Service Manual: JCB Service Rocester, Staffordshire, St14 5Ls. England

SERVICE MANUAL
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JCB SERVICE @
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ROCESTER, STAFFORDSHIRE,
ST14 5LS. ENGLAND.
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TEL. AOCESTER (0889) 590312 I

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Printed 'in England.
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Contents
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General 1
Hydraulics 2
Attachments 3
Body & Framework 4
Gearboxes 5
Track & Running Gear 6
Engine 7
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Electrics I
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lndex
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805,8058
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8068,8078
808
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Publication No. 9803/3150
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Introduct¡on
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This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received
training by the JCB Technical Training Department.
il
It is assumed that such personnel have at least a sound knowledge of workshop practice, safety procedures and
general techniques assoc¡ated with the maintenance and repair of hydraulic earthmoving equipment. Details of such
)
are therefore generally omitted from this manual, the intention being to convey only the more specialised information
concerning particular aspects of the machine or component in question.
For example, renewal of oil seals, gaskets etc. and any component showing obvious wear or damage is expected as a
matter of course and information on these matters is therefore only included where a specialised procedure or range
of wear tolerances is required. Similarly, it is expected that components will be thoroughly cleaned and lubricated
where appropriate, also that any opened hose or pipe connections will be blanked to prevent entry of dirt and
1.
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excessive loss of hydraulic fluid.
For convenience the manual is compiled in sections, e.g. "Hydraulics", "Gearboxes" etc., but to find details of a
specific component, reference should be made to the alphabet¡cal index at the back of the book.
lllustrations showing a dismantled component are numbered as a guide to the dismantling sequence which can
generally be reversed for assembly.
Torque settings quoted are given as'mean'figures which may be varied by i gø. 'Left Hand'and 'Right Hand'are i
as viewed from the rear of the machine.
Replacement or additional pages for this manual will be issued from t¡me to time and should be inserted in place of
the existing pages which should be removed and destroyed.
Where possible, revised pages will bear an asterisk (*) against the new information, the page issue number in the
bottom right hand corner being similarly marked.
A Service Tools Catalogue, detailing special tools required, is available separately
.1
W JCB SERVICE
CATALOGUE /NINUAL - REPTACETEI{T PAGES

805,8058,8068,8078,808
Service Manual
4th SetJuly 1981 Publication No. 9803/3150
These pagesshould be inserted immediately in their correct positions, and pages of a lower issue No. removed and
destroyed. The total contents of this publication can be checked using the index below. Retain index at front of
book. Replaoement pages issued in thisset are indicated by an asterisk *
Page No. lssue Page No. lssue Page No. lssue Page No. lssue
1 8-1 2 17-7 1* Section 5

8-2 2 17-a 1rÈ 1-1 1
1 8-3 1 17-9 1* 1-2 1
1-1 4* 84 1 17-10 1* 1-3 1
2-1 2 8-5 2* 17-11 1* 2-1 1
2-2 2 8-6 1* 17-12 1* 2-2 1
3-1 2 8-7 1* 17-13 1* 2-3 I

3-2 3 9-1 1 17-14 1* 24 1
9-2 1 18-1 1 2-5 1
Section 2 9-3 1 18-2 1 3-1 1
1-1 I 10-1 2 18-3 2 3-2 I

1-2 3 10-2 2 19-1 2 3-3 1
1-2A Deleted 10-3 1 20-1 3 4-1 2

t-3 3* 10-4 1 20-2 2 5-1 1
1-4 1* 10-5 1 20-3 1 6-1 1
1-5 1* 11-1 1 21-1 2 6-2 2

2-1 3 11-2 1 21-2 1
2-2 3 1 1-3 1 21.-3 1 Section,6

2-3 I 12-1 1 22-1 1 1-1 1
'3-1 2 12-2 1 22-2 1 2-1 1
3-2 Deleted 12-3 1 22-3 1 2-2 1
3-3 Deleted 13-1 1 22-4 1 3-1 1
3-4 Deleted 13-2 1 22-5 I 4-1 1
3-5 Deleted 14-1 1 22-6 1 4-2 1
3-6 Deleted 14-2 4 22-7 1 5-1 1
3-7 Deleted 14-3 1 22-8 1 6-1 1
3-8 Deleted 1s-1 2* 22-9 1 6-2 I

3-9 Deleted 15-2 2 22-10 1
4-1 2 15-3 2 22-11 1 Section 7

4-2 Deleted 154 1 23-1 1 1-1 3*
4-3 Deleted 16-1 1* 23-2 1 2-1 1
5-1 1 16-2 1* 23-3 I 2-2 1
5-2 2 16-3 1* 3-1 1
à-s 1 16-4 1* Section 3 4-1 1
54 2 16-5 1* 1-1 1 4-2 1
5-5 1 16-6 1* 2-1 1 4-3 1
6-1 1 16-7 1* 2-2 1 44 1
6-2 I 16-8 1* 4-5 1
6-3 1 16-9 1* Section 4 5-1 1
6-4 1 16-10 1* 1-1 1 6-1 3*

6-5 1 16-11 1* 2-1 1 7-1 1
6-6 2 17-1 1* 2-2 I 8-1 1
6-7 1 17-2 1* 3-1 1 a-2 1
6-8 I 17-3 1* 4-1 1
6-9 1 174 1* 4-2 1
7-1 1 17-5 1* 4-3 2

7-2 2 174 1* 4-4 1
Date of lnærporation
\b\\T\ s¡on"*nÇlrf- 4
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Page No. lssue Page No. lssue Page No. lssue Page No. lseue
Sestion I
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1-1
2-1
1
1 I
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2-2 I
2-3 1
2-4 1 (ì
2-5 I
2-6 I
3-1 I
+-1 1
5-1 1
'5-2 1
6-1 I
7-1 1
7-2 1 I
8-1 1
9-1 I
9-2 1
lndex
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¡¡¡ 4*
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Þ JCB SERVICE
CATALOGUE /il,âJ'J|UAL
- REPLACETE]IT PAGES
805,8058,8068,8078,808
,", March 19Bl Publication No. 9803/3150
Service Manual lrro
These pages should be inserted immediately in their correct positions, and pages of a lower issue No. removed and
book. Replacement pages issued in this set are indicated by an asterisk *
Contents 1 8-2 2* 22-9 1{ß 4-2 1

8-3 1* 22-10 1* 5-1 1
Section 1 84 1* 22-11 1* 6-1 1*
1-1 3* 8-5 1{È 23-1 1* 6-2 1*
2-1 2 9-1 1 23-2 1*
2-2 2 9-2 1 23-3 1* Section 7
3-1 2 9-3 1 1-1 2*
3-2 3* 10-1 2 Section 3 2-1 1
10-2 2 1-1 1 2-2 1
Section 2 10-3 1 2-1 1 3-1 1
1-1 1 104 1 2-2 1 4-1 1
1-2 3 10-5 1 4-2 1
1-2A 2* 11-1 1 Section 4 4-3 1
1-3 2 11-2 1 1-1 1 4-4 1
2-1 3* 11-3 1 2-1 1 4-5 1
2-2 3* 12-1 1 2-2 1 5-1 1
2-3 1* 12-2 1 3-1 1 6-1 2*
3-1 2* 12-3 1 4-1 1 7-1 1
3-2 Deleted 13-1 1 4-2 1 8-1 1
3-3 Deleted 13-2 1 4-3 2* 8-2 1
3-4 Deleted 14-1 1 44 1
3-5 Deleted 14-2 4* Section I
3-6 Deleted 14-3 1 Section 5
3-7 Deleted 15-1 1 1-1 1 1-1 1
3-8 Deleted 15-2 L 1-2 1 2-1 1
3-9 Deleted 15-3 2 1-3 1* 2-2 1
4-1 2x 154 1 2-1 1 2-3 1
4-2 Deleted 16-1 Deleted 2-2 1 24 1
4-3 Deleted 18-1 1n 2-3 1 2-5 1
5-1 1 18-2 1 24 1 2-6 1
5-2 2 18-3 2\ 2-5 1 3-1 1
5-3 1 19-1 2 3-1 1 4-1 1
5-4 2 20-1 3* 3-2 1 5-1 1
5-5 1 20-2 2x 3-3 1 5-2 1
6-1 1 20-3 1* 4-1 2 6-1 1
6-2 1 21-1 2x 5-1 1 7-1 1
6-3 1 21-2 1* 6-1 1 7-2 1
6-4 1 21-3 1* 6-2 2* 8-1 1
6-5 1 22-1 1* 9-1 1
6-6 2* 22-2 1* g-2 1
6-7 1 22-3 1* Section 6
6-8 1 224 1* 1-1 lndex
6-9 1 22-5 1* 2-1 i 3*
7-1 1 22-6 1* 2-2 ¡i 3*
7-2 2* 22-7 1* 3-1 i¡¡ 3*
8-1 2* 224 1* 4-1 iv 3*
v 3*
Date of lncorporation Signature

3
j
Þ JCB SERVIGE
CATALOGUE / N¡NUAL - REPLACETIEI{T PAGES
805,8058,8068,807 8,808
Service Manual
2nd Set January 1980 Publication No. 9803/3150
book. Replacement pages issued in this set are indicated by an asterisk *
Page No. lssue Page No, lssue Page No. lssue Page No. lssue
9-3 1/ Section 5
10-1 2'/ 1-1 1/
2/,
10-2
10-3
10-4
1/
1r/
1-2
2-1 t-1
2-2
ift
10-s 11 2-3 1/_
11-1 2-4 1,/'
11-2 ;/ 2-5 t/
11-3 1/, 3-1 1'
12-1
12-2 t/,
3-2
3-3 ti
I,
12-3 1/, 4-1 2'
13-1 1r', 5-1 1'/
13-2 1/ 6-1 1/
14-1 1r' 6-2 -r 2{
14-2 ,T I+*
14-3 1
./t,
15-1 1 Section 6
15-2 2 1-1 1
15-3 2 2-1 1
15-4 1 2-2 1
.J1t
1/
x 3-1
4-1
1
./
'f{-L 1
18-3 rLl, 4-2 1
19-1 2r/ 5-1 1
20-1 2t# b-l

to-T
ry
*
20-2^
40 -t
2¿ *
I x
21-1 L z l. Section 7
2r-2 *
I 1-1 +2*
¿r-\ I ì< 2-1 1/'
Section 3 2-2 1"-
1-1 1 3-1 1/
2-1 1 4-1 1".'
2-2 1 4-2 1/
4-3 1./
4-4 1-.
Section 4 4-5 yr
1-1 1 J 5-1 1./
2-1 1 6-1 2ztl<
2-2 1 7-1 1/
3-1 1 8-1 1/.
4-1 1 8-2 1"
4-2
tz*
1
4-3
4-4 1 ,"/
2-2-| t ?2- tla^* lt'
Z?-t *zt- T-t'^o I *
Date of lncorporation TJìt'i rqþ Signature f(?e 2

CATALOGUE /NÂffTUAL
- REPTACETEI{T PAGES
l- 805,8058,8068,807 8,808
lst Set Nov 1979 Publication No. 9803/3150
Se¡uice Manual
destroyed. The total contents of this publication cao be checked using the index below. Retain index at front of
book. Replacement pages issued in thisset are indicated by an asterisk *
Contents I 9-3 1 Section 5 Section 8

10-1 2* 1-1 1-1 I
Section I 10-2 2* 1-2 2-1 1
1-1 2* 10-3 I 2-1 2-2 1
2-1 2* 10-4 1* 2-2 2-3 1
f
-'\ 2-2 2* 10-5 1* 2-3 24 1
I 3-1 2* 11-1 1 24 2-5 1
3-2 2* 11-2 I 2-5 24 I
11-3 1 3-1 3-1 I
12-1 I 3-2 4-1 1
Section 2 12-2 1 3-3 5-1 1
1-1 1 12-3 1 4-1 2* 5-2 1

1-2 2* 13-1 1 5-1 1 6-1 I
1-3 2* 13-2 1 6-1 1 7-1 1
2=1 2* 14-1 1 6-2 1 7-2 I
2-2 2* 14-2 2* 8-1 I
3-1 I 14-3 I 9-1 I
3-2 1 15-1 I Section 6 g-2 I
3-3 I 15-2 2* 1-1 1
3-4 I 15-3 2* 2-1 1
3-5 I 15-4 1* 2-2 1 lndex

I, 3-6 2* 16-1 1 .3-1 I i 2*
3-7 2* 18-2 I 4-1 1 ¡¡ 2*
3-8 1* 18-3 I 4-2 I ¡¡¡ 2*
3-9 1* 19-1 2* 5-1 1 iv 2*
4-1 1 20-1 2* v 1*
4-2 1 20-2 1*
4-3 1 21-1 I Section 7
5-1 1 1-1 1
5-2 2* 2-1 I
( 5-3 1 Section 3 2-2 1
5-4 2* 1-1 1 3-1 1
5-5 2-1 1 4-1 1
l_ 6-1
6-2
2-2 I 4-2
4-3
1
I
6-3 44
t)
1
64 Section 4 4-5 I
6-5 1-1 5-1 I
6-6 2-1 6-1 I
L
6-7 2-2 7-1 1
6-8 3-1 8-1 1
6-9 4-1 8-2 1

I
i 7-1 4-2
7-2 4-3
8-1 4-4
r) 8-2
9-1
g-2
tjit
Date of lnærpontion Signature 1

Ii E
( Sheet 1 of 1 E12O/H - lssue 1
March 1985 8116/E - lssue 1
Gear Pumps and Motors

(
Service Procedure
(
lnstances have occurred where dealers have changed pumps
and motors under warranty due
to 'scuffing' of the body at relatívely low hours.
(
The scuff ing of the housing of gear pumps and motors is an essential part
of their performance.
Allowing the gear tips to cut into the housing ensures tr," rinir..¡¡n;i;¡t
teeth under pressure.
i..ìi;;; across the
{ .The initial cutt¡ng occùrs during manufactü?e, the amorn-t of scuffing
can vary from assembly to assembly bui on average ¡sb.OZS
to 0.lmm. (0.OOl to 0.004in.).
These markings are of no detriment to the performance of pumps or motors but are a
necessary part of their design.
T.P.D. E85/O9
r-
a 1
1-1
General
1-1
1
e LUBRICANTS AND CAPACITI ES
I
I
ITEM LUBRICANT CAPACITY Litres (Ullgal)
e * Engine
(Also Fuel lnjection Pump on
Perkins 4.248
Perkins 6.354
16
25
(3.5)
(5.5)
2700 Series) Perkins 6.3544
( 13.5 (3.0)
-8058
Mobil Delvac 1310 14.0 (3.1)
-18 to -l deg C -8068,8078
a -1 to 27 deg c
Above 27 degC
JCB Super X Universal (20W20)
or Mobil Delvac 1320
Mobil Delvac 1330
Perkins T6.354
Perkins T6.3544
27128 4Cvl.
27.3
14.5
12.5
(6.0)
(3.2)
(2.751
2715E 6 Cvl-
( -To mlc77891 20.0 14.41
(5.5)
-From 77892 25.5
( * Irack Gearbox JCB 'special' Gear Oil (4000/0501ì 6.8 (1.5)
*Slew Gearbox JCB Slew O¡l (4000/0701) "t5.4 (3.4)

(
Hydraulic Tank JCB'Special' Hydraulic Fluid 805 254 (56)
8058 409 (e0)
( 8068.8078,808 339 (74.51
Track ldler Wheels Mobil Delvac 1330
Track Rollers (Top & Bottom) Mobil Delvac 1330
Slew Ring-Bearings û4pb¡'l{.lcn',4r¡- SC'ß \n¡i"'å frPr-

-Gear Teeth Mobiltac E (SeeWARNING below)
All Other Grease Points +¡qc¡¡þ¡cx-+7, JCB'Special'

MPL Grease or Mobilgrease Super
Sliding Beam JCB'Special' Slide Lubricant
WARNING: Mobiltac E has a lead content of 1.53%

Contaminated materials, e.g. rags, containers etc., must only be disposed of in accordance with
regulations governing the disposal of toxic waste.
Litres (UK gal)
Fuel Tank Capacity 291 64

-805
323 71
-8058
482 106
-8068,8078,808
*Coolant Capacity 26 5.75
-Perkins 4.248
28 6.25
-Perkins 6.354
(8058) 26 5.75
-Perkins 6.3544
(8068,8078 ) 26.8 5.9
-Perkins 6.3544
(to m/c 76160) 32 7
-Perkins T6.354
(from m/c 76161 28 6.25
-Perkins T6.354 )
27.5 6.1
-Perkins 16.3544
9803/31 50
lssue 4*
1 General 1
2-1 2-1
I
i
SERVICE SCHEDUTE D tst/Zn¿ Free Service I Routine Service

Every Every Every Every Every Every Every ì
10 50 100 200 400 800 1600
I
Check Hours Hours Hours Hours Hours Hours Hours

Hydraulic fluid level _1
Hose and pipework for lea I nl T
Tightness of ram end ca I ¡r T
Condition of ram piston rods-4
Pump drive I
Operation of services I I I nr ,I
-Excavator- 7 I T rlI T r-r I I
-Transmission I T NI I nt I
-Brakes (track & slew)- g t nl I nl I
Main relief valve pressure(s 10 TII I I
Off loading valve pressure_1 1 nt I I
Auxiliary relief valve pressures-l 2 I
All grease seals-l3 nt I Trl I
load_20
Slewing ring bolts torque I T I
Gearbox oil (track & slew) levels_21 I NI I nl I
Track roller levels-22 I Ttl t I
Track plate condition - 23 I nl I I
Track adjustment nl| I T
Track and running gear condition.-25 I I t-r I I I
Engine oil level-3O I I
Fuel injection pump oil (2700 Series)-3,l I n
Engine coolant (anti-freeze)_ 32 I I nt I .nl
Fuel system for leaks--33 I NT r
Valve clearance and lubrication _34 n ¡I I
Engine mounting bol +ê
35 nl
Exhaust (excessivesmoke)-36 I I
Max, governed engine speed-37 NT I
ldling speed nl I
Turbocharger boost pressure
Air cleaner hose security nl
Exhaust systemsecurity-4l nt I
Fan belt adjustment-42
-39 I
Starter motor/alternator brush gear_b0 t
Operation of electrical equipment _ 5l I l, I
* Battery electrolyte level 52 I
(8058 Fulmen Battery Ar 1600 hours or yearly)
-
9803/3150 lssue 2t
\
rì
n1 2-2
General
2-2
1
o I lst/2n¿ Free Service I Routine Service

SERVICE SGHEDULE
rì Every Every Every Every Every Every Every
10 50 100 200 400 800 1600
Change Hours Hours Hours Hours Hours Hours Hours
Engine oil-60 T1 t TII I I
Engine oil f ilter element r-'l I NI I
Air cleaner element (outer) A' I
l"-\ (inner)-63
Air cleaner element
Fuel filter element 64 nl
* Fuel injection pump oil (2700 Series)-65 I I I
Gearbox oil (track & slew)_--66 tr
Hydraulic fluid and clean suction strainer 67
* Hydraulic fluid f ilter element--68 n
Clean
Fuel lift pump-75 n nl I l,
Drain fuel filters I I
Drain fuel sediment trap-- 77 I nl t I I
lnjectors and test 78 I
Battery terminals 79 I
(' Radiator matrix 80 I
Grease
(\
Rotary Coupling 90 nl I I
nipples-91
Slewing ring grease I I
( nl I NI I
Slewing ring teeth-92
All pivot pins-93 I I trl I
(,
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(_,
L-,
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l-) 9803/31 50 lssue 2'
U
1 General 1
3-1 3-1
)
\
GREASE POINTS
ALL PIVOT
PINS 10 Hours
EACH SLEWING
RING NIPPLE AND
)
ROTARY
COUPLING
* 4 shots 50 Hours
)
SLEW]NG RING
TEETH
Repack 1600 Hours
!./
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9803/3150
I
lssu.e 2t
{
f'\
f--' 1 General 1
3-2 3-2
GREASE POINTS
ALL PIVOT
PI NS 10 Hours
EACH SLEWING
RING NIPPLE AND
ROTARY
COUPLING
4 shots 50 Hours
SLEWING R ING
TEETH
Repack 1600 Hours
SLIDING BEAM
Grease as required
I
\ 48674
i.
9803/31 50 lssue 3
I
cccccccceeee) I I I f f f f f ) ) i
f)
rì 2 Hydraulics 2
1-1 1-1
r-l
TECHNICAL DATA
r-'
Pump Flow Rates at2250 rev/min
l- ,r
and neutral circuit pressure.
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r' 805,8068(Commercial) 805,8058,8068 ( PAA2 2OgO7 07 I
Litres UK Gal Litres UK Gal

(
-Section 1 118 26 132 29
-Section 2 71 15.5 75 16.5
-Section 3 71 15.5 75 16.5
8078 (Commercial) 8078 (PAA22080909)

r
Litres UK Gal Litres UK Gal
( -Section 1 139 30.5 132 29

-Section 2 93 20.5 93 20.5
-Section 3 93 20.5 93 20.5
t.
808 (PA22100808) 808 (Commercial) 808 (PAA22080808)
t Litres UK Gal Litres UK Gal Litres UK Gal
-Section 1 159 35 132 29 132 29

( -Section 2 132 29 132 29 132 29
-Sectíon 3 132 29 132 29 132 29
l)
L
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L-,
L--
9803/3150 lszue I
t,)
2 Hydraulics 2 {l
1-2 1-2
{)
TECHN ICAL DATA (Continued)
t,rì I
805,8068,8078,808
Relief Valve Operating Pressures
Standard Builds 805 806B,8078,808^

bar lbf ltn2 bar lbf lin¿ t-\
\,
Track M.R.V. A 193 2800 193 2800
Excavator M.R.V. (ln line) 173 2500
Slew M.R.V. t B 117 1 700 131 1900
Off loading Valve c 103 1 500 "t 17 1700
Boom A.R.V. D,E 220 3200 240 3500
Dipper A.R.V. F,G 220 3200 240 3500
Bucket A.R.V. Rod Side H 131 1900 131 1900
Bucket A.Fi.V. Head Side J 220 3200 240 3500
Attachment A.R.V. K 138 2000 138 2000
t Slew M.R.V. pressure variations:-
bar lbf/in2
8068,8078,808 with Hamworthy 2200 series slew motor 138 2000
8078 with turbocharged engine 152 22OO
NOTE: Some 8068/8078 machines have in-line slew M.R.V. and off-loading valves.
Pressure sett¡ngs are as given above.
River Maintenance Rig
All pressures as above except:-

I
(1500 tbtlin2l
Boom A.R.V. - D (Rod Side only) 103 bar
(1900 wÍfin2l
Bucket A.R.V. - J (Head Side) 131 bar
'1
Iì
1l
9803/31 50 lssue 3!
( ii
i
n
2 Hydraulics 2
1i
1-3 1-3
e
C' .8058 Relief Valve Operating Pressures (Rubery Owen Control Valves)
e To m/c no. 200205-Excavator block X (f¡tted with one slew M.R.V.)
JCB Standard ISO Standard

l- Boom Control
on L.H. Lever
Boom Control
on R.H. Lever
Item bar lbf /in2 Item bar lbt/in2
Track M.R.V. A 193 2800 A 193 2800
(
Excavator M.R.V. B 173 2500 B 173 2500
Slew M.R.V. c 152 2204 c 152 2204
( Offloading Valve D 138 2000 D 138 2000
Boom A.R.V. E,F 220 3200 J,K 220 3200
Bucket A.R.V. Rod Side G 1900 G 131 1900
Bucket A.R.V. Head Side H -131 220 3200 H 220 3200
(- Dipper A.R.V. Head Side J 182 2650 F 182 2650
Dipper A.R.V. Rod Side K 220 3200 E 220 3200
Attachment A.R.V. w 138 2000 W 138 2000
( NOTE: To m/c no.2OQ147 the 8058 had an in-line offloading valve set at the above pressure.
Offloading valve D was also fitted but prevented from operating by an internal blanking plug.
From m/c no. 200206-Excavator block Y (f¡tted with two slew A.R.V.'s).
JCB Standard ISO Standard

( Boom Control Boom Control
on L.H. Lever on R.H. Lever
Item bar lbÍlin¿ Item bar lbt/in¿
Track M.R.V. A 193 2800 A 193 2800
( Excavator t\lLR.V. B 173 2500 B 173 2500
Slew A.R.V. L,M 117 1700 L,M 117 1 700
Offloading Valve N 138 2000 N 138 2000
t: Boom A.R.V. P,R 220 3200 U,V 220 3200
Bucket A.R.V. Rod Side S 131 1900 S 131 1900
Bucket A.R.V. Head Sidet T 220 3200 T 220 3200
( Dipper A.R.V. Head Side U 182 2650 R 182 2650
Dipper A.R.V. Rod Side V 220 3200 P 220 3200
Attachment A.R.V. W 138 2000 W 138 2000
L t When optional dipper extension is fitted, bucket head side A.R.V. is set at 110 bar (1600 lbt/inzl
L
L
L-
L-
{
i
9803/31 50 lssue 3*
I
2 Hydraulics 2
1-4 1-4
TECHN ICAL DATA (continued)
8058 with Hamworthy Gontrol Valves (l.S.O. Pattern)

Relief Valve Operating Pressures
Item bar bf /in2
Track M.R.V. A 193 2800

Excavator M.R.V. B 173 2500
Slew M.R.V. c 117 1700
Offloading Valve D 138 2000
t Boom Head Side A.R.V. E 220 3200
Boom Rod Side A.R.V. F 220 3200
t Dipper Head Side A.R.V. G 182 2650
Dipper Rod Side A.R.V. H 220 3200
Bucket Head Side A.R.V. J 220 3200
Bucket Rod Side A.R.V. K 220 3200
Note: See page 2/17-14 for A.R.V. pilot setting pressures.
tFor JCB pattern controls, the positions of items E and G are interchanged
t'l
n
980s/31 50 lssue 1
[-
I 2 Hydraulics
1-5
2
1-5
(-,
(
Rams
C
Torque Settings for later type rams with Loctite or tab lock reta¡ned piston heads.
e' Ram Dia. Item Torque Settings
mm. in Nm kgf m lbf ft
a 114 4.5 Piston Head 408 41.6 300
Cylinder End Bolts 680 69.4 500
( Wiper Seal Housing Bolts
4.3 31
- 318 in dia 42
75
- 1/2 in dia 102 10.4
(
127 5.0 Piston Head 408 41.6 300
- 3/8 in dia 42 4.3 31
102 75
- 112 in dia 10.4
152 6.0 Piston Head 408 41.6 31

- 3/8 in dia 42 4.3 31
75
( - 1/2 in dia 102 10.4
Filtration
(
Type JCB Full Flow (Overload BY-Pass)
Relief Valve Setting 1.4bar (ZOlbllin2l
( Paper
Element
Filtration Size 60o/o-15 micron; 15o/o-5 micron
('-
t--
I
lssue 1
9803/3150
t, .)
i.
..ì
)
n
2 Hydraulics 2
Õ
2-1 2-1
e,
FILTER OPERATION
(^'
ç
N
e
lr
(o
--E
-l-
l-.
l- 1
(
l-
(
(ì
t_
L,
L
L
U
U
U 9803/31 50 lssue 3
l._-
\
2 Hydraulics 2
2-2 2-2
HYDRAULIC FITTER
(Early Type)
RENEW EveTy
ELEMENT 400 Hours
1 Carefully remove
hydraulic oil filler cap4
2 Remove plug B to
prevent excess loss of
f luid.
3 Remove U-bolt C.
4 Unscrew bolt D until
body can be withdrawn.
Note: A considerable
amount of fluid will
flow from the filter at
this stage.
5 Remove bolt Ð, body,
and element F.
6 Wash all metal parts in G>

JCB'Special' Hydraulic
Fluid.
7 Re-assemble using new
element and seal F.
I Repeat for second filter

I Top up at filler cap.
2856A
(
9803/31 50 lssue 3
n
a 2 Hydraulics 2
2-3 2-3
a
HYDRAULIC FILTER
( (Later Type)
( Renew Element EverY 400 Hours.
To prevent siphoning of tank

when draining filter, remove
tank filler cap and filter Plug
A.
(
2. Drain filter at plug C.
Note: On 805,8068,8078 and 808

Remove access plate B.
( 3. Unscrew bolt D (nut D on

later 8058) and element E
4. Wash all metal parts in JCB

'Special' Hydraulic Fluid.
( 5. Reassemble using new element

and seal F which should be
lu bricated before f itting.
6. Top up hydraulic tank.
(
re
\
t
(,
(_-,
L,
(_)
9803/31 50 lssue 1
I
I
2 Hydraulics 2 ì
3-1 3-1
PUMP OPERATION
I
I
o
F
e
@
)
-ì
t
t I
\l
t
9803/31 50 lssue 2
t1
n'
2 Hydraulics 2
Õ
4-1 4-1
l_-
MOTOR OPERATION
(-'.
@
N
o
o
a-.
r-'
a'
l''
(-'
( çD
(
\.
L
L
L
9803/3 r 50 lssue 2
1r
2 Hydraulics 2 {
5-1 5-1
65
q*
@
55
il-ez )
60
(
57 46
31
67
24
õ o
a
Ø
c 14
21 4
q1
33138
,)
9803/31 50 lssue 1
I
o
ñ 2 Hydraulics 2
5-2 5-2
e,
PUMPS & MOTORS (HAMWORTHY)
C, Dismantling and Assembly
* NOTE: Main illustration 0.05mm. (0.002in.) below face
l-t shows
a typical three sectíon pump of bearing bore.
with alternative later type wear
r- plates at A. For clarity, pipe
connections have been omitted
Renew wear plates 5,9,26,30,
49 and 53 if scored or eroded.
from centre pump section 25.
r- Motors have only one pair of
gears with the wear plate and
Ensure that all wear plates are
f¡tted with their slots correctly
seal arrangement shown at B; positioned relative to the gears
ft otherwise construction is
similar.
and to the suction and pressure
ports as shown. Plates 9, 30
and 53 must fit fully home in
the housings and move freely.
( When Dismantling
Mark housings and end covers Ensure that seal supports 7, 11,
to ensure correct re-assembly. 28,32,51 and 55 also seals
Use a soft faced hammer to part 6, 10, 27,31,50 and 54 are
components. Do not use levers correctly trimmed and do not
or machined surfaces may be become trapped between wear
damaged. plates and housing wall.
Mark adjacent teeth of gears lf the original refitted,

gears are
(' with indelible ink before align the marks made during
removal. Retain gears in pairs. dismantling.
( Use Service Tool 8T2464 to Torque Settings

withdraw bearings 12, 21,35,
45, 58 and 65. Item Nm kgf m lbf ft
1 42 4.3 31
Remove sharp edges, burrs and 2 163 17 120
light scoring from gears, shafts 22 42 4.3 31
and housings. Use a fine 24 163 17 120
abrasive stone. Wash off any 47 163 17 120
grit or metal particles with clean
hydraulic fluid.
t, When Assembling
Renew any pair of gears if:-

L,, a) Journal area of shaft is
pitted or worn in excess
[$
t) of 0.025mm. (0.001 in.).
L)
b) Keyway, splines or gears
are badly worn or cracked rBe 433't3
Renew bearings if worn or if

gears are renewed. They must fit
U flush with or not more than
U 9803/31s0 lssue 2+
li
2 Hydraulics 2
5-3 5-3
A \\
42 29
J
eù A
38 t
36
ê
31
43
%
40 A I
35 42 43 12
J
4
18
+
b
26
43
42 q,
@ 1l
41
@ 42
%@
4 (
8
lt
38 A
@
) l (
3 (
42
6
43 q, ()
9 @
% 41664
(l
9803/3150 lssue 1
(
{
2 Hydraulics 2
5-4 5-4
*PUMPS & MOTORS {COMMERCIAL}
Dismantling and Assembly

*NOTE: lllustration shows an Renew gears if pitted, scored or
805/8068 pump. Other pumps chipped or if wear on shaft
have an additional bearing diameter exceeds 0.05mm.
housing 10 in place of adapter (0.002in.). Shaft wear is most
flanges 18 and 20. Motors likely on the contact area of
have only one pair of gears, ring seals 39. Wear on gear
otherwise construct¡on is similar teeth width must not exceed
0.025mm. (0.001 in.) below
When Dismantling the nominal size of 1.000in.
(25.40mm), 1.250in. (31.75mm)
Mark housings and end covers to or 1.500in, (38.1Omm). When
ensu recorrect replacement. renewing gears, fit in matched
When separat¡ng these components, pairs and renew the bearings.
take care to avoid damage to the
machined faces.
lnstall new ring seals 39 with
Before removing gears, mark notched faces towards the
adjacent teeth with indelible bearings. See page 2/5-5 for
ink to ensure correct installation of pocket seals A.
replacement. Do not centre lnstall lip seal 37 (also 23 and
punch or stamp. Retain gears 26 where fitted) facing in the
in pairs. direction shown. Press items
23 and 26 to the bottom of
Check gear housings 5, 13 and recess and item 37 flush with
29 for wear as at B. lf gear surface. Secure with Loctite
cut-out exceeds 0.1 2mm.
(0.005in.), the housing must be 222.
renewed.
Torque Settings
Use extractor MD956 (see
Service Tools catalogue) to Item Nm. kgf m lbf ft
remove bearings 38. Bearings 1t
should bea light press fitin their Tfll 27o 2s 200
bores. Loose bearings may rle I
indicate worn bores.
*Check security of plug(s) 40. tNote: ltems 17 and 19 are
not used on 8078 and 808.
Only remove if damaged, noting
position for re-assemblY.
When Assembling
Remove burrs and sharp edges Q

from splines, shafts and housings, \
(J\
using a fine abrasive stone. (J
(-,
Renew wear plates 3,9,11,16, C)
28 and 33 if worn to a thickness
of less than 9.47mm.(0.373in.),
or if scored, eroded or pitted.
ç) O
*On pumps, Posit¡on the Presure ^$
relief groove towards the high N) $s
pressure side (see page2/5-51.
9803/3150 lssue 2t
2 Hydraulics 2
5-5 5-5
PUMPS AND MOTORS

(Commercial)
Pocket Seal Fitting

I
The following instructions apply

when fitting seals to all thrust
plates.
0 I
Cut two centre-seals to a
length of 5.5mm. (O.22in.l
Coat the seals with grease and

insert into the centre slots of the
thrust plate as at A.
Place thrust plate,seals facing

downwards, into position over
the bearings as at B and tap with
a soft hammer until clearance
between thrust plate and housing
is approximately 0.8mm (0.030 in.).
Note: On pumps the pressure relief
groove X must be towards the high (J
pressure side,
(J
Cut four seals to an approximate
length of 6.5mm. (0.25in.). TJ
--/
Push the seals into the radial slots
as at C until contact is made with
the bearings. Tap the thrust plate
firmly down against the machined
surface. Use a sharp razor blade
to trim the exposed ends of the
seals until they are square and
flush with the thrust plates.
<,)
c) Q
21,6t
(.
9803/3150 lssue 1
t
( 2 Hydraulics 2
6-1 6-1
(
CIRCUIT OPERATION
(
When the spool is in the neutral
position oil from the pump passes
( through the centre or neutral circuit
of the valve.
lf a service is selected bY moving

the spool either up or down, the
neutral circuit is blocked bY the
( spool. The oil then f lows into the
parallel gallery, past the non-return
valve'Aand through the open port
to the ram or motor.
{
Simultaneously, oi I returning f rom
the ram or motor enters the valve
block, passes into the exhaust
gallery and so back to tank.
30434
t
9803/31 50 I ssue 1
2 Hydraulics 2
6-2 6-2
CIRCUIT OPERATION
The illustration on the previous

page shows the parallel gallery fed
directly from the neutral gallery.
Where several spools are housed
within one block however, each
spool is supplied by a common
parallel gallery A running the length
of the valve block. The parallel
gallery itself is fed from the neutral
gallery upstream of the first spool
as shown. Alternatively it may be
fed from outside the block by
means of a High Pressure Carry-over
line as described later. More than
one spool may thus be operated at
any one time.
--
-' ,-/ --'
3(X4A
9803/31 50 lssue I
tl
l-l 2 Hydraulics 2
6-3 6-3
f,
STANDARD SPOOL OPE RATION
The standard spool is used in

conjunction with a non"return valve
l) to operate a service where back-

pressure in the service line will
occur due to a gravity loading
(--\ opposing the action of the ram.
ti(lia
Example: ô
ir ln the upper illustration the dipper

ram spool is being selected but, due
to the loaded bucket Ã, the back-
( pressure in the ram feed line is
greater than the PumP output
pressure in the parallel gallery at'B'.
( This higher pressure causes the non-

return valve'C'to remain closed,
preventing the possibility of reverse
( oil flow which would allow the
load to drop.
When the spool is fullY selected,

the neutral circuit'D' is ccmpletely
cut off and the pressure rises in the
paral lel gallery'E'until it exceeds
that in the ram feed line. At this
point the non-return valve 'F'oPens,
permitting oil to flow to the ram
and so raise the load.
The use of non-return valves also

( prevents interaction between spools.
For example, if non-return valves
were not f¡ttd and two loads were
(
being raised simultaneouslY, the
heavier of the two loads would fall
and oil from that ram would flow
to the more lightlY loaded ram and
increase its lifting speed. With
non-return valves in the system
(.
however, the oil ¡s Prevented from
flowing from one service to another.
(.
(
30454
t;
U 9803/31 50 lssue 1
l._,'¡
2 Hydraulics 2
6-4 6-4
MOTOR SPOOL (HUSCO}WITH BRAKE

VENT VALVE
$
Motor circuits are subject to 'reverse
pressure' hydraulic conditions created
by the tendency of the driven load
to'overrun'. The control valve spool
is therefore designed such that, when
set to the neutral position, both
motor ports are vented to low pressure. J c
Example
Under slewing conditions, the

superstructure of an excavator
attains considerable momentum.
This causes the mass to 'run on'
after the control lever has been
reset to neutral. When this occurs
the motor'A' acts as a pump (being
driven by the load through the
slewing gears) and excessively high
pressure would be developed if the
oil could not escape to exhaust.
The pressure would also tend to
hold off the automat¡c brake 'B'.
Method of Operation
When a service is selected, the main

spool blocks the neutral circuit
and diverts oil into the parallel
gallery, through the open port to
one side of motor, a reduced f low
also passes through restrictor'E'
to the automat¡c brake.
release
Shuttle valve 'C' prevents short
circuiting of the motor by the
brake supply.
Exhaust oil from the motor returns

to the valve block low pressure
gallery.
As the control lever is returned to

neutral, both motor ports are
opened to exhaust. Any pressure
which might be generated by the
motor ¡s therefore safely dissipated.
Brake Vent valve 'D' also opens to
provide a direct route to tank for
oil from the brake, thus ensuring
39594
rapid brake application.
9803/31 50 lssue 1
r-l
TELEFAX MESSAGE
2
Þ
Aün:
F¡&
Pld I 2.ì
Cotttp¡rly:
6-5 a Dat¡: { 6-5 -ì
Fpm:
F¡r.
D€Pt
ComP¡nY:
3
4
5
6
l
19
18 -)
')
5
)
4
)
16
I )
2
3 )
14 )
13
)
9 l )
)
5310
16
14
13 I
)
15
2
)
1
,)
,_)
9803/3150 I ssue 1 -J
l*J
I
L
n,
l'i 2 Hydraulics 2
6-6 6*6
(-'
TYPICAL SPOOL_TRACK, EXCAVATOR
& ATTACHMENT SERVICE VALVES
t, Dismantling and Assembly
NOTES:
r- 1. ltems 1 to 6 are common

to all valves:-
A 8058 Track Valve.
(" B Excavator Valve (all
machines).
C Track Valve 805,8068,
r' 8078,808.
D Attachment Service Valve.
*2. Track valve detent items 7
(' to 19 are fitted to all 8058's
and optional on 8068,
8078 and 808.
(
3. ltems 82 to 86 are for all
other valves.
4. ltem 20 is a typical spool
When Dismantl¡ng
('' Label the spool to ensure

replacement in the correct bore. B6
() Use spool clamp 992/00900 to

prevent rotat¡on of spool.
B5
Use spanner 892/O0026'tor
screw 83.
Do not attempt to remove B4

scoring from the spool or its
bore. lf either
is damaged,
renew the complete control
valve. B3
When Assembling
Ensu re absol ute cleanl iness. 5333
82
9803/3150 lssue,2*
2 Hydraulics 2
6-7 6-7
t=
t6
+-
12
9
10
1
3699
9803/31 50 I ssue 1
2 Hydraulics 2
6-8 6-8
TYPICAL SPOOL - SLEW
NOTE: Spool 164 is used

only in the USA Husco valve
block.
When Dismantling
Use Socket 892/00026 and

Spool Clamp 992/00900
(Service Tools) to unscrew
item 14.
lf either spool 13 or 16 (or 164) 164

or its bore shows signs of
scoring, the spool and its
mating part must be renewed.
9803/31 50 lsue 1
(
2 Hydraulics 2
6-9 6-9
)
NON_RETURN VALVES
Dismantling and Asembly

3
¡
lnspection
lf the valve has been seat¡ng

correctly the face of the I d
poppet 7 will have a
continuous witness line on
the seat.
2
0 )
Light scoring or pitting of

the seat in the manifold 2
may be removed by fine
lapping compound.
Torque Settings
Item Nm kgf m lbf ft

1 68 6.9 50
3314
30008 \
9803/3150 lssue 1
I
2 Hydraulics 2
7-1 7-1
TRACK RELIEF VALVE OPERATION
At Rest - 1
The track relief valve is pilot

operated and located in the
stat¡onary sleeve'D'.
The radial holes in the sleeve allow

pressrre to be felt on the lower face
of the relief valve poppet'E'and on
the upper end of the poppet via the
hollow piston'F'
The pressure act¡ng on the greater

area of the upper erd keeps the
poppet seated, assisted by the light
spring'Gl
The pilot valve'H'is also held seated

by the sprirg J'which controls the
relief valve setting and is adjusted by
the scro¡u'Kl
Operation - 2
When the system pressure exceeds

the relief valve setting, the Pilot
valve'H'moves off its seat and
allows oil to flow into the return
gal lery'M' through the cross'drilling
in the plug 'L.
This creates a pressure drop across

the hollow piston'F] causing it to
( move upwards until it seats on the
pointed end of the Pilot valve.
( The poppet'E'then moves off its

seat and permits a sufficient oil
flow into the return gallery to
( maintain the system pressure at the
relief valve setting.
(-
3050a
ll
\,, 9803/31 50 lssue I
-l
,l
2 Hydraulics 2
7-2 7-2
I
RELI EF VALVES-TRACK CI RCUIT
When Dismantling 15 14
Mark sleeves A and B to ensure

re-assembly in the correct
bores as shown.
\
Ensure that individual
components of either valve do
not become intermixed. l
When Assembling

correctly, the faces of the 19
poppet 7 and the plunger 18
will each bear a narrow,
unbroken witness line and
their seats will be sharp and
unbroken. Do not grind in
these components, but renew
as necessary.
4
* lf not already fitted, add spring
7a to make seat¡ng of poppet 7
more positive. The spring is a
tight 'screw fit' in the poppet.
"After building up the pilot

valve assembly 3, push the
spigot of the plug 19 fully
home into the sleeve A or B.
Check that the poppet is
positioned on its seat and is
free to lift against the action 5
of the springs.
Without using force, feed the

two assemblies 5 and 3 together
into the control valve. Ensure
that the end of the sleeve enters
the recess in plug 1.
I
2?49A.
(-,
9803/3150 lssue 2*
E
Page 1 of 1 E101/H - lssue 1
June 1982 E97lE - lssue 1
JCB 8058 from m/c no. 200607
Track and Slew Control Valve (Hamworthy)
Control valve part no. 919/50300 is no longer available from the manufacturer. lf a service
replacement is required, use control valve X, part no. 919/52600 with adapters, washers and
re-routed hoses as detailed below.
Service Procedure
Re-connect the existing hoses as to the old control valve but with the following except¡ons.
1. Connect hose A to port B (instead of C) using adapter D and washer E.
2. Disconnect hose F from the excavator valve, reverse and refit as shown using elbow G,
adapter H and washer J.
Parts Required
Item Part No. Description otv

X 919/52600 Control Valve
D 1604/0006 Adapter
E 1406/OO21 Washer
G 81 6/0001 I Elbow
H 1 606/001 5 Adapter
J 1406/0029 Washer
g-t' H
F
V/ J
Ø
X
\
PY
D
E
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THIS DRAWING fS PROPERTY OF
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HAMWORTHY HYORAULICS LÌD. AND
MUST NOT 3E REPRODUCED WITHOUT
JIB t]R16 REF
WFITTEN CONSENl. DO NOT SCAIE DRAWING TI{IRD ANGTE PÍlÍ}JECTIflN ALLD,II'SARETN ------..--- U¡'IESS S1ÁTêO
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EÌ* FhrsHÊs ssowtr rxu. /
TRACK AND SIEW COI{ICL VATVE
ö**- J.c. satsFo*D .rnouoto"" .ro.

o*--*" O) ce..À eh þ
5r ø wd.r ro(.rÁñc. ' p¡^w¡¡a ¡ur¡E.
>-{Ã--" rP.Ec¿o.o
SWEENE.V AOT-
2 3 5
919/503CO
7 9
2
OO N'-- CALE THI \WING ]E MIC UED 9PLY C ;T DBA iNG TË( ,UE
l_ I lro
,ínÞ aNG- ,-RoJÊcrtL,-
UlurcSS OlHrñvvtsÊ SIAIEÞ ALL DIMENSþNS ARE IN MILLIMETßES
gâÎoN A-A _l SãmoN B-å SEmON C-C
â:
c c
o B g
+-
HALF FUI5I2E
Þsry:ød uNÉ
1,.
ÈwttsY |YoñNUCS !lD. ÂilD
vrarc>créññNtv
F5T rcf BE æPFøUCEO WrqOT
ô
SHEET '^' OF ?
TRACK ANÐ SLEW COÑÎROL VALVT
o**-*" o ," EXCAVATORS LID.

"o*ro*o
!o3L!S@V4
iPR...D.D sv ø wHÉ¡ for.Á¡* Þ
D SWEE|JEV
1 2 3 I 4
ltr/"iñ
a
{^r
2 Hydraulics 2
l-'
&-1 8-1
(^
AUXILIARY RELIEF VALVE OPERATION
l'' The illustration shows how excessive

pressure can be induced in the
(' bucket ram during operation of the
dipper. This pressure builds up in
the line tö the valve block A when
l-' the spool is in the neutral position.
As this pressure rises to the setting
of the auxiliary relief valve B, the
( valve will open and relieve the
back pressure within the ram.
( A partial vacuum is created in the

rod side of the ram and pressure in
the exhaust gallery lifts the anti-
cavítation valve C to allow oil into
the rod side of the ram.
(
\
( o
ilil
t
\ 30524
\-
[--i 9803/31 50 lssue 2

(
2 Hydraulics 2
8-2 8-2
EXCAVATOR RELIEF VALVE OPERATION
This type of pilot operated relief valve is used 2. Pilot Valve Opens
for each of the excavator services.
When the circuit pressure reaches the pilot valve i)
Operation setting, the pilot valve F opens, allowing oil to
flow through cross-drilling J, down the outside
1. Valve Closed of sleeve K and into exhaust gallery L.
Pressure in the circuit at A is felt on the lower 3. Dump Valve Opens

l
face of the dump valve B and on its upper face
via the hollow piston C. As the circuit pressure cont¡nues to rise,
pressure in chamber M remains constant as ¡t is
The pressure acting on the greater area of the governed by the pilot valve setting. When
upper face of the dump valve, assisted by circuit pressure at A is approximately 2oo/o
springs D and E, keeps the valve seated. higher than that at M, piston C rises to seat on
the end of the pilot valve and dump valve B rises
The pilot valve F also is held seated by spring G to allow circuit pressure at A to be dumped to
which controls the pilot valve setting, exhaust L.
adjustable by screw H.
When the circuit pressure has fallen sufficiently,
the dump valve is closed by spring D.
@ 5526
9803/31 50 lssue 2
n
o 2
8-3
Hydraulics
8-3
2
tì EXCAVATOR RELIEF VALVE OPERATION
r- (continued)
When the valve is used as an A.R.V.

the sleeve poppet N permits the
(--' additional function of anti-cavitation.
r- Anti-Cavitation
When negative pressure exists in the

service line O, the low but positive
a' pressure in the exhaust gallery P lifts
the sleeve poppet off its seat and
f'' allows oil from the exhaust gallery

to make up the deficiency in the
service line.
(-'
(-'
( 30514
('
(l
('
t
(t-_
(_.,
L,,
U
lì
\J 9803/31 50 lssue 1
ir)
| \,-/
{
2 Hydraulics 2
8-4 8-4
RELIEF VALVES - EXCAVATOR &

ATTACHM ENT SE RVICE VALVES
Dismantling and Assembly 1

2
A Slew M.R.V. 8058 (up to
m/c no. 2OO2O5!.,8068, 2
8078 and 808. 4
B Slew A.R.V.8058 (from
m/c no. 200206\. )
5
C Attachment Service A.R.V
D Excavator A.R.V.
NOTE: When fitting a new
relief valve, always check the
pressure setting.
When Dismantling
Remove the complete unit from =

the control valve casting by
unscrewing the valve body 19. e_8
@_s
Examine the seating E in the 9..--..---..-ro
g
valve block. lf this is damaged
the complete block must be ã-.-.-.------.--tt
renewed.
Ensure that the components

of the various valves do not
become intermixed.
When Assembling

e--16
@__-17
correctly, the faces of poppets 13
6, 15 and 18 will each bear a
narrow unbroken witness line
and their seats will be sharp
and unbroken. Do not grind
in these components, but
renew as necessary.
lnsert the large end of spring 1l

into the bore of plug 7.
Check that poppets are free to

lift and return under spring
pressure.
\,
29528
9803/3f50 lssue I
l-
2
e 2
8-5
Hydraulics
8-5
a R E LI E F VALVES-EXCAVATOR &
ATTACHMENT SE RVICE VALVES
( (USA Husco)
22 to
C This type of relief valve is lt
fitted to the U.S.A. Husco
l- excavator valve and may also

be fitted as service replacement
for the valve shown on page
12
2/8-4. Before fitting the valve 9

(- to the machine, check that the
p.ressure setting is cgrrect as 23
described on page 2/8-7.
(
Dismantling and assembly
I
procedures are similar to those
( for the original valve, the main
difference being the fitting of
disc springs 13 which must be
( arranged as shown at F.
21
( 7
6
16
2
19
5
17 4
3
2
1
1
14
13
lssue 2
9803/31 50
2 Hydraulics 2
8-6 8-6
EXCAVATOR RELIEF VALVES

(Late type - 11ttø in. thread)
When Assembling 1
Remove the complete unit from the

control valve casting by unscrewing the
valve body 21.
Ensure that the components of the various

valves do not become intermixed. 5
When Assembling
lf the valve has been seating correctly, the

faces of the poppets 7 and 15 will each bear
a narrow unbroken witness line and their
seats will be sharp and unbroken. Do not
I
grind in these components but renew as I
necessary.
€.)
lf fitting a new relief valve, check that the
pressure sett¡ng is correct as described on I
page 2/8-7. 21
Check that the valve block bore is clean so

asto provide an effective sealing face for 11
'O'ring 18.
10 20
12
14
15
I
13
17
I
qa
1
9803/31 50 lssue I
a
2 Hydraulics 2
e,
8-7 8-7
e,
AUXILIARY RELIEF VALVES
l- (Rubery Owen and Husco)
e Testing and Adjustment
* Connect hand pump and
e pre$¡ure gauge (see Service

Tools Catalogue) te test
fixture as illustrated. Use
l- test fixture 892/00153 for
later type valve shown on page
2L8-6. Use testfixture
(- 892/OOO29 for all other
Rubery Owen and Husco A.R.V.'s.
( Operate the hand pump and

observe the gauge reading,
The maximum obtainable
reading ¡nd¡cates the setting of
( the relief valve.
Adjust pressure setting as shown

( at A. Refer to Technical Data
for correct pressure values.
Unscrew the adjuster two or
(- three turns to release trapped
dirt before setting. @Ðwo
(
2993
9803/3150 I ssue f
2 Hydraulics 2
9-1 9-1
9803/31 50 lssue 1
:
rË
.
2 Hydraulics 2
r*ffi
9-2 9-2
MAIN RELIEF VALVE OPERATION

(Parker Hannifinl
l-f.'
rÊ This valve is used as excavator
M.ñ.V. on 805 and 8058 also as
slew M.R.V. on 8068 and 8078
'
(t[, machines fitted with USA-Husco

excavator valve. Port A is the
pressure feed, port B exhaust.
t
tt^{i:,
;'r
/i;J At illustration 1 the valve is shown
at rest. Pressure in cavity C is
prevented from venting to exhaust
+^@ by pilot plunger D being held on its
seat E by spring F.
r{ As the pressure rises the force of

spring F is exceeded, the pilot
.
(:,.
! r,T
plunger lifts and oil begins to flow
C \-;" to exhaust via gallery G as shown at
2. Oil cannnot entercavity C via
the small hole H as quickly as oil is
( 'l-i
.\_,;, exhausting. A pressure drop therefore
occurs in cavity C causing the main
plunger J to lift and allow pressure to
t'_ lìi be vented direct to exhayst a¡ at 3.
t [-i
L,G
(fu
rf
rt
.à
[,('
lr
l.(-'
LL:
rIì ì
ij# 9803/31 50 lssue I
¿B
{
2 Hydraulics 2 (
I
9-3 o_?
(
r
MAIN RELIEF VALVE
(Parker Hannifin) /-

(
When Dismantling
As an interference fit is (
employed, remove seats 16

and 17 only if they or their
respective poppets are worn.
¡
^t
ln this case poppets and seats
.4 should be renewed in pairs. 4ì
I
When Assembling
¡'
Ensure that the bleed hole in ø
poppet 15 is free from
obstruction.
14
17
11
12
13
16
10
5211 A
(
7
i
J 9803/3 1 50
1
lssus 1
{.á:
-1
:
d
2 Hydraulics 2
10-1 10-1
OFF LOADING VALVE OPERATION

* (ln Valve Block-Direct Acting)
This is located in the excavator valve

block downstream from the slew
service.
Under light load operating conditions

oil from one section of a multiple pump
flows through the valve from port A to
port C to join the main flow at the
track manifold. Non return valve B is
held open by oil pressure.
lf the service pressure requirement

increasæ beyond the offload pressure
setting the pressure rise is sensed at
chamber D. As the pressure increases
piston F moves away from fixed
poppet E against spring G. This
causes the oil flow to be dumPed
directly into the exhaust gallery H.
The non return valve closes to
prevent high pressure oil from the
track pump sections being short
circuited to exhaust. This process
unloads the pump section
concerned and thus allows the engine
to develop higher pressure at
reduced flow in the remaining
pump sections.
A small drilling K through caP J

allows oil to slowly fill up or be
displaced from the space left bY
the moving piston, thus Providing
a damping effect and ensuring
smooth, positive piston action.
As the system pressure demand falls,

pressure also falls in the chamber.
This allows the spring to return the
piston to its normal position, thus
allowing the flow from all pump
sections to again be utilised.
30558
9803/3150 lssue 2*
2 Hydraulics 2 t
10-2 10-2
l
ì
l
11
3- Ð
&
13
I I,
17
2994A
\
(
9803/3150 lsq¡e 2
r)
Hydraulics 2
a) 2
10-3 10-3
o OFF.LOADING VALVE
r) Dismantl ing and Assembly
o, When Dismantling When Assembling
o After removal of the spring

adjuster 1 ensure that the
piston 3 does not drop out of
Rerew and lubricate all 'O' rings
and assemble the components
of the spring adjuster 1.
the bore and become damaged
l_- Assemble the piston 3 and,
lf the piston sticks in the bore, using the threaded rod screwed
(l screw the 5/16 UNC threaded

rod part no. 892/00028
lightly into its lower end, feed
up the bore until the top is flush
(Service Tools) into the lower with upper face of the valve
end of p¡ston 14 and withdraw housing as at C.
(-' the assembly from the housing.
Whilst pressing the cap 7,
Prior to removal of plug and together with the plug and
( screw 6, slacken the screw 8 screw 6, on to the top of the
one or two turns. This piston D, feed the units down
position should be retained for the bore. Maintain upward
(' re-assembly. pressure on the threaded rod
until the cap is positioned
Do not attempt to remove the squarely on its seat, then
(' plug from the lower er¡d of firmly tighten plug 10 and screw
piston 14. SasatE.
( lnspection Remove the threaded rod
whilst supporting the P¡ston
Ensure that pistons 13 and 14 with spring 2 then fit adjuster
(, are a free sliding fit and that assembly 1.
both they and their bores are
free from scratches and burrs. Fit nut 4 and washer 5.
Pay particular attention to the
metering land at A.
Torque Settings
( The cap 7 and its mating face
in the housing must be Item Nm kgf m lbf ft
11 28 2.8 20
t sufficiently f lat so as to make
good metalto metal seal.
a
Failure to correctly align the

(_ cap may have caused local
distortion of the bore at B. lf
as a result, the piston is
(. prevented from sliding freelY,
rect¡fy the distortion bY
careful use of a bearing scraper
(.-- at this point onlY.
lJ
I
9803/3150 I ssue 1
l.
2 Hydraulics 2
10-4 10-4
OFF LOADING VALVE OPERATION

(ln Valve Block-Pilot Operated)
This valve is located in the excavator

valve block, downstream from the
slew spool.
Under light load operating conditions,

oil from one section of the multiple
pump flows through the valve from
port A, via non-return valve B, to port
C and on to join the flow from the
other pump sect¡ons at the track
valve manifold.
Oil is fed also into chamber D, via

orifice E, thus creating a pressure
balance across spool F. The force of
spring G acting on the spool ensures
that exhaust port H remains closed.
As pressure demand on the system

increases, pressure also builds up in
chamber D until it exceeds the
setting pressure of pilot valve J.
This then opens to allow oil in the
chamber to flow to exhaust more
rapidly than it can be replaced by
oil flowing in through the orifice.
A pressure differential is thus

created across the spool which is
driven open against the spring. The
total pump section output ¡s
thereby díverted to exhaust via
port H, thus reducing the load on
the engine which is then able to
drive the remaining pump sections
at increased pressure.
Non-return valve B closes to prevent

the high pressure flow lshort
circuitinf to exhaust. l
9803/31 50 lssue 1
2 Hydraulics 2
I
10-5 10-5
(
OFFLOADING VALVE
(ln Valve Block-Pilot Operated)
When Dismantling
Seal stiction may cause sleeve 2 to

be withdrawn as pilot valve assembly
1 is removed. Otherwise remove
plug 3 and push out the sleeve.
Plug 9 is secured by Loctite and

should only be removed if seals 10
and 11 require renewal. Hold sleeve
in clamp 992/00900.
(
When Assembling
Ensure that small drilling through

centre of spool 5 is clear.
Fit fine mesh screen 19 between

coarse mesh screens 18 and 20.
Use Loctite 270 when refitting

plug 9.
Fit assembled sleeve 2 and spring 4 t5

into valve block, fit and fully tighten
pilot valve assembly 1. Ensure that
rod 15 is screwed fully into plug 3
before fitting to valve block.
Tighten plug 3, then tighten rod 15
,$w
to secure sleeve.
(
çq"
a¿
( 5
( TT
19
9803/31 50 lssue 1
/--
\
J
2 Hydraulics 2
11-1 11-1
(
OFFLOADING VALVE OPERATION
(Commercial)
(
This valve is used on some JCB machines
( to control the output of a multiple
pump unit.
Under normal operating conditions all

sections of the pump supply oil to
the excavator system. lf the
power requirement of the system
(
increases (as for example. when using
the machine to prise out rock) the
pumps are unable to maintain full
{ flow output and, at the same time,
produce the extra pressure required.
lf one section of the pump could be
(
bypassed, the remaining section would
be able to utilise the full engine power
to provide a reduced flow at a higher
pressure. The Off-loading valve
achieves this condition by automatically
'dumping' the flow from one section of
the pump when system pressure rises to
a pre-determined level.
Operation
At normal pressures, oil flows directly

through the valve. the non return valve
A being held open and a pressure balance
existing across orifice B. As the pressure
demand on the system increases, pressure
also builds up slowly in chamber C until
it exceeds the setting pressure of pilot
valve D. This then allows the pressure
in the chamber to'bleed' through to exhaust
more rapidly than oil can flow through
( the orifice to replace it.
The pressure on the 'system' side of the

(
orif ice therefore drives the main spool
E open against its spring and the pump
sect¡oo output flows directly to exhaust.
t
The non return valve closes to prevent
high pressure oil from the other pump
sect¡on'short circuiting' to exhaust.
tl 9803/31 50 lssue 1
(ì
1r
2 Hydraulics 2 I
11-2 11-2
)
2 20
I
6)
3 17
@t
ffil-"
4
e-l
16
5
13
6
C)
Ç-'
C) 12
(-)
7
9
I
11
10
S
ù
25
15
6219
23
(
I
9803/31 50 lssue I
n
2 Hydraulics 2
a,
11-3 11-3
a,
OFF LOADING VALVE
(Commercial)
l'^'
[^'
r When Assembling
lf seat 25 has been removed,
r replace using Loctite 601.
Ensure that plugs 14 and 2O

are replaced in their original
r' positions (ltem 20 has a
through drilling which must
be kept clear).
(
t
(_
t.
L,
L
t_
L.
9803/31 50 lssue 1
L.-J
2 Hydraulics 2 I
1 2- 1 1 2-
I
I
o o
oo o
oo
a o
oo
29968
9803/3150 lssue I
rì
t^l 2 Hydraulics 2
12-2 12-2
(-,
PRESSURE TESTING
( Main Relief Valves-Track Block
(JCB 805,8068,8078 & 808)
( Dependent upon which valve is being tested,

install chock A part no. 892/00030 (see
Service Tools catalogue) into the track
sprocket on the appropriate side of the machine.
Connect pressure gauge 892/00001 to the

respective pump outlet adapter (X-left-hand
track, Y-right-hand track) using snap
connector B, part no. 892/00099.
( Run the engine at maximum speed, select the
full speed forward position on the track control
and check the gauge reading.
(
lf necessary, adjust the relief valve as at C until
the gauge reading is equal to the correct
( operating pressure of the valve (see Technical
Data). Before setting the pressure, unscrew the
adjusting screw two or three turns to release
any trapped dirt.
(
Repeat the operation for the remaining track.
( lf the correct pressure setting cannot be reached,
carry out the following check:-
( Stop the engine, operate all controls to vent

residual pressures and tilt the cab.
Connect the gauge into the excavator valve as

( at D, using a 3/8 BSP adapter.
Run the engine and operate the track control

( as before. After checking the operat¡ng
pressure, allow the control to return to neutral
and stop the engine, when the gauge reading
(. should fall to approximately 35 Bar (500
lbf linzl and be maintained at this level for
approximately 2 minutes before falling to zero.
t lf the pressure falls more rapidly, then a likely
cause is a defective non-return valve in the track
valve manifold. Alternatively there may be a
( fault in the excavator valve, e.g. leakíng spool
or cracked valve block.
{.
t,. 9803/31 50 lssue I

2 Hydraulics 2ír
12-3 12-3
PRESSURE TESTING
Track Main Relief Valves-8058
lnstall chock A, part no,

892/00030 into the appropriate
track sprocket.
Connect pressure gauge

892/00001 to the respective
pump outlet adapter
(X - left hand track, Y right
hand track).
-
Run the engine at maximum
speed, select the full speed
forward position on the track
control and check the gauge
reading against the pressure
shown in Technical Data.
lf necessary adjust at B. Repeat

the operation for the remaining
track.
lf the correct pressure sett¡ng

cannot be reached, carry out
further test with gauge
connected at the excavator
valve as described on page
2 12-2.
5329
9803/3150 lssue 1
n
r-)2 Hydraulics 2
13-1 13-1
C,
PRESSURE TESTING
t-) -\ì
-Þ
Excavator Main Relief Valve-Parker Hannifin
r) (JCB 805 from m/c no. 77199)
Connect gauge 892/00001 to

f' either number 2 or number 3
pump outlet adapter using snap o o0
connector, part number c) ,(-,, (a
892/00099 (see Service Tools
catalogue).
o o o oo
(s NOTE: Before checking the

excavator M.R.V. both track
M.R.V.'s must be correctlv
l
adjusted
U
(', speed, operate the dipper
service as at B and check the
maximum gauge reading when
the ram has reached the end of
its stroke. lf necessary, adjust
the M.R.V. as at C until the
,
(r gauge reading is equal to the
correct setting (see Technical
Data). Before setting the
( pressure, unscrew the adjusting
screw two or three turns to
(
release any trapped d¡rt.
Failure to obtain a correct

a
v'
rôading may indicate a
( defective pump, non-return
valve or, under except¡onal
circumstanceq leakage at the
TRACK valve internal high
pressure blanking plug D.
l+
I I
() I
lr
(_)
IJ 5239
l--) 9803/3150 lssue 1
r_)
(
2 Hydraulics 2 (
13-2 13-2
PRESSURE TESTING
Excavator Main Relief Valve-8058

(
Óonnect gauge 892/0000'l to
either number 2 or.number 3
pump adapter.
NOTE: Before checking the

excavator M.R.V. both track I
M.R.V.'s must be correctly

adjusted.

speed and operate the boom
service. When the rams reach
the end of their stroke, check
the gauge reading against the
presssure shown in Technical
Data.
lf necessary, adjust as at A.

reading may indicate a
defective pu mp, non-retu rn
valve or, under except¡onal
circumstances, leakage at the
TRACK valve internal high
pressure blanking plug
-
(ltem D on previous page).
N (
5330 (.
(
9803/31 50 lsue 1
i
n'
n 2 Hydraulics
14-1
2
14-1
r-
PRESSURE TESTING
r-
Slew Main Relief Valve -Except 8058
(-', (lntegral w¡th Valve Block)
r'
number one pump outlet
o
o
using snap connector 892/00099.
r' Slew the machine against a

solid obstruction as shown.
-' speed and hold the slew service \
(-
fully selected, when the
maximum gauge reading will
indicate the operating pressure
of the slew M.R.V.
[ili
lf necessary (see Technical
Data) adjust the operating
pressure as at A. Before setting
the pressure, unscrew the
( adjusting screw two or three
turns to release any trapped
dirt.
t Failure to obtain a correct
reading may ¡ndicate a
( defective pump or relief valve
( o
t
(
(,_
(_,
l_,
U 9803/3150 lssue 1
l--/
2 Hydraulics 2
14-2 14-2
PRESSURE TESTING
Slew Relief Valve(s) - 8058

number one pump adapter.
WARNING
To promote safety, follow the I

procedure given. Other methods
may be dangerous as high slew
torque could cause the under-
carriage to shift (especially on
hard standing).
Disconnect the slew service

hoses from the excavator valve
and securely cap the adapters .ll
A and B.

speed, operate the slew control
and check the gauge reading
against the pressure shown in
technical data.
* +
NOTE: Prior to m/ c no.
200206, one slew M.R.V. C
is fitted. Later machines have
two slew A. R.V.'s:
D for slew left. E for slew right.
These must be checked with the
ô
slew control selected in the
appropr¡ate d irection.
5592
9803/31 50 lssue 4*
2 Hydraulics 2
14-3 14-3
PRESSURE TESTING
Slew Main Relief Valve

(Line-Mounted)
Connect gauge 892/00001 to ê"t o o

number 1 pump outlet adapter
using snap connector part
lol
lo ol
@
oo
number 892/00099 (see
Service Tools catalogue).
Slew the machine against a

solid obstruction as shown.
Run the engine at max¡mum
speed and hold the slew service
fully selected, when the
maximum gauge reading will
indicate the operating pressure
rill
of the slew M.R.V.

Data), adjust the operating
pressure as at A. Before
setting the pressure, unscrew
the adjusting screw two or
three turns to release any
trapped dirt.
Failure to obtain the correct

defective pump or relief valve.
NOTE: The line-mounted slew

M.R.V. is used only on machines
f¡tted w¡th the U.S.A.-Husco r/{lli
excavator valve.
52¡t3
9803/3150 lssue 1
!L
2 Hydraulics 2
15-1 15-1
PRESSURE TESTING
Off Loading Valve

(lntegral with Valve Block)
Before proceeding, ensure that

the slew and excavator M.R.V.'s
are correctly adjusted.

number one pump outlet o
using snap connector part
number 892/00099.

speed and slowly operate the
dipper service. As the ram
approaches full travel, the
gauge reading should rise
steadily, then fall back to zero.
The maximum gauge reading
indicates the operating pressure
of the off loadíng valve.
*lf necessarv (see Technical Data),
adjust the off loading pressure
as shown: o
A - Direct Acting Valve
B - Pilot Operated Valve
Before setting the pressure,
unscrew the adjusting screw two
or three turns to release any
trapped dirt.

defective pump or off loading
valve.
2998C
9803/3150 lssue 2*
( I
I
rr
I
2 Hydraulics 2
15-2 15-2
e,
PRESSURE TESTING
(
Off Loading Valve 8058
*To m/c no.2OO147-
t First ensure that the slew and

excavator M.R.V.'s are correctly
adjusted.
It

number one pump adapter.
I
(
dipper. As the ram approaches
full travel, the gauge reading
( should rise steadily then fall
back to zero. Check the
maximum reading against the
pressure shown in Technical
(
Data.
lf necessary, adjust as at A.
(
(_
t
(
(_
5327
/Ì
t... _z
t., 9803/31 50 lssue 2*
ll
2 Hydraulics 2
15-3 15-3
PRESSURE TEST¡NG
Off Loading Valve-8058

From m/c no. 200148'
First ensure that the slew and

excavator MRV's are correctly
adjusted.
Connect gauge 892/00001 to number

one pump adapter.
ì
Run the engine at maximum speed

and slowly operate the dipper, As
the ram approaches full travel, the
gauge reading should r¡se steadily
then fall back to zero. Check the
maximum reading against the
pressure shown in Technical Data.
lf necessary, adjust at A.
I
lsue 2
t,
9803/3150
(i
{ì
rl 2
15-4
Hydraulics
15-4
2
o PRESSURE TESTING
a)
Off Loading Valve
(LineMounted)
r-,
Before proceeding, ensure that
r-l the slew and excavator M.R.V.'s
are correctly adjusted.
a Connect gauge 892/00001 to

number one pump outlet using
snap connector part number
C: 892/00099 (see Service Tools
catafogue).
(, Run the engine at maximum
I I
\ ( +
l'' dipper service. As the ram
approaches full travel, the
gauge reading should rise @
steadily, then fall back to zero
(' The maximum gauge reading
indicates the operating
pressure of the off loading
(.' valve.

(' Data), adjust the off loading
pressure as at A. Before sett¡ng
the pressure, unscrew the
(; adjusting screw two or three
turns to release any trapped dirt.
(. ,, Failure to obtain a correct
reading may indicate a defective J4ìllí<_
pump or off loading valve.
tl NOTE: The line-mounted off
loading valve is used on 8068
L, and 8078 machines fitted with
the USA-Husco excavator
valve.
L)
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(._,)
6242
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HYDRAUL¡C CIRCUIT - NEUTRAL

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TRACK/SLEW VALVE BLOCK - NEUTRAL CIRCUIT
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HYDRAULIC CIRCUIT - SLEW OPERATING n/,
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TRACK/SLEW VALVE BLOCK _ SLEW OPERATING
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9803/31 50 lssue 1
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2 Hydraulics 2
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16-5
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16-6 16-6
TRACK/SLEW VALVE BLOCK _ ONE TRACK OPERATING
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9803/31 50 lssue l
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16-7
Hydraulics
16-7
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16-8 16-8
HYDRAULIC CIRCUIT _ EXCAVATOR OPERATING
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9803/31 50 lssue.l
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16-9
Hydraulics 2
16-9
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9803/31 50 lssue,l
2 Hydraulics 2 .l
16-10 16-10
EXCAVATOR VALVE BLOCK - MRV OPEBAT¡NG
+
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(
9803/31 50 lssue.l
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2 Hydraulics 2
16-11 16-11
EXCAVATOR VALVE BLOCK - ARV OPERATING
9803/31 50 lssue 1
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2 Hydraulics 2
17-1 17-1
7
8
tl
9
to
11 I
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4
18 27
I
5 )
6
16
)
25 ,
17
20
22
21
15
14
13
12
9803/31 50 lssue 1
t,ri
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(' 2 Hydraulics 2
17-2 17-2
(-,
TRACK & SLEW VALVE (Hamworthy)
Track Spools
(

(
When Dismantling
(- Remove nuts 1 and withdraw spool

and detent housing assembly 2.
'O' rings 3 and 6 with their retainers
( 4 and 5 can then be removed from
the spool.
( Remove nuts 7 and plate I to gain

access to seals 9 and 1 1.
( T
(
(.
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(
f-.
L,
L, 9803/31 50 lssue f
l._,,
i -'ì
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Hydraulics 2
e 2
17-3 17-3
(
TRACK & SLEW VALVE (Hamworthy)
Slew Spool
(
Dismantl ing and AssemblY 7
(
E
When Dismantling
I
( Remove nuts 1 and take off housing
2. 'O' ring 3 is then accessible. 9
( Withdraw spool assemblY 4 from
the valve block and take off 'O' ring 10
5.
(
Remove nuts 6 and plate 7 to gain
access to seals I and 10. 5
(
( 11
(
È
15
(
d 14
(
13
(
( 12
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6239
{._,_
'-t'-.' 9803/31 50 lssue 1
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2 Hydraulics 2 I
17-4 17-4
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12
1
14
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2
16
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22
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12
1
15
1
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9803/31 50 lssue 1
e,
2 Hydraulics 2
e, 17-5
17-5
(-,
TRACK & SLEW VALVE
(Hamworthy)
(
Slew Relief Valve (A) Non-Return Valves (C, D & E)
( When Dismantling When Assembling
Do not attempt to separate items 9a Ensure that poppets with centre

( and 9b, as these are pressed together drillings Z are fitted next to the cap
and can only be rePlaced as an ends of the spools.
assembly.
(
When Assembling
( Note that outside diameter of

sleeve 16 is ground to fit the valve
block bore.
(
Do not fit pipe X but Plug Port Y
until after the valve has been fitted
( and adjusted as follows:-
Note: This procedure is for initial
adjustment after re-assemblY'
( For routine adjustment, see Page
2117-12.
1. Screw sleeve 5 f ullY home,
2. Disconnect slew service hoses and

( securelY cap the adapters on the
valve block.
( 3. Connect gauge to No. 1 PumP

adapter.
( 4. Operate slew control and check

gauge reading. Adjust screw I
until reading is 151 bar (2200
( tbf lin2l.
5. Unscrew sleeve 5 to obtain a

(.- gauge reading of 117 bar
(1700 lbf/in2).
( 6. Tighten locknuts 3 and 4. Fit

cap 1 and reconnect PiPe X.
( Offloading Valve (B)
When Assembling
Note that outside diameter of spool

15 is ground to fit the valve block bore.
(---,
lssue,l
L-, 9803/31 50
\
o
o 2
17-6
Hydraulics
17-6
2
f, EXCAVATOR VALVE (Hamworthy)
e Spools
f- Dismantling and AssemblY
When Dismantling
-l
17
l- Remove bolts 1, housing 2 and

gasket 3.
18
e', Withdraw spool assembly 4.
Remove bolts 5 and plates 6 and 8

(' access to seals 7 and 9.
to gain
(r Hold spool in clamp 992|O12OO

when removing retainer 10 and eye
end 17.
( .!oe
('
(
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( I
(
1 16
L
t 15
t: I 6240
U
U 9803/31 50 lssue 1
U,
2 Hydraulics 2 l
17-7 17-7
t- @
7
o
<=t
1
12
13
15
I e) 5
6
9
6241
9803/3f50 lssue I
a
2 Hydraulics 2
r- 17-8 17-8
u EXCAVATOR VALVE
(Hamworthy)
(-
Track and Excavator M.R.V. (X)
e When Dismantling
e Remove plug 16 so that cartridge 18

can be driven out in direction of
e arrow.
Auxiliary Relief Valves (Y)
C When Dismantling
Use extractor 592/O28OO to remove

cartridge 4 from valve block.
To hold cartridge in a vice, use

( barrel clamp 892/00039.
When Assembling
(
Note that two sizes of A.R.V. seats
I are used and must be refitted ¡n
( their correct positions together with
their corresponding A.R.V. cartridges.
( Seat Dia. Cartridge Code
A Smm. (0.197in.1 321197

(_ B 5mm. (O.tgZ¡n.) 321157
c 7.9mm.(0.312in.t.27/312
L
L
L
L-
L,
L
t_,
9803/31 50 lssue 1
\,
2 Hydraulics 2 I
17-9 17-9
rl
9803/31 50 lssue I
2 Hydraulics 2
17-10 17-10
PRESSURE TESTING
(Hamworthy)
Pressure settings must be checked 2. Dipper Head Side A.R.V.

in the following sequence:
2.1 Connect gauge to either no. 2
1. Track M.R.V. or no. 3 pumP outlet adaPter.
2. Dipper Head Side A.R.V.
3. Excavator M.R.V. 2.2 Turn screw C clockwise using
4. Slew M.R.V. finger pressure only, until
5. Offloading Valve it just contacts screw B.
Note: The dipper head side A.R.V. 2.3 Run engine at minimum speed,
pressure may be checked either in extend dipper ram and as the
situ or in a test rig. When checking ram reaches the end of its stroke,
in situ, the excavator M.R.V. check the maximum gauge
pressure must be temPorarilY reading against the pressure
increased as at 2.2 below. All given in Technical Data. lf
other A.R.V's can only be checked incorrect remove A.R.V. D
in a test rig (see page 217-14l,. and adjust pilot setting
(see pase 2117 -141.
1 Track M.R.V.
(positioned in excavator block) Note: lf machine has JCB pattern
controls, dipper head side A.R.V.
1.1 lnstall chock 892/00030 into will be at eye end of spool no. 2.
track sprocket.
2.4 Re-set excavator M.R.V. (see below).
1.2 Connect a 0-400 bar
(0-6000 lbf/in2) pressure 3. Excavator M.R.V.
gauge to appropriate pump
adapter (no. 2-right hand 3.1 With gauge connected to either
track, no. 3-left hand track). no. 2 or no. 3 pumP outlet
adapter, run engine at maximum
1.3 Run engíne at maximum speed,
speed and extend bucket ram.
select full speed forward As the ram reaches the end of
position on the track control
its stroke check the maximum
and check the gauge reading gauge reading against the
against the Pressure given in M.R.V. pressure given in
Technical Data. Technical Data.
lf thereading is incorrect,
3.2 lf the reading is incorrect
repeat the test on the other adjust M.R.V. at screw G,
track. lf the two track
pressures are different, this Cont.
may be caused by oil leakage
or a defective check valve
which must be rectified before
continuing the test.
When both track Pressures are

equal, adjust if necessary bY
removing cap and screw
assembly A and turning screw B.
lssue 1
9803/31 50
\
'._J
2 Hydraulics 2
17-11 17 -11
9803/31 50 lssue'l
\
\-s-
e
2 Hydraulics 2
l-.
17-12 17-12
c',
PRESSURE TESTING
Hamworthy-conti nued
( ( )
4 Slew M.R.V. 5.3 lf the pressure does not return

to zero or if correct pressure
( 4.1 Connect gauge to no. 1 pump cannot be achieved by
outlet adapter. adjustment at L, proceed as
l- 4.2 Disconnect slew service hoses

and securely cap the adapters
follows:
a) Remove pipe F and plug

on the valve block. port G. Remove cap H.
(-,
4.3 Run engine at maximum speed, h) Operate slew service with
operate slew control and check ports capped as at 4.2 and
( gauge reading against the turn sleeve K clockwise
pressure given in Technical until gauge reading is 172
Data. bar (25001bf/in2)" lf
(' sleeve bottoms before this
4.4 lf the reading
is incorrect, pressure Çan be reached.
remove pipe F and plug port G leave the sleeve screwed
( Remove cap H and adjust fully home and adjust
pressure at screw J. Do not screw J to achieve this
alter position of sleeve K. pressu re.
( Refit pipe and cap after
adjustment. c) Repeat operation 5.2
( 5 Offloading Valve d) Operate slew service with

ports capped and turn sleeve
5.1 Connect gauge to no. 1 PumP K (not screw J) anti-
( outlet adaPter. clockwise until gauge reading
is 1 1 7 bar (1 700 lbf/¡n2).
5.2 Run engine at maximum speed
( and slowly operate the dipper' e) Repeat operation 5.2
As the ram approaches full
travel, the gauge reading should 5.4 lf correct offload pressure still
( rise slowly to the Pressure cannot be achieved, dismantle
given in Technical Data and offloading valve and check for
then return to zero. correct seating.
(
lf incorrect pressure is shown lf correct pressure is reached
t before the gauge returns to

zero, adjust at screw L.
but does not return to zero,
check non-return valve M for
correct seating.
t
(.
L.
(-
U 9803/31 50 lssue 'l
\--,
2 Hydraulics 2
17-13 17-13
9803/31 50 lssue I
t,
a
2
a 2
17-14
Hydraulics
17-14
a
PRESSURE TESTING
e (8058 Hamworthy)
A.R.V. Testing and Adiustment

C
Note: Operating pressure of the
dipper head side A.R.V.
a' can be checked in situ
(see page 2117-101.
a Pilot settings of all A.R.V.'s

can only be checked and
adjusted as detailed below.
( Note the pressure code etched on

the valve at the coned end.
( lnsert the cartridge (coned end first)

¡nto the test f¡xture 992/01000 and
fit the seal and plug 2. Connect a
( 0-400 bar (0-6000 tbt/in2l
pressure gauge and hand pump as
shown. Pressurise until oil escapes
( at port 3 when the gauge reading
should be within 3.5 bar (50 lbf/¡n2)
of the pilot sett¡ng shown in the
(- table below.
+
Adjust the pilot setting by gripping
(' the cartridge in a barrel clamp,
slackening locknut 4 and turning 2339
screw 5.
Pilot Setting Operating Pressure

tem Code Seat dia. bar lbl/in2 bar lbf /in2
t Boom Head Side E 321197 5mm.(0.197in.) 189 2740 220 3200

Boom Rod Side F 32/197 5mm.(0.197in.) 189 2740 220 3200
I Dipper Head Side G 27 /312 7.9mm.(0.312in.1122 1760 182 2650
Dipper Rod Side H 32/197 5mm.(0.197in.) 189 2740 220 3200
Bucket Head Side J 321197 5mm.(0.197in.) 189 2740 220 3200
Bucket Rod Side K 321197 5mm.(0.197in.) 189 2740 220 3200
tNote: A.R.V. positions given above

are for l.S.O. pattern For
"o¡1¡s15.
positions
JCB pattern, the of items
E and G are interchanged.
9803/31 50 lssue 1
r-\
r-,
2 Hydraulics 2
ñ
18-1 18-1
a RAM OPERATION
r'
r
r-
r-
(
(
t
-- -
>_--__-\
-.
5488
9803/31 50 lssue 1
2 Hydraulics 2.,
18-2 18-2
I
)
I
15
13
(lt 1
5
17
,-g
5331
18
21
4
3
11 1
Çttl
s03/3150 lssue 1
n
o2 Hydraulics
18-3
2
18-3
e',
RAMS

* Upper lllustration: 8058 Boom
When fitting tab-locked retained
and Bucket only. (From m/c p¡ston use service tool 892/00125
200284, items 10 and 11 are to knock down the tab into the
deleted from the boom ram). groove at 180 degrees from the old
Lower I llustration: 805, 8058 position-
Dipper, 8068, 8078 and 808.
Torque Settings
When Dismantling
(, See Technical Data.

Use 'C' spanner 915/0720O to
remove screwed end cap 1.
( It may be necessary to use

hydraulic pressure or compressed
air to drive out the p¡ston
assembly.
WARNING: Ensure that the

end cap 1 or 10 is securely
retained during this operation
as severe injury can be caused
( by a suddenly released p¡ston
rod.
( When removing Loctite

retained piston head, heat to
approximately 1 80oC (3650F)
( to break the Loctite bond.
When removing tab-locked

( piston head, remove any
weakened sections of the piston
end flange to prevent the
possibility of these breaking off
in service and causing damage.
Use one of the following peg

spanners for either type of
piston.
s"!*1
114mm. (4.5inldia.992/07300 I go( ß ''v{t i f f r^r. \''n
127mm. (5in) dia. 992/O71OO )
(.) 152mm. (6in) dia. 992/O72OO
When Assembling
U When fittíng Loctite retained
rj piston, apply Loctite 601 to

clean dry threads and torque
tighten within 3 minutes.
L) 9803/31 50 lssue 2*
r_)
2 Hydraulics 2
19-1 19-1
VARIABLE BOOM DROP RESTRICTOR 2

(from m/c no.773O7l
4
Dismantling and Assembly 3
ro
54A7
9803/31 50 lssue 2
2 Hydraulics 2
2A-1 20-1
BEAM CLAMP OPERATION
'+
+
t +
øo77
9803/31 50 lssue 3
2 Hydraulics 2
20-2 20-2
BEAM CLAMP CYLINDER

I
When Dismantling
lf hydraulic pressure is used to I
force off the cylinder 4, tit

)
two 7/16in. UNF x 7in. (175mm)

studs and nuts in place of bolts
3 to prevent the cylinder from
falling dangerously.
When removing piston head 13,

heat to approximately 180oC
1
(365oF) to break the Loctite
bond.
To disconnect piston rod 16

from the wedges 19, first 7
remove the sliding beam from
the boom base. With the
piston at the bottom of its
stroke, swing the wedges into
the vertical position and rotate
the assembly through 45
16
degrees, so that pivot pin 18
can be removed.
*NOTE: From m/c no. 200293
v'
10
items 10 and 11 are replaced by 5
spring ring 114. 1 A
When Assembling
11
Apply Loctite 601 to clean dry

threads of the piston rod and
torque tighten the piston head
within 3 minutes.
Torque Settings
5
Item Nm m
kgf lbf ft I
3 74.6 7.6 55
13 408 41.6 300
NOTE: ln the event of a hydraulic

failure, the clamp may be locked
in the "ON" position by replacing
plug A by a3/4 UNC x 3in.
(75mm) setscrew.
@
&-
5505A
A
9803/3150 lssue 2*
,"1
.ì2 Hydraulics 2
20-3 20-3
:l
BEAM CLAMP CONTROL VALVE
'J (to m/c no.2OO297l
'l Dismantling and Assembly
When Dismantling
'l Remove all adapters 3

before attempt¡ng to
with their seals 5
remove ball spindle 9,
With the control lever ín the'ON' position as
shown, ensure that the flow paths marked on
otherwise serious damage will be caused. the spindle (as at A) are aligned with the correct
') ports.
When Assembling
Port Gonnections
To prevent damage to 'O' ring 8, locate it on
the shoulder below the thread in the body, B Pump
instead of on plug 7. c Cylinder, head side
'') D Tank
F¡t adapters 3 finger tight only and operate E Cylinder, rod side.
valve a few times. Check spindle 9 for free
') movement as each adapter is finally tightened.
)
ê 3
)
4
)
) @
=
3
J I
2
4
J
5 11
_) 910
.J 3 7 sbo6
J 3
J 9803/31 50
lssue 1
J
I
\_
(._
('-
2 Hydraulics 2
21-1 21-1
ROTARY COUPL ING OPE RATION
: l
,:N
hr=
9803/31 50 lssue 2
(
2 Hydraulics 2 (
21-2 21-2
ROTARY COUPLING
1
Dismantli ng and Assembly
Some machines do not have

blanking plug or adapter 14.
When Assembling 2
Remove light scuffing and

scoring from the body I and
the shell 13. lf heavily C.-)
scored renew these components. (.-)
Before fitting back-up rings g 5
and 11, soak in hydraulic fluid 4
untíl supple. (
7
3
I
o
71
13
2975 A
12
g.. 3305
(
9803/3 I 50 lssue 'l
f' I
--l 2 Hydraulics 2
21-3 21-3
)
ROTARY COUPLING
)
When Assembling
) Remove light scuffing and
scoring from body 7 and shell
11. lf heavily scored, renew
) these components.
Before fitting back-up rings

) I and 10, soak in hydraulic
fú¡d until supple. 2
)
3
)
)
6
) 8- I
)
æë
@
)
7
) 11
_) 9803/31 50 lssue 1
)
2 Hydraulics 2
22-1 22-1
34
33
29
I
I
I
I
I
I
I
10 I
18 I
I
'l- 26
J
*l
t__ _ _J
16
8298
9803/3 I 50 lssue 1
2 Hydraulics 2
22-2 22-2
CIRCUIT DIAGRAM JCB 805, 8068, 8078 and 808

Neutral Circuit (Bold Line) Boom, Dipper and Bucket Services
Fluid is drawn from tank 1 by pump 2 which When a spool is selected, blocking the neutral
has three sections 2A,28 and 2G. Section 2A circuit, the service is fed via the parallel gallery
directly feeds the slew spool 3. located with 25 from the high pressure carry-over line 26
the slew M.R.V. 4 in the excavator valve block Feed through this line will occur even when
5. When the slew service is in neutral, the flow the track services are being operated.
continues through off-loading valve 6 and on
to the track valve block 7.ln the track valve Excavator pressure is controlled on the 805
manifold it divides and joíns tne flows from by line-mounted M.R.V .27 and on other
sections 28 and 2G, so as to g¡ve an machines by the track M. R.V.'s.
independent supply to each of the track
spools (8 and 9) and their respective M.R.V.'s Off-Loading Valve
(10 and 11).
When operat¡ng pressure rises to a pre-determined
From the track valve, the neutral circuit setting, the off-loading valve opens, allowing
continues via line 12 to the excavator valve, the f low from pump sect¡on 2A to be exhausted
passíng boorn, dipper and bucket spools (13, to tank. The load on the engine is therefore
14 and 15) before returning to tank via oil reduced, thus permitting the other pump section
cooler 16 (and 164 on 808 machines) and to generate maximum pressure without stalling
filters 17. the engine.
Track Service * Note A pilot operated off-loading valve, as
shown on page 22-8 (item 6), is fitted
When a track service is selected, the neutral from the following machine numbers:-
circuit is blocked by the spool and fluid is
directecl via rotary coupling 18 to the relevant 8068 z 78177
track motor 19 and simultaneously through 8078 : 78079
shuttle valve 20 to release track brake 21. 8078 Turbocharged : 78059
808 : 78079
When both track services are operated together
each will have equal power because the track
Component Key
motors are supplied by separate pump sections
of equal displacement. 1 Tank 18 Rotary Coupling
2 Triple Pump 19 Track Motor
Slew Service 3 Slew Spool 20 Shuttle Valve
The whole of the flow from pump section 2A
4 Slew M.R.V. 21 Track Brake
is supplied direct to the slew spool, thereby
5 Excavator Valve 22 Slew Motor
ensuring that the slew service can be operated
Block 23 Slew Brake
while the other pump flows are utilísed to
6 Off-Loading 24 Slew Vent Valve
operate the remaining excavator or track services.
Valve 25 Parallel Gallery
7 Track Valve 26 High Pressure
Block Carry-Over Line
When the slew service is operated, the neutral 8 Track Spool L.H. 27 Excavator M.R.V.
circuit is bloeked by the spool and fluid is I Track Spool R.H. (805 Only)
directed to the slew motor 22 and slew brake 10 Track M.R.V. L.H. 28 Shuttle Valve
23. When the spool is returned to neutral, the 11 Track M.R.V. R.H 29 Boom Rams
momentum of the superstructure causes a 12 See Text 30 Dipper Ram
tendency to continue slewing, thus generating 13 Boom Spool 31 Bucket Ram
pressure on the exhaust side of the slew motor
which, if not vented, would hold off the slew
14 Dipper Spool 32 Excavator A.R.V.'s
15 Bucket Spool 33 One-Way Restr¡ctor
brake. This is averted by the slew vent valve 24
which allows the pressure to be vented back to
16 Oil Cooler 34 Variable Restr¡ctor
16A Oíl Cooler 35 Non-Return Valve
tank. (808 Only) 36 Motor Bleed Line
17 F ilters
9803/3150 I ssue 1
(-'
(_-
n
,^)2 Hydraulics 2
22-3 22-3
CIRCUIT DIAGRAM JCB 805,8068,8078 and 808
Attachment Service Circuit
This circuit is employed on

machines fitted with an
optional Attachment Service
and with the exception of the
portion illustrated is ídentical
to the standard system.
From pump section 28. the

neutral circuit (bold line) is
routed to the Attachment 26
Service valve block 37 before
cont¡nuing to the track valve -->II
block 7 and proceeding as in
the standard system.
When the Attachment Service

is selected, the neutral circuit
is blocked by the spool 38
and fluid is directed to the
required function. The service
is protected from mechanical
overloads by A.R.V's 39.
Exhaust fluid from the
attachment returns to the
valve block and flows back
to tank along with fluid from
the excavator and track services.
Component Key
1 Tank
2 Triple Pump
5 Excavator Valve Block
7 Track Valve Block
26 High Pressure Carry-over Line
37 Attachment Service Valve Block
38 Attachment Seruice Spool
39 Attachment Service A.R.V's
40 Attachment Service Feed and
Return Lines.
5299
9803/3150 I ssue I
2 Hydraulics 2
22-4 22-4
34
31 33
14 I
2A
Ð
2 24
_.t_ 32 32
35
t--
-t
1G
L-
5300
9803/31 50 lssue't
íl
,l 2 Hydraulics 2
22-5 22-5
'-l
CIRCUIT DIAGRAM JCB 8068 and 8078
-l (Machines with USA-Husco Excavator Valve)
'-) Some JCüÌ 8068 and 8078 Component Key

machines are fitted with an
1 Tank
'l excavator valve block
manufactured by Husco in the
USA in lieu of the British
2 Triple Pump
3 Slew Spool
counterpart manufactured by 4 Slew M.R.V.
-) Rubery-Owen. Machines with 5 Excavator Valve Block
the USA-Husco valve are 6 Off- loading Valve
identifiable by the use of line- 7 Track Valve Block
.\ mounted slew relief and I Track Spool L.H.
I off-loading valves (4 and 6) 9 Track Spool R.H.
whereas the standard production 10 Track M.R.V. L.H.
machines have these units 11 Track M. R.V. R.H.
incorporated in the Rubery-Owen 12 See Text
valve block. A further difference 13 Boom Spool
is that due to the design of the 14 Dipper Spool
parallel gallery 25, machines with 15 Bucket Spool
the USA Husco valve are not 16 Oil Cooler
fitted with a high pressure carry- 17 Filters
) over líne. 18 Rotary Coupling
19 Track Motor
The operation of the circuit on 20 Shuttle Valve
) USA Husco maclrines is identical 21 Track Brake
to that of the standard machines 22 Slew Motor
(see page 18-5) with the 23 Slcw Brake
) fol lowing exceptiorr: - 24 Slew Vent Valve
25 Parallel Gallery
Boom, Dipper and Bucket Services 28 Shuttle Valve
) 29 Boom Rams
When a spool is selected, the 30 Dipper Ram
neutral circuit (line 12) is 31 Bucket Ram
) blocked by the spool and flow 32 Excavator A.R.V.s.
is diverted from the neutral 33 One-way Restr¡ctor
circuit into the parallel gallery 34 Variable Restrictor
) 25 and on to the selected service. 35 Non-return Valve
36 Motor Bleed Line
.-)
J
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.J
J
J 9803/3150 lsue I
J
2 Hydraulics 2
22-6 22-6
33 30
L-
53348
9803/31 50 lssue 1
2 Hydraulics 2
22-7 22-7
CIRCUIT DIAGRAM JCB 8O5B

To m/c no.2QO147
Oil is drawn from tank 1 by pump 2 which When a spool is selected, blocking the neutral
has three sections 2A,28 and 2C. Section 2A circuit, the service is fed via the parallel gallery
directly feeds the slew spool 3, located with 25 from the high pressure carry-over line 26.
5. When the slew service is in neutral, the flow the track services are being operated.
to the track valve block 7. ln the track valve Excavator pressure is controlled by line-
manifold it divides and joins the flows from mounted M.R.V. 27.
sect¡ons 28 and 2C, so as to give an
independent supply to each of the track Off-Loading Valve
spools (8 and 9) and their respective M.R.V.'s
(10 and 1 1). When operating pressure rises to a pre-determined
sett¡ng, the off-loading valve opens, allowing
From the track valve, the neutral circuit the flow from pump section 2A to be exhausted
continues via line 12, to the excavator valve, to tank. The load on the engine is therefore
passing dipper, bucket and boomspools (13, reduced, thus permitting the other pump sections
14 and 15) before returning to tank via oil to generate maximum pressure without stalling
cooler 16 and filter 17. the engine.
Track Service Beam Clamp
When a track service is selected, the neutral The feed to the beam clamp cylinder 36 is
circuit.is blocked by the spool and oil is taken from pump sectíon ZAvia control
directed via rotary coupling 18 to the relevant valve 37. When the control valve is set to the
track motor 19 and simultaneously through 'ON' posítion, pressure is built up to the clamp
shuttle valve 20 to release track brake 21. by the operation of the slew servíce (or by
other services until the off loader operates).
When both track services are operated together Pressure is retained by non-return valve 38,
each will have equal power because the track thus holding on the beam ðlamp. ln the'OFF'
motors are supplied by separate pump sections posítion, pressure is diverted to the upper side
of equal displacement. of the p¡ston to ensure that the clamp is
positively released.
Slew Service
1 Tank 20 Shuttle Valve
The whole of the flow from pump section 2A 2 Triple Pump 21 Track Brake
is supplied direct to the slew spool, thereby 3 Slew Spool 22 Slew Motor
ensuring that the slew service can be operated 4 Slew M.R.V. 2? Slew Brake
while the other pump flows are utilised to 5 Excavator Valve 24 Slew Vent Valve
operate the remaining excavator or track Block 25 Parallel Gallery
services. 6 Off-Loading 26 High Pressure
Valve Carry-Over Line
When the slew service is operated, the neutral 7 Track Valve 27 Excavator M.R.V.
circuitis blocked by the spool and oil is Block 28 Shuttle Valve
directed to the slew motor 22 and slew brake I Track Spool R.H. 29 Boom Rams
23. When the spool is returned to neutral, the I Track Spool L.H. 30 Dipper Rams
momentum of the superstructure causes a 10 Track M.R.V. R.H. 31 Bucket Ram
tendency to continue slewing, thus generating 11 Track M.R.V. L.H. 32 Excavator A.R.V.'s
pressure on the exhaust side of the slew motor 12 See Text 33 One-Way Restrictor
which, if not vented, would hold off the slew 13 Dipper Spool 34 Variable Restrictor
brake. This is averted by the slew vent valve 14 Bucket Spool 35 Non-Return Valve
24 which allows the pressure to be vented back 15 Boom Spool 36 Beam Clamp-
to tank. 16 Oil Cooler Cylinder
17 F ilter 37 Beam Clamp-
18 Rotarv Coupling Control Valve
19 Track Motor 38 Non-Return Valve
9803/31 50 lssue f
(
2 Hydraulics 2 (
22-8 22-8
{< ruore: From m/c no.

200160 machines
destined for the UK
market may have boom
and dipper spools
interposed. 33 30
L r
26t
L-
55904
(,
9803/31 50 lssue 1
\
"'l
') 2 Hydraulics 2
22-9 22-9
-)
'l From m/c no. 200148 to 2OO2O5.
) Oil drawn from tank 1 by pump 2 which

is When a spool is selected, blocking the neutral
has three sect¡ons 2A.,28 and 2C. Section 2A circuit, the service is fed via the parallel gallery
directly feeds the slew spool 3, located with 25 from the high pressure carry-over line 26.
) 5. When the slew service is in neutral, the flow the track services are being operated.
I to the track valve block 7. ln the track valve
manifold it divides and joins the flows from
sections 28 and 2C, so as to give an
Excavator pressure is controlled by line-
mounted M.R.V.27.
independent supply to each of the track Off-Loading Valve

) spools (8 and 9) and their respective M.R.V.'s
(10 and 1 1). When operating pressure rises to a pre-determined
') settíng, the off-loading valve opens, allowing
From the track valve, the neutral circuit the flow from pump sect¡on 2A to be exhausted
continues via line 12,to the excavator valve, to tank. The load on the engine is therefore
passing dipper, bucket and boom spools (13, reduced, thus permitting the other pump sections
14 and 15) before returning to tank via oil to generate maximum pressure without stalling
) cooler 16 and filter 17. the engine.
Track Service *
Beam Clamp
)
When a track service is selected, the neutral The feed to the beam clamp cylinder 36 is
circuit is blocked by the spool and oil ís taken from pump section 2Avia control
directed via rotary coupling 18 to the relevant valve 37. When the control valve is set to the
track motor 19 and simultaneously through 'ON' position, pressure is built up to the clamp
shuttle valve 20 to release track brake 21. by the operat¡on of the slew service (or by
other services until the off loader operates).
) When both track services are operated together Pressure is retained by non-return valve 38,
each will have equal power because the track thus holding on the beam clamp. ln the 'OFF'
\ moúors are supplied by separate pump sections position, pressure is diverted to the upper side
I of equal displacement. of the piston to ensure that the clamp is
positively released.
Slew Service
) 1 Tank 20 Shuttle Valve
The whole of the flow from pump sect¡on 2A 2 Triple Pump 21 Track Brake
is supplied direct to the slew spool, thereby 3 Slew Spool 22 Slew Motor
) ensuríng that the slew service can be operated 4 Slew M.R.V. 23 Slew Brake
while the other pump flows are utilised to 5 Excavator Valve 24 Slew Vent Valve
operate the remaining excavator or track Block 25 Parallel Gallery
services. 6 Off-loading 26 High Pressure
_) Valve Carry-Over Line
When the slew service is operated, the neutral 7 Track Valve 27 Excavator M.R.V.
circuit is blocked by the spool and oil is Block 28 Shuttle Valve
_) directed to the slew motor 22 and slew brake I Track Spool R.H. 29 Boom Rams
23. When the spool is returned to neutral, the I Track Spool L.H. 30 Dipper Rams
momentum of the superstructure causes a 10 Track M.R.V. R.H. 31 Bucket Ram
) tendency to continue slewing, thus generating 11 Track M.R.V. L.H. 32 Excavator A.R.V.'s
pressure on the exhaust side of the slew motor 12 See Text 33 One-Way Restr¡ctor
which, if not vented, would hold off the slew 13 Dipper Spool 34 Variable Restrictor
brake. This is averted by the slew vent valve 14 Bucket Spool 35 Non-Return Valve
-) 24 which allows the pressure to be vented back 15 Boom Spool 36 Beam Clamp-
to tank. 16 Oil Cooler Cylinder
17 F ilter 37 Beam Clamp-
) 18 Rotary Coupling Control Valve
19 Track Motor 38 Non-Return Valve
J 9803/31 50 lssue 1
.)
2 Hydraulics 2
22-10 22-10
33 30
20
21 21 \.
(,
9803/3 r 50 lssue l
(
fl
'l 2 Hydraulics 2
22-11 22-11
I
From m/c no. 200206
I
Neutral Circuit (Bold Line) Off-loading Valve
) Oil is drawn lrom tank 1 by pump 2 which has three When the slew service is not being operated the flow
sect¡ons, 2A, 28 and 2C. Section 24, the largest of from pump section 2A supplements the other pump
the three, feeds oil direct to slew spool 3 which is flows in the operation of track or excavator services
located, with its A.R.V.'s 4 in the excavator valve 5. only at pressure lower than the setting of the off-loading
) When the slew service is in neutral, the flow continues valve. When pressure reaches this setting the off-loading
through off-loading valve 6 to track valve 7. At the valve opens, allowing the flow from pump section 2A
track valve manifold this flow is divided into two to be exhaused to tank. The load on the engine is
ì halves which join the flows from pump sections 28 therefore reduced, permitting other pump sections to
generate maximum pressure without stalling the engine.
and 2C. Each of these provides an independent feed
to one of the track spools I or 9 via its respective
M.R.V. 10 or 11. On previous machines which were fitted with a slew
) M.R.V., the off-loading valve pressure could be no
Downstream from the track spools, the independent higher than the slew M.R.V. pressure, otherwise the
flows unite and the neutral circuit continues via line slew M.R.V. would relieve first and prevent off-loading
12 to the excavator valve. Here it flows past the pressure being achieved by pump section 24.
) l¡oom, dipper and bucket spools (13, 14 and 15)
before returning to tank via oil cooler 16 and filter 17 Replacing the slew M.R.V. by two A.R.V.'s, positioned
between the slew spool and the motor, allows
) Track Service completely independent control of slew and off-load
pressures.
When a track service is selected, the neutral circuit is
blocked by the spool and oil is directed via rotary Beam Clamp (from m/c no. 200298)
) coupling 18 to the relevant track motor 19 and
simultaneously, through shuttle valve 20, to release The feed to the beam clamp cylinder 36 is taken from
track brake 21. pump section 2Avia control valve 37. When the
control valve is set to the 'ON' position, pressure is
)
When both track services are operated together, each built up below the clamp piston by the operation of
will have equal power because the track motors are the slew service (or bV other services operating below
supplied by separatc pump sections of equal off-loader pressure). Pressure is maintained by
) displacement. non-return valve 38, thus holding on the beam clamp,
When the control valve is set to the 'OFF' position,
Slew Service pressure ¡s generated above the clamp piston and in
\ the pilot line to the non-return valve which then
.) The whole of the flow from pump section 2A is opens to allow pressure below the clamp p¡ston to be
supplied direct to the slew spool, thereby ensuring vented to exhaust, thus releasing the clamp.
that the slew service can be operated while other
pump flovw are being utilised to operate the remaining Note: See pages 2122-8 and 2122-9 for beam clamp
) prior to mlc 200298.
excavator or track services.
When the slew service is operated, the neutral circuit 1. Tank 22. Slew Motor
) is blocked by the spool and oil is directed to the slew 2. Triple Pump 23. Slew Brake
motor 22 and slew brake 23. When the spool is 3. Slew Spool 24. Slew Vent Valve
returned to neutral, the momentum of the super- 4. Slew A.R.V.'s 25. Parallel Gallery
structure causes a tendency to continue slewing, thus 5. Excavator Valve 26. High Pressure Carry-
) generating pressure on the exhaust side of the slew 6. Off-loading Valve over line.
motor which, if not vented, would hold off the slew 7. Track Valve 27. Excavator M:R.V.
brake allowing further over-run. This is averted by 8. Track Spool R.H. 28. Shuttle Valve.
) slew vent valve 24 which allows the pressure to be 9. Track Spool L.H. 29. Boom Rams
vented back to tank. 10. Track M.R.V. R.H 30. Dipper Ram
11. Track M.R.V. L.H 31. Bucket Ram
Boom, Dipper and Bucket Services 12. See text 32. Excavator A.R.V.'s
) t 13. Dipper Spool 33. One-way Restrictor
When a spool is sèlected, blocking the neutral circuit, T 14. Bucket Spool 34. Variable Restrictor
the service is fed via the parallel gallery 25 from the 15. Boom Spool 35. Non-return Valves
high pressure carry-over line 26. Feed from the line Oil Cooler (Track Valve Manifold)
) will occur even when the track services are being
16.
17. Filter 36. Beam Clamp Cylinder
operated. 18. Rotary Coupling 37. Beam Clamp Control
19. Track Motor Valve.
) Excavator pressure is controlled by line-mounted 20. Shuttle Valve 38. Non-return valve.
M.R.V.27. 21. Track Brake I UK machines rnay have boom
and dipper spools interposed.
,) 9803/31 50 lssue'l
)
2 Hydraulics 2
23-1 23-1
FAULT FINDING
Before carrying out the checks listed, first ensure that:
1. The hydraulic system is filled w¡th the correct fluid and is free from obvious leaks.
2. The filters and strainers are clean.
f f possible, operate the machine to determine the fault area and to bring the system to working
temperature.
A. lf there is an excavator fault, start at check 1.
B. lf there is a slew fault, start at check 21.
C. lf there is a track fault, start at check 30.
CHECK ACTION
1. ls the fault in all services or one only? ALL Check 2

ONE Check 3
2. Are the services inoperative or lacking INOPERATIVE: Check 11

in performance? POOR
PERFORMANCE: Check 13
3. Are the rams seals defective? YES Replace

NO: Check 4
4. ls the valve spool stickingf YES Overhaul valve block

NO: Check 5
5. ls the A.R.V. operating correctly? YES Check 6

NO: Overhaul and set
6. ls the load-hold non-return valve YES: Clean or renew

sticking open? NO: Check 7
7. ls the restrictor blocked? YES: Clear blockage

NO: Check I
8. ls the control linkage correctly adjusted? YES Check 9

NO: Adjust
9. ls the valve block cracked? YES: Renew valve block

NO: Check 10
10. Are the valve spools leaking externally? YES: Renew seals
NO: Check valve block for cracks
9803/3r 50 lssue 1
'l
I 2 Hydraulics
23-2
2
23-2
I FAULT FINDING (Continued)
.)
CHECK ACTION
) 11. ls the pump drive broken? YES Renew
NO: Check 16
12. ls the track manifold leaking? YES Tíghten connections or renew

manifold.
NO: Check valve blocks for cracks.
13. Are the dipper and bucket correctly YES Check 14

positioned? NO: Position correctly.
14. ls the engine performance satisfactory? YES Check 15

NO: Check engine
15. ls the control linkage correctly adjusted? YES: Check 16

NO: Adjust
16. ls the MRV opemt¡ng correctly? YES: Check 17

NO: Adjust
17. Are the pump flow rates correct? YES: Check 18

NO: Overhaul or renew
18. ls the non-return valve stickíng open? YES Free or renew

NO: Check 19
19. ls the offloading valve operat¡ng YES: Check 20

correctly? NO: Overhaul or renew
20. ls the track H.P. plug loose? YES Tighten

NO: Check 12
21. ls the slew fault in the operation or OPERATION: Check 22

over-running? OVER-RUNN ING Check 28
22. ls the slew relief valve operating YES Check 23

correctly? NO: Adjust
23. ls the shuttle valve working correctly? YES: Check 24

NO: Free off or renew
24. ls the pump flow rate correct? YES: Check 25

(No. 1 section) NO: Overhaul or renew
25. ls the slew vent valve defective? YES: Overhaul or renew

NO: Check 26
9803/31 50 lssue 1
2 Hydraulics 2 t'-
23-3 23-3
FAULT FINDING (Continued)
CHECK ACTION
26. ls the slew motor defective? YES: Overhaul or renew

NO: Check I
27. ls the slew brake releasing? YES: Check I
NO: Overhaul Brake
28. ls the slew spool sticking? YES F ree off

NO: Check 29
29 ls the slew vent valve blocked? YES Clear blockage

NO: Check slew brake
30. ls the fault in one track or both? ONE: Check 31

BOTH: Check 38
31. ls the track tension correct? YES Check 32

NO: Adjust
32. ls the track MRV pressure correct? YES: Check 34

NO: Check 33
33. Will the MRV adjust to the correct YES: Check 34

pressu re? NO: Check 38
34. ls the shuttle valve working correctly? YES Check 35

NO: Free off or renew
35. ls the track gearbox defective? YES Overhaul
NO: Check 36
36. ls the track motor defective? YES Overhaul or renew

NO: Check 37
37. ls the valve spool sticking? YES Free off

NO: Check 38
38. Are the pump flow rates correct? YES: Check 39

NO: Overhaul or renew
39. Are the rotary coupling seals leaking? YES Overhaul or renew
NO: Check 40
40. ls the valve block cracked? YES: Renew

NO: Check 8 or 12
(
(
9803/3150 lssue 1
(
e_ceeeeeeeee I
ltltl))fll
I
I
x
x
x
x
rl
') 3 Attachments 3
1-1 1-1
:'l
ATTACHMENT SERVICE VALVE.
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)
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)
Hose Connections
.-) 3. Feed from pump centre

section
4. Service Lines.
) 5. To track valve manifold.
6. Return to tank.
U 9803/3150 lssue I
U
íì
3 Attachments 3 (
2-1 2-1
14
13
#
12
5
1f
16
44 -{
42
22
40
39
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35 27
30
29
36 -32 q,
28
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33
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B 2
31 51
B
3665
I
lssue 1 (..
9803/31sO
(
n
íl 3 Attachments 3
2-2 2-2
[)
GRAB GEARBOX
f)
z .\ Rotating Head
)
'l When Dismantling
Withdraw capscrews 15 evenly

') to allow expansion of brake
springs 19.
:) Clamp body casting 52 in a

vice and install 0.625in.
(15.8mm) diameter bolts or
,) studs in holes B in flange 51.
Apply a substantial lever
across the bolts to break the
i) 'torque lock' between flange
and body casting.
i) NOTE: lt is possible to renew

'V' seal ríng 53 without
removing flange 51 from the
:) body casting. Take care not to
damage the seal when stretching
it over gear teeth.
.)
When Assembling
tr,
)
Appfy Loctite 275to thread of
body casting 52, torque flange
51 to approx 1000 lbf ft.
(138 ksf m).
NOTE: Pre-assemble items 53,

47 and 46 on body casting
) before fitting the flange.
J Renew brake plate 27 if friction

material thickness is less than
.032in. (0.8mm).
J Soak new p¡ates in gear oil for
30 minutes before fitting.
ij Adjust nut 6 to compress
friction discs 10 so that
lJ complete grab unit will just
'self centre' after sideways
movement.
U
U 9803/3150 I ssue 1
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J bodyand
U framework
J
J
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-l 4 Body & Framework 4
1-1 "t-1
)
CAB
)
Glazing
)
)
When fitting glazing to the panel edge, allow a small Commencing at the bottom corner, carefully fit the
) overlap before cutting to length. glass panel. This operation is simplified by using
suction glazing cups, service tool 23-5.
Press both ends together and push them back on to
) the panel ensuring that they ale correctly located.
\(f r651
)
:rii' tæ z
Complete the glass installation by the use of a glazing Remove the hook from the glazing tool and fit the
.l tool,992/01100 NEVER USE FORCE. correct size eye for the filler strip which should now be
threaded through both the eye and the handle.
)
:655
) Starting at a point away from the glazing rubber joint, When cutting the f iller strip, allow sufficient overlap to
insert the tool eye into the filler strip channel then, ensure that the joint is placed under pressure. The
holding the end of the filler strip in place, commence joint and any small sections of the filler strip which
J drawing the tool eye around the channel. may not be locating correctly should now be pressed
home firmly using a spur tool.
J 9803/31 50 lssue 1
J
(
4 Body & Framework 4(

2-1 2-1
Õ
:
Rù (
-r
3f69A
(
9803/31 50 I ssue I
(
n
-l4 Body & Framework 4
2-2 2-2
')
'l CAB
Removal and Replacement

:l NOTE: For manual tilt cabs
follow steps 1 to I and 11, for
"l hydraulic tilt cabs follow
stepsltoSandgtoll.
-) CAUTION: Before the cab is
tilted the excavator control
levers and any loose oblects
') must be removed. Ensure
that the door and front screen
are CLOSED SECURELY.
) When Removing
') Raise the cab to the position

shown at 5 to unload torsion
bar bolts and (where fitted) to
enable screenwash hoses and
:) Carmax heater cable to be
disconnected.
'-
)
')
)
1@
_)
) 4t!96
J
J
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J
J
J 9803/31 50 lssue I
U
/1
:
4 Body & Framework 4 ir

3-1 3-1
HYDRAULIC TILT CAB
System Bleeding
WARNING: lt is essential that

this procedure is carried out
whenever a hydraulic tilt
component or connection has
been disturbed.
Raise cab and support with

hoist.
s
Remove pivot pin B
Select' LOWE R' position

by turning control lever C \
clockwise and pump ram D
fully closed.
Top up system with JCB

'Special' hydraulic fluid until
0
@
reservoir E is full.
c c
Disconnect hose F, select 'LIFT'
position and operate pump until
air free fluid flows from the
hose. Reconnect hose and
cont¡nue pumping until ram is
fully opèn. T
Top up reservoir disconnect
hose G, select'LOWER' and
operate pump until air free
fluid flows from hose. Reconnect
hose.
Purge any air remaining by

pumping the ram alternately
closed and open several times. i
Refit pivot pin B.
Ensure that there is no leakage

and that the reservoir is at least
half full.
9803/3150 lssue 1
4 Body & Framework 4
4-1 4-1
\\
,Ð
32739
9803/3 1 50 lssue I
(-
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t
n
.l4 Body & Framework 4
4-2 4-2
SLEW RING
WARNING:
This operation should be carried
out on hard, level ground.
Ensure stability of blocks at
alltimes.
When Removing
R otate superstructure so
that track motors are forward.
Position support blocks and
joist as slrown. Use 180mm x
100 mm x 21.6 kg/m section,
4 metres long (7in. x 4in. x
14.5 lb/ft. 13ft long).
At 3 join track motor hoses

as shown using adaPters
Part No. 1604/0006. Blank
off third hose (where fitted).
At 6 disconnect shuttle valves,

plug open ends and connect
hand purrrp as shown.
Note position of sPacers C

r____1
||r
(¡f f ¡tted) to ensure correct r__J
re-assembly.
,è
At 8 raise superstructure
evenly until undercarriage will
pass under the steel joist.
Pack under joist as
proceeds.
lifting Ê6
3274 A
9803/3150 I ssue 1
(l
4 Body & Framework 4 r'ì
4-3 4-3
SLEW RING
When Replacing
lf the slew ring is fitted with

dowels 12,locate these in the
superstructure and undercarriage.
\
lf locating dowels are not fitted,
ensure that:- \
1 Tappings for grease tubes
A lie on the transverse axis
of the turret.
2 'Soft Spots' B are correctly

positioned relative to the
turret, as illustrated, with
the inner ring soft spot on
the longitud¡nal centre
line at the rear of the
superstructure.
NOTE: The soft spots are

indicated by stamped letters
S/S or S/P, at two points on the
outer ring and one on the inner.
Where applicable ensure that the

K
correct size spacers C are fitted,
reference Technical lnformation
819/H,818/E.
*
Apply Loctite 242 to bolts 7
and torque tighten using thin-
wall spanner parr no. 892/001,lb
in conjunction with a standard
torque wrench. To allow for
the leverage provided by the
tool set the torque wrench at
25 Nm. (2Q kgf m or 20 lbf ft)
less than thè.specified torque
sett¡ng.
Pack slew ring teeth with

Mobiltac E.
Torque Settings

7 405 41.5 300
3450
9803/3150 lssue 2*
t_l
'l 4 Body & Framework 4
,-) 4-4 4-4
SLEW RING SEAL

,.)
Replacement
1 Cut seal to a length 50

to 75mm. (2 to 3¡n.)
'l shorter than seal groove

circumference.
IMPORTANT: Cut ends
off square.
')
2 Sparingly apply fuac+fÎè aÅjÅ** (tt¿^lt t*4L * (*J"nÀ c3 )
IW 16)
to one end of seal.
) WARNING: Avoid skin
contact with læiæ o-¡Xnl','"u
^ @
t)
)
3
J54€q, immediately wash
off with warm soapy water.
Ensure seal is not twisted

t
then ¡oin ends and press (-
lightly together for 60
') seconds.
4 Clean grease from seal

groove.
)
5 Grease seal lip, carefully
insert at joint and
) continue to locate in
groove as shown at A
using Seal Fitting Tool
) Part No. 992|O14OO
(See Service Tools).
)
6 To avoid stretching, push
seal back as shown at B
after each 200mm. (8in.)
,)
is located in the groove,
ensure correct all round
) location.
Note: Further
) dismantling of slewing
ring is not recommended J
',.) 3272
,-)
J 9803/3150 I ssue I
rJ
a-
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.) 5 Gearboxes 5
\' 1-1 1-1
í)
TRACK GEARBOX
'l
'l
'l
CHECK LEVEL Every 50 Hours
-) 1 Position machine with
plugsCandDas
-) illustrated.
2 Remove level plug C.

Add oil if necessary.
)
DRAIN & Every 1600
REFILL Hours
)
1 To drain, remove plugs
B and D.
) 2 To refill; replace plugs
I and D. F¡ll through.4
and C until oil overflows.
) Replace plugs at.4 and C.
)
TRACK BRAKES
)
Located at F
Automat¡cal ly d isengages
and engages when drive is
selected and released.
)
J
J
J
J
J
J 9803/3f50 lssue 1
J
5 Gearboxes 5a
1-2 1-2
SLEW GEARBOX
CHECK LEVEL 50 Hours
DRAIN &
REFI LL 1600 Hours
Ëî -
i
1 Remove plug,4 and
I
allow to drain.
2 Replace plug A.
3 Refill at I until the oil

level when settled,fil ls
the bottle.
2856
(
9803/31 50 lssue I
(
I
'l 5 Gearboxes 5
,l 1-3 1-3
SLEW GEARBOX OIL LEVEL

--) 8058 (from m/c no. 2001941
o
') Check Level 50 Hours
Drain and Refill 1600 Hours

,)
1. Drain gearbox at plug A.
2 Refill at B until oil, when

, settled, is up to the level
mark C.
')
)
ø
)
)
i
..J
J
J
J 9803/31 50 lssue 1
J
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C
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(.-
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.l 2-1 2-1
,l TRACK GEARBOX
-l
'l
I
)
@
)
) r\ i
)
f,
)
)
41?¡
)
)
A-
J B-
c-
Track Motor
Spur Gear Train-1st stage reduction
Track Brake
D- Planet Gears
.) E_ Annulus 2nd stage reduction
F_ Planet Carrier
J G_ Main Shaft
H_ Planet Gear
J_ Annulus 3rd stage reduction
K_ Planet Carrier
J L_ Adjustment Nut - bearing preload
M_ Track Sprocket
J 9803/3150 I ssue 1
J
( -^'
5 Gearboxes 5 ('
2-2 2-2
5-*g
23
ü
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m-_2a
@-23
-€- Ð: @--22
11
I
12
3058
9803/3 1 50 lssue 1
t
5 Gearboxes 5
2-3 2-3
TRACK GEARBOX (Primary Reduction)
When Assembling
Renew thrust washers if worn

below the following thickness.
Item mnì, in.
16 2.54 0.100
22 2.03 0.080
Apply Loctite 275 to mat¡ng

faces of items 9 and 15, 15
and 26 and also to mounting
face of brake.
Secure bolt 14 with lockwire.
Torque Settings
Item Nm kgf m bf ft
7 118 12 87
8 118 12 87
14 118 12 87
18 20 2.1 15
9803/3150 lssue 1
5 Gearboxes 5 ì
2-4 2-4
B
@-s
<>
/'\
ffi,o1
(r) 194
2 ì
ffi-to
&-- g @-g g-o
2
13
@-r'
168
17 3060
9803/31 50 lssue 1
/
t-l
.l 5 Gearboxes 5
,l 2-5 2-5
'l TRACK GEARBOX (Secondary Reduction)
When Dismantling
I Remove plastic plugs from

extractor holes in planet
carrier 2. Holes are threaded
'l 5/8in. UNF.
Use spanner 892|OOO32

-) (Service tools) to remove
locknut 13.
When Assembling
)
Renew thrust washers if worn
below the following thickness
)
Item millimetres inches
9 2.03 0.080
) 23 2.54 0.100
Lockwire bolts 21 in pairs.

)
For lnspection and renewal of
face seals 18 see page 5 4-1.
)
Rotate sprocket 17 in both
directions whi lst tightening
) locknut 13 to 350 lbf ft
(48.4 kgf m). Slacken locknut
approximately 1 /8 turn,
) ensure that no end float exists
in the bearings. Peen locknut
into slots in bearing support 22.
)
Apply Loctite 275 (Service
J tools) to mating faces of items

2 and 17.
J Refit plastic plugs ín extraction

holes.
Torque Settings (Dry threads)

)
tem Nm kgf m lbf ft
237 24.2
J 1
3
21
61 6.2
406 41.5
175
45
300
J
J 9803/3150 lssue 1
J
a-
(-
('-
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5 Gearboxes 5
3-1 3-1
SLEW GEARBOX
-*-9''
<)
ê
A_ Slew Motor G,
B_ Spur Gear €t
c- :'bpur uear
:-- lst staqe reduction
ê
D_ Slew Brake Shaft G,
E_ Slew Brake 6
F_ Planet Gear
G_ Annulus 2nd stage reduction
H_ Planet Carrier
J_ Mainshaft
K_ Drive Gear
M_ Brake Release Piston
N_ Brake Disc
P_ Bellville Springs
9803/3 1 50 lssue 1
(
5 5 (
3-2 3-2
I
t
1
€-,et-g.- 25
Øa
á rl
x
,6
I
5
7-
29
33
12
14
35
I (
30644
(.-
9803/31 50 I ssue 1
\.-
ì
t* (
5 Gearboxes 5
3-3 3-3
SLEW GEARBOX
When Dismantling Use Loctite 542 on the threads

of plug X.
Use spanner 892/00033 to
remove locknut 24. Torque Settings (Dry threads)
Do not remove bearing outer ltem Nm kgf m

t_ \Þ2r lbf ft
races 26A and 294 unless the
bearings are to be renewed. 3l- 1n n 87
101
When Assembling 17 20 2.1 15
24 680 69 500
Renew all 'O' rings and seals, 2750536
Grease pack seal 33 between
krla' \4^-bo\
lips.
Renew locknut 24. Apply

ñ,#,
Loctite
/t
2*(to threads. /-
..J
Preload taper roller bearings

v
by torque tightening the J"^^+)
locknut to 677 Nm. (Og kgf m
500 lbf ft) whilst rotating the
pinion shaft 28 in both
U.^ni
yfl-
directions.
Lock the nut by bending tabs

as shown at B.
NOTE: Ouantity of needle

bearings 22 is 48 per planet gear.
Apply Loctite 275to the mating

faces of housings, covers and
brake unit.
Use Loctite 241 on the threads ,

of all bolts. ezePt'# b"lþ L
Renew thrust washers 12 and

20 íf worn below the following
th icknesses: -
Item Millimetres lnches
12 2.54 0.10
20 2.03 0.08
Lockwire the head of bolt 10

to the gear housing.
9803/31 50 lssue I
( l
5 Transmission 5 (-
4-1 4-1
(
METALLIC FACE SEALS

(
Removal
* Caution: Avoid skin contact with surface A I
as corrosion may be caused.
Retain seals in pairs when they are removed

(
Fit as a matched pair if suitable for further
use.
(
lnspection
1?50
lf contact (
surface A is undamaged, estimate
remaining life as follows.
New seals. Contact area is a narrow band

at outer edge.
Partly worn Contact area is wider but

seals. does not extend full width.
Scrap seals. Contact area is worn to full (

width.
Renew pair of seals if contact surface is (

scratched, pitted or corroded.
Examine outer edges B, housing ramp C and (

lip D. Carefully polish away light damage or
corrosion.
Thoroughly clean and dry seals, 'O' rings and

housings before fitting seals as follows:
NOTE: Do not allow oil to come into

contact with the'o' rings or
housings until assembly is complete (
Fit new'O' rings on to the seals, check that

they seat evenly and are not twisted. (
Fit tool E, 892/00016, to each assembly.

Press'O' ring past lip D. Check that dimension
is constant round circumference of seal.
t_ I (
T
* lmmediately before final assembly clean dust (
etc. from surface A and lightly coat with
clean oil of the appropriate grade.
(
9803/31 50 lssue 2*
(
t
rl
I 5 Gearboxes 5
5-1 5-1
¡
rl TRACK BRAKE
1
-^
) When Dismantling
Slacken bolts 1 evenly to

allow expansion of springs 4.
3
NOTE: From Machine number
76139 thrust ring 4A is fitted.
4
When Assembling
Renew housing 10 if scored or

6
if
splines are damaged. Minor 7
blemishes may be removed by
polishing.
Renew plates 12 if worn below

1.96mm. (0.077in.) thick or if
damaged or showing signs of
overheating. Soak new plates 9
in JCB 'Special'gear oil for
30 minutes before fitting. I
Ensure that piston seals 6 and
I
I are correctly fittecl with their
back up rings 7 and 9.
0@
Align brake plates using Service
tool 892/00034.
@
Apply Loctite 242 (Service
tools) to the threads of bolts 1.
Torque Settings

1 49 5.0 36
2959 A
9803/31 50 lssue I
(l
5 Gearboxes 5(
6-1 6-1
4
"ì
5
qmÞ g 7
12 @,
â
23
A
11
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20
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29588
(
9803/3 1 50 I ssue 1
I
n
'l 5 Gearboxes 5
6-2 6-2
.l
.J SLEW BRAKE
When Dismantling Check the quantity and

sequence of brake plates (see
'-) Withdraw capscrews I evenly table below). Use Service
to allow expansion of Tool 892/00034 to align the
belleville springs 11. plates.
:l When Asembling lnspect housing 18 for spline

damage; light burring and
-) Check friction plates 14 for sharp edges may be removed
wear or damage. with a fine stone. t\?* ¡io
*
Minimum Thickness: lf plate 22has aO.7mm._--. o r"p'
) (0. 030í n. ) rel ieved side-,th is
Bronze 1.96mm. (0.077in.) must face piston 7.
Carbon 1.67mm. (0.066in.)
) Smear all machined faces with
*Before fitting, soak new plates
JCB Special Gear Oil. Apply
in clean warm gear oíl for Loctite 242 to threads of all
) 30-60 m¡nutes. lf replacing bolts.
bronze plates by carbon,
') reduce friction and counterplate Torque Settings
quantities bY one each and
increase spacer quantity by one Item Nm kgf m tbf ft
)
(see Brake Plate Table). 174 7.6 55
420 2.1 15
Renew counterplates 15 (steel)
if burnt, scored or otherw¡se
) damaged.
) *BRAKE PLATE TABLE 805/8058 8078 808 & Swedish

8068 Swedish 8078 808
-Machines fitted with Bronze Friction
Plates
,.)
First Plate (X) Steel Steel Steel Steel
Total number of Bronze Fríction Plates {14) 6 7 I I
,_J Total number of Steel Counterplates ( 15) 7 I I 10
Last Plate (Y) .., ( ¡
Steel Steel Steel Steel
Number of Spacers (Z) t .. !
.1
i 3 2 1 NIL
' o '-
,_J ,'t
"t
-Machines with Carboñ Friction
Plates
First Plate (X) Steel Steel Steel Steel

) 8
Total number of Carbon Friction Plates (14) 5 6 7
Total number of Steel Counterplates ( 15) b 7 I I
-J Last Plate (Y)
Number of Spacers (Z)
Steel
4
Steel
3
Steel
2
Steel
1
J
J 9803/31 50 lssue 2*
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x
x
x
x
Ix
x
x
x
x
x
Ix
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T
--) 6 Track & Running Gear 6
1-1 1-1
'l TRACKS
)
INSPECT
) Track rollers, sprockets and

idler wheels for damage, or
oil leaks.
'-)
CLEAN
Raise track.
----.-\
1
) 2 Rotate.
3 Lower track.
) CHECK
4 = 25¡¡¡¡. (1in.)
) To obtain correct tension run
machine backwards and
forwards several times.
Tension must only be checked
) after running machine
forwards.
ADJUST
)
To tighten, pump grease or
gear oil through nipple L
) To slacken release Plug C.
Note. Always ensure track
tension is not less than
) 25mm. (1in.) or severe
stra¡n to track will
result.
) Caution: Recoíl unit servicíng
must only be
carried out by JCB
) Distributors.
J
\
J
-)
.-)
.J
.-J 9803/3150 lsue 1
*)
(
6 Track & Running Gear 6 (

2-1 2-1
o (
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2573
9803/31 50
(
I ssue 1
(
'ìl
1 6 Track & Running Gear 6
.l 2-2 2-2
TRACK
,-)
--)
When Removing
-l Position master pin 1 as

shown, support track and
slacken tension nut 3.
-)
Remove two track plates and
press out master pin using
track press ( Service tools).
:^)
Slowly reverse the machine
until the track is laid on the
ground.
i) WARNING: Keep clear of

revolving sprocket.
When Replacing
)
Drive machi¡s oúftÁ+ådrry'i
onto the female end of the
''.) replacement track. Guide the
track over the top roller and
idler wheel (as the machine is
driven slowly forwards) until
the ends can be joined.
Adjust track tension to give

1in. (25mm) at A.
Torque Settings
805,8058,8068,8078.
:_)
10 285
J 808
29 210
i) Item Nm kgf m lbf ft

10 393 40 290
,J
J
J
J 9803/3't 50 lssue f
U
6 Track & Running Gear 6
3-1 3-1
ROLLERS
lnspection and replacement of

metallic face seals 6 are
detailed on a separate page
(Refer to lndex).
Refill at A.
I
3
I
7
2976A
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9803/3 1 50 lssue 1
I
't6 Track & Running Gear 6
4-1 4-1
,l IDLER WHEEL/RECOfL UNIT
To Remove
'l 1 Separate and support track.
) 2 Remove recoil unit

mounting bolts.
,-l 3 Remove idler wheel and
yoke assembly.
-) 4 Remove recoil unit.
To Replace
)
Reverse the removal sequence.
i
Adjust track tension 25mm.
(1in.) at A
)
.)
.tJ
.J\
2971A
*J
J ll
J 9803/31 50 lssue 1
rJ
(

4-2 4-2
IDLER WHEEL & YOKE

(
When Dismantling
Pump oil or grease through (

valve A to push out p¡ston I
When Assembling (
Renew seals 10,1 1,12 and 13

ensuring correct fitting as at
B and C.
jn""
Grease piston before insertion. lr\ 0,'
lnspection and replacement of

Õ
metallic face seals 6 are detailed \
on a separate page (see index). {
\
Refill at D. ,, _,i
(
s r/ ß
12
(
w
10
&t
6
(
I
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2977
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9803/31 50 \7-c'' lssue I
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1.',
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i-l
'l 6 Track & Running Gear 6
5-1 5-1
RECOIL UNIT
Dismantling and Assembly When Dismantling.
WARNING: The spring exerts Use Hydraulic Press (Service

a force of over 7700 kg. tools) to compress spring 4
(17000 lb)and can cause seríous until nut 2 has been removed.
injury if suddenly released.
Keep clear of the ends of the Note: ltems 3a and 3b app*y to
unit when locking pin 1 is to 808 machines only.
removed. Scrap units must be
dismantled before they leave When Assembling
the workshop. Do not use
f lame cutt¡n g equipment. Fit mounting plate 3 as shown
at A.
-) To retain pin 1 after fitting,

peen over both ends of
drilling in nut 2.
)
) q @
3a
I
)
Y
)
)
2
._) f
/
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.J
3015A
__)
-, 9803/3f 50 I ssue 1
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6-1 6-1
I
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2447
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9803/31 50 lssue I
\ .--t
l
-l
I 6 Track & Running Gear 6
6-2
.l 6-2
SPROCKET RENEWAL
'l
For track removal, refer to page
,) 6/2-1.
Removal
'*\
I
1 Carefully cut through the
welds on the outer side of
I 2.
the sprocket rim.
Cut through the welds on the

inner side of rim.
NOTE: An electrical cutting tool

-) must be used to localise the heat.
3. Withdraw the rim, if necessary

') cut into segments as shown at
A.
Replacement
)
Before fitting the new rim,
the sprocket hub and welding
) area B must be thoroughly
cleaned.
) 2. Locate the three lugs Z and

tack weld the new rim in
position as at C.
)
3. Sequence weld between each
of the lugs, i.e. two equally
) spaced welds Y on face and
three equally spaced welds X
,') on reverse side.
NOTE: Welding should be carried

out with 6 Gauge, low hydrogen
.__) Rods at 209-220 amps. Surfaces
must be clean, dry and free from
grease. On JCB 808 machines the
.-J rim must be pre-heated to 200 deg
C before carrying out operation 3.
J
J
-J 9803/31 50 lssue 1
.)
/'-
li/-' ll
I
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x
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7 Engine 7
1-1 1-1
TECHNICAL DATA
Type 4.248-4 Cylinder 6.354-6 Gylinder T6.354-6 Cylinder

*Bore (nominal) 100.96mm. (3.975in.) 98.4mm. (3.875in.) 98.4mm. (3.875in.)
*Stroke (nominal) 127mm. (5in.) 127mm. (5in.) 127mm. (5in.)
Swept Volume 4.06 litres (24gin3) 5.g titres (354in3) 5.8 litres (354in3)
Compression Ratio 16:1 16: 1 16:1
Valve Clearance (cold) 0.30mm.(0.012in.) 0.30mrn. (0.012in.) 0.30mm. (0.012in.)
Firing Order 1,3,4,2 1,5,3,6,2,4 1,5,3,6,2, 4
lnjection Timing 220 B.T.D.C. 220 B.T.D.C. 280 B.T.D.C.
*Max. Speed (no load) 2350 revlmin. 2350 rev/min. 2350 revlmin.
Oil Pressure 2."1-4.1bar 2.1-4.1bar 2.1-4.1bar
at'2000 revlmin. (30-60 tbflin2l (30-60 tbf/in2l 30-60 tbflin2l
*Type 6.3544-6Cylinder T6.3544-6Cylinder

Bore (nominal) 98.4mm. (3.875in.) 98.4mm. (3.875in.)
Stroke (nominal) 127mm. (5in.) 127mm. (5in.)
Swept Volume 5.8 litres (354in3) 5.8 litres (354in3)
Compression Ratio 16:1 15.5: 1
Valve Clearance (Cold)

-ln let 0.20mm. (0.008in.) 0.20mm. (0.008in.)
-Exhaust 0.45mm. (0.018in.) 0.45mm. (0.018in.)
Firing Order 1,5,3,6,2, 4 1, 5, 3, 6,2, 4
lnjection Timing 280 B.T.D.C. 280 B.T.D.C.
Max. Speed (no load) 2480 rev/min. 2460 rev/min.
Oil Pressure (minimum)
at 2000 revlmin. 2.1bar (30 lbf/in2) 2.1bar (30 lbf/in2)
Type 2712E-4 Cylinder 27158-6 Cylinder

*Bore (nominal) 107mm. (4.22in.1 107mm. (4.22in.1
*Stroke (nominal) 115mm. (4.52in.) 115mm. (4.52in.)
Swept Volume 4.15 lítres (254i n3) 6.22litres (380¡n3)
Compression Ratio 16: 1 16: 1
Valve Clearance (hot) 0.38mm. (0.015in.) 0.38mm. {0.015in.)

Firing Order 1,2, 4,3 1,5,3,6,2,4
lnjection Timing 200 B.T.D.C. 200 B.T.D.C.
*Max. Speed (no load) 2300-2350 revlmin 2450-2500 revlmin.
Oil Pressure 3.1-3.5 bar 3.1-3.5 bar
at 2000 revlmin. (45-50 tbf/in2l (45-50 tbÍfinz\
Note:- For complete engine data, refer to the following publications:
4,248 9806/0045
6.354 & T6.354 9806/0060
6.3544 & T6.35¿14 9806/0064
27128 &2715Ê 9806/1 100
9803/31 50 lssue 3*
f
I
7 Engine 7 t
2-1 2-1
ENGINE OIL
PERKINS
CHECK LEVEL Every 10 Hours
DRAIN & Every 200

REFILL Hours
-b)
A Dipstick-8058 is on the --x-
opposite side of engine.
B Filler Cap
C Drain Plug
NOTE: lt is necessary to use

only one of the drain plugs
provided.
Turbocharged Engines
After every oil change, inspect

the turbocharger oil supply
and return pipes for loose
connections, leakage and
damage. Any restriction (on
flow or return) will cause oil
starvat¡on.
uq,Ì
7'-
Before restart¡ng the engine,
"motor" the engine with the
stop control pulled out until
the oil pressure warning light
is extinguished.
Check the turbocharger boost Õ.Ðrl

pressure (see Perkins Workshop
ô
Manual, Section P).
2839A
(.
9803/3150 lssue 1
(
I
I
7 Engine 7
2-2 2-2
I
ENGINE OIL
)
2700 sERlEs
) CHECK LEVEL Every

10 Hours
) DRAIN& Every
REFTLL 200 Hours
) A Dipstick
) B Filler Cap
C Drain Plug
) NOTE: lt ¡s necessary to use
both of the drain plugs
provided.
)
,)
4039
.)
J 9803/31 50 lssue 1
J
7 Engine 7
3-1 3-1
ENGINE OIL FILTER
RENEW
ELEMENT 200 Hours
NORMAL LY.ASPI RATE D ENG IN ES
1 Unscrew bolt.4 and I
remove filter body and

element 8.
2 Discard element and
clean all metal parts.
3 Reassemble with new
element and seal C.
TURBOCHARGED ENG¡NES
1 Unscrew element D.
2 Discard element and
clean filter head.
3 Reassemble with new
element.
ALL ENGINES
Run engine at idling speed
for a few seconds and check
for oil leaks.
After 50 hours check that (-)
the filter is still tight.
ao
oo
9803/31 50
(
lssue 1
(.
n
7 Engine 7
4-1 4-1
î
E]UGIilE FUEI FITTERS
:.)
"l DRAIN Every 50 Hours
1) RENEW
ELEMENT
Every 400
Hours
-) 1 Support sediment bowl

.4, unscrew bolt B and
remove bowl and
'-) element C.
2 Discard element C and

) clean all metal parts.
3 Re-assemble in reverse
i) order with new element
C and seals D.
') Note: Repeat for second

filter and then prime
the fuel system.
')
.J
J
J
J
J
J
J 9803/3150 lssue f
J
rl
7 Engine 7ar
4-2 4-2
EilGINE FUEL
SEDIMENT BOWI I
DRAIN Every 50 Hours -ì

Drain off any water in glass
bowl by turning tap A.
CLEAN
ì
Periodical ly dismantle.
1 Clamp inlet fuel line to

prevent loss of fuel.
2 Support bowl B and

unscrew bolt C.
3 Wash element D in clean

fuel.
4 Re-assemble in reverse
order ensuring gaskets
are in position and bolt
is not overtightened.
¿
5 Remove fuel line clamp. I
1"
( J
9803/31 50 lssue
(_ j
1
(
-\
I
'l 7 Engine 7
4-3 4-3
)
ENGINE FUEI IIFT PUMP
)
)
CLEAN 400 Hours.
) 1 Unscrew boltA, remove

cover B and gauze C.
) 2 Wash gauze witlr pel,rul

and a soft brush.
) 3 Re-assemble, tightening
bolt just sufficiently to
make seal.
) 4 Bleed fuel system
at f ilter.
)
,)
)
\
)
.J 9803/31 50
lssue 1
i
(
7 Engine 7 (
4-4 4-4
EÍIIGINE FUEL SYSTEM

PERKINS /=-.
( -l q \
BLEEDING \ L
lf engine fails to start or
lil 1
€J
misfires, or if any part of the
fuel system has been disconn-
ectd, vent system as follows.
I Slacken vent screws,4,
i
B and C.
-l
I
L-
2 Prime lift pump until air I
free fuel flows from

points.4, B and C. I
Tighten in the order C, B

andA.
Noto: lf the l¡ft pump

priming lever F
cannot be operated,
turn engine until lever
can be moved.
3 Slacken union D,
operate lift pump until
air free fuel flows from
union and tighten.
4 Slacken union E, open

throttle, push in engine
stop and operate starter \
until air free fuel flows

from union and tighten.
;e\s
I
_,- r__.{i,l____t_ -r t
__-l lì-
jJ4
D (
9803/315() l¡¡ue I
(
(
-l
a 7 Engine 7
4-5 4-5
I
EñIGIñIE FUEI SSTEM
') 2700 sERtEs
-)
BLEEDING
.J lf engine fails to start or
misfires, or if any part of the
fuel system has been
-ì disconnected, vent system as
follows:- I
1 Slacken vent screws,4 (qj
and 8. \ô
\Ô
qC)
2 Prime lift pump until air (rú)
(6)
free fuel flows from
pointsA and B.
i) Tighten in the order A,B
Note: lf the l¡ft pump priming

lever C cannot be
operated, turn engine
until lever can be
'-) moved.
3 Slacken vent screws D

,) and E, operate lift pump
until air free fuel flows
from vent screws and
tighten in the order E,D.
)
)
E
)
J
J ¡lltlB
J
J
U
J 98O3f31 50 I$uo 1
J
-
7 Engine 7 l-.
5-1 5-1
EñIGIñIE FUEI
.---l
I]IIJEGTIOñI PUMP
2700 SERtES
,_ì
CHECK OIL .-ì

LEVEL 50 Hours
DRAIN AND -l
REFILL 200 Hours
A Level Plug ì
B Drain Plug
C Filler Plug
IMPORTANT: lnjeetion pump

must not be overfilled.
ì
I
)
/,/ ø-
I
)
T(
I
)
I
)
ì
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,l\/
,ì
Li
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980313150 h¡r I \_.,,
LJ
7 Engine 7
6-1 6-1
COOTING SYSTEM
CHECK
LEVEL Every 10 Hours
Remove filler cap when engine

is cold andtop up as necessary
with the correct mixture of
water and anti-freeze (where
required).
Keep expansion tank half full
FROST PRECAUTIONS
lf temperatures below OoC

(32oF) may be expected the
appropriate strength anti-freeze
solution should be used.
Before adding anti-freeze, drain
and flush the system, ensure
that hoses are in good condition
and that there are no signs of
leakage.
NOTE: The anti-freeze solutions

used on production by JCB start
to freeze at the temperatures
shown in the table. For effective
temperatures of anti-freeze used
in service, refer to manufacturer's
instructions.
*Engine Anti freeze
System Capacity 25o/o 57% Anti'freeze
Protection to -12oC (goF) protection to _30oC (_22oFl
Litres UK P nts Litres UK Pints Litres UK Pints

4.248 26 46 6.5 11.5 15 27
6.354 28 50 7 12.5 16.5 28.5
T6.354
to m/c 76160 32 56 I 14 18.5 32
from m/c 76161 28 50 7 12.5 16.5 28.5
2712E 25 44 6.5 11 14.5 25
27158 27 48 7 12 15.5 27.5
*6.3544 (8058) 26 46 6.5 1 1.5 15 27
x6.3544
(8068 & 8078) 26.8 47 7 12 15.5 27
*T6.3544 27.5 49 7 12.5 16 28
9803/3f50 lssue 3 *
(,t
7 Engine 7 (-
7-1 7-1
FATìI BELTS
CHECK TENSION 50 Hours
ADJUSTMENT
1. Slackent bolts A, B and C.
2. Reposition alternator until

belt deflection at D is
approximately 1Omm.
(0.4in.)
/\
CAUTION: lf any leverage is
necessary, use a length of wood OJ
against the drive end bracket,

\ 6,. l, 'r ) i
otherwise damage to the
6;y
,
() -:_.?
alternator may be caused. rv
3. Tighten bolts in the ù

sequence C,B,A.
ú
NOTE: 'lf new belts are required,
matched pairs should be used.
9803/3150 l¡¡ue 1
(
t.
rl
I 7 Engine 7
8-1 8-1
:-l
AIR FILTER
"l To Machine No. 76951
(Excluding JCB 805 and 8058)
RENEW Every
ELEMENT 800 Hours
Do not disturb filter element ì

between service intervals unless
the warning light is illuminated.
The element may then be
checked and cleaned as follows:
Slacken clamp A, remove cap B

and baffle C. Tip out dust.
Unscrew wing nut and remove

element D.
Blow dirt from element with

compressed air at a pressure o!
no more than 7 bar (7 kgtlcm2,
1'OO tbf lin¿). DO NOT tap or
knock element.
Check for perforation by

placing a strong light inside
the element - renew if damaged
When refitting element, seal

should be lightly smeared with
grease and seated correctly as
shown at E.
NOTE: Filter X is used on four

cylinder engines.
Filter Y is used on six

cylinder engines.
5205
9803/31 50 lssue 1
(l
7 Engine 7 a--'
8-2 8-2
I
I
SAFETY AIR FILTER

I
x - JCB
JCB 805, 8058.
Y - 8068,8078 ì
and 808 from m/c no. 76952
RENEW OUTER Every I

ELEMENT 800 Hours
Do notdisturb f ilter elements ì

between service intervals unless
the warning light is illuminated.
The outer element may then be
checked and cleaned as follows:
Remove end cover A (A1-8058)

( c
and extract outer element B. c
C(
Blow out dust with compressed

air at a pressure of no more than
7 bar 17 ksf/cm2, 1oo lbf/in2).
DO NOT tap or knock element. c
C
e 'C ( (
Check for perforation by placing (C
a strong light inside the element ((( a
,I
î(
- renew if damaged.
Clean the canister and the dust ì

j
valve C and where fitted, remove
and clean behind the baffle D.
When refitting element, seal E

should be lightly smeared with
grease and seated correctly as
shown.
Check security and condition of

induction hose at regular
intervals.
RENEW INNER Every

ELEMENT 1600 Hours
(
CAUTION: To avoid entry of )
dust into the engine, remove
the complete filter from the
machine before removing the ac
inner element. úcoc
oô
ooô
Remove outer element as above
to gain access to nut F. lnner
element G can then be removed
5206
and renewed.
)
9803/31 50 lssue 1
tl
i
C C C C CC C C O OOO l'f f f ))) f )
n
o I
1-1
Electrics 8
1-1
o TECHNICAL DATA
e
System - 12 volt Negative Ground chassis return
(',-, Battery - LucasAmp
128 hour.
Starter Motor - M50
Alternator - 49
Lucas 18 ACR 43 amp output max.
n Working Lights
lnterior Light
- 1.8 Watt BPF.
- 2 Watt B7s.
Watt festoon
Warning Lights - 36 Watt BPF.
e Rotating Beacon
Circuit Protection
- 8058:.6 Fuses
-
Other Machines: 'Circilit ^
i...ryOt 0,r'f ZsÊ*f)
Breakers,
e; 4-way single reset,

20 amp continuous rating,
t
C
(-l
(
(-r
t
L-,
U
U
U
O'
U
U
U 9803/3150 lssue 1
Lrì
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I Electrics I I
2-1 2-1
I
7
.t ,l ì
{^ì i .'
' ì'it r ¡,r \,"J¡¡ \1rrìr;ì' o u'l' n' oi)*
2 , ,' { r
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3
PB
24 21
G
25 22
G G U---------------O
GU
14
11
GS
17
"=
26
t.G---------------- B--f_
3
G
12 -23
5
4 15
27
"--l_ ,\
--J 6 Hrs
2A
E B
-J-
=
3
B =
18 =
29
--l_
19
30
P-
3 I
-wo---
I T
I
L_- I
"--
RY--Î--
I
fl
20 t___
fr B--=_
\
3978
9803/3f 50 lssue 1
n
rr I Electrics I
2-2 2-2
f^
ctRcutT DTAGRAM 805, 8068, 8078, 808
n To m/c no.77681 (Perkins) ot 77739 (2700 Series)
Main Components Warning Lights

r-'
1 Battery 24 Oil Pressure
25
r- 2
3
Starter Switch
Circuit Breaker (4 way single reset) 26
Water Temperature
Air Filter
r 4
5
6
7
lnline Fuse
Audible Warning Buzzer
Diode Bank
Starter Motor
27
Lights
No Charge
r 10
I
I
Thermostart
Cigar Lighter
Horn
28
29
30
Right Hand Working
Left Hand Working
Flashing Beacon (Option)
( 11 Heater .31 Cab lnterior

12 Screen Wiper 32 Boom Base (Option)
13 Alternator
14 Heater Resistor Cable Colour Code
(
15 Ballast Resistor
B Black
Switches G Green
( N Brown
16 Horn Push O Orange
17 Heater P Purple
( 18 Working Lights R Red
19 Flashing Beacon S Slate
(.
20 Boom Base Lights U Blue
21 Oil Pressure W White
22 Water Temperature Y Yellow
(- 23 Air Filter LG Light Green
L
L-
L
L
L,
t-. 9803/31 50 lssue I
U
I
I Electrics I I I
2-3 2-3
l
1 I
7
I
-l
ì I
't
I
----- --ìå
B
,o
B
+
=
19 _!.___-
:5
30 B
+
I
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¿
-!____
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I
I
21
I
I
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L P _o"_____Ar_r_ B
¿
----+
I 5336
9803/3 1 50 lssue I
I
I Electrics B
2-4 2-4
ctRcutT DTAGRAM 805, 8068, 8078, 808

From m/c no.77682 (Perkinsl or 7774O (2700 Series)
Main Components Warning Lights
1 Battery 25 Oil Pressure

2 Starter Switch 26 Water Temperature
3 Circuit Breaker (4 way single reset) 27 Air Filter
4 lnline Fuse 28 No Charge
5 Audible Warning Buzzer
6 Diocle Bank Lights
7 Starter Motor
8 Thermostart 29 Right Hand Working
9 Cigar Lighter 30 Left Hand Working
10 Horn 31 Flashing Beacon (Option)
11 Heater 32 Cab lnterior
12 Screen Wiper 33 Boom Base (Option)
13 Alternator
14 Heater Resistor Cable Colour Code
15 Ballast Resistor
16 Hou rmeter B Black
G Green
Switches N Brown
O Orange
17 Horn Push P Purple
18 Heater R Red
19 Working Lights S Slate
20 Flashing Beacon U Blue
21 Boom Base Lights W White
22 Oil Pressure Y Yellow
23 Water Temperature LG Light Green
24 Air Filter
9803/3150 lssue 1
I
I Electrics B l
2-5 2-5
ì
I 2
ì I
_14__
N I
45
1
ôt
-\
"1
--?-
$-.
I
I
I
I
21
_av__f_ a
J--
I
I
I
22 I
ê- ó
47
¡
t
!
5335
i
9803/3150
I ssuel
I
fu-
ù'.. I Electrics I
2-6 2-6
e¡.-
CIRCUIT DIAGRAM 8O5B
f->-
Main Components Switches
l^Þ 1 Battery 40 Starter
r} 2
3
4
5
Starter Motor
Alternator
Fuse
Horn
41
42
43
44
Horn Button
Oil Pressure
Water Temperature
Air Filter
(ì- 6 Wiper Motor 45 Heater
7 Heater Motor 46 Working Light
8 Thermostart 47 Boom Base Working Light
I Cigar Lighter
f-¡-- 10 Heater Resistor Cable Colour Code
11 Ballast Resistor
12 Hourmeter B Black
CÞ 13 Audible Warning Buzzer G Green
14 N Brown
15 lnline Fuse P Purple
R Red
Lights S Slate
U Blue
(Þ 20 R.H. Working W White
21 L"H. Working Y Yellow
22 Boom Base Working (Option) LG Light Green
(L- 23 Cab lnterior
24 HydraulicCompartment
25
tÌ- Engine Compartment
Warning Lights
Ir 30
31
Oil Pressure
Water Temperature
32 Air Filter
(_.-- 33 Alternator
Y*rf,:åt';ffir*ss @
JcB:86¡rlsf.
From
L.i-'-
illl, e"s crçrn*¡ ;:: ?:.t r . S8.
Li-- 9999/8532
l--
LÞ
LÞ-
(}
r¡ 9803/31 50 lssue 1
L.}*
I
B Electrics 8 'l
3-1 3-1
BATTE R I ES
Testing - Specific Gravity Readings should be as tabulated and should not vary
between cells by more than 0.04. A greater variation
The specif ic gravity of the electrolyte gives an indicates an internal fault on that particular cell.
indication of the stage of charge of the battery.
Readings should be taken using a hydrometer, when lf the electrolyte temperature is other than l boC
the electrolyte temperature is 15oC (600F). lf the (600F) a 'correct¡on factor' must be appliecl to the
battery has recently been on charge, wait approximately reading obtained. Add 0.007 per 1OoC (180F) if the
one hour (or slightly discharge the battery) to dissipate temperature is higher than 15oC (60oF) and subtract
the 'surface charge' before testing, the same if the temperature is lower.
Specific Gravity at 1soc (600F)
Fully Charged Half Discharged Fully Discharged
Ambient Temperature up to 27oC (BooF) 1.270-1.290 1.19O-1.210 1.110-1.130

Ambient Temperature above 27oC (80oF) 1.240-1.260 1.170-1.190 1.090-1.110
High Rate Discharge Test
The test is used to determine the

electrical condition of the battery
and to give an indication of the
remaining useful'life'.
Before testing ensure that the battery

is at least 75% charged.
U
Adjust the discharge tester (Service
tools Wl L/l8) to 3 x Amp hour rating
of the battery (approximately 380
amperes) and connect to the battery
term inals, observi ng polarity.
Note the voltmeter reading. The

battery should be capable of
maintaining at least 9 volts for 10
seconds. A rapidly falling voltage
indicates a fault in one or more cells.
Do not leave the discharge tester in

circuit for longer than is necessary to
complete the test.
41t2
9803/31 50 lssue 1
(l
o I
4-1
Electrics I
4-1
ei
ALTERNATORS
o General Description
r} The alternator is a three phase generator having are'cuti by the rotat¡ng magnet¡c field. A
built-in diode bank rectifies the current for
a rotating field winding and static power
n windings
When the start sw¡tch isturned on, current

supply to the battery. A small proportion of
the rectified current is fed back to the rotor
to maintain the magnetic field.
f) from the battery flows by way of the 'No
Charge'warning lights, to the field winding.
This creates a magnetic field which
Output is controlled by a solid state regulator
which varies the field current in accordance
with electrical demand.
lì supplements the residual magnetism in the
rotor poles. As the engine is started, the fan
belt drives the rotor and alternating current
Servicing is restricted to periodic inspection
of slip ring brushes. Bearings are 'sealed for
is generated in the power windings as they life' ball races.
(;
(:
Service Precautions
(ì 1. Use on Negative Earth systems only 5 During arc welding on a machine, p[otect
the alternator by removing the moulded
2. Ensure that battery Negative terminal is plug.
( connected to the earthing cable.
6 lf slave starting is necessary, connect the
(i 3. Never make or break connections to the
battery or alternator or any part of the
charging circuit whilst the engine is
second battery in parallel without
disconnecting the vehicle battery from
the charging circuit. The slave battery
tr running. Disregarding this instruction

will result ín damage to the regulator or
rectifying diodes.
may then be safely removed a.fter a start
has been obtained. Take care to connect
batteries positive to positive, negat¡ve
to negative. See also Note 3.
Li 4. Main output cables are 'live' even when
engine is not running. Take care not to
earth connectors in moulded plug if
Lr removed from alternator.
U
t/
r)
LJ
uÌ
(-) 9803/3150 lsg¡o 1
U
I Electrics B I
5-1 5-1
I
CHARGING CIRCUIT CHECK
Ensure that all battery and lf the No charge warning bulb

alternator connections are in is in good order, withdraw
place, secure and making good the triple plug from the back of
metal to metal contact, especially the alternator. Make a temporary
'earth' connections to chassis connection between the SMALL
and engine. terminal in the plug and earth as
shown. lf the No charge warning
Adjust alternator drive belt bulb still fails to light check the
tension if necessary and make Brown/Black cable for continuity.
sure that the battery is well lf the bulb now lights check the
charged. alternator for defective regu lator
(See Alternator Testing).
Turn start switch to the on
position.
'Oil pressure' and 'No charge'

warning lights should glow.
lf any lights fail, proceed to

Check 1.
Start engine, all warning lights

should extinguish rapidly
lf No charge warning remains

ON proceed to Check 2.
lf oil pressure warning remains

on STOP ENGINE
IMM ED IATE LY and investigate
engine lubrication system. v
Check 1
With start switch 'ON' try

heater motor and screen wiper
lf items operate normally,

cheek warning light bulb(s) for
blown filament.
Simultaneous failure of all

items indicates a fault at the
start switch. Check for cable
disconnection before
condemning the switch itself.
9803/31 s0 lssue I
n
a 8 Electrics B
5-2 5-2
r-
CHARGING CIRCUIT CHECK
r'
Check 2
(.
Stop engine and turn start lf the ammeter reading is low
r switch OFF.
Withdraw the alternator plug

check that all charging cables
and connectors are cool. A hot
connection is'resistive' and
r and, using the voltmeter

section of a suitable test meter
(Service Tools) check for
battery voltage between the
should be cut back and remade.
lf the meter reading is low but
everything else is satisfactory,
stop the engine and carry out
( large terminals and 'earth'. lf further tests as indícated under
the reading is zero, check the Alternator Testing.
brown cables for continuity,
( particularly at the starter
terminals.
(
lf the voltage is correct, check
the alternator output as follows:
Using a dummy connector X,

( connect the ammeter section of
the test meter between the
alternator and the alternator v
( plug as shown (positive meter
lead to alternator).
( Connect the voltmeter sect¡on
of the test meter across the
battery (observe polarity).
(_
Start the engine and run at

2000 revlmin.
(
As the engine starts, the
voltmeter reading should rise
L rapidly to charging voltage
(14 to 15 volts).
L Switch on all lights and

auxiliaries and check the
ammeter reading. This should
L be approximately 40 amperes.
t-
L-
L
82683
L 9803i 31 50 lssue 1
L
l
8 Electrics I ì
6-1 6-1
l
ALTERNATOR
Testing
Before testing alternator, carry lf the ammeter now indicates a

out charging circuit checks high rate of charge, (approximately
1 and 2. 40 amps) the alternator is in good ì I
order but the regulator is defective.

Failure of the alternator to
charge the battery may be lf the ammeter continues to ì
caused by one of the following show a low reading, disconnect Ì
conditions. These are listed in the surge protection diqde A

approximate order of and repeat the test.
probability.
lf the ammeter reading is now
1. Defective regulator satisfactory, the diode is
defective. Otherwise, remove
2 Dirty slip rings or worn the alternator for further testing.
slip ring brushes.
3. Defective Rectifier
4. Defective surge protect¡on

diode.
5. Open or short circuited

field (rotor) winding.
6. Open or short circuited

power (stator) windings.
Regulator Check
Remove alternator end cover

and temporarily connect the
regulator field to earth as at X
or Y, according to the type of
regulator fitted:
14TR Regulator (X) -

Regulator case to alternator
frame.
8TR Regulator (Y) -

Green wire to alternator frame.
Connect test meter (Service

Tools) in circuit, using a dummy
alternator connector as shown I
in Charging Circuit Check 2. .I
Run the engine at 2000 rev/min,

switch on all lights and auxiliaries
and check the ammeter reading.
B 3807A
I
¡
9803/31 50 lssue 1
I
I
Ç,c c c e c e e ce - -î 1 III ^) I I II 1
I Electrics B l
7-1 7-1
30
28
24
22
1
29
20
12---€, 15 19
4
14
16
3
11
I
7
18
38064
9803/3150 lssue 1 ,--

B Electrics I
7-2 7-2
ALTERNATOR_18ACR

c
When Dismantling
Leads A and B must be

unsoldered when separating
items 16 and 20 and items
22 and 31.
Use Service T ool 892/ OOO44

to drive out rotor 31 and its
bearings from the end brackets.
CAUTION: When unsoldering

or soldering cables to rect¡f¡er
16, it is essential to avoid
overheating the diodes or
bending the diode pins. Carry
out soldering as quickly as
possible whilst gripping the
pins with long nosed pliers to
conduct away excess heat.
Ensure that leads are soldered
to the correct positions:
C, D and E.
Clean faces of slip ring 22 with

petrol moistened cloth, or very
fine glass paper if burning is
evident. Do not use emery cloth
Renew brushes 9 if their length

is less than 8mm. (0.3in.) or if
the spring pressure is less than
198 to 283g (7 to 10oz) with
brush pressed flush with the
housing.
To ensure free movement of

brushes, lightly polish side
faces.
o
Regulators X (14TR) and
Y (8TR ) are alternatives. lf
interchanged follow instructions
supplied with new unit.
38074
9803/3 1 50 lssue 1
i
{
Í
¡
t.
I
I
{-
I Electrics I
8-1 8-1
STARTING CIRCUIT TEST
Before carrying out voltmeter tests check the battery lf the reading is less than specified, qonnect
condition (see Battery Testing) and ensure that all voltmeter between starter switch terminal D and
connections are clean and tight. earth. An increase in the reading to 8.0 volts
¡nd¡cates a fault in the wiring between the sw¡tch
Check readings in the following sequence using the and the solenoid. lf the voltage between D and
voltmeter sect¡on of the recommended test meter earth is below 8.0 volts, the voltmeter should be
(see Service Tools catalogue). Unless stated otherwise, connected between terminal E and earth. An
the readings must be taken with the stop control increase in the reading to 8.0 volts will then
pulled out and the starter switch in the'start' position. indicate a fault in the switch.
1 Connect voltmeter across battery terminals. 4. Connect voltmeter between battery negative and
Reading in 'start' position: 10.0 volts starter earth connection B.
approximately. The voltmeter reading in'start'position should be
pract¡cally zero.
A low reading probably indicates a fault in the
starter motor. lf the reading is appreciably above zero, a high
res¡stance in the earth lead or connections ¡s
2. Connect voltmeter between starter ma¡n indicated.
term¡nal A and commutator end bracket B.
ln'start' position, the reading should be not 5. Connect voltmeter. between battery positive and
more than 0.5 volts below the reading obtained starter main terminal A.
in test 1.
With the starter switch 'off'the voltmeter
lf the reading is within this limit carry out test should indicate battery voltage but fall pract¡cally
3. lf the reading is outside the l¡mit, proceed to to zero when the switch is closed.
tests 4 and 5.
lf the reading is appreciably above zero, a high
3. Connect voltmeter between the solenoid resistance is present ¡n the insulated lead or in
term¡nal C and a good earth. the solenoid. Connect the voltmeter between
Minimum Reading in 'start' position: 8.0 volts. the battery positive and solenoid connect¡on F.
lf the voltmeter now reads zero with the switch
closed, the fault is in the solenoid.
WR
9803/3150 l¡¡r¡e 1
I Electrics I i
9-1 9-1
4 10
7 32
J
11
13
l2
14
e
16
35
I 36'.
20 v
30
28
I
36 B 5
15 39
u 27 33
18 77 38
P 26
A
25
23
20438
9803/31 s0 lssue 1
n
n 8 Electrics 8
9-2 9-2
r-
STARTER MOTOR-LUCAS MsO
a
Dismantling
(-'
NOTE: Dismantle only to item short circuit between the coils
r 34 unless the field windings 38

are to be renewed. Test the
windings electrical ly before
and the yoke. Renew the coils
as necessary, use Pole Shoe
screwdriver C50 (Service tools)
r removing them from the motor

yoke 15.
Use a slotted steel tube to

to remove screws 36.
Check bronze bushes 32 and 34

for wear. Soak new bushes in
displace ring 23 to allow clean, warm engine oil for
(-' withdrawal of ring22. 2 hours before fitting.
Allow brake shoes 28 to remain Align crosspin C with the notches

( in the endplate (11) unless the in the brake shoes (28) before
shoes require renewal. assembling brush carrier and
( back plate to motor yoke. Make
Servicing and Assembly sure that brushes 144 are
installed in the insulated brush
Renew brushes 14 and 144 if boxes.
( their length is less than 8mm.
(0.3in.). Set the movement of drive
pinion 24 as follows:
t Clean the commutator (A) with Connect a 6v battery and
petrol or carbon tetrachloride switch as shown. Operate
(see Care and Safety section for switch and check dimension D.
t precaut¡ons), lf individual copper Adjust to 0.38-0.63mm.
bars are burnt or eroded the (0.01 5-0.025in. ) by slackening
armature has broken windings and locknut 17, rotating eccentric
t_ must be renewed. Otherwise pin 18 as necessary and retightening
polish with fine grade glass locknut.
paper (not emery). Renew
f. armature if the commutator
diameter is 38mm. (1.5in.) or
less.
L Check the field winding for
open circuits by connecting an
L Ohmmeter (0 to 100 ohms)
between the stud terminal B
and each positive brush (144)
t. in turn. A high or'infinity'
reading indicates an open circuit.
Similarly, connect the meter
L between brushes 144 and the
motor yoke 15. Any reading zsüra D
other than infinity indicates a
U
U
L 9803/3 1 50 lssue 1
t-
I
i
t
I
t-
t
e¡
lndex
ai
(-¡
805 To 8058 To 8068 To 808 To
m/c no. m/c no 8078 m/c no. m/c no.
(-,
Alternator
Description 8/4-1 814-1 8/4-1 8/4-1
C, Dismantling & Assembly
Testing-Alternator
8/7-2
816-1
817-2
816-1
8/7-2
816-1
8/7-2
8/6-1
-Charging Circuit 815-1 8/5-1 8/5-1 8/5-1
f-¡ Attachment Service Valve 311-1 3/'t-1 3/1:-1
Spool Dismantl ing Assembly 216-5 2/6-5 2/6-5
(¡
*Auxiliary Relief Valves (See Relief Valves)
(¡ Batteries
Testing 8/3-1 813-1 8/3-1 8/3-1
(r Boom
Beam Clamp Operation 2/20-1
Beam Clamp Dismantling &
( Assembly 2120-2
Beam Clamp Valve Dismantling &
Assembly 2120-3 200297
( Variable Drop Restrictor 2/19-1 2119-1 2/19-1 2/19-1
Brakes
( Slew, Dismantling & Assembly 516-1 516-1 5/6-1 5/6-1

Track, Dismantling & Assembly 5/5-1 5/5-1 5/5-1 5/5-1
( Cab
Glazing 4/1-1 4/1-1 4/1-1 4/1-1
Removal & replacement 4/2-1 4/2-1 4/2-1
( Tilt-System Bleeding 4/3-1 413-1 4/3-1
Gapacities 1/1-1 1/1-1 1 /1-1 1 /1-1

(
Check Valves (See Non-return valves)
t *
Circuits
Electr¡c (Perkins Engine) 8/2-1
812-3
77681 8/2-5 8/2-1
8/2-3
77681 8/2-',\
8/2-3
77681
Elecrric (2700 Engine) 8/2-1 77739 8/2-1 77739 8/2-1 77739

L 812-s 8/2-3 8/2-3
Hydraulic 2/22-1 2/22-6 200147 2/22-1 2/22-1
2/22-8 200205
2/22-10 200606
2116-1
(_i with Auxiliary Service
with U.S.A. Husco Valve
2122-3 2/22-3
2/22-4
2/22-3
L,"
U'
u 9803/31 50 lssue 4*
¡
lndex I
1l
805 To 8058 To 8068 To 808 To

m/c no. m/c no. 8078 m/c no. m/c no.
Cooling System 7 /6-1 7/6-1 7 /6-1 7 /6-1

Engine
Oil Filter (See Filters)
Oil Level 712-1 7 /2-1 7 /2-1 7 /2-1
Technical Data 7 /1-1 7 /1-1 711-1 7 /1-1
Excavator Relief Valves (See Relief Valves)
Fault Finding
Hydraulics 2123-1 2/23-1 200606 2/23-1 2/23-1
Fan Belt
Adjustment 7 /7-1 7 /7-1 7 /7-1 7/7-1
Filters
Engine Air 7/8-2 718-2 7/8-1 76951 7 /8-1 76951
7/8-2 7 /8-2
Engine Oil 7/3-1 7/3-1 713-1 7/3-1
Fuel 7/4-1 7/4-1 7/4-1 7/4-1
Hydraulic-Operation 2/2-1 2/2-1 2/2-1 2/2-1
-Dismantling & Assembly 212-2 77377 2/2-2 200022 2/2-2 77377 212-2 77377
2/2-3 212-3 212-3 2/2-3
Fuel
Filter (See Filters)
lnjection Pump 7 /5-1
Lift Pump 714-3 714-3 7 /4-3 7/4-3
Sediment Bowl 714-2 7/4-2 7 /4-2 7/4-2
System Bleeding 7/4-4 7 /4-4 7 /4*4 7 /44
Gearboxes
Grab, Dismantling & Assembly 3/2-1 3/3-r 3/2-1
Slew, Dismantling & Assembly 5/3-2 5/3-2 513-2 5/3-2
Slew, General View 5/3-1 5/3-1 5/3-1 5/3-1
Slew, Oil Level 511-2 5/'t-2 5/1-2 5/1-2
Track, Dismantling & Assembly 5/2-2 5/2-2 5/2-2 5/2-2
Track, General View 5/2-1 512-1 5/2-1 5/2-1
Track, Oil Level 5/1-1 5/1-1 511-1 5/1-1
Glazing (See Cab)
Grab (See Gearboxes)
Greasing (See Lubrication)
9803/3r 50 lssue 4
o
o ill
lndex
ilt
o 805 To 8058 To 8068 To 808 To

m/c no. ny'c no. 8078 m/c no. m/c no.
Õ
Hydraulic
Circuit (See Circuits)
r-i Filter (See Filters)
l) ldler Wheel (See Track)
Lubrication
o Lubricants & Capacities

Greasing
111-1
113-1
111-1
1/3-2
1/1-1
1/3-1
1/1-1
1/3-1
Main Relief Valve (See Relief Valves)

fi Metallic Face Seals 514-1 514-1 5/4-1 5/4-1
Motors
Operation 2/4-1 214-1 2/4-1 2/4-1
'Dismantl ing & Assembly (Commercial) 2/5-3 2/5-3 2/5-3
Dismantling & Assembly( Hamworthy 215-1 215-1 2ß-1 2/5-"1
Non Return Valves

( Ì Track & Excavator 216-9 216-9 2/6-9 2/6-9
Offloading Valve (Com mercial )

Operation 2111-1 200147 2111-1
(\ Dismantling & Assembly 2/11-2 200147 2/11-2
Testing (See Pressure Testing)
(-' *Offloading Valve (ln Valve Block-Direct
Acting)
Operation 2/10-1 2/10-l See 2/10-1 78078
(-' Dismantling & Assembly 2/10-2 2/10-2 Note 2/10-2 78078
( *Offloading Valve (ln Valve Block-Pilot

Operated)
e Operation
Dismantling & Assembly
21104
2/10-5
2/'to-4
2/10-5
2/10-4
2110-5
U Pocket Seal Fitting

Commercial 2/5-5 2/5-5
L" Note: Pilot operated offloading valve was introduced at the following machine numbers:-
8068-78177
Lt 8078 Normally Aspírated-7 8079

8078 Turbocharged-78059
808-78079
(--'
U'
U 9803/31 50 lssue 4*
U
lndex
IV IV
To 8058 To 8068 To 808 To

*Pressure Testing
Auxiliary Relief Valve 2/8-7 2/8-7 200606 2/8-7 2/8-7
2/17-13
Excavator Main Relief Valve 2/13-1 2113-2 200606
2/17-9
Offloading Valve 2/15-1 2/15-2 200147 2/15-1 2/15-',|
2/15-3 200606
2/',t7-10
Offloading Valve (U.S.A. Husco) 2/15-4
Slew Relief Valve 4-1 2/14-2 200606 2/14-1 2/14-1
2/17-10
Slew Main Relief Valve (U.S.A.Husco) 2/14-3
Track Main Relief Valve 2-1 2/12-3 200606 2/12-1 2112-1
2/17-9
Pumps
Operation 1 2/3-1 2/3-1 2/3-1
Dismantling & Assembly 2/5-3 215-3
Dismantling & Assembly (Hamworthy 215-1 215-1 2/5-1
Rams
Operation 8-'l 2/18-1 2/18-1 2118-1
Dismantling & Assembly 18-2 2/18-2 2/18-2 2/18-2
Recoil Unit (See Track)
*Relief Valves
A.R.V. Dismantling & Assembly
-Rubery Owen 2/8-4 200575 2/84 2/8-4
2/8-6 t200605
-U.S.A. Husco 2/8-5
-Hamworthy 2/',t7-7
A.R.V. Operation 1 2/8-1 200606 2/8-1 2/8-1
2116-11
Excavator M.R.V. Dismantling &
Assembly 2/9-s 219-3 200606
2/17-7
Operation 2/9-1 2/9-1 200606
2/16-10
Slew M.R.V. Dismantling & Assembly
-Rubery Owen 2/8-4 218-4 200575 2/8-4 2184
2/8-6 1200605
-Hamworthy 2/17-7
-Parþr Hannifin 219-3
Slew M.R.V. Operation 218-2 2/8-2 200606 2/8-2 2/8-2
Track M.R.V. Dismantling &
Assembly 2/7-2 2/7-2 200606 2/7-2 217-2
2/17-10
Operation 2/7--1 217-1 200606 217-1 2/7-1
2116-10
t 8O5B m/c no. 200606 has relief valves shown on page 2/84.
Rollers (See Track)
9803/31 50 lssue.4*
lndex
V V
805 lo 8058 To 8068 To 808 lo

Rotary Coupling
Dismantling & Assembly 2/21-2 2/21-2 200475 2/21-278t74' 2/21-2 7Èt7L( *
2/21-3 2/21-3 2/2't-3
Operation 2/21-1 2/21-1 2/21-1 2/21-1
Service Sc{redule 1/2-1 112-1 1/2-1 1/2-1
Slew
Brake (See Brakes)
Gearbox (See Gearboxes)
Ring-Removal & Replacement 4/4-1 4/4-1 4/4-1 4/4-1
Seal Replacement 4/4-4 4/4-4 4/44 4/4-4
Starter Motor
Dismantling & Assembly 8/9-1 8/9-1 8lS-',| 8/9-1
Testing 8/8-1 8/8-1 8/8-1 8/8-1
Technical Data
Electrics 8/1-1 8/1-1 8/1-1 8/1-1
Engine 7 /1-1 7 /1-1 7 /1-1 7 /1-1
Hydraulics 2/1-1 2/1-1 2/1-1 2/1-1
Track
Adjustment 611-1 611-1 611-1 6/1-1
Removal & Replacement 6/2-2 612-2 6/2-2 6/2-2
ldler Wheel-Removal & Replacement 6/4-1 6/4-1 6/4-1 6/4-1
-Dismantling & Assembly 6/4-2 614-2 6/4-2 6/4-2
Recoil Unit-Removal & Replacem 6/4-1 614-1 6/4-1 6/4-1
-Dismantling & Assembly 6/5-1 615-1 6/5-1 6/5-1
Rollers-Dismantl¡ng & Assembly 6/3-1 613-1 6/3-1 6/3-1
Sprocket Renewal 6/6-1 616-1 6/6-1 6/6-1
*Valves
Beam Clamp Valve Dismantling
& Assembly 2/20-3 200297
Circuit Operation 2/6-1 2/6-1 200606 2/6-1 2/6-1
2/16-1
Spool Dismantling & Assembly
-Excavator 2/6-5 2/6-5 200606 2/6-5 2/6-5
2/17-6
2/6-7 2/6-7 200606 216-7 2/6-7
-Slew
2/17-3
-Track 2/6-5 2/6-5 200606 2/6-5 216-5
2/17-1
Spool Operation
-Excavator 2/6-3 2/6-3 200606 216-3 2/6-3
2/16-8
-Slew 2/6-4 216-4 200606 2/6-4 2/6-4
2/16-4
-Track (Hamworthy) 2/16-6
Variable Boom Drop Restr¡ctor 2/19-1 2/19-1 2/19-1 2/',t9-1
Wiring Diagrams (See Circuits)
9803/3 1 50 lssue 4*
I s a )
I
t!.

Service Manual: JCB Service Rocester, Staffordshire, St14 5Ls. England

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SERVICE MANUAL

TEL. AOCESTER (0889) 590312 I

as viewed from the rear of the machine.

A Service Tools Catalogue, detailing special tools required, is available separately

CATALOGUE /NINUAL - REPTACETEI{T PAGES

1 8-1 2 17-7 1* Section 5

1 8-3 1 17-9 1* 1-2 1

1-1 4* 84 1 17-10 1* 1-3 1

2-1 2 8-5 2* 17-11 1* 2-1 1

2-2 2 8-6 1* 17-12 1* 2-2 1

3-1 2 8-7 1* 17-13 1* 2-3 I

9-2 1 18-1 1 2-5 1

Section 2 9-3 1 18-2 1 3-1 1

1-1 I 10-1 2 18-3 2 3-2 I

1-2A Deleted 10-3 1 20-1 3 4-1 2

1-4 1* 10-5 1 20-3 1 6-1 1

1-5 1* 11-1 1 21-1 2 6-2 2

2-2 3 1 1-3 1 21.-3 1 Section,6

3-2 Deleted 12-3 1 22-3 1 2-2 1

3-3 Deleted 13-1 1 22-4 1 3-1 1

3-4 Deleted 13-2 1 22-5 I 4-1 1

3-5 Deleted 14-1 1 22-6 1 4-2 1

3-6 Deleted 14-2 4 22-7 1 5-1 1

3-7 Deleted 14-3 1 22-8 1 6-1 1

3-8 Deleted 1s-1 2* 22-9 1 6-2 I

4-1 2 15-3 2 22-11 1 Section 7

5-1 1 16-2 1* 23-3 I 2-2 1

5-2 2 16-3 1* 3-1 1

à-s 1 16-4 1* Section 3 4-1 1

54 2 16-5 1* 1-1 1 4-2 1

5-5 1 16-6 1* 2-1 1 4-3 1

6-1 1 16-7 1* 2-2 1 44 1

6-2 I 16-8 1* 4-5 1

6-3 1 16-9 1* Section 4 5-1 1

6-4 1 16-10 1* 1-1 1 6-1 3*

6-6 2 17-1 1* 2-2 I 8-1 1

6-7 1 17-2 1* 3-1 1 a-2 1

6-8 I 17-3 1* 4-1 1

6-9 1 174 1* 4-2 1

7-1 1 17-5 1* 4-3 2

Contents 1 8-2 2* 22-9 1{ß 4-2 1

Date of lncorporation Signature

19-1 2r/ 5-1 1

20-1 2t# b-l

Date of lncorporation TJìt'i rqþ Signature f(?e 2

Contents I 9-3 1 Section 5 Section 8

1-1 1 12-3 1 4-1 2* 5-2 1

3-4 I 15-3 2* 2-1 1

3-5 I 15-4 1* 2-2 1 lndex

5-5 2-1 1 4-1 1

6-8 3-1 8-1 1

6-9 4-1 8-2 1

Date of lnærpontion Signature 1

Gear Pumps and Motors

e LUBRICANTS AND CAPACITI ES

( * Irack Gearbox JCB 'special' Gear Oil (4000/0501ì 6.8 (1.5)

*Slew Gearbox JCB Slew O¡l (4000/0701) "t5.4 (3.4)

Track ldler Wheels Mobil Delvac 1330

Track Rollers (Top & Bottom) Mobil Delvac 1330