with HBCV 331/17731 3770 Nm (2780 lbf ft) (384 kgf m)
Fig. 42
9803/6310 Issue 2*

on the piston rod & cylinder bottom side 11
(cont)
11 Fit the steel ball (Fig. 43).
Fig. 43
12 Fit stop screw (Fig. 44). Tighten the screw to 46.9 to 12

66.9 Nm (34.6 to 49.3 lbf ft) (4.8 to 6.8 kgf m).
Make two punch marks on each side of the stop screw
so that the material is clearly bent
Fig. 44
Assembly of piston rod in cylinder tube

1 Make sure that assembly tools and cylinder tube are
clean before assembly. The piston rod pack must be
protected from dirt up until this stage. Assembly should
be made vertically.
Secure the cylinder tube (Fig. 45) and bring the end of
the piston rod to the cylinder tube opening.
Release the end-flange cover on the cylinder tube in
order to let air out from the tube during assembly.
Make sure the piston rod head is turned in the right
position in relation to the bottom of the cylinder.
2 Before assembly, make sure that guiding slits on the
piston are not aligned (Fig. 46).
Fig. 45
Fig. 46
9803/6310 Issue 1*
Assembly of piston rod in cylinder tube

(cont)
3 Put the piston rod pack into the cylinder tube. Make
sure that the piston guiding ring does not get jammed
during assembly.
Clean hydraulic oil will help, but do not use a brush as
hairs may come off.
When running the piston rod in, turn the cylinder head
into the right position. Finish doing this before the
cylinder head O-ring has reached the cylinder tube (Fig.
47). Do not use assembly grease.
Fasten the cover.
Fasten cylinder head screws and torqe tighten to the
following values:
Ram Part No. Torque

Boom non HBCV 331/17710 267 Nm (197 lbf ft) (27.2 kgf m)
Bucket 331/17711 171 Nm(126 lbf ft) (17.4 kgf m)
Arm 331/17712 267 Nm (197 lbf ft) (27.2 kgf m)
Boom with HBCV 331/17731 267 Nm (197 lbf ft) (27.2 kgf m)
4 Tighten in order according to Fig. 48.

Note: Be careful not to damage the piston rod!
Fig. 47
Fig. 48
9803/6310 Issue 1*

JCB JS175W Service Manual PDF

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General Information 1

Care & Safety 2

Contents Page No.

Contents Page No.

Contents Page No.

* Hydraulic Rams - from various serial numbers (see page 48-1)

Type Variable displacement, two element piston pumps in

Manufactured in two halves and bolted together.

Left Hand Valve (3 spool) Servo actuation of bucket, boom options/dozer.

Drive Variable displacement, axial piston motor.

Bar (lbf/in2) Bar (lbf/in2) Bar (lbf/in2) Bar (lbf/in2)

2 Stage Main Relief

Boost/’F’ Mode 340 (4930) 340 (4930) 340 (4930) ± 5 (72)

* TAB 363 (5264) 363 (5264) 363 (5264) ± 5 (72)

Servo Pressure - Continuous 40 (580) 40 (580) 40 (580) ± 2 (29)

Clutch Pilot Pressure - Continuous 32 (464) 32 (464) 32 (464) ± 2 (29)

Service Brake Pressure - On Latch 48 (696) 48 (696) 48 (696) ± 2 (29)

Park Brake Pressure - Clutch Residual15 (218) 15 (218) 15 (218) ± 1 (14.5)

Service Brake Accumulators (x 4) - Nitrogen Pre-charge 37 (536) 37 (536) 37 (536) ± 2 (29)

Park Brake Accumulator - Nitrogen Pre-charge 6 (87) 6 (87) 6 (87) ± 1 (14.5)

Reverse Lights - Pressure Switch Rising 5 (72) 5 (72) 5 (72) ± 1 (14.5)

Pressure Sequence Valve - Clutch Priority 28 (406) 28 (406) 28 (406) ±2 (29)

Clutch Priority Accumulator - Nitrogen Pre-charge 8 (16) 8 (16) 8 (16) ±1 (14.5)

JS130W/JS145W/JS160W ‡48 Servo Control (Foot Operated, TAB)

J160W/JS175W Boom Circuit (TAB Option)

PRE CHARGE 0.8MPa

PRE CHARGE 1.5MPa

2-STAGE RELIEF MAX FLOW CONTROL P

JS175W 49 Remote Valve

PRE CHARGE 0.8MPa

PRE CHARGE 1.5MPa

2-STAGE RELIEF MAX FLOW CONTROL P

The above circuit is for JS175W only.

Some problems which may occur in the hydraulic system are

Symptom Possible Cause Action

4 A ram is worn. Repair or renew the ram.

5 Negative pressure is low. Check circuit pressure.

6 A valve is cracked. Renew the valve.

9 Circuit filters are clogged. Clean or renew filters.

10 The circuit pipes are restricted. Check the piping.

Symptom Possible Cause Action

2 Hydraulic Pump (cont'd)

2 Clogging of the tank strainer. Clean strainer. If strainer is severely

4 Coupling defective. Check shaft run out.

6 Internal damage to pump. Dismantle and inspect pump, paying

d Engine overload 1 Regulator torque set too high. Adjust as necessary.

3 Pump is seized or worn. Dismantle and inspect pump, paying

2 Damaged or blocked drain pipe. Inspect and renew as necessary.

3 The service pipe connection Check tightening torque.

5 Pressure too high. Check system pressure.

6 A spool is bent. Renew the control valve section.

7 A return spring is broken. Renew as necessary.

Symptom Possible Cause Action

3 Control Valve (cont'd)

9 Temperature distribution within Warm the entire system up before

2 Oil is bypassing dipper/boom spool. Renew control valve section.

4 Main Relief Valve

Symptom Possible Cause Action

5 Slew Motor (cont'd)