JCB 3CX, 4CX, 214e, 214, 215, 217 & VARIANTS Backhoe Loader. Service Manual

Section D

Controls

Section D

71 - 2

Control Cables

71 - 2

Removal and Replacement

Stabiliser Controls

The stabiliser controls A and associated cables are housed

in the R.H. side console as shown.

There are two control cables which operate the R.H. and

L.H. stabiliser control valves on the excavator valve block.

Note the routing of the existing cables and route the new

cable(s) in the same way.

Removal

Park the machine on firm level ground, apply the

parking brake. Lower the loader arms and excavator to

the ground, switch OFF the engine and remove the

starter key.

Working under the machine at the excavator valve,

undo the locknut B. Remove the screws C and slide

back the housing D to reveal the clevis as shown.

Remove the clevis pin E to release the cable from the

spool.

Feed the end of the cable back underneath the cab to

the rear wheel arch on the R.H. side of the machine and

release the cable from the clamp assembly at position X

as shown.

Working in the cab, remove the fixings F from around

A394410

the base of the control levers and carefully withdraw the

lever assembly from the side console to reveal the

cables connected on the underside.

Remove the clamp G securing the cables to the

bracket. Remove the spring clip and clevis pin H to

release the cable.

From inside the side console, carefully pull the cable up

into the cab through the aperture in the cab floor.

Replacement

Replacement is the reverse of the removal sequence.

After fitting the cable(s), operate the controls and check that

the stabilisers function correctly.

A405180

9803/3280

Issue 1

Section D

Controls

Section D

72 - 2

Control Cables

72 - 2

Removal and Replacement

Boom Lock Cable

Boom Stop Setting

The boom lock control A and associated cable is housed in

The boom stop block should be set as follows:

the R.H. side console as shown.

Lightly secure the boom stop block 1 in its lowest

Note the routing of the existing cable and route the new

position.

cable in the same way.

Raise the boom lock 2 using the control knob in the

Removal

cab.

Park the machine on firm level ground, apply the

Fully raise the boom (i.e. the boom ram fully retracted)

parking brake. Lower the loader arms and excavator to

and engage the boom lock using the control knob in the

the ground, switch OFF the engine and remove the

cab.

starter key.

With the engine switched OFF, operate the excavator

Working at the boom, remove the cable ball stud B from

control levers several times to vent any resisdual

the boom lock casting.

pressure from the boom ram.

Loosen the lock nut and disconnect the bulkhead fitting

Adjust the boom stop block 1 until there is 3 mm (1/8

C from the bracket. Feed the end of the cable back

in.) gap between the stop and the boom profile as

underneath the cab to the rear wheel arch on the R.H.

shown at 3.

side of the machine and release the cable from the

clamp assembly at position X as shown. Remove the

Tighten clamping bolt 4. Tighten grubscrew 5 and lock

spring clip D from the outer sleeve.

nut 6.

Working in the cab, unscrew the knob and lock nut from

Switch ON the engine. Fully raise the boom (i.e. the

the boom lock control A. Remove the fixings from the

boom ram fully retracted) and raise the boom lock using

side console panel and carefully lift up the rear corner

the control knob in the cab.

of the side console panel over the boom lock control

outer sleeve.

If the boom lock does not release readjust the stop

block as follows:

With the rear corner of the side console panel lifted up,

carefully pull the boom lock cable up into the cab

a Loosen the lock nut 6 and slacken the grubscrew 5

through the aperture in the cab floor.

a further half turn.

Replacement

b Loosen clamping bolt 4 and reposition the stop

block. Retighten bolt 4 and lock the grubscrew.

Replacement is the reverse of the removal sequence.

Operate the boom and check that the boom lock will

After fitting the cable, with the control knob pressed

engage and disengage correctly using the control knob

down adjust the bulkhead fitting C to take up any slack

in the cab.

in the cable. The cable should be tight but must not lift

the boom lock from its fully down position.

Torque Settings

Operate the boom and check that the boom lock will

Item

kgf m

lbf ft

engage and disengage correctly using the control knob

476

352

in the cab. Check the boom stop setting, see Boom

Stop Setting.

9803/3280

Issue 1

Section D

Controls

Section D

73 - 2

Control Cables

73 - 2

Removal and Replacement

Engine Throttle Cable

The engine throttle cable is routed from the L.H. side of the

engine compartment to connect with the footpedal A at the

engine compartment bulkhead, and to the hand throttle lever

B housed in the R.H. side console as shown.

Removal

Park the machine on firm level ground, apply the

parking brake. Lower the loader arms and excavator to

the ground, switch OFF the engine and remove the

starter key.

Open the bonnet and remove the engine side covers.

At the L.H. side of the engine compartment, disconnect

the throttle cable by loosening the lock nut C and

unhooking the cable from the fuel injector pump lever D

as shown. Feed the end of the cable back across the

engine compartment to the bulkhead on the R.H. side.

Working at the R.H. side of the engine compartment at

the bulkhead, remove the screws E and ease back the

rubber bulkhead cover to reveal the end of the

footpedal lever as shown. Remove the nut F and

disconnect the cable pivot block from the footpedal.

Loosen the lock nut G and release the cable from the

bracket. Feed the cable back underneath the cab to the

rear wheel arch on the R.H. side of the machine.

A394410

Working in the cab, remove the fixing H at the top of the

instrument panel and carefully lift the panel forward to

reveal the hand throttle lever and mounting bracket

assemby J inside the side console as shown.

Remove the hand throttle lever knob. Remove the

screws K, taking hold of the hand throttle lever

assembly withdraw the handle through the slot in the

panel.

From inside the side console, carefully pull the cable up

into the cab through the aperture in the cab floor.

Replacement

Replacement is the reverse of the removal sequence.

After fitting the cable, operate the hand and foot throttle

controls and check that they function correctly.

9803/3280

Issue 1

Section D

Controls

Section D

74 - 1

Control Cables

74 - 1

Removal and Replacement

Auxiliary Footpedal Cable

The auxiliary footpedal control A is mounted in the cab floor

as shown. The cable operates the auxiliary control valve

located adjacent to the excavator valve. The cable is

accessible underneath the rear L.H. corner of the cab.

Note the routing of the existing cable and route the new

cable in the same way.

Removal

Park the machine on firm level ground, apply the

parking brake. Lower the loader arms and excavator to

the ground, switch OFF the engine and remove the

starter key.

Working at the rear of the machine at the auxiliary valve,

undo the locknut B. Remove the screws C and slide

back the housing D to reveal the clevis as shown.

Remove the clevis pin E to release the cable.

At the footpedal remove the U-clamp F securing the

cable to the bracket. Remove the spring clip G to

release the cable. If the cable is to be replaced, remove

and retain the microswitch operating tab H from the old

cable as shown.

Replacement

A394410

Replacement is the reverse of the removal sequence.

A404720

A404710

9803/3280

Issue 1

Section E

Hydraulics

Section E

Contents

Page No.

Service Tools

1-1

Technical Data

Hydraulic Pumps

Fixed Flow

2-1

Variable Flow

2-3

Relief Valve Pressures

Loader Valve - Fixed Flow

2-4

Loader Valve - Precision Control (Servo)

- Machines up to serial no. 931159

2-5

- Machines from January 2003

2 - 5A

Loader Valve - Variable Flow

2-7

Excavator Valve - Fixed Flow

2-8

Excavator Valve - Precision Control (Servo)

- Machines up to serial no. 931159

2 - 10

- Machines from January 2003

2 - 10A

Auxiliary Valve - Fixed Flow

2 - 11

Smooth Ride System

2 - 13

Basic System Operation

Component Location and Neutral Circuit Descriptions

Fixed Flow - Single Pump

3-1

- Double Pump

3-3

Variable Flow

3-7

Introduction to Hydraulic Schematic Symbols

3 - 10

Circuit Schematics

Fixed Flow

3 - 20

Variable Flow

3 - 26

Precision Control (Servo)

- Machines up to serial no. 931159

3 - 31

- Machines from January 2003

3 - 33

Circuit Descriptions

Hydraulic Pump - Fixed Flow

Single Pump Operation

5-1

Double Pump Operation

5-1

Hydraulic Pump - Variable Flow

Operation

5-3

Pressure/Flow Regulator Valve

5-5

Loader Valve

Manual Control

- Neutral Circuit

6-1

- Unloader Operation

6-1

- Hydraulic Speed Control (HSC)

6-3

- Load Hold Check Valves Operation

6-5

- Arms Lower

6-7

- Float

6-7

- Auxiliary Relief Valve (ARV) Operation

6-9

- Main Relief Valve (MRV) Operation

6 - 11

9803/3280

Issue 4*

Section E

Hydraulics

Section E

Contents

Page No.

Loader Valve - Variable Flow

Operation

7-1

Priority Inlet Section Operation

7-2

Auxiliary Spool

7-4

Loader Shovel Spool

7-5

Loader Lift Spool

7-6

Shuttle Valve Signal Network

7-7

Excavator Valve

Manual Control

- Neutral Circuit

8-1

- Load Hold Check Valves Operation

8-3

- One Way Restrictor Operation

8-5

- Slew Operation

8-5

- Slew ARV and Anti Cavitation Operation

8-7

- Auxiliary Relief Valve (ARV) Operation

8-7

- Pilot Operated Pressure Relief Valve Operation

8-9

- Hydraclamp Valve Operation

8 - 11

Precision Control (Servo)

- Machines up to serial no. 931159

8 - 13

Hydraclamp Valve Operation

8 - 17

- Machines from January 2003

8 - 18

Smooth Ride System

10 - 1

Hose Burst Protection Valves (if fitted)

Boom & Dipper Operation

11 - 1

Loader Operation

11 - 5

Fault Finding

Hydraulic System

Fixed Flow

15 - 1

Variable Flow

15 - 10

Smooth Ride System

15 - 12

Service Procedures

Hydraulic Contamination

20 - 1

Fixed Flow Pumps

Flow and Pressure Testing

21 - 1

Variable Flow Pumps

Flow and Pressure Testing

22 - 1

Regulator Valve Adjustment

22 - 5

Renewing Drive Shaft Seal

22 - 7

Shuttle Valve Signal Network - Testing

22 - 8

Loader Valve - Pressure Testing

Main Relief Valve (MRV)

23 - 1

Unloader Valve

23 - 2

Hydraulic Speed Control (HSC)

23 - 3

Auxiliary Relief Valves (ARV's)

23 - 5

Excavator Valve - Pressure Testing

Auxiliary Relief Valves (ARV's)

23 - 9

Excavator Valve - Precision Control (Servo)

- Machines up to serial no. 931159

Pressure Testing -

Load Sense Drain Regulator and Relief Valve

23 - 10

9803/3280

Issue 4*

Section E

Hydraulics

Section E

iii

Contents

Page No.

Excavator Valve - Precision Control (Servo)

- Machines from January 2003

Pressure Testing - Load Sense Relief Valve

23 - 11

Pressure Compensator Network - Testing

23 - 12

Ram Creep Tests - All Services

24 - 1

Quick Release Couplings

Connecting & Disconnecting

25 - 1

Smooth Ride System

Charging/Discharging the Accumulator

26 - 1

Hose Burst Protection Valves (if fitted)

Checking

27 - 1

Lowering a Load - In a Failure Condition

27 - 1

Pressure Testing - Loader Lift Ram

27 - 2

Main Pump

Fixed Flow

Removal and Replacement

30 - 1

Dismantling and Assembly

31 - 1

Variable Flow

Dismantling and Assembly

35 - 1

Loader Valve - Fixed Flow

Removal and Replacement

Manual Control

50 - 1

Dismantling and Assembly

Main Relief Valve (MRV)

50 - 6

Auxiliary Relief Valves (ARV’s)

50 - 8

Unloader Valve

50 - 10

Standard Spool - Manual

50 - 12

Float Spool - Manual

50 - 14

Electric Detent Spool - Manual

50 - 16

Bolt on Auxiliary Spool Section

50 - 24

- Auxiliary Relief Valves

50 - 26

Precision Control (Servo)

- Machines from January 2003

51 - 1

Standard Spool

51 - 3

Electric Detent Spool

51 - 5

Mechanical Detent Spool

51 - 7

Loader Valve - Variable Flow

Removal and Replacement

55 - 1

Dismantling and Assembly

Priority Inlet Section

55 - 2

Auxiliary Spool

55 - 4

Loader Shovel Spool

55 - 6

Loader Lift Spool

55 - 8

Fitting Spool Seal

55 - 10

9803/3280

Issue 4*

Section E

Hydraulics

Section E

Contents

Page No.

Excavator Valve

Removal and Replacement

Manual Control

60 - 1

Variable Flow

60 - 4

Precision Control (Servo)

60 - 6

Dismantling and Assembly

Manual Control

61 - 1

- Auxiliary Relief Valves (ARV’s)

61 - 3

- Hydraclamp Valve (Sideshift Machines)

61 - 5

- Hoses and Pipes

61 - 6

Precision Control (Servo)

- Machines up to serial no. 931159

62 - 1

Drain Regulator and Relief Valve

62 - 3

Hydraclamp Valve

62 - 5

- Machines from January 2003

62 - 20

Flow Regulator Valve

62 - 22

Load Sense Relief Valve

62 - 23

Auxiliary Relief Valves (ARV’s)

62 - 24

Anti-cavitation Valve

62 - 25

Hose Burst Protection Valves (if fitted)

Removal and Replacement

70 - 1

Dismantling and Assembly

70 - 2

Hydraulic Rams

Removal and Replacement

Loader Lift Ram

75 - 1

Loader Shovel Ram

76 - 1

Slew Ram

77 - 1

Stabiliser Ram - Sideshift

78 - 1

Stabiliser Ram - Centremount

78 - 3

Dipper Ram

79 - 1

Bucket Crowd Ram

80 - 1

Boom Ram

81 - 1

Dismantling and Assembly

Loader Lift Ram

85 - 1

Loader Shovel Ram

85 - 1

Boom Ram

85 - 1

Bucket Ram

85 - 1

Stabiliser Ram

85 - 1

Dipper Ram

86 - 1

Slew Ram

87 - 1

Power Sideshift Ram

88 - 1

JCB Ram Sealing Procedure

89 - 1

9803/3280

Issue 4*

Section E

Hydraulics

Section E

1 - 1

Service Tools

1 - 1

Hydraulic Circuit Pressure Test Kit

892/00253

Pressure Test Kit

:892/00201

Replacement Gauge 0-20 bar (0-300 lbf/in²)

:892/00202

Replacement Gauge 0-40 bar (0-600 lbf/in²)

:892/00203

Replacement Gauge 0-400 bar (0-6000 lbf/in²)

:892/00254

Replacement Hose

S267300

993/69800

Seal Kit for 892/00254 (can also be used with

probe 892/00706)

892/00706

Test Probe

S188121

S188131

Pressure Test Adapters

Pressure Test 'T' Adapters

892/00255

1/4 in BSP x Test Point

892/00256

3/8 in BSP x Test Point

S200141

892/00262

1/4 in M BSP x 1/4 in F BSP x Test Point

892/00257

1/2 in BSP x Test Point

816/55038

3/8 in M BSP x 3/8 in F BSP x Test Point

892/00258

5/8 in BSP x Test Point

816/55040

1/2 in M BSP x 1/2 in F BSP x Test Point

816/15118

3/4 in BSP x Test Point

892/00263

5/8 in M BSP x 5/8 in F BSP x Test Point

892/00259

1 in BSP x Test Point

892/00264

3/4 in M BSP x 3/4 in F BSP x Test Point

892/00260

1.1/4 in BSP x Test Point

892/00265

1 in M BSP x 1 in F BSP x Test Point

892/00261

5/8 in UNF x Test Point

Flow Test Equipment

892/00268

Flow Monitoring Unit

892/00269

Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)

892/00293

Connector Pipe

892/00270

Load Valve

1406/0021

Bonded Washer

1604/0006

Adapter 3/4 in M x 3/4 in M BSP

1612/0006

Adapter 3/4 in F x 3/4 in M BSP

892/00271

Adapter 3/4 in F x 5/8 in M BSP

892/00272

Adapter 5/8 in F x 3/4 in M BSP

816/20008

Adapter 3/4 in F x 1/2 in M BSP

892/00275

Adapter 1/2 in F x 3/4 in M BSP

892/00276

Adapter 3/4 in F x 3/8 in M BSP

892/00277

Adapter 3/8 in F x 3/4 in M BSP

892/00273

Sensor Head 0 - 380 l/min

892/00294

Connector Pipe

1606/0015

Adapter 1.1/4 in M BSP x 1 in M BSP

892/00078

Connector 1 in F x 1 in F BSP

1604/0008

Adapter 1 in M x 1 in M BSP

1606/0012

Adapter 1 in M x 3/4 in M BSP

S188151

816/20013

Adapter 3/4 in F x 1 in M BSP

9803/3280

Issue 1

Section E

Hydraulics

Section E

1 - 2

Service Tools

1 - 2

Components for Valve Block A.R.V. Testing

For 4CX Variable Flow machines use 25/201103

892/00881

Valve Spool

892/00309

A.R.V. Pressure Test Kit

Seal Fitting Tool

: 892/00340

Test Block Body

: 892/00341

Setting Body

: 993/68300

Adjusting Pin

: 892/00343

Spanner

: 892/00345

Anti-cavitation Lock Out Bung

892/00335

A.R.V. Cartridge Removal Tool

S261220

S196700

Hand Pump Equipment

892/00223

Hand Pump

Bonded Washers

892/00137

Micro-bore Hose 1/4 in BSP x 3 metres

892/00274

Adapter 1/4 in M BSP x 3/8 in M BSP Taper

1406/0011

1/4 in. BSP

892/00262

1/4 in M BSP x 1/4 in F BSP x Test Point

1406/0018

1/2 in. BSP

892/00706

Test Probe

1406/0014

5/8 in. BSP

892/00278

Gauge 0 - 40 bar (0 - 600 lbf/in²)

1406/0021

3/4 in. BSP

892/00279

Gauge 0 - 400 bar (0 - 6000 lbf/in²)

1406/0029

1.1/4 in. BSP

S188140

S193850

Male Adapters - BSP x NPT (USA only)

Male Adapters - BSP x BSP

816/00439

3/8 in. x 1/4 in.

1606/0003

3/8 in. x 1/4 in.

816/00440

1/2 in. x 1/4 in.

1604/0003

3/8 in. x 3/8 in.

816/15007

3/8 in. x 3/8 in.

892/00071

3/8 in. x 3/8 in. taper

816/15008

1/2 in. x 3/8 in.

1606/0004

1/2 in. x 1/4 in.

1606/0007

1/2 in. x 3/8 in.

1604/0004

1/2 in. x 1/2 in.

1606/0017

5/8 in. x 1/2 in.

1606/0008

3/4 in. x 3/8 in.

1606/0009

3/4 in. x 1/2 in.

1604/0006

3/4 in. x 3/4 in.

1606/0012

3/4 in. x 1 in.

1606/0014

3/4 in. x 1.1/4 in.

1606/0015

1 in. x 1.1/4 in.

S193860

9803/3280

Issue 1

Section E

Hydraulics

Section E

1 - 3

Service Tools

1 - 3

Female Cone Blanking Plug

892/00055

1/4 in. BSP

Male Cone Blanking Cap

892/00056

3/8 in. BSP

816/00294

1/4 in. BSP

892/00057

1/2 in. BSP

816/00189

3/8 in. BSP

892/00058

5/8 in. BSP

816/00190

1/2 in. BSP

892/00059

3/4 in. BSP

816/00197

5/8 in. BSP

892/00060

1 in. BSP

816/00196

3/4 in. BSP

816/00193

1 in. BSP

S193880

S193870

S193890

S193900

892/00047

3/8 in. BSP (A) x 1/4 in. BSP (B)

892/00048

1/2 in. BSP (A) x 1/4 in. BSP (B)

892/00049

5/8 in. BSP (A) x 1/4 in. BSP (B)

Female Connectors

816/50043

3/4 in. BSP (A) x 1/4 in. BSP (B)

892/00051

1 in. BSP (A) x 1/4 in. BSP (B)

892/00074

3/8 in. BSP x 3/8 in. BSP

816/50005

1/2 in. BSP (A) x 1/2 in. BSP (B)

892/00075

1/2 in. BSP x 1/2 in. BSP

816/60096

3/4 in. BSP (A) x 3/4 in. BSP (B)

892/00076

5/8 in. BSP x 5/8 in. BSP

816/00017

1 in. BSP (A) x 1 in. BSP (B)

892/00077

3/4 in. BSP x 3/4 in. BSP

992/09100

Excavator Spool Clamp

Hexagon Spanners for Ram Pistons and End Caps

892/00011

Spool Clamp

992/09300

55mm A/F

992/09400

65mm A/F

992/09500

75mm A/F

992/09600

85mm A/F

992/09700

95mm A/F

992/09900

115mm A/F

992/10000

125mm A/F

S216210

9803/3280

Issue 1

Section E

Hydraulics

Section E

1 - 4

Service Tools

1 - 4

7mm

11o

10mm

20mm

5mm

110mm

175mm

892/01027

Piston Seal Assembly Tool

338500

S216250

892/00334

Ram Seal Fitting Tool

S338410

Ram Seal Protection Sleeves

892/01016

For 25 mm Rod Diameter

892/01017

For 30 mm Rod Diameter

892/01018

For 40 mm Rod Diameter

892/01019

For 50 mm Rod Diameter

892/01020

For 50 mm Rod Diameter (slew ram)

892/01021

For 60 mm Rod Diameter

892/01022

For 60 mm Rod Diameter (slew ram)

892/01023

For 65 mm Rod Diameter

S308271

892/01024

For 70 mm Rod Diameter

892/01025

For 75 mm Rod Diameter

892/00948

Charging Kit (without gauge)

892/01026

For 80 mm Rod Diameter

892/00949

Gauge

892/00167

For 90 mm Rod Diameter

9803/3280

Issue 1

Section E

Hydraulics

2 - 1

Technical Data

2 - 1

Hydraulic Pumps

Fixed Flow

Model/Reference

Double pump/4070H

Mounting

Gearbox

Theoretical displacement:

cc/rev

cu in/rev

Pump section 1 (mounting flange end)

2.01

Pump section 2

1.40

Flow at 2200 rev/min and system pressure (90% min displacement):

litres/min

UK gal/min

US gal/min

Pump section 1 (mounting flange end)

65.3

14.4

17.2

Pump section 2

45.5

10.0

12.0

Maximum speed @ pressure P1

3000 rev/min

Minimum speed @ pressure P1

500 rev/min

Approximate Weight

24kg (53 lbs)

Model/Reference

Double pump/83103

Mounting

Gearbox

Theoretical displacement:

cc/rev

cu in/rev

Pump section 1 (mounting flange end)

2.19

Pump section 2

1.59

Flow at 2200 rev/min and system pressure (90% min displacement):

litres/min

UK gal/min

US gal/min

Pump section 1 (mounting flange end)

71.3

15.7

18.8

Pump section 2

51.5

11.3

13.5

Maximum speed @ pressure P1

3000 rev/min

Minimum speed @ pressure P1

500 rev/min

Approximate Weight

23.8kg (52 lbs)

Model/Reference

Double pump/7441N

Mounting

Gearbox

Theoretical displacement:

cc/rev

cu in/rev

Pump section 1 (mounting flange end)

2.50

Pump section 2

1.59

Flow at 2200 rev/min and system pressure (90% min displacement):

litres/min

UK gal/min

US gal/min

Pump section 1 (mounting flange end)

81.2

17.9

21.5

Pump section 2

51.5

11.3

13.5

Maximum speed @ pressure P1

3000 rev/min

Minimum speed @ pressure P1

500 rev/min

Approximate Weight

24.5kg (54 lbs)

Model/Reference

Double pump/4071F

Mounting

Gearbox

Theoretical displacement:

cc/rev

cu in/rev

Pump section 1 (mounting flange end)

2.50

Pump section 2

1.77

Flow at 2200 rev/min and system pressure (90% min displacement):

litres/min

UK gal/min

US gal/min

Pump section 1 (mounting flange end)

81.2

17.9

21.5

Pump section 2

57.4

12.6

15.1

Maximum speed @ pressure P1

3000 rev/min

Minimum speed @ pressure P1

500 rev/min

Approximate Weight

24.5kg (54 lbs)

continued

9803/3280

Issue 2*

Section E

Hydraulics

2 - 2

Technical Data

2 - 2

Hydraulic Pumps

Fixed Flow (continued)

Model/Reference

Double pump/PGP620/Common outlet

Mounting

Gearbox

Theoretical displacement:

cc/rev

cu in/rev

Pump section 1 (mounting flange end)

1.77

Pump section 2

1.40

Flow at 2200 rev/min and system pressure (90% min displacement): litres/min

UK gal/min

US gal/min

Pump section 1 (mounting flange end)

57.4

12.6

15.1

Pump section 2

45.5

10.0

12.0

Maximum speed @ pressure P1

3000 rev/min

Minimum speed @ pressure P1

500 rev/min

Approximate Weight

24kg (53 lbs)

9803/3280

Issue 2*

Section E

Hydraulics

2 - 3

Technical Data

2 - 3

Hydraulic Pumps

Variable Flow

Type

Variable Displacement

Reference

A10VO - 978753

Mounting

Gearbox

Load Sense Pressure (in neutral position)

Maximum permitted - 5 bar; 72.5 lbf/in²

Load sense pressure relief Valve (if fitted)

230 bar; 3335 lbf/in²

Stand-by Pressure

20 bar; 290 lbf/in²

Maximum Hydraulic Stall Pressure

460001 to 472554 without relief valve

232 bar; 3364 lbf/in²

460001 to 472554 with relief valve and all from 472555

270 bar; 3915 lbf/in²

Maximum Displacement

74cc/rev; 4.5 in³/rev

Flow at 2200 rev/min and 2500 lb/in² pressure †

- minimumum acceptable flow rate (new or rebuilt pump)

75 -80 litres/min; 16.5 - 17.6 UK gal/min

- minimumum acceptable flow rate (used pump)

70 - 75 litres/min; 15.4 - 16.5 UK gal/min

Flow in the Load Sense Line at 2200 rev/min (no pressure)

1 - 5 litres/min; 0.22 - 1.1 UK gal/min

Weight

TBAkg (TBA lbs)

† Note: It is not possible to test full pump flow at system pressure, figures quoted give a ‘snapshot’ indication of pump

performance. For more detail refer to Service Procedures, Variable Flow Pumps - Flow and Pressure Testing.

9803/3280

Issue 2*

Section E

Hydraulics

2 - 4

Technical Data

2 - 4

Relief Valve Pressures

Loader Valve - Fixed Flow

bar

kgf/cm²

lbf/in²

Main Relief Valve (M.R.V.)

236 - 241

240 - 245

3420 - 3500

Unloader Valve

207 - 214

207 - 211

3000 - 3100

Auxiliary Relief Valves (A.R.V.)

Loader

Shovel Ram Head Side

172 - 179

176 - 183

2500 - 2600

Shovel Ram Rod side

310 - 317

316 - 323

4500 - 4600

Note: Instructions for pressure testing and adjustment are described in Service Procedures, Loader Valve - Pressure

Testing.

Weight

25kg (55lbs) (3 spool)

TBA (2 spool)

Component Key:

Arms lift service

Unloader solenoid

Shovel service

Auxiliary relief valve

Auxiliary (optional)

Tank port

Pump section 1 - inlet

High pressure carry-over (HPCO) port

Pump section 2 - inlet

Service ports

Pressure test port

Load hold check valve assemblies

Unloader Assembly

Data plate

2 3

A262160

9803/3280

Issue 1

Section E

Hydraulics

2 - 5

Technical Data

2 - 5

Relief Valve Pressures

Loader Valve - Precision Control (Servo)

(Machines up to serial no. 931159)

bar

kgf/cm²

lbf/in²

Main Relief Valve (M.R.V.)

227 - 231

232 - 235

3300 - 3350

Unloader Valve

203 - 207

207 - 211

2950 - 3000

Auxiliary Relief Valves (A.R.V.)

Loader

Shovel Ram Head Side

172 - 175

175 - 179

2500 - 2550

Shovel Ram Rod side

308 - 312

315 - 318

4475 - 4525

Bolt on Auxiliary Spool (extending dipper, if fitted)

Top relief valve

136 - 140

139 - 142

1975 - 2025

Bottom relief valve

205 - 208

209 - 212

2975 - 3025

Note: Instructions for pressure testing and adjustment are described in Service Procedures, Loader Valve - Pressure

Testing.

Component Key:

Arms lift service

Shovel service

Auxiliary (optional)

Pump section 1 - inlet

Pump section 2 - inlet

Pressure test port

Unloader Assembly

Unloader solenoid

Auxiliary relief valve

Tank port

High pressure carry-over (HPCO) port

Service ports

Load hold check valve assemblies

Main relief valve (MRV)

Bolt on auxiliary spool

Data plate

A402480

9803/3280

Issue 3*

Section E

Hydraulics

2 - 5A

Technical Data

2 - 5A

Relief Valve Pressures

Loader Valve - Precision Control (Servo)

(Machines from January 2003)

bar

kgf/cm²

lbf/in²

Auxiliary Relief Valves (A.R.V.)

Shovel Ram Head Side

310

315

4500

Shovel Ram Rod Side

170

175

2500

Note: Instructions for pressure testing and adjustment are described in Service Procedures, Loader Valve - Pressure

Testing.

Component Key:

Auxiliary (options)

Shovel service

Arms lift service

Auxiliary relief valves

Electric detent spool connector

Inlet port (secondary pump section P2)

Tank port

Inlet port (main pump section P1)

Service ports

1 2 3

A403690

9803/3280

Issue 1

Section E

Hydraulics

2 - 7

Technical Data

2 - 7

Relief Valve Pressures

Loader Valve - Variable Flow

bar

kgf/cm²

lbf/in²

Priority Relief Valve†

170 - 176

173 - 179

2450 - 2550

Auxiliary Relief Valves (A.R.V.) @ 0.5gal/min (1.9 litres/min)

Shovel Ram Head Side

170 - 174

173 - 177

2465 - 2520

Shovel Ram Rod side

306 - 314

312 - 320

4450 - 4550

† Note: Steer circuit pressure is controlled by a relief valve housed in the hydraulic steer unit (Refer to Section H Steering).

The priority relief valve housed in the loader valve must be set at 2500 lb/in², this will ensure it does not interfere with the

operation of the relief valve housed in the hydraulic steer unit.

Weight:

2 Spool - TBA kg (TBA lbs)

3 Spool - TBA kg (TBA lbs)

Component Key:

Auxiliary (optional) service

Shovel service

Arms lift service

Pump inlet

Tank port

Load sense port (to pump)

Priority load sense port (from steer unit)

Priority work port (to steer unit)

Load sense carry over port (to backhoe valve)

Service ports

Auxiliary relief valve (rod side)

Auxiliary relief valve (head side)

Priority relief valve †

3 21

A273670

9803/3280

Issue 2*

Section E

Hydraulics

2 - 8

Technical Data

2 - 8

Relief Valve Pressures

Excavator Valve - Fixed Flow

bar

kgf/cm²

lbf/in²

Boom Ram Head Side

248 - 255

253 - 260

3600 - 3700

Boom Ram Rod Side

345 - 352

351 - 358

5000 - 5100

Bucket Ram Head Side

Centremount (17' , 15’ 6” backhoe - except knuckle)

310 - 317

316 - 323

4500 - 4600

Centremount (14' backhoe, 15’ 6” backhoe with a knuckle fitted)

248 - 255

253 - 260

3600 - 3700

Sideshift

248 - 255

253 - 260

3600 - 3700

Bucket Ram Rod Side (Machines with Rockbreaker only)

248 - 255

253 - 260

3600 - 3700

Dipper Ram Head Side

248 - 255

253 - 260

3600 - 3700

Dipper Ram Rod Side

248 - 255

253 - 260

3600 - 3700

Slew Left and Right

262 - 269

267 - 274

3800 - 3900

Weight:

44 kg (97 lbs) - Centremount

46 kg (101 lbs) - Sideshift

Note: Instructions for pressure testing and adjustment are described in Service Procedures, Loader Valve - Pressure

Testing.

† System shown is for JCB plus pattern and JCB diagonal pattern. For ISO system, the boom and dipper spools change

position, i.e. boom is position 2 and dipper is position 5. The bottom ARV from spool 5 will also be swapped with the

bottom ARV from spool 2.

Component Key:

Tank port

Bucket crowd

High pressure carry-over (HPCO) port

Dipper †

Service ports

Stabiliser

Load hold check valve assemblies

Stabiliser

Make-up check valve assembly

Boom †

Inlet port

Slew

Hydraclamp solenoid

Auxiliary relief valve

0 0

A401470

9803/3280

Issue 2*

Section E

Hydraulics

2 - 10

Technical Data

2 - 10

Relief Valve Pressures

Excavator Valve - Precision Control (Servo)

(Machines up to serial no. 931159)

bar

kgf/cm²

lbf/in²

Boom Ram Head Side

248 - 255

253 - 260

3600 - 3700

Boom Ram Rod Side

345 - 352

351 - 358

5000 - 5100

Bucket Ram Head Side

248 - 255

253 - 260

3600 - 3700

Bucket Ram Rod Side

248 - 255

253 - 260

3600 - 3700

Dipper Ram Head Side

248 - 255

253 - 260

3600 - 3700

Dipper Ram Rod Side

248 - 255

253 - 260

3600 - 3700

Slew Left and Right

262 - 269

267 - 274

3800 - 3900

Load Sense Relief Valve †

208 - 212

213 - 216

3025 - 3075

Note: Instructions for pressure testing and adjustment are described in Service Procedures, Loader Valve - Pressure

Testing.

† Note: For pressure testing and adjustment of the load sense relief valve, see Service Procedures, Pressure Testing, Load

Sense Drain Regulator and Relief Valve.

Component Key:

Pilot operated check valve (hydraclamp)

Bucket

Service ports

Dipper

Load sense valve

Stabiliser

Load sense drain regulator and relief valve

Stabiliser

Inlet port

Boom

Hydraclamp solenoid

Slew

Auxiliary spool

Auxiliary relief valve

Tank port

A402500

9803/3280

Issue 3*

Section E

Hydraulics

2 - 10A

Technical Data

2 - 10A

Relief Valve Pressures

Excavator Valve - Precision Control (Servo)

(Machines from January 2003)

bar

kgf/cm²

lbf/in²

Auxiliary Relief Valves (A.R.V.)

Boom Ram Head Side

245

250

3550

Boom Ram Rod Side

350

355

5000

Bucket Ram Head Side

255

260

3700

Bucket Ram Rod Side

255

260

3700

Dipper Ram Head Side

255

260

3700

Dipper Ram Rod Side

255

260

3700

Slew Left and Right

265

270

3850

Load Sense Relief Valve †

250

255

3650

Note: Instructions for pressure testing and adjustment are described in Service Procedures, Loader Valve - Pressure

Testing.

† Note: For pressure testing and adjustment of the load sense relief valve, see Service Procedures, Pressure Testing, Load

Sense Relief Valve.

Component Key:

Auxiliary (options)

Anti-cavitation valve

Bucket

Load sense relief valve

Dipper

Flow regulator valve

Stabiliser

Hydraclamp solenoid

Stabiliser

Inlet port

Boom

Tank port

Slew

Service ports

Auxiliary relief valves

A403680

9803/3280

Issue 1

JCB 3CX, 4CX, 214e, 214, 215, 217 & VARIANTS Backhoe Loader. Service Manual - page 11