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Manual Training Hydraulic System Caterpillar Backhoe Loaders
Manual Training Hydraulic System Caterpillar Backhoe Loaders
MALAGA
Backhoe Loaders
Sara
MARCH 1997
BACKHOE LOADERS
CHAPTER : Hydraulic System
C Series
Hydraulic tank
Pump
Implement controls
Torque Limiter
Page:
VI-1
Page:
VI-2
QUIZ
LOAD SENSING/PRESSURE COMPENSATING
TWO VALVE OPERATION
BACKHOE LOADERS
BACKHOE LOADERS
CHAPTER : Hydraulic System
QUIZ
1.-
If two valves are operated at the same time and at valve A the work port pressure (signal 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 :
Valve A work port pressure = 1800 psi
P across pressure reducing valve = _________ psi - _________ psi = _________ psi
P across control spool = _________ psi - _________ psi = _________ psi
Valve B work port pressure = 700 psi
P across pressure reducing valve = _________ psi - _________ psi = _________ psi
P across control spool = _________ psi - _________ psi = _________ psi
2.-
If two valves are operated at the same time and at valve A the work port pressure (signal pressure) is 3000 psi and at valve B the work port pressure is 1000 psi then:
System pressure will be : _________ psi + _________ psi = _________ psi
CALCULATIONS :
Valve A work port pressure = 3000 psi
P across pressure reducing valve = _________ psi - _________ psi = _________ psi
P across control spool = _________ psi - _________ psi = _________ psi
Valve B work port pressure = 1000 psi
P across pressure reducing valve = _________ psi - _________ psi = _________ psi
P across control spool = _________ psi - _________ psi = _________ psi
Page:
VI-3
Page:
VI-4
END
COVER
Directions: Label all valves, the tanks, filters, cooler, pump, and HMU.
BACKHOE LOADERS
INLET
MANIFOLD
Page:
VI-5
TANK
END
COVER
E-STICK
HMU
STICK
SWING
BOOM
INLET
MANIFOLD
S
T
E
E
R
L
I
F
T
T
I
L
T
A
U
X.
BACKHOE LOADERS
RIGHT
STABILIZER
LEFT
STABILIZER
BUCKET
Page:
VI-6
HMU
STICK
BOOM
RH
STAB
LH
STAB.
END
COVER
S
T
E
E
R
A
U
X.
T
I
L
T
L
I
F
T
BACKHOE LOADERS
SWING
BUCKET
Page:
VI-7
BOOM
SWING
LEFT
RIGHT
STABILIZER STABILIZER
BUCKET
STICK
PRIMARY
RESOLVER
SECONDARY
RESOLVER
HMU
BACKHOE LOADERS
LOADER
LIFT
LOADER
TILT
Page:
VI-8
SWING
BUCKET
STICK
PRIMARY
RESOLVER
SECONDARY
RESOLVER
BACKHOE LOADERS
LOADER
LIFT
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 during the slide presentation.
PUMP
OUTPUT
C
D
A
F
E
A
F
Page:
VI-9
Page:
VI-10
PRESSURE
CUTOFF
PUMP
OUTPUT
LARGE ACTUATOR
SWASHPLATE
TORQUE
LIMITER
SMALL ACTUATOR
AND BIAS SPRING
BACKHOE LOADERS
MARGIN
SPOOL
Page:
VI-11
PUMP
OUTPUT
LARGE ACTUATOR
YOKE PAD
SWASH PLATE
PRESSURE
COMPENSATOR
PISTON &
BARREL ASSEMBLY
SMALL ACTUATOR
& BIAS SPRING
BACKHOE LOADERS
FLOW
COMPENSATOR
DRIVE
SHAFT
Page:
VI-12
TORQUE LIMITER
NORMAL
ADJUSTMENT
SCREW
SIGNAL
SPRING
SLOT
PASSAGE TO
TANK
SIGNAL
BACKHOE LOADERS
REDUCED
FLOW
SPOOL
SLEEVE
ACTUATOR
PISTON
Page:
VI-13
TORQUE
LIMITER
SIGNAL
BACKHOE LOADERS
PRESSURE
COMPENSATOR
FLOW
COMPENSATOR
PUMP
OUTPUT
BACKHOE LOADERS
CHAPTER : Hydraulic System
SIGNAL
MARGIN
SPOOL
LARGE ACTUATOR
TORQUE
LIMITER
PASSAGE TO
TANK
SMALL ACTUATOR
AND BIAS SPRING
The torque limiter monitors the pump swashplate angle and the pump
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
allowable pump displacement is inversely proportional to the pump discharge pressure. The higher the pressure, the less pump flow is available.
The pressure setting of the torque limiter varies with the swashplate
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 pressure 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
SPRING
SLEEVE
SLOT
SPOOL
ACTUATOR
PISTON
REDUCED
FLOW
PASSAGE TO
TANK
SIGNAL
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-15
BACKHOE LOADERS
CHAPTER : Hydraulic System
TORQUE
LIMITER
SIGNAL
FLOW
COMPENSATOR
PUMP
OUTPUT
PRESSURE
COMPENSATOR
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. A pressure 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. 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
E
N
G
I
N
E
R
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
S
T
E
M
P
R
E
S
S
U
R
E
3000 PSI
A
TORQUE LIMITER
CONTROL RANGE
FLOW RATE
Page:
VI-17
43 GPM
BACKHOE LOADERS
CHAPTER : Hydraulic System
Page:
VI-18
BACKHOE LOADERS
CHAPTER : Hydraulic System
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 standby. When performing the margin pressure test, follow the Service Manual Procedures with the following 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 pressure 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 pressure 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 difference between the pump supply pressure and the steering signal is margin pressure.
Page:
VI-20
BACKHOE LOADERS
CHAPTER : Hydraulic System
Test Two
Test Three
Test Two
Test Three
Test Two
Test Three
Page:
VI-21
Test Two
Test Three
Recheck cycle
BACKHOE LOADERS
CHAPTER : Hydraulic System
BACKHOE LOADER HYDRAULIC TESTS
DATE
_______________________________
MACHINE MODEL
NAME/CODE
_______________________________
___________________
CUSTOMER ______________________________
________________________
JOB ______________________________________
DEALER
_____________________
APPLICATION ____________________________
_______________________________
SERVICEMAN
___________________________
MACHINE AT NORMAL
OPERATING TEMPERATURES
CYCLE TIMES
TEST
1ST
Bucket Dump
L
O
A
D
E
R
(Leveler Off)
Tilt Back
(Leveler Off)
Raise
(Leveler Off)
Bucket Dump
Bucket Load
Stick In
Stick Out
Swing
B
A
C
K
H
O
E
(Stop to Stop)
Swing
(Stop to Snubber)
E-Stick Extend
E-Stick Retract
Left Stab. - Raise
Left Stab. - Lower
Right Stab. - Raise
Right Stab. - Lower
Boom Pause
Auxiliary 1
Auxiliary 2
Page:
VI-22
2ND
3RD
4TH
AVG.
SPEC