SECTION 35 - HYDRAULIC SYSTEM 21

Load sensing valve with pump running - Steering in neutral

Return to oil tank
Trapped oil
Pressure oil
1. Orifice 5. To steering priority flow (CF)
2. Rear systems (EF) 6. Orifice
3. Filter 7. Inlet port (from rear port)
4. Spool

The pressure on (CF) increases until the pressure value (stand-by pressure) is sufficient to move the spool
valve in a way to divert the flow toward (EF).

Load sensing valve with pump running - Steering working

Trapped oil
Return to oil tank
1. Orifice 5. To steering priority flow (CF)
2. Rear systems (EF) 6. Orifice
3. Filter 7. Inlet port (from rear port)
4. Spool

During steering two actions are performed:

1. The fluid moves to the steering through (CF).
2. The (LS) signal is in communication to the steering.
22 SECTION 35 - HYDRAULIC SYSTEM

COMPONENTS

1. Screw 19. Bushing

2. Steering control valve 20. Gasket
3. Spool 21. Bushing
4. O-ring 22. Elastic retainer
5. Plug 23. Bearing
6. Valve 24. Gear
7. Filter 25. Gear
8. Fitting 26. Front pump body
9. Spring seat 27. Gasket
10. Spring 28. Gear
11. O-ring 29. Flange
12. Cover 30. Seal ring
13. Relief valve 31. Seal ring
14. O-ring 32. Snap ring
15. Poppet 33. Pressure seal
16. Spring 34. Gear
17. Seat 35. O-ring
18. Rear pump body 36. Screw
 SECTION 35 - HYDRAULIC SYSTEM 43

CONTROL VALVES
The hydraulic circuit is a load-sensing flow sharing LOADER CONTROL VALVE
system working together with a hydraulic pump.
The loader control valve is mounted on the right
This system has the advantage that at any time the side of the machine adjacent to the pump.
distribution of flow to the services being operated is The control valve assembly consists of a maximum
in proportion to the openings of the control valve of three sections and provides oil to the loader
spools. attachment, to the bucket and to the 4x1 bucket, if
The flow distribution to the backhoe and loader installed.
control valves is independent of the load and it is
therefore possible to operate two or more spools at BACKHOE ATTACHMENT CONTROL VALVE
the same time. The backhoe attachment control valve is located in
Important components of the system are the pres- the rear part of the machine.
sure compensator valves in each control valve sec- The control valve consists of a maximum of 7 or 8
tion, together with the load-sensing line which sections and provides the oil flow for operating the
connects all spools of the loader and backhoe lifting, the digging, the bucket, the stabilizers, the
attachment control valves. swing, the (optional) telescopic arm and the auxil-
With the fixed-flow-rate hydraulic pump, the load- iary services, if installed.
sensing line only connects the loader and backhoe
attachment control valves and does not have any
connection to the hydraulic pump.
The hydraulic pump draws oil from the tank and
flow from the front pump is directed to the centre
galleries of the loader and backhoe control valves
assemblies.
The flow coming from the rear section of the pump
passes through the flow divider valve and sends
the priority flow to the steering system, while the
remaining flow adds to the flow from the front
pump, directed to the loader and backhoe attach-
ment systems.
The centre gallery of both the loader and backhoe
control valves are blocked by the end plate.
Pressure in the supply system is controlled by the
pump flow balancer valve in accordance with the
pressure in the load-sensing line.
Consequently, the higher the load sensing pressure
is, the less flow is returned to the tank, with a corre-
sponding increase in flow/pressure to the hydraulic
systems.
Maximum system pressure is limited by the load
sense pressure relief valve which relieves pressure in
the load sense line when it reaches 210 bar (304 psi).
Since the flow balancer valve is influenced by the
load-sensing pressure, the valve diverts a sufficient
quantity of oil to the tank to maintain the maximum
system pressure of 210 bar (304 psi).
44 SECTION 35 - HYDRAULIC SYSTEM

SYSTEM DIAGRAM (BACKHOE ATTACHMENT MECHANICAL CONTROLS)

Hydraulic system oil Suction oil

Steering system oil Return to oil tank
Load-sensing line oil

1. Hydraulic tank 8. Backhoe hammer control valve

2. Hydraulic pump 9. Backhoe hammer
3. Power steering 10. Oil cooler
4. Hand hammer control valve 11. Return line distributor block
5. Hand hammer 12. Filter
6. Backhoe attachment control valve 13. Oil cooler by-pass valve
7. Loader attachment control valve
NOTE: for variable flow-rate piston pump refer to
Hydraulic Diagram - Section 35 Hydraulic System.
 SECTION 35 - HYDRAULIC SYSTEM 45

SYSTEM DIAGRAM (BACKHOE ATTACHMENT PILOT CONTROLS)

Hydraulic system oil Suction oil

Steering system oil Return to oil tank
Load-sensing line oil Control circuit oil
1. Hydraulic tank 9. Backhoe hammer
2. Pump 10. Oil cooler
3. Power steering 11. Return line distributor block
4. Hand hammer control valve 12. Filter
5. Hand hammer 13. Oil cooler by-pass valve
6. Backhoe attachment control valve 14. Solenoid valve for piloting backhoe control valve
7. Loader attachment control valve 15. Hydraulic control lever
8. Backhoe hammer control valve 16. Accumulator
NOTE: for variable flow-rate piston pump refer to
Hydraulic Diagram - Section 35 Hydraulic System.
46 SECTION 35 - HYDRAULIC SYSTEM

OIL FLOW OPERATION

All loader/backhoe attachment systems are in
neutral position
Each control valve section within the backhoe or
loader control valve assemblies contains a spool,
two check valves and a load-sensing pressure com-
pensator.
A load-sensing gallery connects the compensators
in each control valve section.
When all control valves are in neutral position, the
spools stop the oil flow in each system and the pres-
sure of the load-sensing line can bleed to the tank
through the relevant return-to-tank port.
Because there is no load sense pressure being
applied to the rear face of the flow balancer valve,
the valve will move against the spring and off its
seat when pump pressure reaches 15 bar. The
pump flow is now diverted back to the tank and the
balancer valve maintains a stand-by pressure of 15
bar while the systems are in neutral position.

Flow balancer valve operation - All spools in neutral

Pump stand-by pressure 15 bar Return to oil tank

1. Load sense bleed orifice 1 l/min 4. Load sense line

2. Load-sensing limiter 5. Pump flow balancer (unload) valve
(system pressure relief valve) 6. Pump flow IN
3. Return to oil tank 7. To backhoe control valves
 SECTION 35 - HYDRAULIC SYSTEM 47

Load sensing flow sharing - All spools in neutral

Pump pressure Return to oil tank
Trapped oil

1. Load non-return check valve 3. Pressure compensator

2. Load sense line 4. Spool
48 SECTION 35 - HYDRAULIC SYSTEM

One hydraulic circuit operating

When a single hydraulic circuit is operated the When pump pressure overcomes the pressure
spool in the control valve section is moved allowing behind the load check valve, the valve opens allow-
oil to flow past the lands of the spool and apply ing oil to flow into the cylinder port.
pressure to the metering element of the pressure Exhaust oil from the cylinder returns to tank through
compensating valve. the other port in the control valve section.
The metering element moves upwards to allow oil
If pressure in a load-sensing system reaches 195 bar
to flow to the load check valve and at the same time
(2828 psi), the relief valve is activated.
uncovers the drilling in the spool portion of the
pressure compensator valve enabling operating Pump pressure is now limited to 210 bar (304 psi).
pressure to be sensed in the load sense gallery. This is the pressure required to overcome the pres-
sure of the flow balancing valve spring [15 bar
As pressure increases to open the check valve, the (217 psi)] plus the load sensing pressure controlled
load-sensing pressure is applied to the spring side at 195 bar (2828 psi).
of the flow balancer valve.
A higher pressure is now required to operate the
flow balancer valve and pump pressure increase
accordingly.

Flow balancer valve operation - Hydraulic systems operating

Pump pressure
Load-sensing pressure
Return to oil tank
1. Load sense bleed orifice 1 l/min 4. Load sense line
2. Load-sensing limiter 5. Pump flow balancer (unload) valve
(system pressure relief valve) 6. Pump flow IN
3. Return to oil tank 7. To backhoe control valves
 SECTION 35 - HYDRAULIC SYSTEM 49

TBR00295

Load sensing flow sharing - One spool operating

Pump pressure
Trapped oil
Return to oil tank
1. Load non-return check valve 3. Pressure compensator
2. Load sense line 4. Spool
50 SECTION 35 - HYDRAULIC SYSTEM

Two or more hydraulic systems operating

When two or more hydraulic systems operate, each Pump pressure will rise until it exceeds the pressure
system operates at a different pressure. of the check valve of the system operating at the
heaviest load and the pressure in the load sensing
If pump flow to a specific system is not controlled, the
line has a value similar to that of the high pressure.
system requiring a lower operating pressure will work
faster than the system requiring a higher pressure, The pressure required to operate the system with a
because the flow will have to overcome less resist- lower load is now too high and, if not limited, it will
ance. result in this system operating instead of and faster
than the system with a higher load.
To prevent this situation, the pressure compensating
valve regulates the oil flow directed to the system To compensate for this condition, the load sensing
operating at a lower load. pressure moves the metering element of the pressure
compensating valve in the system with a lower load
When two spools are operated simultaneously pump
downwards and restricts the flow to the system.
pressure is applied to the metering element of the
pressure compensating valve in both valve sections. This balancing of flow and pressure according to the
load ensures that both systems operate simultane-
Both metering elements therefore move upwards
ously and at a balanced flow rate.
allowing oil to flow to the load check valves. At the
same time, the port in the spool section of the pres-
sure compensating valve is uncovered to allow oper-
ating pressure to be sensed in the load-sensing
gallery.

Load sense relief valve operating

Pump pressure at 210 bar (304 psi) Return to oil tank
Load sense pressure at 195 bar (2828 psi)

1. Load sense bleed orifice 1 l/min (0.22 gal/min) 5. Pump flow balancer (unload) valve
2. Load sense limiter (system relief valve) 6. Pump flow IN
3. Return to oil tank 7. To backhoe control valves
4. Load sense line
 SECTION 35 - HYDRAULIC SYSTEM 51

TBR00296

Load sensing flow sharing - Two spools operating

1st spool operating pressure (higher) Trapped oil
2nd spool operating pressure (lower) Return to oil tank

1. Load non-return check valve 3. Pressure compensator

2. Load sense line 4. Spool
52 SECTION 35 - HYDRAULIC SYSTEM

LOADER CONTROL VALVE

The loader control valve is mounted on the right side
of the machine adjacent to the pump.
This control valve may be of 2 types, similar to each
other, according to the hydraulic pump assembled to
the machine:
- gear pump (with fixed flow rate);
- piston pump (with variable flow rate).
The control valve consists of 2 or 3 sections, an end
cover and an inlet section.
The 3 control valve sections are:
- loader attachment lifting;
- loader bucket;
- 4x1 loader bucket.
The loader attachment control valve has three sec-
tions when the 4x1 bucket is installed on the
machine.

LOADER ATTACHMENT CONTROL VALVE WITH GEAR PUMP (WITH FIXED FLOW RATE)

TBR00297

A. 4x1 loader bucket section

B. Bucket section
C. Loader attachment lifting section
1. End cover
2. Bucket relief valve (rod side) - 240 bar (3481 psi)
3. Bucket relief valve (piston side) - 165 bar (2393 psi)
4. Hydraulic unloader relief valve - 165 bar (2393
psi)
5. 4x1 bucket relief valve - 240 bar (3481 psi)
6. Hydraulic unloader solenoid
7. Inlet section
 SECTION 35 - HYDRAULIC SYSTEM 67

Disassembly of the cover

Remove the check valve (21).
Remove the valve (20).

Disassemble the control valve sections

NOTE: the figure shows the swing section, the - if necessary, replace the O-ring (28);
valves may be different in the other sections. - remove the spring (29) and the relevant spring
Remove the check valves (22). guide (30);
[Tightening torque = 30 Nm (22 lbf·ft)] - loosen and remove the screws (31);
Remove the flow balancer valve (24). [Tightening torque = 10 Nm (7.4 lbf·ft)]
[Tightening torque = 60 Nm (44 lbf·ft)] - remove the cover (32);
Remove the pressure relief valve (23). - if necessary, replace the O-ring (33);
[Tightening torque = 70 Nm (52 lbf·ft)] - remove the spring (34) and the relevant spring
guide (35);
- extract the spool (25).
Remove the spool:
- loosen and remove the screws (26);
[Tightening torque = 10 Nm (7.4 lbf·ft)]
- remove the cover (27);
68 SECTION 35 - HYDRAULIC SYSTEM

RELIEF VALVES
There are different relief valves installed on the
loader and backhoe attachment control valves.
The relief valves may be operated with anti-cavita-
tion feature (1) or direct acting (2) and protect the
single systems from excessive pressure.

OPERATION
Relief valve inoperative
When the system is not subject to overload condi-
tions pressure in the system is insufficient to over-
come pilot valve spring pressure and move the
valve of its seat.
System pressure sensed on the larger rear face of
the poppet valve maintains the poppet and sleeve
firmly on their seats.
1. Sleeve
2. Poppet valve
3. Pilot valve
4. Pilot valve body
Exhaust oil
5. Piston High pressure oil
6. Control valve (cylinder) exhaust gallery
7. Cylinder supply gallery
 SECTION 35 - HYDRAULIC SYSTEM 69

Pilot valve operation

When the cylinder is subjected to shock forces, the
pressure increase in the cylinder supply gallery
exceeds the pilot valve spring pressure: this valve
lifts off its seat.
System pressure on the rear face of the poppet
valve escapes to tank between the sleeve poppet
and valve body causing a pressure differential
between the front and rear face of the poppet valve.
The higher pressure in the cylinder supply gallery
unseats the poppet valve and moves the piston to
seat against the pilot valve.
1. Sleeve Exhaust oil
2. Poppet valve High pressure oil
Reduced pressure oil
3. Pilot valve
4. Pilot valve body
5. Piston
6. Control valve (cylinder) exhaust gallery
7. Cylinder supply gallery

Pilot and poppet valve operation

The excessive system pressure in the cylinder sup-
ply gallery now flows past the poppet valve to the
cylinder exhaust gallery and back to tank.
NOTE: during this operation the sleeve poppet is
held in the fully seated position by pressure oil.
1. Sleeve
2. Poppet valve
3. Pilot valve
4. Pilot valve body
5. Piston
6. Control valve (cylinder) exhaust gallery High pressure oil
7. Cylinder supply gallery Exhaust oil
Reduced pressure oil
70 SECTION 35 - HYDRAULIC SYSTEM

Anti-cavitation operation
Relief valves with an anti-cavitation feature are fitted
in systems where a rapid extension of the cylinder
could create a void condition and permit the transfer
of oil from the high pressure side of a cylinder to the
low pressure (void) side.
When for example the boom is rapidly lowered and
the cylinder rod end circuit relief valve operates, oil
has been removed from the rod end of the cylinder
and a void created in the piston end. This oil is auto-
matically replenished by the anti-cavitation device in
the opposite circuit relief valve as follows:
The void creates a pressure lower in the cylinder
supply gallery and back pressure in the control
valve exhaust gallery acts on the outer face of the
sleeve poppet moving it to the right.
Exhaust oil is then directed into the cylinder supply
gallery to stop cavitation.

High pressure oil Relief valve exhaust oil

Anti-cavitation oil supply to cylinder

1. Anti-cavitation system pressure relief valve 4. Control valve exhaust gallery

2. Cylinder rod 5. Spool
3. System pressure relief valve
 SECTION 35 - HYDRAULIC SYSTEM 71

Pilot-operated pressure relief valve with anti-cavita-

tion feature subjected to overload and fully relieving
high-pressure oil
1. Sleeve
2. Poppet valve
3. Pilot valve
4. Pilot valve body
5. Piston
6. Control valve (cylinder) exhaust gallery
7. Cylinder supply gallery

Anti-cavitation cylinder resupply oil

Exhaust oil

Direct-acting pressure relief valve operation

High-pressure oil in the system is sensed in the cyl-
inder supply gallery and acts on the surface of the
pressure relief valve poppet.
When pressure in the system exceeds the pressure
relief valve setting, the oil pressure lifts the poppet,
allowing excess pressure in the overloaded cylinder
to escape to the drain gallery.

A. Direct acting circuit relief valve

Valve not subjected to overload conditions
B. Direct acting circuit relief valve
Valve subjected to overload conditions
1. Relief valve seat
2. Relief valve poppet
3. Valve pressure adjusting screw
4. Spring
5. Control valve exhaust gallery
6. Cylinder supply oil

Exhaust oil
High-pressure system oil
72 SECTION 35 - HYDRAULIC SYSTEM

OVERHAUL
Before removing the relief valves from the machine,
lower the loader and backhoe attachment to the
ground, stop the engine and relieve pressure in all
systems by moving the backhoe attachment, loader
attachment and telescopic dipper controls through
all operating positions. If the pressure relief valves
are suspected of contamination, they may be disas-
sembled and inspected for wear. During assembly,
restore the correct pressure.
During disassembly examine the poppet and seat in
the plunger assembly for a complete seating sur-
face.
Pilot operated relief valve

1. Body 9. Nut
2. Shutter 10. O-ring
3. Spring 11. Adjusting screw
4. Spring 12. Spring
5. O-ring 13. Pilot valve
6. O-ring 14. Poppet
7. Valve 15. Piston
8. Cover + O-ring
 SECTION 35 - HYDRAULIC SYSTEM 85

Pump pressure oil

1st stage restricted return oil
2nd stage restricted return oil
Return to oil tank

1. Control valve swing section 5. Left hand cylinder

2. Limiter 6. Compressor rod
3. Cushioning rod 7. Limiter
4. Right hand cylinder
86 SECTION 35 - HYDRAULIC SYSTEM

HYDRAULIC CYLINDERS

TBR00294

1. Loader attachment boom cylinder 7. Telescopic cylinder

2. Loader bucket cylinder 8. Swing backhoe cylinder
3. 4x1 loader bucket cylinder 9. Stabilizer cylinder (center pivot models)
4. Backhoe boom cylinder 10. Stabilizer cylinder (sideshift models)
5. Backhoe dipper cylinder 11. Backhoe sideshift locking cylinder (sideshift
6. Backhoe bucket cylinder models)
 SECTION 41 - STEERING SYSTEM 5

OPERATION
Power steering - Neutral position

Pump pressure Trapped oil

Stand-by pressure Return to oil tank

When the steering wheel is held still, the leaf springs

return and hold the power steering spool in neutral
position.
This ensures that no more oil is supplied to the
steering cylinder.
The spool also traps the oil in the steering cylinder
and allows the oil in the sensing lines to return to the
tank, thus allowing the priority flow divider to move
to the left.
NOTE: for machines with variable-flow-rate pump
refer to hydraulic diagram - Section 35 Hydraulic
System.
6 SECTION 41 - STEERING SYSTEM

Power steering - Turning right

Pump pressure Trapped oil

Metered pressure Return to oil tank

When the steering wheel is turned, the movement As the metering unit is turned by the drive shaft, it
of the power steering spool forms a series of pas- directs a measured quantity of oil along another set
sages. of passages in the spool then from these to the
During right turn, oil flows through the spool along a steering cylinder.
groove and into a passage in the housing which Return oil from the other side of the cylinder is
leads to the metering unit. A gallery is also lined up directed through the spool to a return passage in
to allow pressure oil to flow down the sensing line the housing.
to the priority flow divider.