Section E Hydraulics Service Manual - Side Engine Loadalls ‘Section 1 - General Information ‘Section 2- Care and Safety ‘Section 3 - Routine Maintenance ‘Section B - Body and Framework ‘Section C- Electrics ‘Section E - Hydraulics ‘Section F - Transmission ‘Section G - Brakes ‘Section H - Steering ‘Section K - Engine ‘Section M - Electronic Data Systems Publication No. 9803/3750-05 od’ Po adie daa ab SRINES ACR ERIES A eee mace, eee sere tee prmsnFanicweaece ny MENON Te TRIAS, C8 eat THR em es So STH ST HSSSection E - Hydaulics Notes: Eo '9803/3750-05 EoSection E - Hydraulics Contents Applications Table Systems and Schematics Introduction Systems ‘Schematics - Machines with Dual Lever Controls ‘Schematics - Machines with Servo Controls (S1) Schematics - Machines with Servo Controls (S2) Parallel Hydraulic SYSTEM Introduction Related Topics ‘Specifications: Operation Overview Hydraulic Operation and Schematios Fautt Finding Test Procedures Bleed Procedures Parallel Servo Hydraulic SYSTEM Introduction Related Topics Specifications Operation Qverview Hydraulic Operation and Schematics Fault Finding Test Procedures, Bleed Procedures. Hydraulic Interlock SYSTEM Introduction Related Topics ‘Component Location Operation Overview Interlock Characteristics Electrical Operation and Schematios. Parallel Control Valve - 6 Section Introduction Related Topics Removal and Replacement Dismantle and Assemble Parallel Control Valve - 5 Section Introduction Related Topics Removal and Replacement Dismantle and Assemble Parallel Control Valve - 2 Section Introduction Related Topics Removal and Replacement Dismantle and Assemble Page No. E0-1 em B12 E14 E18 1-12 E24 £23 E24 E28 E245 £2.29 £234 52-44 E34 £33 3-4 E39 3-46 £3.29 £3.33 3.41 E44 £42 £43 E45 ean £413 £64 £52 £63 £55 E641 £62 £63 E65 ers £72 E73 e7-4Section E - Hydraulics Contents ‘Servo Control Valves Introduction Related Topics Removal and Replacement Servo Solenoid Diverter Valve Block Introduction Related Topics Removal and Replacement Dismantie and Assemble Stabiliser Isolation Valve Introduction Related Topics Removal and Replacement ‘SwayiFan Selector Valve Introduction Related Topics ‘Component Location and identification Hydraulic Operation and Schematios Electrical Operation and Schematics Electrical Connectors Removal and Replacement (1) Removal and Replacement (2) Dismantle and Assemble Main Pump Introduction Related Topics Operation Overview Hydraulic Operation and Schematios Removal and Replacement Dismantie, Inspection and Assemble Steering Priority Valve Cooling Fan Motor Introduction Related Topics Specifications Operation Overview Hydraulic Operation and Schematios Removal and Replacement Dismantle, Inspection and Assemble Extension Ram Introduction Related Topics Removal and Replacement - 3 Stage Boom Outer Ram Removal and Replacement - 4 Stage Boom Outer Ram Removal and Replacement - Inner Ram Lift Rams: Introduction Related Topics Page No. Ee £82 E83 E94 £92 £93 E94 E104 £102 E103 ea E112 E13 ens E16 Enz E18 E119 Ent E124 £122 E123 £125 E126 £128 E1242 E134 £132 £133 £134 E136 E136 E138 e144 E142 e143 E145 E147 E154 £152 EiSection E - Hydraulics Contents Removal and Replacement Tilt Ram Introduction Related Topics Removal and Replacement Displacement Ram Introduction Related Topics Removal and Replacement ‘Sway Ram Introduction Related Topics Removal and Replacement Stabiliser Rams Introduction Related Topics Removal and Replacement Ram Maintenance Introduction Related Topics Single Piston Rams Piston Head Retention Twin Piston, 4 Stage Boom Outer Ram Extension Ram Make-Up Valve (if fitted) Page No. £153 e164 E162 e163 e174 17-2 e173 e184 E182 E183 E194 £192 E193 £204 20-2 £203 £208 20-9 20-18 E-iliSection E - Hydraulics Contents Page No.B Section EO - Hydraulics Applications Applications Table Important: The machine model names are NOT referred ton the topics. You must refer to the applications table for Table the applicable machine models. Table entries shaded grey Indicate @ topic not included in this issue of the manuel, Machine models Topic |Title Variant {540-470 | 560-140 | 640-140 | 650-170 | 596-125 | 636-140 Ref SAF | 5AG | SAL | 5AM | Hiviz | Hiviz SAN | SAP Et _ | Systems and Schematics e e e e e e 2 | Parallel Hydraulic SYSTEM e e e e S| Parallel Servo Hydraulic . e ‘SYSTEM 4 |Hydraulie Interlock SYSTEM e e 5 | Parallel Control Valve - 6 To e e To e e ‘Section January January 2009) 2008 6 | Parallel Control Valve - § From From ‘Section January January 2009) 2008 7 [Parallel Control Valve - 2 e e Section EB | Serve Control Valves e e 9 | Servo Solenoid Diverter Valve e e Block E10 | Stabiliser Isolation Vaive e e Et | SwayiFan Selector Valve . . . e e e E12. [Main Pump 410 Uin e e e e 470 Winin e e E18 | Cooling Fan Motor e e e e e e E14 [Extension Ram e e e e e e Ets |LitRams e e e e e e 16 [Tit Ram e e e e e ° E17 [Displacement Ram e e e e e e E18 [Sway Ram e e e e e e E19 | Stabiliser Rams 2 pin type ToDes | © @ | ToDe. | e stabiliser 2008) 2000) Tpin type From From stabiliser Dec, Dec, (common pivot | 2008 2009 for foot and ram) E20 | Ram Maintenance e e e e e e '9803/5750-05 (AE-00-02),Ww Section E0 - Hydraulics Applications Table Page left intentionally blank E0-2 '9803/5750-05 (AE-00-02), E0-2Ww Section E1 - Hydraulics Systems and Schematics Introduction Systems and Schematics Introduction This topic contains hydraulic schematics for the complete system, Detalled schematics for individual systems are given ‘throughout the manual 2 Systems (DE1-2) = Schematics - Machines with Dual Lever Controls ([\E1-4) 635-125 HiViz, 535-140 Hivie (T)E1-6) 3 535, 540, 550 ([) E1-7) 2 Schematics - Machines with Servo Controls (S1) ([)E1-8)" 3 540, 550 (without Speed-up Kit) ([) E1-10) 2 540, 550 (with Speed-up Kit) ([) 1-11) =D Schematies - Machines with Servo Controls (S2) (T\E1-12)" 2 540, 550 (D1Et-14) (1). Specification variant. Make sure you refer to the correct specifications. Table 1, Procedure and Specification Variants Procedures, Specifications” Machine Model Application 540-170 SAF 350-170 5AM Schamatlos- Machines with Sere Convors (61) 3)_| Machines wih © spool Machines wih® spool valve block to January |valve block to January 2009 2009 @ Schematies - Machines with Servo Controls (S2) ([\ET-12) |Machines with 6 spool ___|Machines with 6 spool valve block January _|valve block. January 2009 on 2009 on (1) The table fists procedure and specification variants and the applicable machine models, Use the table fo make sure {you refer to the correct information aa 960575750-05 (E0002) E11Ww Section E1 - Hydraulics Systems and Schematics ‘systems Systems Table 2. System Variants - Identification References SYSTEM Type [SYSTEM Topic Main Pump Type Control Lever Type (Parallel Parallel Hyaraule | Fredo tiple gear pump. Paral controlvalve (ack) win Sm] system with | SYSTEM (T}E2-1) manual spools. Separate control Dual Lever levers for bor, stabiliser and Controls auxiliary services. 2 Schematies - ‘Machines with Dual Lever Controls (T\E1-4) Parallel > Paravel Seve. Fixed Flow tiple gear pump. Parallerconalvanve (back win three system with | Hydraulic ‘servo pilot and three manual spools. Single Lever | SYSTEM (D1 E3-1) ‘Second parallel control vatve (black) Controls (St) ‘with two gervo pilot spools. Cab mounted servo control levers for boom services. Manual control levers for stabiliser and auxiliary services. 2 Schematics - ‘Machines with Servo Controls (S1) (TET-8) ra 960575750-05 (E0002) E12Ww Section E1 - Hydraulics Systems and Schematics ‘Systems ‘SYSTEM Type [SYSTEM Topic Main Pump Type Controt Lever Type Parallel Parle Servo. Fixed flow tiple gear pump. Parallel control valve (black) win two system with | Hydraulic ‘servo pilot and three manual spools. Single Lever | SYSTEM ([)E3-1) Second parallel control valve (black) Controls ($2) ‘with two serve pilot spools. Cab ‘mounted servo control levers for boom services, Manual control levers for stabiliser and auxilary services. 2 Schematics - ‘Machines with Servo Controls (S2) (T)E1-12) E13 '$603/3750-05 (E-00-02) E13ria 50-0518/0006 (0-002 va The schematics shows a number of options, check your machine to see which options apply 2 Fig 1. 636-125 HiViz, 636-140 HiViz ([) E1-6) 2 Fig 2. 535, 540, 550 (1) E1-7) ‘Component Key: B Pressure cap breather F Return line fiter FI iter by-pass S Pump suction strainer T Tank 1 Pump assembly 1A Main pump 18 Fanpump 1C Steer pump- if fited 1D Priority vai 1E Test point(s) 2 Valve block 2A Main relief valve (RV) 2D —_Liftspool 2E Extension spool 2F Tit spool 26 Auxiliary spool 2H Auxiliary relief valve (ARV) 2) Auxillary lief valve (ARV) 2K Auxiliary raliaf valve (ARV) 2L —_Auniltary relia valve (ARV) 2M Load hold check valves (LHCVs) 2P —Unloader vaive -if fited Schematics - Machines R 2s a 38 38 3c 38D 4 40, 5 5A 5B 8 8A 9 10 108 1" 1A 1B 12 13 134 138, 13c 14 148, Stabliser RH - i fited Stabiliser LH - ifited Steer unit assembly Steer valve ‘Shook valves (option) - if fted Main relief valve Non-return valve Cooling fan motor (non-reversible) Reliof valve Reversible cooling fan motor (option) - if fitted Relief valves Fan change-over solenoid Lftram Counter-balance valve Displacement rams) Titram Counter-balance valve Extension ram(s) Counter-balance valve Regenerative valve -iffited ‘Auxiliary 1 boom quick release couplings (standard build) ‘Second auxiliary (option) - it fited Diverter valve (boom) Auxiliary 1 boom quick release couplings ‘Auxiliary 2.b00m quick release couplings ‘Second auxiliary with hydraulic pin locking (option) - i fited Diverter valve (boom) 148 140 140 14E 14F 18 188 158, 18¢ 16 16A 168, 16c 160 7 417A 8 18A 19 20 204 208 20c 200 2 214 28 2c Dual Lever Controls Auxiliary 1 boom quick release couplings ‘Auxiliary 2 boom quick release couplings Manual change-over valve Flow restrictor Hydraulic pin locking cylinder ‘Sway control valve (option) «i fited ‘One way restrictors Pilot operated check-valve ‘Sway hydraulic cylinder Steer mode valve ‘Two Wheel steer solenoid Four Wheel and crab steer solenoid Four Whee! steer solenoid Crab steer solenoid Front power track-rod Front steer rams - if fitted Rear power track-rod Rear steer rams - if fitted Restiicted non return valve Lift circuit with optional Smooth Ride System (GRS)- i fitted Solenoid valve ‘Solenoid valve Accumulators Pressure switch Traller brake valve assembly (option) - i fitted Pilot valve Brake valve ‘Trailer brake coupling SsjosjU09 Jana7 Jeng Ua SaUIYoRYY - SapELUAYOS Sonewayag pue sUlaIShS soljnespfy = | uoyDagg 5 : ola 21D 2 220 28 226 220 206 23 234, 238 24 24a 248 6 o @ @ Brake circuit connection ‘Auxiliary 1 with trailer hitch (option) -iffitted ‘Solenoid diverter valve (chassis mounted) Trailer hitch ram Auxiliary 4 boom quick release couplings Traller/Auxilary quick release coupling Restrictor adaptor ‘Stabillser hydraulic eylindar RH - i ftted Lockout vale if fitted Pressure saitch (option) - if fitted Sabiliser hydraulic cylinder LH - ifited Lockout valve i fitted Pressure switch (option) - # fitted Load Control Valve (option) -ifftted Pump flow goes direct to the fan motor on non- ‘sway machines. Electrically operated stoer mode valve shown. Manual version also avaiable. ‘Schematic shows latest type steer mode valve. For schematics of al steer mode valves refer fo Section H - Steering. SsjosjU09 Jana7 Jeng Ua SaUIYoRYY - SapELUAYOS ‘SoneUIDYDS pue SUIaISAS soljnespfy = | uoyDagW Section E1 - Hydra ‘Systems and Schematics ‘Schematics - Machines with Dual Lever Controls Fig 4, $85.125 HiViz, 535-140 HiViz E1-6 "9808/3750-05 (E-00-02) 1-6Section E1 - Hydraulics ‘Systems and Schematics ‘Schematics - Machines with Dual Lever Controls Fig 2. $35, 540, 550 "9808/3750-05 (E-00-02) E17g 5 : sla Schematics - Machines with Servo Controls (S1) Spools 11A, 11B and 11 are manually operated by levers in the cab, The unloader valve 11 isolates the stabilisers: when the solenoid is de-energised the stabilisers do not operate, The stabilisers are isolated whenever the boom is raised or isolated manually by a switch in the cab. Spools 11D, 11F and 11G are pilot operated, controlled by servo joysticks 8 and 9, via servo diverter valve 26. Solenoid valves 26D, 26F, 286 and 26H are used as isolation valves to lock the control levers, The valves are controlled by a rotary switch in the cab, Lf valve block 10 is mounted on the chassis under the boom, Spools 10A and 10B are pilot operated and are controlled by servo joystick 8 and servo diverter valve 26. The boom section cverter valve 23 switches hydraulic flow to either the outer 24 or inner 22 boom extension rams. 2 Fig 3. 540, 560 (without Speed-up Kit) (DEP-10) 2 Fig 4. 640, 660 (with Speed-up Kit) (D) E1-11 ‘Component Key: T Tank P Pump Pt — Main services pump P2 Steer pump P32 Swaylfan pump Pa Priority low diverter 1 Pressure cap breather 3A 5A 5B 5c 5D 10 108, 108, 10c 10 1" 1A 1B nc 1D Retuin tine fter Steering valve Anti-cavitation valve Engine cooling fan motor Steer mode valve! Two Wheel steer solenoid Four Wheel and crab steer solencid Four Wheel steer solenoid Crab steer solenoid Front steering cylinders. Rear steering cylinders. ‘Two axis servo hand controler Port Lift Port 2 Retract Port Lower Port 4 Extend ‘Single axis servo hand controler — Port Crowd ~ Port2 Dump ‘Two spool valve block Extension spool Lit spoot MRV Port A. Load hold check valves (LHCV) ‘Sk spool valve block Left hand stabiliser spool Right hand stabiliser spoo! LUnieader section Tilt spool ne nF 116 1H 1d nk 1b 1M +N "P a mR ns 2 128 8 198 138 14 148 148, 15 154 168 16 7 417A 18 19 Auxiliary spool Extension spool Lift spool RV Pressure maintaining valve Pressure reducing valve TRARY Pot B TRARY Port A Auxiliary ARV Port B ‘Auxiliary ARV Port A Load hold check valves (LHCV) Tittisolator section Extension spool (from SiNo 1037852) ‘Sway control valve Sway relefvalve ‘Sway cylinder Pilot operated check valve ‘One way restrictor Lett hand stabiliser cylinder Stabiliser lockout valve Pressure switch Right hand stabiliser cylinder ‘Stabllser lockout valve Pressure switch Stabiliser isolation valve Tikoylinder Counterbalance valve Displacement cylinders Restricted checkvaive (13) stamuog onas yim saurjoen - soneuiayas g gs ae $5 om 2m Be eZ ze $9 ae g aog 5 : 61a 20 Auxiliary connectors, inner boom section 21 Auxiliary high flow connectors, outer boom section (ifftted) 22 Inner extension cylinder 22h — Counterbalance valve 23 Boom section diverter valve 24 Outer telescopic extension cylinder 24A Regeneration valve 248 Counterbalance valve (located inside telescopic extension cylinder 24) 25 Lifteylinder 25A —Counterbalance valve 26 Servo diverter valve 264 Fiter 268 Check valve 26C Test point 260 Accumulator 26E —Controlisolate valve 26F —Liftisolate valve 266 Crowd isolate valve 26H Dump isolate valve (1). Schematic shows latest type steer mode valve. For schematics of all steer mode valves refer 0 Section H - Steering, (1g) sjonuo9 oniag enim seunsoent - sonewayos gs ae $5 om 2m Be eZ ze $9 ae g aoW Section E1 - Hydraulics ‘Systems and Schematics ‘Schematics - Machines with Servo Controls ($1) Fig 3. 540, 550 (without Speed-up Kit) E1-10 '9803/3750-08 (E-00-02) 1-10W Section E1 - Hydraulics ‘Systems and Schematics ‘Schematics - Machines with Servo Controls (S1) Fig 4. 840, 550 (with Speed-up Kit) E111 "9808/3750-05 (E-00-02) E1-11(0-003) so-oszere0e6 zea wa Schematics - Machines with Servo Controls (S2) Spools 11A, 11B and 11 are manually operated by levers in the cab, The unloader valve 11 isolates the stabilisers: when the solenoid is de-energised the stabilisers do not operate, The stabilisers are isolated whenever the boom is raised or isolated manually by a switch in the cab. Spools 11D and 11F are pilot operated, controlled by servo joysticks 8 and 9, via servo diverter valve 26, Solenoid valves 26D, 26F, 266 and 26H are used as isolation valves to lock the control levers, The valves are controlled by 2 rotary switch in the cab, Lift valve block 10 is mounted on the chassis under the boom, Spools 10A and 10B are pilot operated and are controlled by servo joystick 8 and servo diverter vyalve 26. The boom section diverter valve 23 switches: hydraulic flow to either the outer 24 or inner 22 boom extension rams, 2 Filg 6. 640, 660 (1) E1-14) ‘Component Koy: T Tank P Pump Pt Main services pump P2 Steer pump P32 Swaylfan pump Pa Priority flow diverter 1 Pressure cap breather 2 Return line fiter ‘Steering valve 38 4 5 5A 58 5c 5D 6 10 108, 108, soc 10E 1" 1A 1B 1c uD ne 1F Anti-cavitation valve Engine cooling fan motor Steer mode valve ‘Two Wheel steer solenoid Four Wheel and crab steer solenoid Four Whee! steer solenoid Crab steer solenoid Front steering cylinders. Rear steering cylinders Two axis servo hand contraller: Port Lift Por 2 Retract Port Lower Port 4 Extend Single axis servo hand controler: — Port 1 Crowd = Port2 Dump ‘Two spool valve block Extension spool Lift spool MRV Port A. Load hold check valves (LHCV) ‘Sk spool valve block Left hand stabiliser spool Right hand stabiliser spoo! Unioader section Tit spool Auxiliary spool Extension spool 11H 1 "kK 111. 11M IN "P 11a 4R 12 128 13 138, 138, 14 148 148 15 416A 158, v7 17a 8 19 20 a4 22 228 23 MRV Pressure maintaining valve Pressure reducing valve TIRAR Pot B TRARY Port A Auxillary ARV Port B Auniliary ARV Port A Load hold check valves (LHCV) Titiisolator section Sway control valve Sway relletvalve ‘Sway cylinder Pilot operated check valve ‘One way restrictor Lett hand stabiliser cylinder ‘Stabilser lockout valve Pressure switch Right hand stabiliser cylinder ‘Stabilser lockout valve Pressure switch Tikeyinder Counterbalance valve Displacement cylinders Restricted checkvalve Auxiliary connectors, inner boom section Auxiliary high flow connectors, cuter boom section (fitted) Inner extension cylinder Counterbalance valve Boom section diverter valve (Ze) siomuao onag ym sauRjoeW - sonewaYoS g gs ae $5 om 2m Be eZ ze $9 ae g ao24 244 246 ebba 28 254 26 286A 268, 26c 260 28E 26F 266 26H (0-003) so-oszere0e6 era Outer telescopic extension cylinder Regeneration valve Counterbalance valve (located inside telescopic extension cylinder 24) Liteylinder Counterbalance valve Seno diverter valve Fiter Check vale Test point ‘Accumulator Control isolate valve Littisolate valve Crowd isolate valve Dump isolate valve (Ze) siomuao onag ym sauRjoeW - sonewaYoS g gs ae $5 om 2m Be eZ ze $9 ae g aoW Section E1 - Hydraulics ‘Systems and Schematics ‘Schematics - Machines with Servo Controls (S2) Fig 5. 540, 550 E114 "9808/3750-05 (E-00-02) E1-14Ww Section E2 - Hydraulics Parallel Hydraulic SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either ‘mechanically, hydraulically or electrically. Make sure you are referring to the correct system, Refer to the applications ‘table, > Related Topics ([} E2-3) Descriptions and procedures relate to the system and not the individual devices, For information about the devices refer tothe relevant topics. Related Topies ([E2-3) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as rermoval and replacement and dismantle and assemble, 2 Related Topics (T)E2-3) + Specifications (1) E2-4) = 6 Spoo! Valve Block (St) (\E2-4)" 6 Spoo! Valve Block (S2) (TE2-5)"” 2 Hydraulic Pump (DE2-6) 3 Cooling Fan Motor ([3 E2-7) 2 Operation Overview (E28) = Component Location and Identification (P\E2- 01 Pump (1) E2-11) 2 Control Valve Block ([)E2-11) = Main Relief Valve (MRV) Operation ([) E2-12) 3 Auxiliary Relief Valve (ARV) Operation (() E2-13) 2 Hydraulic Operation and Schematics ([) E2-16) 3 No Services Operated ([) E2-15) 3 Service Operation ([\E2-15) 3 Main System Pressure Relief ([) E2-15) = 6 Spoo! Control Valve with Unloader Section ([)E2-19) = Parallel Lift ([) E2-20) 2. Boom Regenerative Vaive (if fitted) (1) E2-26) = Fault Finding (PD) E2-29) 3 Test Procedures ([\E2.34) 2 Checking Pump Flow (1) E2-34) 2 Testing Main Relief Valve (MRV) (T\E2- 3 Testing ARV's Set Lower than the MRV ([) E2-37) 3 Testing ARV's Set Higher than the MRV (Pt) ([)E2.38)" 3 Testing ARV's Set Higher than the MRV (P2) ([E2-40)" 2 Relief Valve Adjustment (7) £2-42) ma 3003750-05 (E903) E24B 3 Measuring Spoo! Displacement (Manual Spools) 3 Bleed Procedures ([) E2-44) 3 3-Stage Boom Extension Ram Circuit ([) E2-44) Tilt Ram Circuit (1) E2-46) ® Sway Ram Cireuit ([) E2-47) (1). Specification variant. Make sure you refer to the correct specification. Section E2 - Hydraulics Paralle Table 1. Procedure and Specification Variants Hydraul SYSTEM Introduction Procedures, Specifications!” Machine Model Application ‘850-140 | 540-140 | 536-125 | 535-140 SAG | SAL | Hiviz | Hiviz SAN | SAP DS Spool Valve Block ST) (EPA) . ° D6 Spool Valve Block (S2) (T\E2-5) e e Testing ARV's Set Higher than the MRV. E238) e e Testing ARV's Set Higher than the MRV (P2) (2-40) e e (1) The table fists procedure and specification variants and the applicable machine models. Use the table fo make sure ‘you refer to the correct information. E22 '9603/3750-05 (E-01-03) E22B Section E2 - Hydraulics Parallel Hydraulic SYSTEM Related Topics Related Topics Table 2. Related Topics in This Publication to Section # - Applications. “The table ists other topics in the manual that contain information related to this topio. Refer to the applicable topios to ‘complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correctiinformation. Some machines have different systems and devices, Make sure you refer tothe correct topic, refer Sections [Topic Titles ‘Sub Titles: 7 “Applications AL 2 ALL (are and Safety)” AL 3 ‘Hydraulic System Checking the Hydraulic Fluid Level B ‘Srabilisers ALL E @ Systems and Schematics (NET E '@ Parallel Control Valve - 6 Section (E67) [ALL E @ Main Pump (T\E12-1) ALL E '® Cooling Fan Motor ((1E73-1) ALL H ‘Manual Steer Mode SYSTEM ALL H ‘Auto Steer Mode SYSTEM ALL H Priority Valve Test Procedures (1). You must obey all of the relevant care and safety procedures. Table 3. Service Tools. service tools BEFORE you start the procedures ‘The table lists the service fools you will need to do come of the procedures in this topie. Make sure you have the correct Tool Part Number Description "30200268" Flow Monitoring Kitand Relevant Adaptors 3021002537 Hydraulic Pressure Test Kit and Relevant Adaptors 892002707) Load Valve (1) Tool available from JCB Service, refer fo Section 1 ~ Service Tools E23 '9603/3750-05 (E-01-03) E23B Section E2 - Hydraulics Parallel Hydraulic SYSTEM ‘Specifications Specifications 6 Spool Valve Block ($1) 6 Spoo|, parallel service, double acting spools Spool t Boom Raise & Lower Service Manually operated Spool Boom Extend & Retract Service Manually operated Spool Carriage Tit Service Manually operated Spool ‘Auxiliary / Sway Service Manually operated Spo0lS RH Stabiliser Manually operated Spool TH Sabiiser Manually operated Note: Spools 2 and 3 are reversed on machines fited with @ placing contol pattern, Relief Valve Pressures: 3 Fig 7. (D1E2-4), 2 Fig 2. (DE?-4) ar kgfiem? Tene 2A - Main Relief Valve (MRV) 2a 245 3500 ‘Auxiliary Relief Vaves (ARV's) 2K - Auniliary Ram Rod Side 798220") _|[140@25") | 2000 6200") 21 - Auxiliary Ram Head Side 738 140 2000 2J- Carriage TiltRam Rod Side 330 336 4800 2H - Carriage Tit Ram Head Side 276 281 4000 (1). Machines with pick-up hitch. Since this ARV also controls the pressur pressure wil not cause damage fo attachments used with the machine. 2k 2K: 10 * Oa 2H 2K- fe to the boom auxiliary service, ensure that this sO © Oa 2Q § Oa 7O * Oa 2b 2H sO 3 Oa E24 '9603/3750-05 (E-01-03) E24Ww Section E2 - Hydraulics Parallel Hydraulic SYSTEM ‘Specifications 6 Spool Valve Block (S2) 8 Spool parallel service, double acing spooks Spool t Boom Raise & Lower Service Manvally operated a Boom Extend & Retract Service Manually operated ‘Spool Caniage Tit Service Manually operated Spool ‘unliary / Sway Service Manvally operated Spool RH Siabilser Manually operated Spool LH Stabilser Manually operated Note: Spools 2and 3 are reversed on machines fitted with a placing contol pattern Relief Valve Pressures: => Fig 1. ([)E2-4), > Fig 2. (T)E2-4) bar kgficm? Ibffin? 2A - Main Relief Valve (RV) 260 25 3770 ‘Auxiliary Relief Valves (ARV's) 2K - Auxiliary Ram Rod Side 138 (220!) 140 (223°) 2000 (3200) 2L- Auxilary Ram Head Side 138 140 2000 24 - Carriage Tit Ram Rod Side 28 281 2000 2H - Carriage Tit Ram Head Side 26 281 4000 (1). Machines with pick-up hitch, Since this ARV also controls the pressure to the boom auxiliary service, ensure that this pressure will not cause damage fo aitachments used with the machine, ay '9603/3750-05 (E-01-03) E25B Section E2 - Hydraulics Parallel Hydraulic SYSTEM ‘Specifications Hydraulic Pump ‘Triple Pump. Table 4.110 litresimin. Type Gear pump ‘Wountng Gearbox Direction of Rotation Ani clockwise Theoretical displacement cclrev eu infrev Main services pump (mounting flange end) 2 477 Steering pure 9 178 Cooling fan pump 5 0.98 low at 2200 revimin and system pressure (0% min. ciaplacemeni_|iitres/min | UK galmin | US gallmin Main services pump (mounting flange end) 57.4 126 18.1 Steering pump 378 as 90 Coalng fan pump 3i7 70 3a ‘aximam Pressure ar kofem® | ieriné por EF 285 270 3840 portP 200 204 2200 Maximum Speed 2500 revimin Minimum Speed 1500 rev/min Weight 34 kg (75.2 os) Table 5.470 litresimin. Type (Gear pump Mounting Gearbox Direction of Rotation Ant-clockwise Theeretical displacement cirev eu mirev Main services pump (mounting flange end) a 25 Steering pur B 201 Cooling fan pump 16 0.98 Flow at 2200 rev/min and system pressure (90% min. displacement): litres/min UK gal/min | US gal/min “Main services pump (mounting flange end) a2 i798 2S Steering pure Ga 14a 72 Cooling fan pump BT 70 a4 ‘Waximam Pressure bar iglem® Tet? pot EF 265 270 3840 pore [200 204 2900 ‘Maximum Speed: 2500 rev/min Minimum Speed 500 revimin Weight: 34.7 kg (78.5 Ibs) E26 $80370750-06 E01-05) E26B Section E2 - Hydraulics Parallel Hydraulic SYSTEM ‘Specifications Cooling Fan Motor Machines with SE Engines Machines with SE engines Type: Gear motor Direction of Rotation: (Clockwise or Bi directional Motor Displacement 10 cchov Fan Speed (at maximum engine revimin): 72800 Maximum Pressure Setting 198 bar (2871 Iona) Body Colour Black ‘Weight: TBA Machines with SD and SF Engines 'SD 63 KW engines Upto March 08 From March 08 Type Gear motor Gear motor Direction of Rotation: ‘Clockwise or Bi directional Clockwise Motor Displacement ‘Bocrev 19 cclov Fan Speed (at maximum engine rev/min): 7800 TBA Maximum Pressure Setting 56 bar (812 tein’) 56 bar (812 Ibffin’) Body Colour Red Red ‘SD 74 KW and SF engines Upto March 08 From March 08 Type: Gear motor Gear motor Direction of Rotation ‘Clockwise or Bi directional Clockwise oF Bi directional Motor Displacement ‘eodrev TB cohen Fan Speed (at maximum engine revimin): 72500 TBA Maximum Pressure Setting 120 (1740 btn?) (0 bar (1305 Ibn’) Body Colour Black Black '8003/9750-05 (E-07-03)Ww Section E2 - Hydraulics Parallel Hydraulic SYSTEM ‘Operation Overview Operation Overview The main components of the hydraulic system are the tank, the pump, the control valves and hydraulic rams. ‘As well as providing the main hydraulic services the systemalso operates a hyclraulic steering system. Refer to Section H - Steering > Related Topies (TY E2-3) Machines have hydraulically operated stablisers, Refer to Section B - Body and Framework Related Topics ([) E2- E28 '9603/3750-05 (E-01-03) E28B Section E2 - Hydraulics Parallel Hydraulic SYSTEM ‘Operation Overview ‘Component Location and Identification DFig5. (DE: Table 6. Component Key tem [Description 1 |Pump assembly ‘Three section gearpump 1A, 16, 1B > Main Pump (T\E12-1) 2 | Control valve block Parallel valve with manual spools '@ 6 Spoo! Control Vaive with Unloader Section (D) E2-19) 4 [Fan motor Driven by pump section 1B Cooling Fan Motor (\E13-1) % [Hydraulic Oil Cooler | Oilfrom pump section 1B flows through the oll cooler F | Hyelraulic of fiter Positioned in the return line to tank T__[Hydraulietank Table 7. Hydraulic Connections Colour Key Gil from pump section 1A (Oil from pump section 1C Oilfiom pump section 1B il suction line from the tank to the pump sections Retum to tank E29 '8003/9750-05 (E-07-03) E29Ww Section E2 - Hydraulics Parallel Hydraulic SYSTEM ‘Operation Overview Fig 5. Typical Machine a0 3003750-05 (E903) E2-10B Section E2 - Hydraulics Parallel Hydraulic SYSTEM Pump DFig 5. (ME2-10) ll is drawn from the hydraulic tank T by the hydraulic ump assembly 1. The pump assembly is mounted on the rear of the bevel gearbox and is driven by the engine, The pump has three sections, 18, [Link] 1. Oil rom the larger pump section 5-18 flows direct to the control valve block 2. Pump section 1C has an integral priorty valve which always gives priority demand to the steer circuit With the steering in the straight ahead position (i. with no steering demand), oil from pump section 1€ flows through the priority valve and joins with the flow from 1 to feed the conirol vaive block 2. Pump section 1B is dedicated to diving the cooling fan, Oil from pump section 1B flows directly to the cooling fan hydraulic motor 4 The hydraulic oil cooler § in the retum line from the fan hydraulic motor 4, cools the system hydraulic oil as & is continually circulated around the cooling fan circuit For more information on the main hydraulic pump refer to the cortect topic in this section. = Main Pump (1) E12-4 Control Valve Block ‘When the spools are actuated, ol from the pump passes into the service ports, operating the relavant hydraulic ram, 2 Control Valve Block ([) E2-11) The control valve contains the main pressure relief valve (MRV) and the auxiliary pressure relief valves (ARV's) These valves prevent the hydraulic pressure increasing to a level which would cause damage to the hydraulic Components and pipework > Main Relief Valve (MRV) Operation ([\ 2-12) and 2 Auxillary Relief _Vaive (ARV) Operation (TYE2-13 Dual Lever Control Machines with dual lever control use two control levers 2A, and 2B for operation of the three loader service spools. A third lever 26 operates the auxiliary service spool Two levers 20 are fitted o operate the stabiliser service spools The levers operate the spools via mechanical linkages. ‘Operation Overview 2-11 '9603/3750-05 (E-01-03) E2-11Ww Section E2 - Hydraulics Parallel Hydraulic SYSTEM ‘Operation Overview Main Relief Valve (MRV) Operation Fig 6. ‘The main relief valve (M.R.V) 2A Is situated in the control valve 2, bridging the neutral and exhaust galleries, and is designed to prevent the circuitry from damage that could be caused by excessive pressures. 1 Valve at Rest: ‘The services are in neutral and pressure in the neutral gallery (blue) is not sufficient to operate the M.R.V. which is held closed by its spring A. 2 Poppet Opens: A service has been selected and the pressure generated ‘exceeds the setting of the MARV. Pressure acts on the periphery of the hollow poppet B which is forced downwards against the spring, venting pressure into the ‘exhaust gallery (green) '8003/9750-05 (E-07-03) E2-12B Section E2 - Hydraulics Parallel Hydraulic SYSTEM Auxiliary Relief Valve (ARV) Operation The Auxilary Reliot Vales (A.R.V's) are situated in the control valve to limit potentially damaging pressures within specified services du to extemal loadings. ARV's may also be used to limit the maximum pressure in specified service to less than the L SRV setting, 2 Fig 7. (12-14) 1 Valve at Rest: A senvice is selected but pressure in the service gallery (yellow) has not reached the setting of the A.R.V. which is held closed by its spring, 2 Poppet Opens: The setting of the ARV. is exceeded by the service pressure which causes the poppet to rise against spring force allowing the pressure to be vented into the exhaust gallery (green), 3 Anti-cavitation Mode: ‘When a service is operated in such @ way that low pressure, or cavitation, exists in the service line (light green), the relatively high pressure oil in the exhaust gallery (darker green) acts on the lower poppet and flows into the service gallery to make up the deficiency. ‘Operation Overview E2-13 '9603/3750-05 (E-01-03) E213W Section E2 - Hydraulics Parallel Hydraulic SYSTEM Operation Overview Fig 7. Auxiliary Relief Valve (ARV) Operation E2-14 "9808/3750-05 (E-01-08) E214(¢0-10-3) sooszere086 si-za s-za To make the description as clear as possible the diagram shows only part of the complete hydraulic system, For the complete hydraulic schematics, refer to the schematics topic. = Related Topies (T)E2-3) No Services Operated Fig 8. (7) 2-16) Oil from the primary pump 1A flows to the inlet-outlet section of the control valve 2 through the valve spool 2B and returns to tank T. Note that oil from secondary pump 1© supplies the sizer circuit via steer priority valve 1D. As there is no steering load this supply joins with pump supply 14 ‘and flows through the valve spool 2B. Ollttom purnp 18 supplies the hydraulic fan circu Service Operation 2 Fig 9 (1 E2-17 When @ service is operated, boom extend for example, the movement of the control lever and its mechanical linkages operate the valve spool 2B. The hydraulic oil flows through the valve spool 2B to the extend ram 3. CO from the other side of the ram 9 flows across the service spool and back to tank T. Main System Pressure Relief 2 Fig 10, (D)E2-18) When a service ram reaches the end of its stroke, or the seivice meets resistance and generates pressure above a specified pressure, the main relief vave 2A Hydraulic Operation and Schematics ‘opens and oil is dumped to tank, preventing further pressure rise, Note: Note: The pressure values given are examples for the purpose of explanation only. For the correct applicable values see = Specifications ([) E?-4) See also Test Procedures (P\E?-34) Table 8, Colour Key to Oil Flow and Pressure By FulPressure mm Neutral Wy Exhaust soneuieyog pue uoneiado olnespKH WALSAS 21INeAPAH [altered solneupAy - Zy UoKDegW Section E2 - Hydraulics Parallel Hydraulic SYSTEM Hydraulic Operation and Schematics Fig 8. No Services Operated E2-16 '9803/3750-05 (E-01-03) 2-16W Section E2 - Hydraulics Parallel Hydraulic SYSTEM Hydraulic Operation and Schematics Fig 9. One Service Operated E247 '9803/3750-05 (E-01-03) E2-17W Section E2 - Hydraulics Parallel Hydraulic SYSTEM Hydraulic Operation and Schematics Fig 10, Main System Pressure Relief E2-18 E2-18Be 6 Spool Control Valve with Unloader Section Fig 11. Typical 6 Spool Control Valve ‘When the spools are actuated, oil fom the pump passes. into the service pots A or B, operating the relevant hydraulic ram, See the applicable hydraulic schematic for ‘service port connections, Cilfromthe pump enters the control valve at P, passing the: adjustable main relief valve (M.R.V.) 2A. As the spools 2D, 2E, 2F, 2G, 2J and 2K are in neutral, the oll passes round. their central waists, the spool lands preventing the oil om ‘entering the service ports. On reaching the end housing the oll enters the exhaust gallery andis discharged back to tank T. The control valve also incorporates adjustable auxiliary relief valves (A.R.V's) 2N, 2P, 2L and 2M, The unloader section 2H isolates the stabilisers when solenoid 2R is energised, Section E2 - Hydraulics Parallel Hydraulic SYSTEM Hydraulic Operation and Schematics _ fe 4 Fig 12. 6 Spool Control Valve Schematic” E219 TOIRATED SEO) E219B Section E2 - Hydraulics Parallel Hydraulic SYSTEM Parallel Ram Operation The parallel lift system operates when the boom raises or lowers. When the boom ram C raises or lowers the boom displacement ram A extends or retracts. Oil displaced by the ram A flows to the tit ram D which extends or retracts keeping the forks E parallel with the ground, Note: Machines have a single or twin displacement rams, dependant on the machine variant. Fig 13. Displacement ram forward of the boom pivot 8 Hydraulic Operation and Schematics E2-20 '9603/3750-05 (E-01-03) E2-20B Section E2 - Hydraulics Parallel Hydraulic SYSTEM Boom Raise Cycle Dig 14. (1)E2-22) and Fig 15. (E222) as applicable. ‘When lift sp00120 is selected, the neutral circuits blocked and oil feeds lit ram hose-burst check-vaive 8A. Oil flows through free flow direction of hose burst check valve (HECV) 8A and ls the boom. Oils forced out of the rod side of displacement ram 9 as the boom rises. The oil cannot flow past the tilt spool 2F. as the spool isnot selected, Instead, itfiows to the rod side oftit ram 10. Oil dispiaced from the head side of the tit ram raises pilot pressure in HECV 40A. This allows oll to feed back to the head side ofthe displacement ram, Displacementiftlink valve 20 is ited between lit spool 2D and tit spool 2F. The function of this valve is to allow a Testricted flow of ol into the tit circut to increase the lift force available by utilising the displacement ram. Auxiliary relief valve (ARV) 2J opens to protect the tit ram from over pressurisation. The anti-cavitation feature of valve 2H ensures that, in these circumstances, the tit and compensating rams will nt cavitate. This has the effect of allowing the tit ram to extend in proportion to boom Ift, keeping the forks parallel wth the ground. Hydraulic Operation and Schematics E2-21 '9603/3750-05 (E-01-03) E221Ww Section E2 - Hydraulics Parallel Hydraulic SYSTEM Hydraulic Operation and Schematics Fig 14. Boom Raise Cycle (HiViz machines with Single Displacement Ram) ‘a Fig 18. Boom Raise Cycle (Machines with Two Displacement Rams) E2-22 '8003/9750-05 (E-07-03) E2-22B Section E2 - Hydraulics Parallel Hydraulic SYSTEM Boom Lower Cycle DFig 16. (DE2-24) and Fig 17. (T1E2.24) as applicable. ‘When raisellower spool 20 is selected, the neutral circut is blocked and oil feeds the rod side of lit ram 8. Oil displaced from the head side of the lift ram raises pilot pressure in HECV 8A and allows oil out of the lftram back to tank, lowering the boom, {As the boom lowers, oil is forced trom the head side of the displacement ram 8, The oll cannot flow past tit spool 2F. as the spoo! is not selected. Instead, it flows through free flow direction of HBCV 10A to the head side of the titram 10, Oil displaced from the rod side ofthe tit ram feeds back to the rod side of the displacement ram, This has the effect of allowing the titt ram to retract in proportion to boom lower, Keeping the forks parallel with the ground Displaced oil rom the compensating ram closes the check valve in displacement ink valve 20, Auxiliary relief valve (ARV) 2H opens to protect the tit ram from over pressurisation. The anti-cavitation feature of valve 2J ensures that, in these circumstances, the tit and compensating rams will nt cavitate. Hydraulic Operation and Schematics E2-23 '9603/3750-05 (E-01-03) E2-23Ww Section E2 - Hydraulics Parallel Hydraulic SYSTEM Hydraulic Operation and Schematics ) # 108 lg, Fig 17. Boom Lower Cycle (Machines with Two Displacement Rams) E2-24 '8003/9750-05 (E-07-03) E2-24B Boom Regenerative Valve (i fitted) The regenerative valve is fted to the outer extension ram to increase the speed of the boom during the extend cycle, under light load conditions. Hydraulic ol is displaced from the rod side of the inner extension ram to supplement the pump flowto the head side of the outer extension ram. The speed of the extending boom is increased, ‘The only servicing possible in the event of external oil leakage is the renewal of oil seals, or the renewal of a faulty soremin cartridge. For details of the valve operation, under various load conditions: = Boom Extend Cycle - Light Load (Regenerative Cycle) (T3E2-26) = Boom Extend Cycle - Heavy Load ([) £2.27) Section E2 - Hydraulics Paralle Hydraul SYSTEM Hydraulic Operation and Schematics Fig 18. 2 Boom Retract Cycle (7) E2-28) ‘Screw-in Cartridge Components. @ Fig 18. (E225) ‘A _| Outer extension ram hose burst check valve Pressure relief valve B © __ Pilot operated check valve D Non-return vale E2-25 '9603/3750-05 (E-01-03) E2-25Ww Section E2 - Hydraulics Parallel Hydraulic SYSTEM Hydraulic Operation and Schematics Boom Extend Cycle - Light Load (Regenerative Cycle) 13 Fig 19. {As the boom extends with the forks lightly loaded, ol rom the valve block flows through the outer extension ram hose-burst checkvalve (HBCV) 13A to the head side of outer extension ram 12. Oil is cigplaced from the rod side of outer extension ram 12 and passes through inner extension ram HBCV 114 to the head side of inner extension ram 41. nner extension ram 11 starts to extend and oll is displaced from the rod side of the cylinder. Pressure relief valve 13B prevents oll leaving the regenerative valve block and returning to tank Pilot operated check-valve 13C opens to allow the oil to supplement the main pump flow via 13D and increase the speed of extension mae 3003750-05 (E903) E2-26Ww Section E2 - Hydraulics Parallel Hydraulic SYSTEM Hydraulic Operation and Schematics Boom Extend Cycle - Heavy Load 148A einai Fig 20. ‘As the boom extends, oll under high pressure closes check-valve 13D. Oil flows through the outer extension ram ose-burst [Link] 13A to the head side of outer extension ram 12 Oil is displaced from the rod side of outer extension ram 12 and passes through inner extension ram HBCV 11A to the head side of inner extension ram 11. Inner extension ram 1 starts to extend and oll is displaced from the rod side of the cylinder. Pilot pressure opens pressure relief valve 138, Cl displaced from the rod side of the inner extension ram 411 now passes through the extension spool and back to tank. This oil is prevented from supplementing the main pump flow by check-valve 18C. The boom will extend slower, but with more force than the regenerative cycle. ma 3003750-05 (E903) E227Ww Section E2 - Hydraulics Parallel Hydraulic SYSTEM Hydraulic Operation and Schematics Boom Retract Cycle Fig 24 {As the boom is retracted, oil flows through pressure relief valve 13B to the rod side of inner extension ram 11. Oils prevented from entering the regenerative valve block by pilot operated check-valve 13C. Oil is displaced from the head side of inner extension ram 11 through HBCV 114, and 413A and back to tank through the extension spool. Oil cannot flow through the regenerative valve because non return valve 18D is closed. as 3003750-05 (E903) E2-28Ww Section E2 - Hydraulics Parallel Hydraulic SYSTEM Fault Finding Fault Fin: 9 ‘The purpose of this section is to help you trace aparticular “Make sure that the hydraulic fluid is at the correct fault. The tables identity possible causes and give a ‘working temperature (50°C, 122°F), suggested action with specific tests where applicable. 5 IFhydraulic contamination is found, be sure to remove 1 Before you begin fault finding, read the safety ALL debris, and if possible identify its origin. It may be information at the beginning of this manual. part of a component from elsewhere in the hydraulic circuit. 2 — Make any relevant electrical checks before moving on to the hydraulics. 6 What ever the fault, check the condition of the hydraulic fluid, Drain and replace it necessary. 3 Make simple checks before say, stripping @ major hydraulic component 7 Renew any seals such as O-rings when re- assembling hydraulic components. Valve Block Fault 3 Table 9. Lack of power at all hydraulic functions ([) E2-29) = Table 10, All mechanically operated hydraulic services slow 10 operate ([) 2-30) + Table 11. One mechanically operated hydraulic service fails to operate or is slow to operate (T) E2-30) = Table 12. The engine tends to stall when hydraulics are under load ([% E2-20) = Table 13. Ram creep ([) E2-30) 2 Table 14, Boom hoses tangle inside boom ([) £2.34 Table 9. Lack of power at all hydraulic functions. Possible Cause ‘Action Insufficient hydraulic fui Check for leaks and top up as required Hydraulic eaks in system Check hoses, renew as required Engine performance, ‘Check engine performance, MRV setting incorrect. Check and adjust as required Low pump flow. = Check pump flow. — Check for external leaks, renew seals, = Priority valve sticking, see Section H - Steering. = Renew pump 2 960575750-05 (E0703) £2-29B Section E2 - Hydraulics Parallel Hydraulic SYSTEM Fault Finding Table 10. All mechanically operated hydraulic services slow to operate Possible Cause Action ‘Neutral circuit or low pressure lines leaking, damaged, ‘trapped or kinked, CCheck pipe lines and renew as required. MRV selting incorrect Check and adjust as required Low pump fiow = Check pump flow. ~ Check for external leaks, renew seals, — Priority valve sticking, see Section H - Steering = Renew pump. Table 11. One mechanically operated hydraulic service fails to operate or is slow to operate Possible Cause ‘Action ‘See Section E - Circuit Descriptions - interlock Characteristics. ‘Associated service pipe lines leaking, damaged, trapped or kinked Check hoses, renew as required ‘Associated ram leaking. Renew seals, ARV setting incorrect. Check and adjust as required ‘Associated valve block section leaking or not operating, = Check for leaks, rectify as required = Check that the control laver is operating the spool, rectify as required, ‘Associated check valve not opening to allow return of oto tank (Check and rectify as required Diverter not opening Check electrical power supply and valve operation, recty as required ‘Table 12. The engine tends to stall when hydraulics are under load Possible Cause Action RV valve setting incorrect Check and adjust as required Engine performance, Check engine performance, Table 13, Ram creep Possible Cause ‘Action ‘Associated ram or pipe lines from ram leaking (Check and rectify as required Chackvanve. (Check operation and recify as required E2-30 '8003/9750-05 (E-07-03) E2-30B Section E2 - Hydraulics Parallel Hydraulic SYSTEM Fault Finding Table 14. Boom hoses tangle inside boom Possible Gause Action Non JCB hoses fitted Fit genuine JCB hoses. This is important, Special hose construction is used, Hose twisted during assembly, Fit hoses carefully to prevent twisting. ‘Sieel pipes under boom bent due to previous hose failure or abuse, Fit new pipes. Front lower wear pads worn causing hoses to contact boom, Fit new wear pads and shim correctly. Hoses not greased on assembly. Grease heses, Hose rollers have insufficient tension, Adjust to tension correctly Hoses stretched due to three stage boom phasing problems. Fit new genuine JCB hoses and bleed the boom extension circuit. E231 '9603/3750-05 (E-01-03) E2-31B Section E2 - Hydraulics Parallel Hydraulic SYSTEM Boom Extension Fault Finding Table 15, tion Yes No 1 Isthe machine experiencing boom extend orretract Goto Dene problems? 2 _ Bleed air rom hydraulic eyindere, OK now? Done Gowes 3 Does the inneriniermediate boom extend orretiac? __|GotoT Gots 4 Pressure test hydraulic pump. Ractiyfrequired. OK now? | Done Gores 3 Check MV in valve block and for leakage passed pistons [Done Gows in beth rams, Investigate and rectly as fequired, OK now? & Replace hose-burst check valve(@) on innerfouter Done GoweT extension rams). OK now? 7 Are the innerintermediate booms over-running afte de- [Goto 6 Gove selecting extend lever of is there an unexpected surge after a retract operation?” 3 _ Renewmotor spoolin extend slice See TIS/107_ OK now? [Done 9 Dothe innerintermediate booms go out of phase? (Goto 10 Gore? 0. Does the operator periodically uly vetiactinnerand [Goto 12 Goto tt intermediate booms to re-phase hydraulic cylinders? 7 Folly revact inner and intermediate booms to re-phase [Done Gow iz hydraulic oyinders. OK now? 42 Does the inner boom fuly retact leaving niewmedate [Goto 3 Gow is boom sligntiy extended? 18. Stipinner extension cylinder and ensure make-up valvein [Done Gow? piston head is intact and tree trom contamination, ithe valve is damaged, replace wth improved type. Adjust make-up valve and bleed cylinders. OK now? 14 Does the outer boom fuly etract leaving intermediate [Gato 15 Gore? boom slightly extended? 45 Strip outer extension onder and ensure make-up valve Gore? piston head i intact anc free from contamination, ithe valve i damaged, replace with improved type. Adjust make-up valve and bleed cylinders. OK now? F232 90031875005 (E0705) £2-32B Parallel Lift Fault = Table 16. Forks Creep Down ([\E2.: 2 Table 17, Parallel Lift Faulty (TY E2-33) Section E2 - Hydraulics Parallel Hydraulic SYSTEM Fault Finding Table 16, Forks Creep Down Possible Cause Remedy the machine recently? Circuit hosed incorrectly, Has any work been completed on Check circuit. Re route the hoses if necessary, Tittram HECV leaking, tit ram seals leaking, control vave ‘spool leaking or valve block section leaking internally (Check for leakage in the tit ram circut Note: The forks wil continue to crowd back when the ‘boom reaches maximum elevation angle, if the lit lever is not deselected on machines fitted with displacement ink valve 20. This is normal and is caused by oil bleeding from the lit orous to the tit circuit. = Parallel Lift ([)E2-20) ‘Table 17. Parallel Lift Faulty Possible Cause Remedy Displacemeni/ift ink valve broken or leaking, Examine valve; is ball OK? Fit blank to isolate valve from circuit. Fit atest type valve. = Check pipes. tit spool, HECV for missing ball Tilt section ARVs set incorrectly, causing oil to exit from tity compensating ram circuit Check tt ARV setting. Adjust if required. Tilt section ARVs could be sticking open due to contamination, Clean or new as required Leaking seals in tit am or compensation ram. ‘Check titicompensation rams for leakage (use hand pump if available), Renew seals as required E2-33 '9603/3750-05 (E-01-03) E2-33B Section E2 - Hydraulics Parallel Hydraulic SYSTEM Test Procedures Test Procedures Checking Pump Flow Triple Pump The separate sections of the gear pump assembly supply hydraulic ol to the main services circus, to the steering circu and to the hydraulic cooling fan circuit. To determine the source of a problem i.e pump, steer circuit or services circuit, measure the output flow at system pressure from each pump outlet port in turn Awarninc Make the machine safe before working underneath It. Park the machine on level ground, lower the attachments to the ground. Apply the park brake, put the transmission in neutral and stop the engine. Block both sides of all four wheels. Disconnect the battery, to prevent the engine being started while you are beneath the machine, Evatt 1 Carty out General Safety procedures, see Section 2 = General Procedures. AwarNinc Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Make sure the engine cannot be started while the hoses are open. InoH2 2 Vent the hydraulic pressure, see Section 2- General Procedures. Fig 22. Test Equipment 3 Connect a flow meter 22-A, 0-400 bar (0-6000 Ibn?) pressure gauge 22-B and load valve 22-€ into the discharge line from each pump section in tum as described below: Main Services Pump (Section 1): Disconnect hose 23-A from the pipe 23-B, Fit the flow meter and load valve betveen hose 23-A and the pipe 23-B. For machines (over 10,5 metre lit height) only also disconnect hose 23-C from the pipe 23-B. Cap the ‘open port in the pipe, then connect a suitable slave hose 24- D to hose 23-C and route the hase to the hydraulic tank. Slowly remove the hydraulic tank filler ‘cap and place the end of the slave hose 24-D inside the filer tube as shown, = Fig 24. ([)E2-36) Steering Pump (Section 2): Disconnect hose 23- from the priority valve 23-E (port EF). Fit the flow meter and load valve between hose 23-C and the priority valve 23-6. ‘Cooling Fan Pump (Section 3): Disconnect hose 23- F from the pump. Fit the flow meter and load valve between hose 23-F and the pump. Fig 23. Typical Triple Pump Note; Make sure the foad vaive and flow meter is installed the correct way round i@. with the direction arrow pointing away from the pump. A cauTION Make sure the load valve is in the OPEN position, (the adjusting knob screwed fully OUT), before starting the following pressure test. Fallure to do this could damage the pump. Wrest 4 Start the engine and bring the hydraulic system upto ‘working temperature 50° C (122° F). E2-34 '9603/3750-05 (E-01-03) 2-34B Section E2 - Hydraulics Paralle Hydraulic SYSTEM 5 Select the steering and control valve block spools to the neutral position. 6 Set the engine speed to 2200 rev/min. then carefully adjust the load valve 22-C so that the gauge reading increases to 240 bar (3500 Ibin?) 7 Check the flow reading which should be as stated 2 Specifications ([)E2. Ifthe flow reading is low or you are unable to obtain the pressure required. > Fault Finding ([) £2.29) For testing the Priorty Vale, see Section H - Steering. A warninc Take care when disconnecting hydraulic hoses and fitings 2s the ol will be HOT. TRMit2 8 _Aiter completing the test, swich OFF the engine and allow to cool before disconnecting the test equipment and reconnecting the hydraulic hoses. Test Procedures E2-36 '9603/3750-05 (E-01-03) E2-35Ww Section E2 - Hydraulics Parallel Hydraulic SYSTEM Test Procedures Testing Main Relief Valve (MRV) 1 Parkthe machine and makeit safe. Vent the hydraulic pressure, see Section 2 - General Procedures. 2 Connect a 0 - 400 bar (0 - 6000 Ibn’) pressure gauge to the test point A 3. Start the engine and bring the hydraulic systern upto ‘working temperature 50° C (122° F. 4 Select boom lower service and hold ram fully closed Gradually increase the engine speed to 2200 revimin. while checking maximum gauge reading, which should be as stated. = Specifications (1) E2-4 Fig 25. Test Point (Typical Triple Pump) E236 '9603/3750-05 (E-01-03) E2-36Ww Section E2 - Hydraulics Parallel Hydraulic SYSTEM Test Procedures Testing ARV’s Set Lower than the MRV AR\'s which are set below the M.R.V. pressure can be tested simply by operating the relevant service. For tt ram ARV's, which are set above the MR.V. pressure, a different procedure is required. = Testing ARV's Set Higher than the MRV (P1) (Es Important: The engine must not be run at maximum speed as a signficant increase in pressure will be recorded. 1 Parkthe machine and makeit safe. Vent the hydraulic pressure, see Section 2 - General Procedures. 2 Connect 2 0 - 400 bar (0 - 6000 Ibn?) pressure gauge to the test point Testing Main Relief Valve QURV) (TYE2-36) 3 Start the engine and bring the hydraulic systern upto working temperature 50° C (122° F) 4° Set the engine to idle revimin. and operate the relevant service to ful travel, Hold while checking the. maximum gauge reading which should be as stated 3 Specifications (1) E2-4) 5 Ifthe pressure is incorrect, adjust the relevant AR.V. 2 Reliof Valve Adjustment (T) E2-42) E237 '9603/3750-05 (E-01-03) E237B Section E2 - Hydraulics Parallel Hydraulic SYSTEM Testing ARV’s Set Higher than the MRV (P1) Fig 26. Ram c 1 Head side ARV. a Lower the boom fully 4 warninc Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service e line has been vented before connecting or removing hoses. Make sure the engine cannot be started while Test Procedures Disconnect tit ram head side hose 26-A from connector 26-B. Blank off hose 26-A and connect 20-400 bar (0 - 6000 Ibffin®) pressure gauge into the end of connector 26-B. Start the engine and siowly raise the boom to approximately 45° angie, then operate the boom lower service. AS the boom descends the pressure gauge will show the AR. pressure, which should be as.—statod = Specifications ([) E2-4) I the pressure ‘ incorrect, adjust the ARV. 22 Rellef Valve Adjustment ([)E2-42) the hoses are open, A WARNING fp ES Take care when disconnecting hydraulic hoses and b Vent the hydraulic pressure, see Section 2 - fittings as the oil will be HOT. General Procedures, TRANS E238 '9603/3750-05 (E-01-03) E238Section E2 - Hydraulics Parallel Hydraulic SYSTEM f After completing the test, fully loner the boom, ‘switch OFF the engine and ventresidual hydraulic pressure, Disconnect the pressure gauge and Test Procedures reconnect the tit ram head side hose 26-A to connector 26-B, 2 Rodside ARV. a Lower the boom fully Vent the hydraulic pressure, see Section 2 - General Procedures. © Disconnect tit ram rod side hose 27-6 from connector 27-D. Blank off hose 27-C and connect 0-400 bar (0 - 6000 lofi) pressure gauge into the end of connector 27-D. d_ Start the engine and slowly raise the boom to approximately 45° angle, As the boom is raised the pressure gauge will show the A.R.V. pressure, which should be as.— Stated = Specifications (1) E2-4) © If the pressure is incorect, adjust the ARV. 2 Rellet Valve Adjustment ([)E2-42) AwarNinG Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT. TRANS After completing the test, fully loner the boom, ‘switch OFF the engine and ventresidual hydraulic pressure, Disconnect the pressure gauge and reconnect the tit ram rod side hose 27-C to connector 27-D. E2-39 '9603/3750-05 (E-01-03) E2-39Se Section E2 - Hydraulics Parallel Hydraulic SYSTEM Testing ARV's Set Higher than the MRV (P2) Tilt Ram 1 Hoad side ARV, A warninc Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hhose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses, Make sure the engine cannot be started while the hoses are open. mer ‘a. Park the machine and make it safe. Fit the born safety sut. Vent the hydraulic pressure. Obeythe care and safety procedures. ent the hydraulic pressure, © Related Topics ([) E2-3) Test Procedures Disconnect hose A from pipe connector B. Fit a test point C to the pipe connector and reconnect the hose. Fit a 0 - 400 bar (0 - 6000 Ibfin’) pressure gauge to the test point C. Make sure that there will be clearance between the test point and ‘chassis when the boom is lowered. © Start the engine and remove the safety strut. ‘Slowly lower the boom to the horizontal position As tha boom is lowered the pressure gauge will show the ARV. pressure, which should be as stated, = Specifications ([) E24) d If the pressure is incorrect, adjust the ARV. > Relief Vaive Adjustment (7) £2-42) @warninc Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT. THIET E240 9203/3750.05 [E-D1-03)Ww Section E2 - Hydraulics Parallel Hydraulic SYSTEM Test Procedures © After competing the test, ft the boom safety strut Disconnect the pressure gauge, remove the test Vent the hydraulic pressure. Obey the care and point and reconnect the titram head side hose A safety procedures. 3 Related Topics (7) E2-3) to pipe connector B Fig 29, 2 Rod side ARV. 4. If the pressure is incorrect, adust the ARV 2 Relief Valve Adjustment (7) E2-42). Awarninc a Hydraulic Pressure WARNING Hydraulic fluid at system pressure can injure you. Take care when disconnecting hydraulic hoses and Before connecting or removing any hyciraulic hose, _ fittings as the oil will be HOT. residual hydraulic pressure trapped in the service Trans i-2 hose line must be vented, Make sure the hose service line has been vented before connecting or removing @ After completing the test ft the boom safety strut. hoses. Make sure the engine cannot be started while Vent the hydkeulic pressure. Obey the care and the hoses are open. safety procedures. = Related Topics (7 E23) ia Disconnect the pressure gauge, remove the test point and reconnect the tit ram head side hose A ‘a. Park the machine and make it safe. Fit the boom to pipe connector B. safety strut. Ventthe hydraulic pressure. Obey the cere and safety procedures. ent the hydraulic pressure, 3 Related Topics (D\E2-3 Disconnect hose A from pipe connector B. Fit a test point C to the pipe connector and reconnect the hose. Fit a 0 - 400 bar (0 - 6000 Ibfiir) pressure gaugetothetest point C, Make sure that ‘there will be clearance between the test point and chassis when the boom is lowered. © Qart the engine and remove the safety strut. ‘Slowly lower the boom to the horizontal position then slowly raise the boom to approximately 45° angle. As the boom is raised the prassure gauge will show the ARN. pressure, which shouldbe as stated, 3 Specifications ([) E2-4) E241 ‘980/37 50-05 (E-07-03) 2-44B Section E2 - Hydraulics Parallel Hydraulic SYSTEM Relief Valve Adjustment 3. Ifthe pressure is incorrect, adjust the relief valve as described below ‘a. Position the boom and fit the Safety Strut, see ‘Section 2 - General Procedures. Fig 30, Relief Valve Adjuster Screw and Locknut Vent the hydraulic pressure, see Section 2 - General Procedures. © Loosen the locknut B and turn the adjuster screw . Turn the adjuster screw clockwise to increase pressure and anti-clockwise to decrease the pressure. When the pressure is correct, tighten the locknut and check the pressure again, Adjust as required, The location of the relief valve is dependant on the ‘machine type. Identify the positions of the relief valves housed in the control valve block correctly. 2 Specifications ([} 2. Test Procedures Fig 31, Test Point (Typical Triple Pump) E242 '9603/3750-05 (E-01-03) E242B Section E2 - Hydraulics Parallel Hydraulic SYSTEM Measuring Spool Displacement (Manual Spools) Note: This procedure is only applicable to manually operated spooks A warninc ‘Communications Bad communications can cause accidents. Keep people around you informed of what you will be doing Ifyou will be working with other people, make sure any hand signals that may be used are understood by everybody. Work sites can be noisy, do not rely on spoken commands. Note: Two people are required to complete the procedure, Person 1 should be sat in the operator cab, whilst Person 2 requires access to the control valve assembly. 1 Raise the boomand fit the safety strut, see Section 2 - General Procedures. 2 Carty out General Safety procedures, see Section 2 = General Procedures. 3 Vent the hydraulic pressure, see Section 2- General Procedures. 4 Check spool displacement 32.4. a Person 2 - Using the control lever, move and hold the spool in position 32-1. b Person 1 - Measure spool displacement 32-A, 5 Check spool displacement 32-8, a Person 2 Using the control lever, move and hold the spool in position 32-3, b Person 1 - Measure spool displacement 32-8. Test Procedures S) IM aot te A ts ©) ill Fig 32. Manual Spool Displacement 6 Repeat the procedure for each manual spool as necessary. Table 18. Spool Displacement Displacement: ‘Measurement: 328 ‘Bram HF Tm (0.32in +7 O.0Ain) 328 ‘mm ¥ 1mm (0.32 + O.04in) Adjustment ‘Spool displacement is influenced by the control lever linkage. Check, adjust and replace if necessary, If sufficient adjustment can not be achieved it may be necessary to replace the spool assembly, 2 Related Topics ([) E2-3) E243 '9603/3750-05 (E-01-03) E243B Section E2 - Hydraulics Parallel Hydraulic SYSTEM Bleed Procedures Bleed Procedures 3-Stage Boom Extension Ram Circuit Whenever a hydraulic component is removed or disconnected from the boom extension circuit, the circuit must be bled to ensure that any residual air is removed Important: During the following procedure itis impertant that the inner ram is not allowed to extend mare than the outer ram, to prevent damage to the inner ram and auxiliary feed and return hoses. 1 Park the machine on firm level ground, Engage the park brake and set the transmission to neutral 2. Raise the boom to the horizontal position, 3 Stop the engine and remove the starter key. 4 Assemble a suitable bleed hose 33-A, fied with a rmale quick release coupling (QRC) 38-B and female quick release coupling 33-C Note: Ensure the male quick release coupling 33-B is connected to the straight swivel end of the hose. Fig 33. Bleed Hose Specification: Length (Approx) [6900 mm (20 #6 in.) Bore ae" Pressure Rating [High (Guitable for 240 bar operating pressure} 5 Attach the bleed hose assembly to the male quick release coupling 34-D on the top extension hose, Fig 36. 6 Connect the other end of the bleed hose assembly to the female quick release coupling 35-E on the boom Important: Route the hose beneath the boom so that it does not become entangled when the boom is extended/ retracted. Fig 36. 7 Startthe engine and operate the boom service to fully retract the inner and outer boom sections, 8 SLOWLY operate the boom extend and auxiliary service together, until the outer ram 36-F is fully extended, Make sure that the auxiliary service selected provides a return to tank forthe outer ram so that the inner ram does not extend E244 '9603/3750-05 (E-01-03) E244Section E2 - Hydraulics Parallel Hydraulic SYSTEM Fig 36. Should the inner ram extend during this sequence, deselect the auxiliary service and operate the retract, service to fully retract the inner ram before continuing to extend the outer ram with the correct tank line auxiliary service 9 With the outer ram 36-F fully extended and the inner ram fully retracted, fully retract the outer ram using the boom retract and auxiliary service together. Use the auxiliary service in the opposite direction to that used in step 6 to provide an additional pressure feed during the retract function 10. Ensure that the hoses are located correctly in the roller assembly 37-G at the base of the boom. Bleed Procedures A caution Allow the hydraulic fluid temperature to cool before removing the hydraulic tank filler cap. Open the cap slowly to prevent oil being forced out of the filler neck. feat 11 Slowly remove the hydraulic tank filer cap 37-H to vent the hydraulic system and release any residual pressure. Check the hydraulic fluid level and top-up the tank if necessary. Refithydraulic tank filler cap. 12 Detach the bleed hose assembly from the quick release couplings on the machine, 13. On completion, extend and retract the boom fully five times while checking that the boom sections open and close fully together. Inspect the hydraulic connections and check for leaks. 14 If the boom sections do not open and close fully together repeat bleeding procedure If the boom sections do not open and close fully together after repeating the bleeding procedure, see Fault Finding. => Fault Finding (1) E2-29) E245 '9603/3750-05 (E-01-03) E245B Section E2 - Hydraulics Parallel Hydraulic SYSTEM Tilt Ram Circuit 1 Park the machine on firm level ground. Engage the park brake and set the transmission to neutral 2 Raise the boom to a convenient height to access the tilt ram, 3 Stop the engine and remove the starter key 4 Operate the controls back and forth several times to vent residual hydraulic pressure. 5 Release locknut 38-A and back-off the screw 38-B, Note: Later machines have Jocknut 38-A and screw 38-8 ‘on the side of the block 6 Start the engine and operate the tik lever several times. 7 Tighten the screw 98-B and locknut 98-A, 8 Operate the tit lever several times again. Stop the engine, 9 Repeat steps 5 to 8 if necessary, Ensure that screw 38-8 is finally tightened to 15 Nm (11.4 Ibf f) and locknut 38-A is tightened to 12 Nm (@ Ib) Bleed Procedures E246 '9603/3750-05 (E-01-03) E246B Section E2 - Hydraulics Parallel Hydraulic SYSTEM Sway Ram Cire The sway ram has an integral bleed valve, which can be Used to bleed the sway hydraulic circuit Important: Make sure that the boom is in the lowered position when bleeding the sway rem circuit Note: This procedure requires two people. One person to operate the sway conbols and another to tighten the bleed screw when all ar has been expelled. If this procedure is done by one person air may enter the cylinder due to the delay in dismounting from the cab to attend to the sway oylinder. A WARNING ‘Communications Bad communications can cause accidents. If two or more people are working on the machine, make sure each is aware of what the others are doing. Before starting the engine make sure the others are clear of the danger areas; examples of danger areas are: the rotating blades and belt on the engine, the attachments and linkages, and anywhere beneath or behind the machine. People can be killed or injured if these precautions are not taken. inners 1 Park the machine and make itsafe. Lower the boom. Vent the hydraulic pressure. Obey the care and safety procedures, = Related Topics ([)E2-3) Important: Opening the sway ram bleed valve can cause the machine to sway unexpectedly. Only open the bleed valve when the machine is swayed fully to the left or the right Important: DO NOT siand between the chassis end the wheel, You can be trapped or crushed when sway is operated, Important: The bleed valve should only be completely removed from the valve body to allow cleaning of the Integral 1.2mm orifice, 2 Start the engine and operate the sway lever to sway the machine fully to the operators left side (sway ram. extended). Stop the engine and vent the hydraulic pressure. Follow the correct procedure, see Venting the Hydraulic Pressure, Section 2. Bleed Procedures Fig 39. ([\E2-47) Get an assistant to carefully Unscrew the bleed valve 1, be prepared for hydraulic, «il to escape, DO NOT unscrew more than 6.5 mm (0.25in) Start the engine and operate the sway lever to sway the machine fully to the operators left side. Hold the lever in this position until no more air is expelled through the bleed valve 1, Retum the control lever to its neutral position. Immediately tighten the bleed valve 4 to prevent air entering the circuit. Fig 39. Unscrewing the Bleed Valve Operate the sway ram flyin both directions 10 times Repeat steps 2, 9 and 4 ‘Stop the engine and remove the starter key. Check the hydraulic fluid level. = Related Topics (1) £2-3) E247 '9603/3750-05 (E-01-03) E247Ww Section E2 - Hydraulics Parallel Hydraulic SYSTEM Bleed Procedures Page left intentionally blank E248 '9603/3750-05 (E-01-03) E248Ww Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either ‘mechanically, hydraulically or electrically. Make sure you are referring to the correct system, Refer to the applications ‘able, > Related Topics ([} E3-3) Descriptions and procedures relate to the system and not the individual devices, For information about the devices refer tothe relevant topics. Related Topies ([1E3-3) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as rermoval and replacement and dismantle and assemble, 3 Related Topics (T)E3-3) + Specifications (1) 3-4) = Control Valve Block ($1) (TYE3-4)"” Control Valve Block ($2) (TYE3-5)"” .[Link]! Valve Block ([) E3-6) 3 Hydraulic Pump ([)E3-7) 2 Cooling Fan Motor ([) 3-8) 3 Operation Overview (PE3-9) = Component Location and Identification (T)E3- 2 Oil Pump (1) E3-12) Control Valve Block ([)E3-12) = Main Relief Valve (MRV) Operation ([) E3-13) + Auxiliary Relief Valve (ARV) Operation (T) E3-1: 22 Hydraulic Operation and Schematies ([) E3-16) No Services Operated ([) £3-16) 3 Service Operation (11 E3-16) + Main System Pressure Relief ([) E3-16) = Main Control Valve with Unloader Section (S1) ([\E3-20)"! = Main Control Valve with Unloader Section (S2) (D\E3-21)" 3.2 Spool Remote Control Valve (7) E3-22) 2 Parallel Lift (1) £3-23) = Boom Regenerative Valve (D)E3- = Twin Axis Control Valve (7) £3-27) 3 Single Axis Control Valve ([)E3-2 =D Fault Finding (7) E3-29) 3 Test Procedures ([} £3.33) 3 Checking Pump Flow (1) £3-33) 4 380575005 (E9108) E341g 3 Testing Main Relief Valve (MRV) ([)E3-35) 3 Testing ARV's Set Lower than the MRV (D) E3-36) 3 Testing ARV's Set Higher than the MRV ([) E3-37) 2 Relief Valve Adjustment (7) E3-39) Measuring Spoo! Displacement (Manual Spoo's) ([) E3-40) 3 Bleed Procedures ([} £3-44) 2 [Link] Boom Extension Ram Circuit ([) E3-44 2 Tilt Ram Circuit ([)E3-42) > Sway Ram Circuit ([) £3-43) (1) Specifteation variant. Make sure you refer to the correct specification, Table 4. Procedure and Specification Procedures, Specifications Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Introduction Machine Model Application 540-170 SAF, | 540-170 SAF, 560-170 5AM | 550-170 5AM oo, Marines with | Machines with) Sspoolvalve | 5 spool vave block to block January January 2009 _| 20090n 'D Control valve Block (S1) (E24) . '@ Control Valve Block (S2) (TVE3-5) e Main Control Valve with Unioader Section (Si) (1) E3-20) e @ Main Control Valve with Unloader Section ($2) (()E3-21) e (1) The table lists procedure and specification variants and the applicable machine models. Use the table to make sure ‘you refer to the correct information. E3-2 '9603/3750-05 (E-01-06)B Section E3 - Hydraulics Servo Hydraulic SYSTEM Related Topics Related Topics Table 2. Related Topics in This Publication to Section # - Applications. “The table ists other topics in the manual that contain information related to this topio. Refer to the applicable topios to ‘complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correctiinformation. Some machines have different systems and devices, Make sure you refer tothe correct topic, refer Sections [Topic Titles ‘Sub Titles: 7 “Applications AL 2 ALL (are and Safety)” AL 3 ‘Hydraulic System Checking the Hydraulic Fluid Level B ‘Srabilisers ALL E @ Systems and Schematics (ET E '@ Hydraulic Interlock SYSTEM (D1 E44 ALL E = Parallel Control Valve 6 Section (TES) | ALL E '@ Parallel Control Valve - 6 Section (E61) [ALL E ® Parallel Control Valve 2 Section (T\ET-1)_ | ALL E @ Main Pump ((\E12-1) ALL E @ Servo Control Valves ((}E8-1) AL E '@ Cooling Fan Motor (7) E13-1) ALL Ee @ Servo Solenoid Diverter Valve Block (D}ES-1) H ‘Manual Steer Mode SYSTEM ALL B ‘Auto Steer Mode SYSTEM ALL H Priority Vaive Test Procedures (1) You must obey allof the relevant care and safety procedures. Table 3. Service Tools service tools BEFORE you start the procedures The table ists the service tools you will need to do some of the procedures in this topic. Make sure you have the correct Tool Part Number Description "39200268" Flow Monitoring Kit and Relevant Adaptors ‘39200258 Hydraulic Pressure Test Kit and Relevant Adaptors 392100270" Load Valve (1) Tool available from JCB Service, refer lo Section 1 - Service Tools E33 '8603/750-05 (E-07-06) E33Ww Section E3 - Hydraulics Servo Hydraulic SYSTEM ‘Specifications Specifications Control Valve Block (1) 6 Spool, parallel service, double acting spools Spool 1 Boom Raise & Lower Service Serve pilot operated ‘Spool? Boom Extend & Retract Service Serve pilot operated Spools Carriage Tit Service Serve pilot operated Spool ‘Auxiliary / Sway Service Manually operated Spools RH Stabilser Manually operated Spool TH Sebilcer Manually operated Note: Spools 2 and 3 are reversed on machines fited with « placing contol pattern Relief Valve Pressures: 3 Fig 7. (DE3-4 ar kgfiem? Tene “HH Main Relief Valve (WAV) 260 285 377 ‘Auxiliary Relet Valves (ARV'S) TIN- Auilary Ram Rod Side 138 140 2000 {AP - Auxiliary Ram Head Side 198 140 72000 {IM Carriage Tit Ram Rod Side (port A) 278 261 4000 TAL - Carfiage Tik Ram Head Side (port B) [380 338 4800 Pilot Pressure Range: bar kgflem? Tofine 70-30 702-306 185 - 5 [ean Gt 2 & Oa tO 5 On iL 41M © + On 11N 1P Webo> Om 70 2 On 1 41H sO 1 Oa ~WQ_ ov] P Fig : E34 $80573750-05 (E0108) E34B Section E3 - Hydraulics Servo Hydraulic SYSTEM ‘Specifications Control Valve Block ($2) '5 Spool, parallel service, double acting spools. Spool i Boom Extend & Retract Service Servo pick operated Spool? ‘uxilary / Sway Service Manually operated ‘Spool 3. Carriage Tilt Service ‘Servo pilot operated Spool RH Sabilser Manually operated Spool LH Stabilser Manually operated Rollef Valve Pressures: 3 Fig (DE3-5 bar kgflcm? Wffin? “Wain Relief Valve (RV) [260 [255 Ea Auxiliary Relief Valves (ARV's) TIN Ausllany Ram Rod Side 76 740 2000 TAP - Auxillary Ram Head Side 138 140 2000 41M - Carriage Tiit Ram Rod Side (port A) 276 281 4000 “AL - Cariage Tit Ram Head Side (por 6} 330 336 200 Pilot Pressure Range! bar iegfiem? ibn 781-30 7630-006 |28007-435 (1) Pressure to operate p00! maximum few postion ar casos E36 $80370750-06 (07-08) E35B Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM ‘Specifications 2 Spool Valve Block ‘2 Spool, parallel service, double acting spools. Spool t Boom Raise & Lower Service Seno pilot operated ‘Spool? Boom Extend & Retract Service Sew pilot operated Relief Vaive Pressures: ar kfm? Tein? 3.3 Main Relief Valve (MRV) Dat 2A5 3500 Pilot Pressure Range: bar kofiem® Tein 10-30 702-306 (148-45 Fig 3. Cee E36 90031575005 (E07-08) E36B Section E3 - Hydraulics Servo Hydraulic SYSTEM ‘Specifications Hydraulic Pump ‘Triple Pump. Table 4.170 ltresimin. Type (Gear pump ‘Wountng Gearbox Direction of Rotation Ari-clockvise Theoretical displacement ccfrev eu inkrev Main services pump (mounting flange end) ai 25 Steering pure B 201 Cooling fan pump 76 0.98 low at 2200 revrnin and system pressure (0% min. claplacement—_[litresimin [UK gallmin US galimin Main services pump (mounting flange end) 81.2 17.9 25 Steering pure 8 aa q72 Cooling fan pump BAT 70 34 ‘aximam Pressure bar Kgfem® ——erin® pot EF 265 270 3840 portP 200 204 2000 Maximum Speed 2500 revimin Minimum Speed: 500 rev/min Weight BAT kg (765 bs) '8603/750-05 (E-07-06)B Section E3 - Hydraulics Servo Hydraulic SYSTEM ‘Specifications Cooling Fan Motor Machines with SE Engines Machines with SE engines Type: Gear motor Direction of Rotation: (Clockwise or Bi directional Motor Displacement 10 cchov Fan Speed (at maximum engine revimin): 72800 Maximum Pressure Setting 198 bar (2871 Iona) Body Colour Black ‘Weight: TBA Machines with SD and SF Engines 'SD 63 KW engines Upto March 08 From March 08 Type Gear motor Gear motor Direction of Rotation: ‘Clockwise or Bi directional Clockwise Motor Displacement ‘Bocrev 19 cclov Fan Speed (at maximum engine rev/min): 7800 TBA Maximum Pressure Setting 56 bar (812 tein’) 56 bar (612 lofi’) Body Colour Red Red ‘SD 74 KW and SF engines Upto March 08 From March 08 Type: Gear motor Gear motor Direction of Rotation ‘Clockwise or Bi directional Clockwise oF Bi directional Motor Displacement ‘eodrev TB cohen Fan Speed (at maximum engine revimin): 72500 TBA Maximum Pressure Setting 120 (1740 btn?) (0 bar (1305 Ibn’) Body Colour Black Black E38 {9803/3750-05 (E-01-08) E38Ww Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM ‘Operation Overview Operation Overview The main components of the hydraulic system are the tank, the pump, the control valves and hydraulic rams. ‘As well as providing the main hydraulic services the systemalso operates a hyctraulic steering system. Refer to Section H - Steering > Related Topies (TM E3-3) Machines have hydraulically operated stablisers, Refer to Section B - Body and Framework Related Topics ([) E3- Be '9603/3750-05 (E-01-06) E39B Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Operation Overview ‘Component Location and Identification Table 5. Component Key item [Description 1 [Pump assembly Three section gearpump 1A, 10, 1B > Main Pump (TET? 2 |Main contol valve block [Parallel valve with menualand eno hydraulio [> Main Control Valve with spools Unloader Section (S41) (T1E3-20), 2 Spoo! Remote Control Valve (TYES-22) 2A |2epool control valve block | Parallel valve with servo hydraulic spools 2B |Controllever= auxiliary | Mechanical linkage to valve spool 2C | Contiollevers- stabilisers | Mechanical inkage to valve spool 2D __|Conttollever-one axis | Servo control vale 2E_|Controllever- two axis | Servo control vave 3 |Servodvertervave | Enables hydraulic interocks 4 [Fan motor Driven by pump section 16 3 Cooling Fan Motor (TENS: 3 |Fydraulic GGooler | Oilfrom pump section 1B flows throughthe oll cooler F | Fiydrauie of iter Positioned in the return ine to tanie T ‘Hydraulic tank Table 6. Hydraulic Connections Colour Key Be TPT] JOttompunpsecente Toran pine secin ts Oil suction fine from the tank to Return to tank Oilateervo pressure Ii | the pump sections a a '8603/750-05 (E-07-06) E3-10Ww Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM ‘Operation Overview Fig 4. Typical Machine 1 380575005 (E9108) 3-11B Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Pump DFig 4. (ES-14 il is drawn from the hydraulic tank T by the hydraulic ump assembly 1. The pump assembly is mounted on the rear of the bevel gearbox and is driven by the engine, The pump has three sections, 1A,1B and 1G. Oil from the larger pump section 1A flows direct to the control valve block 2. Pump section 1C has an integral priorty valve which always gives priority demand to the steer circuit With the steering in the straight ahead position (i. with no steering demand), oil from pump section 1€ flows through the priority valve and feeds the 2 spool control valve block 2A. Purp section 1B is dedicated to driving the cooling fan. Oil from pump section 1B flows directly to the cooling fan hydraulic motor 4 The hydraulic oil cooler § in the retum line from the fan hydraulic motor 4, cools the system hydraulic oil as & is continually circulated around the cooling fan circuit For more information on the main hydraulic pump refer to the cortect topic in this section. = Main Pump (1) E12-4 Control Valve Block DFig 4. (ES-11 ‘When the spools are actuated, oil from the pump passes into the service ports, operating the relevant hydraulicram. 2 spool valve block 2A operates at the same time as the ‘main control valve 2 to ensure sutfcient hydraulic flow for operation ofthe lit and extend services, The main control valve contains the main pressure rellet valve (MRV and the auxilary pressure relief valves (ARV's). These valves prevent the hydraulic pressure increasing to a level which would cause damage to the hydraulic components and pipework Since valve block 2A is supplied only from pump section 1C it also has a main pressure relief valve to protect the hydraulic system. Diain_ Relief Valve _(MRV) ration ()E3-13) 3 Auxiliary Relief Valve (ARV) Operation (( £3-14 ‘Operation Overview Manual Control Control lever 28 moves in a single axis and operates the auxiliary service spool via a mechanical linkage Control levers 26 move in a single axis and operate the stabiliser service spools via mechanical linkages. Servo Control [A low pressure (pilot) supply of hydraulic ols supplied from the control valve block via servo diverter valve 3 to the ‘win axis and single axis serve control levers (2D and 26), The servo control levers direct pilat flow to the relevant service spool. The pilot flow moves the valve block spool in the required ditecton to operate the boom services, ‘The servo diverter valve 3 enables hydraulic interiocks. 2 Hydraulic Interlock SYSTEM ([) Es. E3-12 '9603/3750-05 (E-01-06) E3-12Ww Section E3 - Hydraulics Servo Hydraulic SYSTEM ‘Operation Overview Main Relief Valve (MRV) Operation Fig. ‘The main relief valve (M.R.V) 2A Is situated in the control valve 2, bridging the neutral and exhaust galleries, and is designed to prevent the circuitry from damage that could be caused by excessive pressures. 1 Valve at Rest: ‘The services are in neutral and pressure in the neutral gallery (blue) is not sufficient to operate the M.R.V. which is held closed by its spring A. 2 Poppet Opens: A service has been selected and the pressure generated ‘exceeds the setting of the MARV. Pressure acts on the periphery of the hollow poppet B which is forced downwards against the spring, venting pressure into the ‘exhaust gallery (green) '8603/750-05 (E-07-06) E3-13B Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Auxiliary Relief Valve (ARV) Operation The Auxilary Reliot Vales (A.R.V's) are situated in the control valve to limit potentially damaging pressures within specified services du to extemal loadings. ARV's may also be used to limit the maximum pressure in specified service to less than the L SRV setting, Fig 6 (1) E3-15) 1 Valve at Rest: A senvice is selected but pressure in the service gallery (yellow) has not reached the setting of the A.R.V. which is held closed by its spring, 2 Poppet Opens: The setting of the ARV. is exceeded by the service pressure which causes the poppet to rise against spring force allowing the pressure to be vented into the exhaust gallery (green), 3 Anti-cavitation Mode: ‘When a service is operated in such @ way that low pressure, or cavitation, exists in the service line (light green), the relatively high pressure oil in the exhaust gallery (darker green) acts on the lower poppet and flows into the service gallery to make up the deficiency. ‘Operation Overview 53-14 '9603/3750-05 (E-01-06) E3-143-15 Fig 6. Auxiliary Relief Valve (ARV) Operation "9808/3750-05 (E-01-08) Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Operation Overview(90-10-3) so-oszere086 gL-ea geal To make the description as clear as possible the diagram shows only part of the complete hydraulic system, For the complete hydraulic schematics, refer to the schematics topic. > Related Topies (T)E3-3) No Services Operated 2 Fig 7. (0) 63-17) Oil from the primary pump 1A flows to the inlet-outlet section of the control valve 2 through the valve spool 2B and returns to tank T. Note that oil from secondary pump 1© supplies the sizer circuit via steer priority valve 1D. As there is no steering load this supply joins with pump supply 1A and flows through the valve spool 2B. Ollttom purnp 18 supplies the hydraulic fan circu Service Operation 2 Fig 8. (1) £3-18) When @ service is operated, boom extend for example, the movement of the control lever and its mechanical linkages operate the valve spool 2B. The hydraulic oil flows through the valve spool 2B to the extend ram 3. CO from the other side of the ram 9 flows across the service spool and back to tank T. Main System Pressure Relief 2 Fig 9. (1) 3-19) When a service ram reaches the end of its stroke, or the seivice meets resistance and generates pressure above a specified pressure, the main relief vave 2A Hydraulic Operation and Schematics ‘opens and oil is dumped to tank, preventing further pressure rise, Note: Note: The pressure values given are examples for the purpose of explanation only. For the correct applicable values see = Specifications ([) E3-4) See also Test Procedures (P\E3-33) Table 7. Colour Key to Oil Flow and Pressure By FulPressure mm Neutral Wy Exhaust soneuieyog pue uoneiado olnespKH WALSAS 21INeAPAH onsas Jaylered solneupAy - ¢3 UoKIegW Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Hydraulic Operation and Schematics Fig 7. No Services Operated E347 '9803/3750-05 (E-01-08) 3-17W Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Hydraulic Operation and Schematics Fig 8. One Service Operated E3-18 '9803/3750-05 (E-01-08) 3-18W Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Hydraulic Operation and Schematics Fig 8. Main System Pressure Relief E3-19 '9803/3750-05 (E-01-08) 3-19B Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Main Control Valve with Unloader Fig 10. Typical 6 Spool Control Vaive ‘When the spools are actuated, ail from the pump passes into the service ports A or B, operating the relevant hydraulic ram. See the applicable hydraulic schematic for ‘service port connections. 2 Related Topics ([} E3-3) ilfromthe pump enters the control valve at P, passing the adjustable main relief valve (MR) ‘11H, the pilot pressure reduction valve 11K and pressure maintaining valve 11J. Valves 11K and 11 are set at the factory and are not adjustable. As the spools 116, 11F, 116, 11D, 11B land 11A are in neutral, the oil passes round their central ‘waists, the spool lands preventing tne oil fram entering the ‘service ports. On reaching the end housing the cil enters the exhaust gallery and is discharged back to tank T. The control valve also incorporates adjustable auxiliary relief valves (ARW’s) 11N, 44P, 14L and 11M, Oil at pict pressure is supplied to the servo solenoid diverter block via port PS. = Related Toples (T1E3-3) Hydraulic Operation and Schematics The unloader section 2H isolates the stabiisers when solenoid valve 2R is energised. Section 11R provides a degree of isolation for the tit function (spool 11D), preventing unwanted interaction with other services. '9603/3750-05 (E-01-06) E3-20B Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Main Control Valve with Unloader T ecaice 41D 4b 11M 11R: : AME 11N : 44P 1F t Pp 44H’ Fig 12. Typical 5 Spool Control Valve ‘When the spools are actuated, ol from the pump passes into the service ports A or B, operating the relevant hydraulic ram. See the applicable hydraulic schematic for service port connections. 3 Related Topics (T1E3-3) Oilfrom the pump enters the control valve at P, passing the adjustable main reliet valve (MR.V) 11H, the pilot pressure reduction valve 11K and pressure maintaining valve 11J, Valves 11K and 11J are set at the factory and ‘are not adjustable. As the spools 11F, 116. 11D, 11B and 114A are in neutral, the ol passes round their central waists, the spool lands preventing the oil from entering the service ports On reaching the end housing the ol enters the ‘exhaust gallery and is discharged back to tank T. The control valve also incorporates adjustable auxiliary reliet valves (ARW’s) 11N, 11P, 14L and 11M Oil at pilot pressure is supplied to the servo solenoid diverter block via port PS. = Related Topies ([E9-3) ‘The unloader section 11€ isolates the stabilisers when solenoid valve 2R is energised Hydraulic Operation and Schematics Seciion 14 provides a degree of isolation for the tit function (spo0l 110), preventing unwanted interaction with other services, uu 2R Lae iL 11M TIN 11P Ps| Fig 13. '9603/3750-05 (E-01-06) E3-21B Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM 2 Spool Remote Control Valve ‘The remote control valve has two spoo's, 10A and 10B, which are pilot operated controlied by the two axis servo Joystick via the servo diverter valve, Sp001 108 provides a lift and lower function; spool 104 allows adtional oll low from the retract circuit to return to tank. ilfromthe pump enters the control valve at P, passing the rmain relief valve (M.R.V,) 106. As shown, the spools 410A, and are in neutral. In this condition, the oll passes around their central waists, the spoo! lands preventing the oll from entering the service ports. On reaching the end housing the oil enters the exhaust gallery and is discharged back to tank ‘When the spools are actuated by pilot pressure applied at cone of the pilot ports 1 to 4, il rom the pump passes into the service ports A or B, adding to the flow to the relevant hydraulic ram, See the hydraulic schematic for service port ‘connections: in this application there is no connection to the boom retract service. Lit valve slice 108 provides lift and lower via the middle ump section P2, The lit valve allows excess return flow from the outer telescopic extension cylinder to return to tankvia slice 404. Hydraulic Operation and Schematics E3-22 '9603/3750-05 (E-01-06) E3-22Ww Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Hydraulic Operation and Schematics Parallel Lift Ram Operation The parallel lift system operates when the boom raises or lowers. When the boom ram C raises or lowers the boom displacement ram A extends or retracts. Oil displaced by the ram A flows to the tit ram D which extends or retracts keeping the forks E parallel with the ground, RR A «eS Fig 16. Displacement rams forward of the boom pivot B soa 380575005 (E9108) E3-23B Boom Raise Cycle Big 17. (DE3-24) ‘When lit sp00120 is selected, the neutral circuits blocked and oil feeds lit ram hose-burst check-vaive 8A. Oil flows through free flow direction of hose burst check valve (HECV) BA and lis the boom, Cilis forced out of the head side of displacement ram 9 as the boom rises, The cil cannot flow past the tit spool 2F, as the spool is not selected. Instead, it lows to the head side of tit ram 10, Oil displaced from the rod side of the tit ram raises pilot pressure in HBCV 10A. This allows oil to feed back to the rod side of the compensating ram, Section E3 - Hydraulics Servo Hydraulic SYSTEM Hydraulic Operation and Schematics Displacement ink valve 20 is fitted between lft spool 20 and fit spool 2F. The function of this valve is to allow a restricted flow of oil into the tit circuit to increase the It ‘force available by utilising the compensating ram. Paral Auxillary relief valve (ARV) 2J opens to protect the tit ram from over pressurisation, The anti-cavitation feature of valve 2H ensures that, in these circumstances, the tit and compensating ras will not cavitate. This has the effect of allowing the tit ram to extend in proportion to boom lift, keeping the forks parallel with the ‘ground. Fig 17. Boom Raise Cycle (Machines with Two Displacement Rams) '9603/3750-05 (E-01-06) 8 P= ‘> E3-24B Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Boom Lower Cycle 2 Fig 18. (D)E3-25) ‘When raisellower spool 20 is selected, the neutral circu is blocked and oil feeds the rod side of lift ram 8. Oil displaced from the head side of the lft ram raises pilot pressure in HBCV 8A and allows oil out of the lit ram back to tank, lowering the boom, As the boom lowers, oil is forced from the rod side of the displacement ram 8, The oil cannot flow past tit spool 2F. a the spool is not selected. Instead, it flows through free Hydraulic Operation and Schematics flow direction of HBCV 10A to the rod side ofthe tit ram 10. This has the effect of allowing the tit ram to retract in proportion to boom lower, Keeping the forks parallel with ‘the ground. Displaced oll from the compensating ram closes the check valve in displacement link valve 20, Auxiliary relief vaive (ARV) 2H opens to protectthe tit ram from over pressutisation, The anti-cavitation feature of valve 24 ensures that, in these circumstances, the tit and compensating rams will not cavitate. Fig 18, Boom Lower Cycle (Machines with Two Displacement Rams) '9603/3750-05 (E-01-06) E3-25Be Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Boom Regenerative Valve Hydraulic Operation and Schematics Fig 19. The regenerative valve 1 is fitted to the telescopic ‘extension ram 2to inerease the speed ofthe boom during, the extend cycle, under light load conditions. The valve is ‘connected to the machine hydraulic system via boom ‘extend verter valve K and the control valve boom ‘extension spool J. Hydraulic ol is displaced from the rod side of the inner and outer sections (H and G) and ‘supplements the pump flow to the head side of both sections, The speed of the extending boomis increased ‘The only servicing possible in the event of external cil Teakage is the renewal of oil seals, or the renewal of a faulty screw-in cartridge. ‘Screwsin Cartridge Components Fig 19. (DEF ‘A [Outer extension ram hose burst check F counterbalance valve B_| Kick down relief vane ‘© _| Pilot operated check counterbalance vaive D_[Non-retura valve [Non-return valve F [Inner extension ram hase burst check 7 counterbalance valve. Located in piston assembly ofram section @ 3-26 '9803/8750-05 (E-01-08),B Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Twin Axis Control Valve ‘The servo control valve operate as direct acting pressure regulating valves, which consist of the control lever and four proportional pilot control valve capsules, Each pilot valve capsule consists of a spool 21-1 with 2 control ‘spring, a plunger 21-2 and plunger retun spring 21-3. In neutral, the control lever is kept central by the force of the plunger return springs 21-3. In this position the joystick ‘service ports are connected to the tank port ‘T’ via the diilings 24 -X in the spools, ‘When the control lever is operated, the relevant plunger 21- 2 pushes on the return spring 21-3 and the spool ‘control spring. The spool control spring in turn moves the ‘spool 21-1 down which connects the selected service port to the pressure port P. ‘The spool 21-4 regulates the incoming hydraulic servo pressure to balance the pressure in the service port with the foroe of the control spring, The interaction of the spool ‘andl contol spring in this way means that the joystick will produce a pilot pressure in the selected service port which is proportional to the position of the contra! lever Hydraulic Operation and Schematics Fig 21. Table 8. Colour Key to Oil Flow and Pressure my Seno Exhaust '9603/3750-05 (E-01-06) E3-27Ww Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Hydraulic Operation and Schematics Single Axis Control Valve ‘The single axis control valve works in the same way as the ‘win axis valve, The valve only has two proportional pilot control valve capsules. Twin Axis Control Valve (1) £3.27) Eso 380575005 (E9108) E3-28B Fault Fin: ‘The purpose of this section is to help you trace a particular fault, The tables identity possible causes and give a suggested action with specific tests where applicable. 1 Before you begin fault finding, read the safety information at the beginning of this manual, 2 — Make any relevant electrical checks before moving on to the hydraulics. 3 Make simple checks before say, stripping @ major hydraulic component Valve Block Fautt: 3 Table 9. Lack of power at all hydraulic functions 2 Table 10, All mechanically 2 Table 11, All solenoid/servo of Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Fault Finding 9 4 Make sure that the hydraulic fluid is at the correct ‘working temperature (50°C, 122°F), 5 IFhydraulic contamination is found, be sure to remove ALL debris, and if possible identify its origin. It may be part of a component from elsewhere in the hydraulic, circuit. 6 What ever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary. 7 Renew any seals such as O-rings when ro- assembling hydraulic components. 3-29) erated hydraulic services slow (0 operate rated hydraulic services slow to operate £3.29) 3-30) 3 Table 12. One mechanically operated hydraulic service fails to operate or is slow to operate ([E3-30) 3 Table 13. One solenoid/servo operated hydraulic services falls to operate (if tted) (P) E3-20) 3 Table 14. The engine tends to stall when hydraulics are under load ([) E3-30) 3 Table 15. Ram croop ([} 3-34 Table 9. Lack of power at all hydraulic functions Possible Cause Action Trsuficient hyraulle fui ‘Check for leaks and top up as required Hydraulic leaks in system ‘Check hoses, renew as required. Engine performance, Check engine perforrrance, RV setting incorrect Low pump flow. Table 10. All mechanically operated hydraulic services slow to operate Possible Cause Check and adjust as required ‘Check pump flow Check for external leaks, renew seals Priority valve sticking, see Section H - Steering = Renew pump. Action ‘Neutral circuit or low pressure lines leaking, damaged, ‘trapped or kinked, MRV selting incorrect ‘Check pie lines and renew as required. Check and adjust as required Low pump flow. = Check pump flow = Check for external leaks, renew seals = rity vaNve sticking, see Section H - Steering = Renew pump Ese 380575005 (E9108) E3-29B Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Fault Finding Table 11. All solenold/servo operated hydraulic services slow to operate Possible Cause Action Table 10. All mechanically operated hydraulic ‘services slow to operate ([) E3-28) Low pilot pressure. = Check that the pressure maintenance valve is not sticking open. = Check the pressure reducing valve, — Check servo pressure, ‘Solenoid power Supply nat present Table 12. One mechanically operated hydraulic service fails to operate or is slow to operate Possible Cause ‘Action ‘Boom and Stabiliser interlocks engaged ‘Educate the operator Ensure operator fully understands the characteristics of the interlock system, /@ Hydraulic Interlock SYSTEM (D.E€-1) ‘Associated service pipe lines leaking, damaged, trapped or kinked Check hoses, renew as required ‘Associated ram leaking. Renew seals, [ARV seiting incorrect (Check and adjust as required ‘Associated valve block section leaking or not operating, — Check for leaks, rectify as required — Check that the control lever is operating the spool, rectly as required. ‘Associated check valve not opening to allow return of ollto tank (Check and rectify as required Diverter not opening Check electrical power supply and vaive operation, rectify as required Table 13, One solenoid/servo operated raulic services fails to operate (if fitted) Possible Cause Action ‘Boom and stabiliser interlocks engaged Educate the operator. Ensure operator fully understands the characteristics of the interlock system = Hydraulic interfock SYSTEM (D E4-1) Table 12. One mechanically operated hydraulic ‘service falls to operate or is slow to operate ([}E3-30) ‘Solenoid not energised, ‘Check for faulty solenoid. Renew if necessary. Check relevant electrical circuit i.e. switches, relays, wiring, etc, and reetify as required, Blockage in solenoid operated valve. Tnspect and clean or renew as necessary. Clean or renew the valve internal fiter as necessary. ‘Table 14, The engine tends to stall when hydraulics are under load Possible Cause Action MRV valve setting incorrect Check and adjust as required Engine performance, Check engine performance, E3-30 '8603/750-05 (E-07-06) E3-30Ww Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Fault Finding Table 15. Ram creep ‘ction ] Check and recy as required Check operation and recy as required Possible Gause ‘Associated ram or pipe lines from ram leaking Check valve E331 '9603/3750-05 (E-01-06) 3-31B Parallel Lift Fault 3 Table 16. Forks Creep Down ([) E3-3: 2 Table 17, Parallel Lift Faulty ()E3-32) Section E3 - Hydraulics Servo Hydraulic SYSTEM Fault Finding Table 16, Forks Creep Down Possible Cause Remedy the machine recently? Circuit hosed incorrectly, Has any work been completed on Check circuit. Re route the hoses if necessary, Tittram HECV leaking, tit ram seals leaking, control vave ‘spool leaking or valve block section leaking internally (Check for leakage in the tit ram circut Note: The forks wil continue to crowd back when the ‘boom reaches maximum elevation angle, if the lit lever is not deselected on machines fitted with displacement ink valve 20. This is normal and is caused by oil bleeding from the lit orous to the tit circuit. = Parallel Lift ([)E3-23) ‘Table 17. Parallel Lift Faulty Possible Cause Remedy Displacemeni/ift ink valve broken or leaking, Examine valve; is ball OK? Fit blank to isolate valve from circuit. Fit atest type valve. = Check pipes. tit spool, HECV for missing ball Tilt section ARVs set incorrectly, causing oil to exit from tity compensating ram circuit Check tt ARV setting. Adjust if required. Tilt section ARVs could be sticking open due to contamination, Clean or new as required Leaking seals in tit am or compensation ram. ‘Check titicompensation rams for leakage (use hand pump if available), Renew seals as required E3-32 '9603/3750-05 (E-01-06) E3-32B Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Test Procedures Test Procedures Checking Pump Flow Triple Pump The separate sections of the gear pump assembly supply hydraulic ol to the main services circus, to the steering circu and to the hydraulic cooling fan circuit. To determine the source of a problem i.e pump, steer circuit or services circuit, measure the output flow at system pressure from each pump outlet port in turn Awarninc Make the machine safe before working underneath It. Park the machine on level ground, lower the attachments to the ground. Apply the park brake, put the transmission in neutral and stop the engine. Block both sides of all four wheels. Disconnect the battery, to prevent the engine being started while you are beneath the machine, Evatt 1 Carty out General Safety procedures, see Section 2 = General Procedures. AwarNinc Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Make sure the engine cannot be started while the hoses are open. InoH2 2 Vent the hydraulic pressure, see Section 2- General Procedures. Fig 23. Test Equipment 3 Connect a flow meter 23-A, 0-400 bar (0-6000 Ibn?) pressure gauge 23-B and load valve 23-€ into the discharge line from each pump section in tum as described below: Main Services Pump (Section 1): Disconnect hose 24-A from the pipe 24-B, Fit the flow meter and load valve between hose 24-A and the pipe 24-B. Disconnect hose 24-C from the pipe 24-B. Cap the ‘open port in the pipe, then connect a suitable slave hose 25- D to hose 24-C and route the hose to the hydraulic tank. Slowly remove the hydraulic tank filler ‘cap and place the end of the slave hose 26-D inside the filer tube as shown, > Fig 26. ([)E3-34 ‘Steering Pump (Section 2): Disconnect hose 24-C from the priority valve 24-E (port EF). Fit the flow meter and load valve between hose 24-C and the prioity valve 24-6. Cooling Fan Pump (Section 3): Disconnect hose 24- F from the pump. Fit the flow meter and load valve between hose 24-F and the pump. Fig 24. Typical Triple Pump Note: Make sure the load valve and flow meter is installed the correct way round ie. with the direction arrow pointing away from the pump. AcauTion Make sure the load valve is in the OPEN position, (the adjusting knob screwed fully OUT), before starting the following pressure test. Failure to do this could damage the pump. HyD-ea4 4 Start the engine and bring the hydraulic system upto working temperature 50° C (122° F) E3-33 '9603/3750-05 (E-01-06) E3-33B Section E3 - Hydraulics Servo Hydraulic SYSTEM 5 Select the steering and control valve block spools to the neutral position. 6 Set the engine speed to 2200 rev/min. then carefully adjust the load valve 23-C so that the gauge reading increases to 240 bar (3500 Ibiin?) 7 Check the flow reading which should be es stated in Technical Data. Ifthe flow reading is low or you are unable to obtain the pressure required, 2 Fault Finding ([) £3.29) For testing the Priorty Vale, see Section H - Steering. A warninc Take care when disconnecting hydraulic hoses and fitings 2s the ol will be HOT. TRMit2 8 _Aiter completing the test, swich OFF the engine and allow to cool before disconnecting the test equipment and reconnecting the hydraulic hoses. Test Procedures £3.34 '9603/3750-05 (E-01-06) 3-34B Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Testing Main Relief Valve (MRV) Main Control Valve MRV 1 Park the machine and makeit safe. Vent the hydraulic pressure, see Section 2 - General Procedures. 2 Connect 2 0 - 400 bar (0 - 6000 Ibn’) pressure gauge tothe tast point A 3 Start the engine and bring the hydraulic systern upto ‘working temperature 50° C (122° F. 4 Select boom retract service and hold ram fully closed Gradually increase the engine speed to 2200 revimin while checking maximum gauge reading, which should be as stated. = Specifications ([) E3-4) Fig 26. Test Procedures 2 Spool Remote Control Valve MRV 1 Park the machine and makeitsafe. Vent the hydraulic pressure, see Section 2 - General Procedures. 2 Connect a 0 ~ 400 bar (0 - 6000 Ibn’) pressure ‘gauge to the test point B. 3 Stat the engine and bring the hydraulic system upto ‘working temperature 50° C (122° F). 4 Select boom lower service and hold ram fully closed. Gradually nczease the engine speed to 2200 rev/min, while checking maximum gauge reading, which should be as stated. © Specifications ([) E3-4) E3-35 '9603/3750-05 (E-01-06) E3-35Ww Section E3 - Hydraulics Servo Hydraulic SYSTEM Test Procedures Testing ARV’s Set Lower than the MRV ARN's which are set below the M.R.V. pressure can be tested simply by operating the relevant service. Important: The engine must not be sun at maximum speed as a significant increase in pressure wil be recorded. 1 Park the machine and makeit safe. Vent the hydraulic Pressure, see Section 2- General Procedures. 2 Connect 2 0 - 400 bar (0 - 6000 Ibn’) pressure gauge to the test point = Main Control Valve MY (D) 3-35) 3 Start the engine and bring the hydraulic systern upto working temperature 50° C (122° F) 4 Set the engine to idle revimin. and operate the relevant service to ful travel, Hold while checking the. maximum gauge reading which should be as stated. 3 Specifications ()E3-4) 5 Ifthe pressure is incorrect, adjust the relevant ARV. 2 Relief Valve Adjustment (7) £3-39) £336 '9603/3750-05 (E-01-06) E3-36B Section E3 - Hydraulics Servo Hydraulic SYSTEM Testing ARV’s Set Higher than the MRV Fig 28 Tilt Ram a 1 Head side AR, Lower the boom fully A warninc 7 Hydraulic Pressure Hydraulic fluld at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service Test Procedures Slart the engine and slowly raise the boom to ‘approximately 45° angle, then operate the boom lower service. AS the boom descends the pressure gauge will show the AR, pressure, which shoud ——be-=as. stated. 2 Specifications (1) E3-4) If the pressure i incorrect, adjust the ARV. = Relief Vaive Adjustment (()E3-29) AWwarninc hose line must be vented, Make sure the hose service Take care when disconnecting hydraulic hoses and line has been vented before connecting or removing _fitings. hoses. Make sure the engine cannot be started while TRAV the hoses are open. f Vent the hydraulic pressure, see Section 2 - General Procedures. © Disconnect tit ram head side hose A from connector B. Blank off hose A and connect a 0 400 bar (0 - 6000 lbffin’) pressure gauge into the lend of connector B. as the oll will be HOT. 2 ‘After completing the test, fully lower the bear, ‘switch OFF the engine and vent residual hydraulic pressure. Disconnect the pressure gauge and reconnect the tit ram head side hose A to connector B, £3.37 '9603/3750-05 (E-01-06) 3-37Ww Section E3 - Hydraulics Servo Hydraulic SYSTEM Test Procedures 2 Rodside ARV, a Lower the boom fully. Vent the hydraulic pressure, see Section 2 - General Procedures. © Disconnect tit ram rod side hose © from connector D. Blank off hose G and connect 2 0 - 400 bar (0 - 6000 lbtfin’) pressure gauge into the fend of connector D, d_ Start the engine and slowly raise the boom to approximately 45° angle, As the boom is raised the pressure gauge will show the A.R.V. pressure, which should be = as. Stated, = Specifications (1) E3-4) © If the pressure is incorect, agjust the AR.V. 2 Relief Valve Adjustment 1) £3.29) AWaRNING Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT. TRANG f After completing the test, fully loner the boom, ‘switch OFF the engine and ventresidual hydraulic pressure. Disconnect the pressure gauge and reconnect the tit ram rod side hose © to connector D. £338 '9603/3750-05 (E-01-06) E3-38B Section E3 - Hydraulics Servo Hydraulic SYSTEM Relief Valve Adjustment 3. Ifthe pressure is incorrect, adjust the relief valve as described below ‘a. Position the boom and fit the Safety Strut, see ‘Section 2 - General Procedures. Fig 30, Relief Valve Adjuster Screw and Locknut Vent the hydraulic pressure, see Section 2 - General Procedures. © Loosen the locknut B and turn the adjuster screw . Turn the adjuster screw clockwise to increase pressure and anti-clockwise to decrease the pressure. When the pressure is correct, tighten the locknut and check the pressure again, Adjust as required, The location of the relief valve is dependant on the ‘machine type. Identify the positions of the relief valves housed in the control valve block correctly. 2 Specifications ([ E3. Test Procedures Fig 31, Test Point (Typical Triple Pump) £3.39 '9603/3750-05 (E-01-06) E3-39B Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Measuring Spool Displacement (Manual Spools) Note: This procedure is only applicable to manually operated spooks A warninc ‘Communications Bad communications can cause accidents. Keep people around you informed of what you will be doing Ifyou will be working with other people, make sure any hand signals that may be used are understood by everybody. Work sites can be noisy, do not rely on spoken commands. Note: Two people are required to complete the procedure, Person 1 should be sat in the operator cab, whilst Person 2 requires access to the control valve assembly. 1 Raise the boomand fit the safety strut, see Section 2 - General Procedures. 2 Carty out General Safety procedures, see Section 2 = General Procedures. 3 Vent the hydraulic pressure, see Section 2- General Procedures. 4 Check spool displacement 32.4. a Person 2 - Using the control lever, move and hold the spool in position 32-1. b Person 1 - Measure spool displacement 32-A, 5 Check spool displacement 32-8, a Person 2 Using the control lever, move and hold the spool in position 32-3, b Person 1 - Measure spool displacement 32-8. Test Procedures S) IM aot te A ts ©) ill Fig 32. Manual Spool Displacement 6 Repeat the procedure for each manual spool as necessary. Table 18. Spool Displacement Displacement ‘Measurement: 3A ren +7 1mm (032in +/- 0.O4in) 328 mm +1. 1mm (032in +/- 0.04in) Adjustment ‘Spool displacement is influenced by the control lever linkage. Check, adjust and replace if necessary, If sufficient adjustment can not be achieved it may be necessary to replace the spool assembly, > Related Topies ([) E3-3) E340 '9603/3750-05 (E-01-06) E340Ww Section E3 - Hydraulics Parallel Servo Hydraulic SYSTEM Bleed Procedures Bleed Procedures 4-Stage Boom Extension Ram Circuit ‘Whenever a hydraulic cormponent is removed or disconnected from the boom extension circuit, the circuit must be bled to ensure that any residual air is removed & A B oie ft cc ‘a, Co Fig 33. Outer Ram Bleed Points The outer ram has three bleed points, which can be used 8 Repeat steps 4 to 7 for each of the remaining bleed to bleed the boom hydrauliccircut All three points must be screws 33-B, and then 33-C in turn bled to ensure all the air is rerioved from the system, 9 Check the hydraulic fluid level and top-up the tank if 11 Park the machine on firm level ground, Engage the necessary, park brake and set the transmission to neutral 10. On completion, extend and retract the boom fully ive 2 Raise the boom to the horizontal position, times while checking that the boom sections open ‘and close fully together. Inspect the hydraulic 3 To ensure that the rams are filed with ol, run the ‘connections and check for leaks. engine at just above idle speed (approx. 1200 RPM) and SLOWLY extend and retract the boom fully two 11 If the boon sections do not open and close fully times. together repeat bleeding procedure 4 Then, extend the boom to just less than full travel stopping approx. 5 cm (2 in) before end of stroke, 5 Aitach a tube to the bleed screw 33-A, ensuring that the other end of the tube is directed into a suitable empty container 6 Carefully open the bleed sorew 1/2 a turn only, then ‘extend the boom ram to full stroke to expel any air, Close the bleed screw and detach the tube, IMPORTANT NOTE: DO NOT open the bleed screw more than 1/2 a turn 7 Retract the boom fully E341 '9603/3750-05 (E-01-06) E341