Service Training

MALAGA

Backhoe Loaders

VI. HYDRAULIC SYSTEM

1. Load Sensing/Pressure Compensated
2. Hydraulic System - Resolver Network
3. Hydraulic Pump
4. Torque Limiter
5. Steering System
Sara
6. Loader Valve Control
MARCH 1997
7. Backhoe Valve control
 BACKHOE LOADERS
CHAPTER : Hydraulic System

Hydraulic System Component Checklist I

Directions: Use this sheet to take notes during the presentation (i.e. location, functions) . During a lab
exercise, use this as a checklist when identifying components.

B Series C Series

Hydraulic tank

Hydraulic oil filter(s)

Pump

Pump control valve

Loader valve group

Backhoe valve group

Implement controls

Pump supply pressure test port

Signal pressure test port

Torque Limiter

Page: VI-1
Page:

QUIZ
LOAD SENSING/PRESSURE COMPENSATING
TWO VALVE OPERATION
VI-2

CHAPTER : Hydraulic System

BACKHOE LOADERS
A

B
 BACKHOE LOADERS
CHAPTER : Hydraulic System

QUIZ

1.- If two valves are operated at the same time and at valve A the work port pressure (sig-
nal pressure) is 1800 psi and at valve B the work port pressure is 700 psi then:

System pressure will be : 1800 psi + _________ psi = _________ psi

CALCULATIONS :

ð Valve A work port pressure = 1800 psi

ÆP across pressure reducing valve = _________ psi - _________ psi = _________ psi

ÆP across control spool = _________ psi - _________ psi = _________ psi

ð Valve B work port pressure = 700 psi

ÆP across pressure reducing valve = _________ psi - _________ psi = _________ psi

ÆP across control spool = _________ psi - _________ psi = _________ psi

2.- If two valves are operated at the same time and at valve A the work port pressure (sig-
nal pressure) is 3000 psi and at valve B the work port pressure is 1000 psi then:

System pressure will be : _________ psi + _________ psi = _________ psi

CALCULATIONS :

ð Valve A work port pressure = 3000 psi

ÆP across pressure reducing valve = _________ psi - _________ psi = _________ psi

ÆP across control spool = _________ psi - _________ psi = _________ psi

ð Valve B work port pressure = 1000 psi

ÆP across pressure reducing valve = _________ psi - _________ psi = _________ psi

ÆP across control spool = _________ psi - _________ psi = _________ psi

Page: VI-3
Page:

428C AND 438C BACKHOE LOADER

HYDRAULIC SYSTEM
DUAL TILT CYLINDERS
VI-4

END
COVER

CHAPTER : Hydraulic System

BACKHOE LOADERS
INLET
MANIFOLD

Hydraulic System Component Checklist

Directions: Label all valves, the tanks, filters, cooler, pump, and HMU.
Page:

428C, AND 438C BACKHOE LOADERS

HYDRAULIC SYSTEM
VI-5

DUAL TILT CYLINDERS

PUMP

TANK
END
COVER
E-STICK
HMU
STICK

BUCKET

CHAPTER : Hydraulic System

RIGHT
STABILIZER

BACKHOE LOADERS
LEFT
STABILIZER
S L T A
SWING T I I U
E
F L X.
E
BOOM R T T

INLET
MANIFOLD
Page:

428B, AND 438B BACKHOE LOADER HYDRAULIC

SYSTEM
VI-6

PUMP

TANK

INLET
MANIFOLD
EXT. HMU
STICK

STICK

CHAPTER : Hydraulic System

BUCKET

SWING

BACKHOE LOADERS
BOOM
S T L
RH T A
STAB U I I
E
E X. L F
LH
R T T
STAB.
END
COVER
Page:

428C AND 438C SIGNAL NETWORK

VI-7

BOOM
SWING LEFT RIGHT BUCKET STICK
STABILIZER STABILIZER

PRIMARY
RESOLVER

SECONDARY
RESOLVER

CHAPTER : Hydraulic System

BACKHOE LOADERS
LOADER LOADER HMU
TILT LIFT

TO PUMP CONTROL VALVE

Page:

416B-438B SIGNAL NETWORK

VI-8

STABILIZER
STABILIZER BOOM SWING BUCKET STICK
PRIMARY
RESOLVER

SECONDARY
RESOLVER

CHAPTER : Hydraulic System

BACKHOE LOADERS
LOADER LOADER HAND METERING
LIFT TILT UNIT

TO PUMP CONTROL VALVE

 BACKHOE LOADERS
CHAPTER : Hydraulic System

"C" Series Hydraulic Pump Components Checklist

Directions: Fill in the blanks next to the letters with the correct term. Use this sheet to take notes dur-
ing the slide presentation.

IMPLEMENT AND STEERING PUMP

LOW PRESSURE STANDBY
PUMP
SIGNAL
B OUTPUT
C
D

A
F
E

F
Page: VI-9
Page:

IMPLEMENT AND STEERING PUMP

LOW PRESSURE STANDBY
VI-10

PUMP
SIGNAL
PRESSURE OUTPUT SWASHPLATE
LARGE ACTUATOR
CUTOFF

CHAPTER : Hydraulic System

BACKHOE LOADERS
MARGIN
SPOOL
TORQUE
LIMITER

SMALL ACTUATOR
AND BIAS SPRING
Page:

416B-438B HYDRAULIC PUMP

VI-11

ENGINE OFF

SIGNAL PUMP LARGE ACTUATOR

YOKE PAD
OUTPUT

SWASH PLATE

DRIVE
SHAFT

CHAPTER : Hydraulic System

BACKHOE LOADERS
FLOW
COMPENSATOR PRESSURE
COMPENSATOR

PISTON & SMALL ACTUATOR

BARREL ASSEMBLY & BIAS SPRING
Page:

TORQUE LIMITER
VI-12

NORMAL

ADJUSTMENT
SCREW

SIGNAL ACTUATOR
SPRING PISTON
SLEEVE SLOT SPOOL

CHAPTER : Hydraulic System

BACKHOE LOADERS
REDUCED
FLOW

PASSAGE TO
TANK

SIGNAL
Page:

416B - 438B HYDRAULIC PUMP

TORQUE LIMITER - OPEN
VI-13

TORQUE
LIMITER
PUMP
SIGNAL OUTPUT

CHAPTER : Hydraulic System

BACKHOE LOADERS
FLOW
COMPENSATOR
PRESSURE
COMPENSATOR
 BACKHOE LOADERS
CHAPTER : Hydraulic System

IMPLEMENT AND STEERING PUMP

TORQUE LIMITER REDUCES FLOW
PUMP
SIGNAL
OUTPUT
LARGE ACTUATOR

MARGIN TORQUE
SPOOL LIMITER

SMALL ACTUATOR
PASSAGE TO AND BIAS SPRING
TANK

C Series Torque Limiter

¥ Torque limiter opera- The torque limiter monitors the pump swashplate angle and the pump
tion signal pressure. The torque limiter will not allow the pump to go to full
stroke as system pressure increases above the torque limiter setting. The
- Destrokes pump as
allowable pump displacement is inversely proportional to the pump dis-
pressure increases
charge pressure. The higher the pressure, the less pump flow is available.
- Spring force varies
with swashplate The pressure setting of the torque limiter varies with the swashplate
angle angle. The greater the swashplate angle, the lower the pressure setting.

If the pump is at maximum flow and the signal pressure increases above
the torque limiter setting, the torque limiter opens and directs some of the
signal oil to the tank through a slot in the torque limiter spool. A pres-
sure drop occurs across the orifice in the signal line which results in a
slight loss of the actual signal pressure. The margin spool then moves up
and allows supply oil to the large actuator piston. The pump will then
destroke.

Page: VI-14
 BACKHOE LOADERS
CHAPTER : Hydraulic System

TORQUE LIMITER

NORMAL

ADJUSTMENT
SCREW

SIGNAL ACTUATOR
SPRING PISTON
SLEEVE SLOT SPOOL

REDUCED
FLOW

PASSAGE TO
TANK

SIGNAL

¥ Maintains input torque The torque limiter will maintain control over the swashplate as long as
setting the signal pressure remains the same or increases for the high flow
demanded. During this condition, the torque limiter remains open and
continues to meter some of the signal oil to the tank.

The reduced pump flow will be at a sufficient level to maintain the input
torque setting. If the cylinder pressure continues to increase, the torque
limiter will again open and destroke the pump more.

In summary, full pump supply pressure is always available. However,

flow is regulated to maintain a required maximum input torque from the
engine. Full pump flow is available when the signal pressure is below
the torque limiter setting.

Page: VI-15
 BACKHOE LOADERS
CHAPTER : Hydraulic System

416B - 438B HYDRAULIC PUMP

TORQUE LIMITER - OPEN

TORQUE
LIMITER
PUMP
SIGNAL OUTPUT

FLOW
COMPENSATOR
PRESSURE
COMPENSATOR

B Series Torque Limiter

¥ Maintains input torque If the pump is at maximum flow and the signal pressure increases above
setting the torque limiter setting, the torque limiter opens and directs some of the
signal oil to the tank. A pressure drop occurs across the orifice in the sig-
nal line which results in a slight loss of the actual signal pressure. The
margin spool then moves up and allows supply oil to the large actuator
piston. The pump will then destroke. The torque limiter will maintain
control over the swashplate as long as the signal pressure remains the
same or increases for the high flow demanded. During this condition, the
torque limiter remains open and continues to meter some of the signal oil
to the tank.

The reduced pump flow will be at a sufficient level to maintain the input
torque setting. If the cylinder pressure continues to increase, the torque
limiter will again open and destroke the pump more.

In summary, full pump supply pressure is always available. However,

flow is regulated to maintain a required maximum input torque from the
engine. Full pump flow is available when the signal pressure is below
the torque limiter setting.

Page: VI-16
 BACKHOE LOADERS
CHAPTER : Hydraulic System

ENGINE RPM VS. THE TORQUE

LIMITER SETTING E
N
Engine RPM and the torque limiter setting
are directly proportional to one another. G
I
At points A and B the input torque is the
same; However, at the higher low idle N
engine speed for point B, the torque limiter E
setting can be set higher. B
R A
P
M

TORQUE LIMITER
SETTING

SYSTEM PRESSURE VS. FLOW RATE

The allowable pump displacement is inversely proportional to the pump discharge pressure. For line B
at 43 gpm (maximum flow) as shown here, the system pressure is less than maximum system pressure.
If the system pressure increases the maximum flow rate is reduced by the torque limiter. The pump at
the higher operating pressure is now in the torque limiter control range. As pressure continues to
increase the flow rate is further reduced.

S
Y 3000 PSI A
S
TORQUE LIMITER
T CONTROL RANGE
E
M
B B
P
R
E
S
S
U
R
E
A
43 GPM

FLOW RATE

Page: VI-17
 BACKHOE LOADERS
CHAPTER : Hydraulic System

Torque Limiter Adjustments

Adjustments to the torque limiter can be made, but are not usually
required.

To determine if the torque limiter is at fault or whether the engine is at

fault, try the following.

Check torque converter stall. If the torque stall specification is incorrect

and the implement hydraulics is causing the engine to stop, then probably
the engine is at fault. DO NOT ADJUST THE TORQUE LIMITER.

If torque converter stall specification is correct, but the hydraulic system

causes the engine to die. The torque limiter may to be adjusted. Before
adjusting the torque limiter make sure that pump standby pressure, maxi-
mum system pressure and margin pressure are correct.

B Series Torque Limiter Adjustments

1) Check Low Idle and adjust to above 950 rpm. Set at least to 970.
The fuel pump low idle spring tends to droop after a number of hours are
put on the machine.

2) Operate boom down at low idle against the boom stop. If the
hydraulic system no longer causes the engine to die, no further adjust-
ment is required.

3) If the engine still dies. Back out the torque limiter to reduce the
spring setting.

4) Operate boom down at low idle against the boom stop. Increase the
torque limiter setting until the engine dies. Back out the torque limiter
about a quarter of a turn.

5) Restart machine. Operate boom down at low idle against the boom
stop. If the engine does not die the torque limiter has been adjusted cor-
rectly.

Page: VI-18
 BACKHOE LOADERS
CHAPTER : Hydraulic System

C Series Torque Limiter Adjustments

1) Check Low Idle and adjust to above 950 rpm. Set at least to 970.
The fuel pump low idle spring tends to droop after a number of hours are
put on the machine.

2) Operate boom down at low idle against the boom stop. The engine
rpm should drop about 100 to 140 rpm from the low idle setting. If this
occurs, then no further adjustment is required.

3) If the engine rpm drops lower than 100 to 140 rpm. Back out the
torque limiter to reduce the spring setting until engine lug falls between
100 to 140 rpm less than low idle.

4) If engine rpm lug is less than a 100 rpm, the torque limiter setting
should be increased.

Page: VI-19
 BACKHOE LOADERS
CHAPTER : Hydraulic System

SYSTEM TESTING

System Tests

The performance of the 416-446 hydraulic systems can be easily tested. Two pressure gauge fittings
are installed on the hydraulic oil pump.

Before performing any pump tests or making adjustments to the pump control valve, measure and
record the machine cycle times. If the cycle times are within specification, checking low pressure
standby or margin pressure may not be required unless the system is overheating. Cycle time checks
will also indicate if all or some of the implements in the system are operating within specification.
This information can be helpful in determining if the pump or the implement is at fault. If all cycle
times are too slow, margin pressure may be set too low. If the machine is too responsive, the margin
pressure may be set too high.

Connect an 8T0859 gauge to each pressure fitting. The oil lines for the gauges should be long enough
so the gauges can be observed from the operator's station.With the gauges installed, follow the testing
and adjusting procedures in the Service Manual for maximum system pressure and low pressure stand-
by. When performing the margin pressure test, follow the Service Manual Procedures with the follow-
ing exceptions:

1. Using a 6V8731 Union in the tilt circuit is not required.

2. Activate any implement slowly and watch the gauges.

If margin pressure needs to be adjusted, the following method is quicker and safer for the mechanic:

1. Compare margin pressure to low pressure standby.

2. Mentally add to or subtract from low pressure standby about the same amount required to set
margin pressure to specification. Since both pressures are adjusted by the same screw, an
adjustment to one also affects the other. This relationship, however, is not linear.

3. Make this adjustment to the flow compensator (margin spool) while the machine is in low pres-
sure standby.

4. Recheck margin pressure after adjusting low pressure standby.

NOTE: Due to the signal pressure limiter, the steering circuit is commonly used to check margin pres-
sure because the steering circuit pressure is below maximum system pressure. When steering is stalled,
a signal of approximately 14000 kPa (2050 psi) is sent to the pump. The pump increases flow due to
oil being sent to tank through the signal pressure limiter. Pump supply pressure increases. The differ-
ence between the pump supply pressure and the steering signal is margin pressure.

Page: VI-20
 BACKHOE LOADERS
CHAPTER : Hydraulic System

B & C Series Backhoe Loader Hydraulic System Lab Sheet

Perform the Following Tasks:
¥ Warm up hydraulic system.
¥ Record initial system pressures below:
Low pressure standby
Maximum system pressure
Margin Pressure

¥ Invert front bucket fully and lower to the ground. Record cycle times for loader lift below:
Loader lift cycle time specification
Test One Test Two Test Three
Average Cycle time

¥ Adjust Low Pressure Standby to 150 psi. Record cycle times for loader lift below:
Test One Test Two Test Three
Average Cycle time

¥ Adjust Low Pressure Standby to 450 psi. Record cycle times for loader lift below:
Test One Test Two Test Three
Average Cycle time

¥ Reset Low Pressure Standby to 320 psi. for the B series and 350 psi for the C series. Recheck cycle
times and margin pressure.
Test One Test Two Test Three
Average Cycle time
Margin Pressure

Describe your conclusions:

Page: VI-21
 BACKHOE LOADERS
CHAPTER : Hydraulic System

BACKHOE LOADER HYDRAULIC TESTS

DATE _______________________________ DEALER _______________________________

MACHINE MODEL ___________________ CUSTOMER ______________________________
NAME/CODE ________________________ JOB ______________________________________
MACH S/N (PIN) _____________________ APPLICATION ____________________________
S.M.U. _______________________________ SERVICEMAN ___________________________

LOW PRESSURE STANDBY ___________________

RUN ALL TESTS AT MAX.
MARGIN PRESSURE ___________________
RPM
MAXIMUM SYSTEM PRESSURE _________________
MACHINE AT NORMAL
ENGINE LOW IDLE SPEED ___________________ OPERATING TEMPERA-
TORQUE LIMITER ENGINE SPEED ___________________ TURES

CYCLE TIMES
TEST
1ST 2ND 3RD 4TH AVG. SPEC
Bucket Dump
L (Leveler Off)
O Tilt Back
A (Leveler Off)
D Raise
E (Leveler Off)
R Raise (Leveler On,
Full Bucker Dump))

Bucket Dump

Bucket Load

Stick In

Stick Out

Swing
B (Stop to Stop)
A Swing
C (Stop to Snubber)
K
H E-Stick Extend
O
E E-Stick Retract

Left Stab. - Raise

Left Stab. - Lower

Right Stab. - Raise

Right Stab. - Lower

Boom Pause

Auxiliary 1

Auxiliary 2

Page: VI-22