Hydraulic Technical

PROGRAMME
Service training
Course Hydraulical principles Date ____________
Course leader _____________________ Other _____________
Time Monday Tuesday Wednesday Thursday Friday

Cleanliness, Components Continuation, servo- LS-hydraulics,
08.00 environment. controlled round- system design
Oils, fluids pumping system
Design, single-lever Design, three-lever Basic troubleshooting

system system
Circulation flow
11.30 control
LUNCH
Introduction, course Components, Servo-controlled Evaluation,
12.30 information, Volvo CE diagram symbols systems, basics conclusion
company information
Hydraulic basic Design, servo- Basics
concepts, revision controlled round- LS-hydraulics,
pumping system variable axial piston
pump
16.30
Volvo Construction Equipment

1
Volvo Construction Equipment 1019354

Customer Support
Flow divider, principle

In the hydraulic bench, we build up a system according to the schematic.
If the variable restriction is closed, then higher flow will go to the hydraulic motor.
The purpose of the exercise is to demonstrate that:
a) the hydraulic oil flow follows the path with the least resistance,
b) the flow determines the hydraulic motor’s speed (rpm).
2

Customer Support
Pump gives flow, no pressure

Build system according to the schematic. Check the pressure gauge at the same time
as the variable restriction is closed. If the restriction becomes tighter, the pressure will
increase, but the flow will still be the same.
1

Customer Support
Pressure-drop
In the hydraulic bench, we build up one of the systems according to the schematic. By
varying the setting of pressure limiter and restrictions, respectively, the pressure-drop
principle can be demonstrated. NOTE! Keep an eye on pressure gauge 1 so that max.
pressure for the hydraulic bench is not exceeded.
2

Customer Support
Pressure-drop
3

Customer Support
Pressure-drop
Customer Support
Pascal’s principle
Cylinder with 2 pressure gauges. If a force is applied, a pressure increase is indicated by
the pressure gauge connected to the cylinder’s plus side. When the cylinder’s plus side
and minus side are connected, the pressure gauges show the same value.
This proves Pascal’s law:

If a fluid in a sealed container is subjected to pressure, that pressure is distributed evenly
in all directions. That’s why the pressure per cm2 is the same against all sides in the
closed space. The total force against a limited surface is thus directly dependent on the
size of the surface. It also shows that the pressure, which is indicated on the pressure
gauges, is the result of the force applied on the piston rod and the piston’s surface.
-

Customer Support
Single-lever system
1. Connect the system according to the schematic.
2. Review (repeat) the principle for setting max. working pressure for a round-pumping
system. (Slacken the spring in the pressure limiter, function without shock valve to
end-position)
3. Flow measurement: Install flow meter and measure the flow, in turn.
a) From pump to control valve
b) From control valve to the cylinder’s plus side
c) From control valve to the cylinder’s minus side
d) From control valve to tank
Measure the flow in three different situations, when the function is run at min. speed, when
the function is run at max. speed, and with the function in end-position.
Let the students discuss which result ought to come from the measurement. Then check
this in practice. The purpose of the flow measurement is to show that even if the system
type sometimes is called constant flow system, the flow will vary at different points due to
where and how you measure. The differences are due to, among others, different volume
in the cylinder’s plus- and minus sides, respectively, and the restriction that was caused by
the control valve when inching.
-

Customer Support
Single-lever system
Version with pressure limiter.
Customer Support AB
Homework
Connect the different components to produce a functional circuit.
Customer Support AB
Homework
Customer Support AB
Homework
1000
kg

Customer Support
Homework
30 bar 40 bar 50 bar

Customer Support
Homework
Pressure build-up
30 bar 40 bar
30 bar 50 bar

Customer Support
Homework
Pressure build-up
30 bar
40 bar
250 bar
50 bar

Customer Support
Homework
Pressure build-up
20 bar
20 bar
20 bar
10 bar
30 bar 30 bar
20 bar
10 bar
10 bar
30 bar 10 bar 20 bar
20 bar

Customer Support
Homework
Pressure build-up
Customer Support
Accumulator
To illustrate what happens in an accumulator circuit, this circuit can be used:
1. Start by setting the pressure limiter at approx. 75 bar opening pressure. This is done
with the restriction completely closed and the accumulator disconnected. The pressure
limiter has the function of a safety valve in the circuit.
2. Then open the restriction so that all flow goes through it and the pressure in the circuit is
maintained at approx. 60 bar. Try turning the bench off and on to see how pressure build-
up and pressure reduction take place, without accumulator.
3. Connect the accumulator. Turn on the bench and compare the pressure build-up. Turn
off the bench and compare the pressure reduction.
4. Also check what happens with the flow by connecting the flow meter between the pump
and non-return valve, and then between the restriction and tank. Run the bench acc. to
step 3.
Evaluation of result
P Q
t t
1. Without accumulator, pressure build-up and pressure reduction will be very quick. The
flow will be constant in the whole circuit as long as the pump operates.
Precharge pressure
t
2. With the accumulator connected, its charging will be seen by the pressure build-up.
Time for charging depends on the flow and accumulator volume, higher flow and smaller
volume = shorter charging time.
Precharge pressure
t
Pressure reduction when the pump is turned off follows the same pattern. There will
be a pressure in the system as long as the accumulator supplies oil to the system. At
precharging pressure, that is, when the diaphragm is fully expanded, the pressure drops
quickly to zero.
Q
t
3. The flow measured between pump and non-return valve will be constant as long as the
pump operates.
However, the flow measured between restriction and tank will vary. As long as the
accumulator is charged, part of the flow will go to the accumulator. Full flow is not obtained
until the accumulator is filled. The corresponding events take place when the pump is
turned off.
4. To show the accumulator’s energy-storing function: repeat measurement 3 but with the
restriction completely closed. How long time does it take before the pressure has dropped
to zero?
Evaluation of 4
A suitable step to do before coffee break or similar. On the condition that non-return
valve and restriction really seal tight, the pressure can be maintained indefinitely. Thus,
a pressure reduction will only be due to internal leakage in different components. A
conclusion is that there may be risks when working with accumulator circuits, even if a
long time has passed since the machine was operated.
Summary
- In hydraulic systems with accumulators, there may be trapped pressurized oil. Therefore,
be careful when working in such systems! Always follow the service manual’s instructions
for depressurizing!
- As shown in exercise 2, the accumulators have a damping effect on pressure build-up
and pressure reduction. This is used, e.g., in steering systems to obtain more comfortable
steering.
- According to exercise 4, also accumulators can store pressurized oil. An application of
this is brake systems, where the accumulators maintain the brake pressure even if the
engine stops.
6
5 3
1 2

Customer Support AB
Search symbols
Allow the students to look up each symbol in the manual and then point out and identify
them on the control valve.
5
1 9
2
6
10
3 7
4 8 11
Customer Support
Search components
Correctly locate and mark the following components on the machine
1. Pump
2. Tank
3. Return filter
4. Breather filter
5. Test outlet (quick-coupling)
6. Pressure limiting valve
7. Pressure reducing valve
8. Hydraulic motor
9. Accumulator
10. Solenoid valve
11. Control valve
One variant is to allow the students to draw the symbols as well.

Pressure limiting valves
The function of the pressure limiting valves is to prevent the oil pressure in a system from
exceeding a set value.
By means of the spring being compressed when the valve opens, the pressure at full fluid
flow-through will always be higher than the opening pressure.
Since the opening pressure is lower than the flow-through pressure, the valve must always
be set to a lower pressure than that which is the highest permissible for the system.
A pressure limiting valve must always be in the pressure line from the pump.
The valve is most often placed as the first component after the pump. Thus it protects all
functions that are supplied by the pump.
This type of valve can also be found in other places in the system, but then with another
name and a slightly different purpose.
We shall go through two types of pressure limiting valves. Direct controlled pressure limit-
ing valve (Bosch valves) and pilot-controlled pressure limiting valve (90D valves).
PRESSURE RELIEF VALVE
Volvo Construction Equipment L67677A

Customer Support AB
Direct controlled pressure limiting valve

Dismantle one of the valves included in the hydraulic bench.
Explain the different parts:

- Spring with adjusting screw
- Cone with ”area”
- Damper function for hysteresis
- Inlet
- Outlet
NOTE: Pressure limiting valves of this model have previously been used for servo pressu-
re on loaders in the 4000-series. The valve has then been used as a ”joint” for other return
lines, with the double outlets as a result.
Shockfunction
1 2 3
5
6 4

Customer Support AB
Pilot-controlled pressure limiting valve

Shock function
When the pressure from the cylinder (6) increases, the pilot valve (1) will open at the
set opening pressure. When the oil starts to flow past the pilot valve the pressure in the
chamber (2) will decrease in relation to the pressure from the cylinder. The sleeve (3)
that works as a moving restriction will follow the flow and will seal against the pilot valve.
The shock pressure will now act on the whole area of the sleeve. The oil in the chamber
is connected with the tank via the open pilot valve. The piston (5) can now open and the
shock pressure can be drained directly to the tank connection.
1 Pilot valve
2 Chamber
3 Sleeve
4 Tank connection
5 Piston
6 Connection to cylinder
- Dismantle the valve.

- Go through and explain the different functions of the internal parts.
- Allow the students to assemble the valve.
- Allow the students to make a pressure setting (220 bar) using tool 9993749, see method
in workshop manual.
Working hydraulic system, servo
hydraulic system
General
Specifications, L90D, capacities
Hydraulic system, total 130 l (34 US gal)

Hydraulic system, total 210 l (55 US gal)
Specifications, general
Hydraulic system
Type Servo-assisted, of "open centre" type
9:3
Working hydraulic system, description
The working hydraulics hydraulic system mainly consists of an
oil tank, hydraulic oil pumps, servo-controlled control valve,
servo valve, solenoid valve(s), hydraulic oil cooler and control
cylinders.
The pressure limiting valve limits the maximum pressure in the
hydraulic system.
The oil tank, which is common to the brake system, steering
system and the working hydraulics, is equipped with a return oil
filter. The tank is ventilated through a separate breather filter.
The servo pump is a vane pump that is common to the servo
system and the brake system. The pump is included in the
hydraulic system double-pump and is mounted on the hydraulic
transmission left power take-off. The servo system has a sepa-
rate pressure limiting valve that restricts the pressure in the
servo circuit.
The servo valve, which receives oil from the servo pump, has a
closed centre. This means that the oil flows via a pressure limit-
ing valve, without passing the servo valve, directly to the tank in
neutral position. The servo valve consists of three sections, one
for each hydraulic function. The servo valve is equipped with
detent solenoids (electromagnets) for float, tilt and boom kickout
positions as well as a microswitch for engaging the float position
on the lift/lower function.
A pressure proportional to the lever stroke is sent out with the
servo valve to the spool for each function. The pressure works
against the return spring of the spool. The spool movement (i.e.
opening to each cylinder/function and the movement speed of
the function) thus becomes proportional to the lever stroke.
The pump for the working hydraulics is a vane pump that is
included in the hydraulic system double-pump and is driven by
the hydraulic transmission left power take-off.
The control valve, which receives oil directly from the working
hydraulics pump, has an open centre. This means that the
hydraulic oil passes through the control valve and directly to tank
when the control valve spools are in neutral position. The control
valve consists of three sections, 3rd hydraulic function, tilt func-
tion, and lift/lower function with float position.
Float position means that the plus and minus sides of the lift cyl-
inders are connected through the return line. The minus side is
directly connected and the plus side has a connection to the
return line via the back-up valve. The spool in each section is
controlled by the servo valve. Each section is equipped with a
load-holding valve which ensures the position of the cylinders
when a movement has been completed, and counteracts unde-
sired movements when starting. Shock valves limit the pressure
in the tilt and lift functions during shock loads.
The tilt and lower functions have anti-cavitation valves which
ensure adequate oil in the cylinders.
The back-up valve pressurizes the return-oil during lowering and
forward tilt, and contributes to improved oil filling.
The solenoid valves for control of different functions receive their
oil from the hydraulic system servo circuit. The solenoid valves
control engagement of the float position and differential lock. In
addition, there are solenoids for optional functions.
9:4
The hydraulic oil cooler, located together with the engine’s cool-
ant radiator, is connected between the servo system pressure
limiting valve and the return oil filter for the hydraulic oil tank.
Control cylinders consist of a tilt cylinder, two lift cylinders, and
any cylinders for other equipment (optional equipment).
There may be a cylinder for hydraulic locking of the attachment
bracket (optional equipment).
The boom is built of two arms attached to the upper part of the
front frame. The arms are joined to form a single rigid construc-
tion, which also carries a linkage system for transferring tilt
movement. The lift cylinders are well protected with high attach-
ment points in the front frame. The placement of the tilt cylinder
and the design of the linkage system allow for parallel move-
ment and high breakout torque throughout the entire lifting
range. These characteristics have given the loader linkage its
name - TP-linkage.
T stands for torque and P stands for parallel. The bucket can be
attached to a special attachment bracket or mounted directly to
the boom.
Fig.1 Hydraulic system, working hydraulics 3rd/4th function

1 Hydraulic oil tank
2 Servo valve
3 Hydraulic oil pump, brake and servo systems
9
4 Control valve
5 Hydraulic oil pump, working hydraulics
6 Oil cooler
7 Solenoid valves
8 Return oil filter
9 Shuttle valve 3rd/4th function
10 Pressure outlet 3rd/4th function
9:5
Fig.2 Hydraulic system, lift
2 Pressure limiting valve, servo pressure
3 Servo valve
6 Steering pump
7 Pressure back-up, servo circuit
8 Control valve
9 Lift cylinder
10 Oil cooler
11 Return oil filter
12 Foot brake valve
9:6
Fig.3 Hydraulic system, tilt
2 Pressure limiting valve, servo pressure
3 Servo valve
6 Steering pump
7 Foot brake valve
8 Control valve
9 Tilt cylinder
10 Oil cooler
11 Return oil filter
12 Pressure back-up, servo circuit
9:7
Hydraulic diagram, working hydraulic system
B Hydraulic pump working hydraulics as well as brake and
servo systems
D Return oil filter
E Hydraulic oil cooler
G Pressure limiting valve
H Brake valve
J Servo valve
K Control valve
P Solenoid valve block
Z Pressure back-up, servo circuit
9:8
Fig.4
42
A K B
P
K1
GR
H G
N A T P J
B
P A
W BL
44
BRAKE
T 3:rd
K2
B
A
8
E B
K7
K3
A
43
Tilt
A Y
B R
R/Y
D
K4 K6 9
Lift
B
Z
K5
D B Z H K P
MA 407 MA 903
P
L66946B
E J F R
9:9
41
9
incl. attachment locking and 3rd function
servo systems
D Return oil filter
H Brake valve
J Servo valve
K Control valve
R Attachment locking
9:10
Fig.5 A
42
K B
P
K1
B
GR
MA 913 G V
H
N A T P J
B
P A
P A
B *
W BL
G1 G2 44
BRAKE
3:rd
K2
T B
A
E B
K7
K3 8
A
Tilt 43
A Y
B R
R/Y
D
K4 K6 9
Lift
B
Z
K5
D B Z H K P
R
*
MA 407 MA 903 MA 905
P
L66947A
E J F R 41
9:11
9
incl. attachment locking and 3rd/4th function
servo systems
D Return oil filter
H Brake valve
J Servo valve
K Control valve
S Shuttle valve, 3rd/4th hydraulic function
9:12
Fig.6
42
A K B
P *
K1
B
GR
MA 913 G V
S
H
N A T P J
P A
P
B
W BL
G1 G2 44 *
BRAKE
3:rd
K2
T
A
E B
K7
K3 8
Tilt 43
A Y
B R
R/Y
D
K4 K6 9
Lift
B
Z
K5 MA 908
D B Z H K P
R
*
MA 407 MA 914 MA 903 MA 905
P
9:13
4
9
Hydraulic diagram L90D, complete
A Steering pump
servo systems
C* Secondary steering pump
D Return oil filter
H Brake valve
I* Parking brake valve
J Servo valve
K Control valve
L* CDC lever steering
M Steering valve
O* Secondary steering valve
U* Boom Suspension System (BSS)
V Steering accumulator
X Sequence valve
1 Rear axle
2 Front axle
3 Left steering cylinder
4 Right steering cylinder
5 Lift cylinder
6 Tilt cylinder
7* 3rd function
8* 4th function
9* 3rd function
* Optional equipment
9:14
Fold-out L66547C to be inserted here
Hydraulic diagram L120D, complete
A Steering pump and fan pump
servo systems
C* Secondary steering pump
D Return oil filter
H Brake valve
I Parking brake valve
J Servo valve
K Control valve
L* CDC lever steering
M Steering valve
N Shift valve
O* Secondary steering valve
U* Boom Suspension System (BSS)
V Steering accumulator
1 Rear axle
2 Front axle
3 Left steering cylinder
4 Right steering cylinder
5 Lift cylinder
6 Tilt cylinder
7* 3rd function
8* 4th function
9* 3rd function
* Optional equipment
9:16
Fold-out L66548B to be inserted here
Working hydraulic system
Specifications, weight
Control valve 50 kg (110 lbs)

Hydraulic oil tank 95 l (25 US gal)

Hydraulic oil tank 155 l (41 US gal)
Specification L90D, general

Operating times (approx.), fast idle speed
Lift, with SAE work load 5.5 s
Lower, without load 2.5 s
Forward tilt, with SAE work load 2s
Forward tilt, without load 2.5 s

Operating times (approx.), fast idle speed
Lift, with SAE work load 6s
Lower, without load 3s
Forward tilt, with SAE work load 2s
Forward tilt, without load 3s
Specifications, general
Control valve
Shock valve, rear tilt (plus 24.5 H0.6 MPa (3553 H87 psi)
side)
Shock valve, forward tilt 17.5 H0.69 MPa (2538 H100 psi)
(minus side)
Shock valve, lift 32.0 H0.6 MPa (4640 H87 psi)
Back-up valve, forward tilt 1.0–2.0 MPa (145–290 psi)
and lower
9:18
Control valve
Fig.7 Control valve

1 Load-holding valve
2 Shock and anti-cavitation valve, lift (+ side)
3 Shock and anti-cavitation valve, rear tilt (+ side)
4 Pressure limiting valve, working pressure
5 Shock and anti-cavitation valve, forward tilt (- side)
6 Anti-cavitation valve, forward tilt
7 Anti-cavitation valve, lower
8 Back-up valve for return pressure, 1.0–2.0 MPa (145–290 psi)
9:19
2
1 + 3
4 + 5
6 6
* *
L67665B
Fig.8 Control valve, connections for servo pressure

1 Lower function
2 Lift function
3 Float position function
4 Tilt function, forward
5 Tilt function, roll-back (rear tilt)
6 Extra hydraulic function
Fig.9 Section of control valve

1 Back-up valve for return pressure
2 Anti-cavitation valve, lower (lift cylinder -side)
3 Anti-cavitation valve, forward tilt (tilt cylinder -side)
9:20
3
2 4
6 5
L68083B
Fig.10 Control valve, neutral position

Valve spool for tilt function with shock valves and anti-cavitation valves as well as load-holding valve in neutral position
1 Valve spool for tilt function
2 Shock and anti-cavitation valve, forward tilt (-side)
4 Shock and anti-cavitation valve, rear tilt (+side)
5 Connection for servo pressure, roll-back (rear tilt)
6 Connection for servo pressure, forward tilt
Green Atmospheric pressure

Blue Increased return pressure
2 4
6 5
L68082B
Fig.11 Control valve, roll-back (rear tilt)

Valve spool for tilt function, in position for roll-back (rear tilt) with shock and anti-cavitation valves as well as load-holding valve
1 Valve spool for tilt function
2 Shock and anti-cavitation valve, forward tilt (-side)
4 Shock and anti-cavitation valve, rear tilt (+side)
5 Connection for servo pressure, roll-back (rear tilt)
6 Connection for servo pressure, forward tilt
9
Red Working pressure
Orange Servo pressure
9:21
1 2 5
7
6
Fig.12 Back-up valve for return pressure, unaffected position

1 Anti-cavitation valve, forward tilt
2 Anti-cavitation valve, lower
3 Back-up valve
4 Tilt cylinder
5 Lift cylinder
6 Control spool, tilt function
7 Control spool, lift, lower function
Red Working pressure

9:22
Shock and anti-cavitation valve
Functions of shock and anti-cavitation valve
– Shock function
– Anti-cavitation function
Shock function
When the pressure from the cylinder (6) increases, the pilot
valve (1) will open at the preset opening pressure.
When the oil starts to flow past the pilot valve, the pressure in
the chamber (2) will drop in relation to the pressure from the cyl-
inder. The pipe (3) which functions as a moveable restriction, will
follow with the flow and seal against the pilot valve.
At this point, the shock pressure acts on the entire area of the
pipe. The oil in the chamber is connected to tank via the open
pilot valve. The piston (5) can now open and the shock pressure
is drained directly to the tank connection.
1 2 3
6 4
L47739B
Fig.13 Shock function
The sequence of events is shown from left to right
1 Pilot valve
2 Chamber
3 Pipe
4 Tank connection
5 Piston

Pink
Red
Partial pressure of working pressure
Working pressure
9
9:23
Anti-cavitation function
When the pressure in the cylinder drops, the pressure in the
chamber (1) also becomes lower than the tank pressure. Now,
the tank pressure acts on the piston (4) and lifts it, and the anti-
cavitation function is engaged.
1 4
3 2
L47740B
Fig.14 Anti-cavitation function
The sequence of events is shown from left to right
1 Chamber
2 Tank connection
4 Piston

L67670C
Fig.15 Anti-cavitation function, L120D
9:24
Servo hydraulic system
Specifications, weight
Control valve 50 kg (110 lbs)

Servo pump (common with brake system) included in
hydraulic system double-pump
Type Vane pump
Displacement 15.9 cm3 (1.0 in3)
Flow rate at 2200 rpm and 31.0 l/min (8.2 US gal/min)
10 MPa (1450 psi) pressure
Servo pressure (throughout 3.0–4.0 MPa (435–580 psi)
entire engine speed range)
Increased pressure, separate 15 H0.5 MPa
attachment locking (optional (2175 H72.5 psi)
equipment)
Accumulator 0.5 l (0.13 US gal) in 1.5 MPa (217.5 psi)
servo circuit, precharge pressure

Servo pump (common with brake system) included in
Type Vane pump
Displacement 15.9 cm3 (1.0 in3)
Flow rate at 2100 rpm and 29.5 l/min (7.8 US gal/min)
10 MPa (1450 psi) pressure
Servo pressure (throughout 3.0–4.0 MPa (435–580 psi)
entire engine speed range)
Increased pressure, separate 15 H0.5 MPa
attachment locking (optional (2175 H72.5 psi)
equipment)
Accumulator 0.5 l (0.13 US gal) in 1.5 MPa (217.5 psi)
servo circuit, precharge pressure
9:25
Hydraulic system, bleeding
Bleeding in connection with repairs or replacement of
hydraulic pumps
A breakdown in a hydraulic pump may be due to several differ-
ent causes. Before a new or repaired hydraulic pump is
installed, the following points should be followed:
1 Inspect the hydraulic tank and clean it if necessary.
2 Clean the return oil filter’s magnetic rod (if fitted).
3 Inspect the return oil filter and change it if visible impurities
are present. If the machine’s running time is more than
50% of the filter’s normal change interval, the filter should
be changed.
4 Top up all hydraulic oil, both fresh and re-used, via the
hydraulic tank’s return filter.
5 Before starting the machine, the pressure limiting valve for
working pressure should be adjusted downwards by
unscrewing the adjusting screw about 1 turn. The reason
for this is that the pressure will frequently have been
adjusted upwards when a worn hydraulic pump is used.
NOTE! To reduce the risk of cavitation damage when start-

ing, the following should be observed:
6 Start the engine and run it at a slow idle for about 15 min-
utes without activating any hydraulic functions.
7 Use all the hydraulic functions a few times with the engine
running at a slow idle.
NOTE! The hydraulic cylinders must not be run to their end
positions.
8 Check that the oil in the hydraulic tank’s level indicating
pipe does not contain any air bubbles. If it does, repeat
points 6 and 7.
9 Activate all hydraulic functions a few times to overflow
(hydraulic cylinder to its end position) with the engine run-
ning at higher speed, about 1200-1500 rpm.
10 Warm up the hydraulic system. Check and adjust the work-
ing pressure.
9:26
Servo valve, functional description
The servo valve consists of six valve spools, one for each
hydraulic function.
In principle, the servo valve functions like a pressure reducing
valve. In the neutral position, the valve spool closes off the servo
1 pressure while the connection from the control valve is con-
nected to tank. When the pressure pin is acted on by the lever
(function activated), the valve spool is pressed down by the
spring and first close the connection to tank. When the move-
ment continues, the valve spool opens for the servo pressure
3 out to the control valve. The output servo pressure also acts on
the valve spool which is pressed up against the spring. When
the output pressure reaches a value corresponding to the lever
stroke and thus the spring force, the valve closes. This results in
a controlled oil pressure acting on the spool in the control valve.
As the valve spool in the servo valve opens, an immediate so-
2 called start pressure is obtained, which is the lowest pressure
that is able to move the spool to the closed position. The start
pressure results in the movement of respective spool in the con-
trol valve to a position just before the connection to the hydraulic
cylinder is opened.
Between the start position and the so-called forced opening in
the servo valve, the output pressure is regulated proportionally
with the lever stroke. The forced opening results in a mechanical
4 contact between the pressure pin and the valve spool.
47994
The output servo pressure just before the forced opening, is the
pressure required to press the spool in the control valve to its
Fig.16 Servo valve
end position. When the forced opening has been reached, the
1 Pressure pin
2 Spring output servo pressure increases to the same level as the input
3 Valve spool servo pressure. For the functions that are equipped with electro-
4 Connection to control valve magnets (detent solenoids), forced opening should be obtained
at the so-called sensing position. The servo valve is in the sens-
ing position when extra resistance can be felt in the lever.
9:27
Fig.17 Pressure diagram, output pressure from servo valve
1 Start pressure, 0.6 (87 psi) respective 0.7 MPa (101.5 psi), see table
2 Forced opening
3 Max. servo pressure
4 Stroke
5 Controlled servo pressure
Table for Fig. 17 and Fig. 18.
Servo valve
B B B
Valve spool A Valve spool B
Output pressure
1 Lift function
Start pressure 0.7 MPa (101.5 psi) 0.6 MPa (87 psi)
Final pressure at 2.1 MPa (304.5 psi) 2.1 MPa (304.5 psi)
forced opening
2 Tilt function
Start pressure 0.7 MPa (101.5 psi) 0.6 MPa (87 psi)
3 2 1 Final pressure at
forced opening
2.1 MPa (304.5 psi) 2.1 MPa (304.5 psi)
3 3rd/4th hydraulic
function
Start pressure 0.6 MPa (87 psi) 0.6 MPa (87 psi)
Final pressure at 2.1 MPa (304.5 psi) 2.1 MPa (304.5 psi)
forced opening
A A A NOTE! 2.1 MPa (304.5 psi) is the highest controlled output

servo pressure before forced opening is obtained.
L50379A
Fig.18 Servo valve
9:28
Fig.19 Pressure pin and guide
A Pressure pin stroke
1 Washer
2 Pressure pin
3 Steering
4 O-ring
5 O-ring
6 Spacer washers for adjusting start position (1.2 mm/0.05 in. stroke) on
pressure pin before the valve spool opens and "start pressure" is obtained.
7 Lock ring
8 Spacer washers
9 Lock ring
10 Seal
9
Fig.20 Spring package with valve spool
1 Spacer washers for adjusting start pressure
2 Screw
3 Spacer washers, forced opening
4 Spring
5 Spring
6 Valve spool
9:29
Servo valve, operating controls, adjusting
Op. no. 91454
Tools:
1 Remove the cover and the switch.
Removing
Fig.21
1 Cover with switch
Control levers
2 Adjust the distance between the lever adjusting screw and

the pressure pin.
Sensing position at 2.1 MPa (304.5 psi)

NOTE! The sensing position is the position that the lever must
pass before the detent solenoid draws (hold position), as well as
the transfer point between the lower and float positions.
Fig.22
1 Adjusting screw
2 Pressure pin
3 The sensing position is adjusted using the adjusting screws

(1) Fig. 23.
NOTE! The adjusting screw must only be turned in com-
plete turns.
Fig.23 Sensing position

1 Adjusting screw
2 Pressure pin
9:30
4 The force required to pass the sensing position is adjusted
with the pressure pin (2) Fig. 23 (2 mm, 0.08 in. Allen key).
Alt. 1: the sensing position should be reached at a distance
of 2–3 mm (0.08–0.12 in) between magnet (solenoid) and
stop washer, see pos A Fig. 24.
Alt. 2: Connect a pressure gauge according to Fig. 40,
adjust so that the sensing position is reached at 2.1 MPa
(304.5 psi).
NOTE! Alt. 1 requires that the hold (detent) solenoid is cor-
rectly adjusted.
Hold (detent) solenoid, bucket leveller, boom kick-out

and float position
5 Move the lever to the sensing position. After adjusting the
sensing position according to Alt. 2 step 4, adjust the clear-
Fig.24
ance between the hold (detent) solenoid and the stop
A 2–3 mm (0.08–0.12 in)
washer to 2–3 mm (0.08–0.12 in), see Fig. 24. Adjust with
1 Stop washer
2 Hold (detent) solenoid
adjusting shims behind the hold (detent) solenoids.
3 Spacer washers
Microswitch
6 The microswitch should be activated when the hold
(detent) solenoid draws (hold position), i.e. the float posi-
tion is engaged, but is unaffected in the sensing position.
5 Adjustment is made by loosening and moving the micros-
witch, see Fig. 25.
Note: Check that the switch for float position, see Fig. 26, is
1 activated.
2 NOTE! The float position must never be engaged before
the sensing position has been passed.
4 3
L50380A
Fig.25
1 Microswitch
2 Lock nut
3 Hold (detent) solenoid, lift (MA902)
4 Hold (detent) solenoid, roll-back (rear tilt)
(MA901)
5 Hold (detent) solenoid, float position (MA904)
Installing
7 Fit the cover and the switch. 9
L57153
Fig.26 SW903 Switch, float position
9:31
Servo pressure, checking and adjusting
(machine with separate attachment locking)
Op. no. 91455
Tools:
999 3831 Support
11 666 019 Pressure gauge 0–6 MPa (0–870 psi)
11 666 037 Hose
The following applies when checking:

Temperature: Normal operating temperature
Engine speed: Entire engine speed range
NOTE! Always use the support to secure the boom when work-
ing under a raised boom.
1 Remove the cover plate from the front frame.
L63130C
Fig.27 Securing boom
1 999 3831
Servo pressure, checking

2 Connect pressure gauge 11 666 019 to the pressure outlet
on the solenoid valve block, located in the front frame
above the final drive, see Fig. 28. Start the engine and read
off the servo pressure.
Servo pressure: 3.0–4.0 MPa (435–580 psi)
IMPORTANT! The switch for increased servo pressure on
the instrument panel must not be touched; the pressure will
then increase to 15.5 MPa (2248 psi) at the pressure outlet.
Fig.28 Checking servo pressure and increased

servo pressure
1 Pressure outlet for servo pressure and
increased servo pressure, separate attach-
ment locking
2 11 666 037 and 11 666 019 (checking servo
pressure) or 11 666 020 (checking increased
servo pressure)
9:32
Servo pressure, adjusting
3 Remove the cover plate on the right side under the cab.
Adjust the servo pressure on the right adjusting screw on
the valve block, see Fig. 30. The pressure is increased if
the screw is turned in.
Increased servo pressure, checking

4 Connect pressure gauge 11 666 020 to the pressure outlet
on the solenoid valve block, located in the front frame
above the final drive, see Fig. 28. Start the engine, activate
the switch for increased servo pressure, see Fig. 29, and
read off the pressure.
Increased servo pressure: 15.0 H0.5 MPa (2175 H72.5)
Increased servo pressure, adjusting

L57138
Fig.29 Switch, increased servo pressure
Adjust the pressure on the left adjusting screw on the valve
block. The pressure is increased when the screw is turned
in. Remove the pressure gauge.
6 Restore the machine to operating condition.
Fig.30 Valve block, separate attachment locking

1 Solenoid valve, increased servo pressure
2 Adjusting screw, servo pressure
3 Adjusting screw, increased servo pressure
9:33
Servo pressure, checking and adjusting
(machine without separate attachment
locking)
Op. no. 91455
Tools:
999 3831 Support
11 666 037 Hose

1 Remove the cover plate from the front frame.
L63130C
1 999 3831
Servo pressure, checking
2 Connect the pressure gauge to the pressure outlet on the

solenoid valve block located in the front frame above the
final drive. Start the engine and read off the pressure.
Servo pressure: 3.0–4.0 MPa (435–580 psi)
Fig.32 Checking servo pressure

1 Pressure outlet for servo pressure
2 11 666 037 and 11 666 019
9:34
Servo pressure, adjusting
Adjust the servo pressure with the adjusting screw on the
valve block.
The pressure is increased when the screw is turned in.
Remove the pressure gauge.
Fig.33 Valve block, servo pressure

1 Adjusting screw, servo pressure
Servo pressure, checking by spool in control

valve
Op. no. 91463
Tools:
999 3831 Support
999 3704 Nipple, 2 pcs.
11 666 019 Pressure gauge, range 0–6 MPa (0–870 psi),
2 pcs.
11 666 037 Hose, 2 pcs.

In case of malfunction in any section, check to make sure
that there are no leaks and that the output servo pressure is
correct.
1 Remove the cover plate in the front frame.
L63130C
1 999 3831
9:35
Servo pressure, checking by spool
2 Fit 999 3704 (2 pcs), one on each side of the valve spool
for the function that is to be checked, connect hoses and
the pressure gauge.
3 Start the engine and let it run at low idle. Check that there is
no output pressure from the servo valve to the control valve
with the servo valve in the neutral position. Check the
output pressure from the servo valve. The pressure must,
depending on the lever deflection, be approx. 0.6–4.0 MPa
(87–580 psi) and no pressure on the opposite side.
Fig.35 Checking servo pressure by valve spool

1 999 3704 (connected one on each side of the
valve spool)
2 11 666 037 and 11 666 019 (two of each)
Pressure back-up for servo circuit,

checking accumulator
Op. no.
Tools:
999 3704 Nipple, 2 pcs.
11 666 019 Pressure gauge, range 0–6 MPa (0–870 psi),
2 pcs.
11 666 037 Hose, 2 pcs.
1 Connect nipple 999 3704 to the upper side of the lift spool.
Connect hose and pressure gauge.
2 Start the engine and run it at idling speed for about 30 sec-
onds. Then stop the engine.
3 Move the lift lever from neutral to maximum lift position.
Repeat this 10 times. The servo pressure should not drop
below 10 bar (145 psi).
9:36
Pump, working hydraulic system
Specifications, tightening torques
Hydraulic system
Hydraulic oil pump (working hydraulics) 220 H22 Nm
(162 H16.2 lbf ft)
L90D specifications, weight

Hydraulic oil pump, working hydraulics (double- 48 kg
mounted with pump for servo system and brakes) (106 lbs)
L120D specifications, weight

Hydraulic oil pump, working hydraulics (double- 55 kg
mounted with pump for servo system and brakes) (121 lbs)

Hydraulic oil pump (working hydraulics) included in
Vane pump, fixed
Type displacement
Displacement 98.3 cm3 (6 in3)
Working pressure, high idle speed 22.5 H0.4 MPa
(3263 H58 psi)
Flow rate at 2200 rpm and 10 MPa 212 l/min
(1450 psi) pressure (56 US gal/min)

Hydraulic oil pump (working hydraulics) included in
Vane pump, fixed
Type displacement
Displacement 136 cm3 (8.3 in3)
Working pressure, high idle speed 22.5 MPa (225 bar)
(3263 psi)
Flow rate at 2100 rpm and 10 MPa 275 l/min
(1450 psi) pressure (73 US gal/min)
9:37
Description
The pump consists of an inlet housing, an outlet housing two
side plates, a drive shaft and a pump unit.
The pump unit consists of an elliptical cam ring, a rotor with
12 vanes and pressure pins, mounted to the drive shaft with
splines.
The hydraulic oil flows into the pump units through the inlet, is
forced out through the side plate and leaves the pump through
the outlet.
Function
6 7
The rotor is turned inside the cam ring by the drive shaft. When
8 the rotor turns, the centrifugal force and the pressurized pins
1
press out the vanes so that they follow the inside of the cam
2 ring. The radial movement of the vanes and the rotation of the
9
rotor causes the spaces between the vanes to increase when
12 they pass the inlet to the cam ring, resulting in the creation of a
4
vacuum and oil being drawn into the spaces between the vanes.
When the oil has passed the inlet, it is trapped between the
vanes, cam ring, rotor and the side plates. The closer the oil gets
to the outlet, the higher the pressure. As the oil reaches the out-
let, the distance between the rotor and the cam ring is reduced,
3 and the oil is forced out.
11 3
10 L55167
Fig.36 Vane pump, diagrammatic drawing
1 Inlet housing 7 Outlet port

2 Outlet housing 8 Cam ring
3 Side plates 9 Rotor
4 Drive shaft 10 Pressure pin
9:38
Working pressure, checking and adjusting
Op. no. 91324
Tools:
999 3831 Support
11 666 037 Hose

Engine speed: High idle speed
1 Remove the cover plate in the front frame.
L63130C
1 999 3831
2 Connect the pressure gauge to the pressure outlet.
Checking working pressure

3 Machines equipped with 3rd or 3rd/4th hydraulic func-
tion:
Disconnect the hydraulic hoses for any attachments that
are connected to the 3rd or 3rd/4th hydraulic function, then
slowly move the control lever to the end position and read
off the pressure.
Machines not equipped with 3rd or 3rd/4th hydraulic
function:
Check to make sure that the float position is not engaged
and slowly move the control lever towards the lower posi-
tion, then read off the pressure when the cylinders reach
their end position.
Working pressure: 22.5 MPa (3263 psi)
Adjusting working pressure

4 Adjustment is performed on the pressure limiting valve on
9
the control valve, pos 1 Fig. 38. The pressure increases
when the screw is screwed in. One full turn changes the
Fig.38 Control valve seen from underside of pressure approx. 10 MPa (1450 psi).
machine
1 Pressure limiting valve, working pressure
2 11 666 037 and 11 666 020
3 Pressure outlet for working pressure
9:39
Shock valve, tilt function, checking and
adjusting
Op. no. 94519
Tools:
999 3831 Support
11 666 037 Hose

Engine speed: Low idle speed
L63130C
1 999 3831
1 Remove the cover plate on the front frame and connect the
pressure gauge to the pressure outlet.
Checking shock pressure, rear tilt (roll-back)

2 Raise the lift arms approx. 1 metre (3 ft) and tilt back the
bucket to the end position. Lower the lift arms. Read off the
pressure when the stop lugs are next to each other and the
tilt cylinder is forced in.
Shock pressure: 24.5 H0.6 MPa (3553 H87 psi)
Fig.40 Checking shock pressure, rear tilt (roll-back)

1 Pressure outlet
2 11 666 037 and 11 666 003
9:40
Shock pressure, adjusting
3 Adjust the pressure at pos 1, Fig. 41. The pressure
increases when the screw is turned in. One full turn
changes the pressure approx. 10 MPa (1450psi).
Fig.41 Adjusting shock pressure, rear tilt (roll-back)

1 Pressure limiting valve, shock pressure, rear
tilt (roll-back) Checking shock pressure, forward tilt
4 Connect the pressure gauge to the pressure outlet.
5 Raise the lift arms approx. 2 m (6.6 ft) and tilt the bucket
forward to its end position. Raise the lift arms. Read off the
pressure when the stop lugs are next to each other and the
tilt cylinder is forced out.
Shock pressure: 17.5 H0.6 MPa (2538 H87 psi)
Fig.42 Checking shock pressure, forward tilt

1 Pressure outlet Shock pressure, adjusting
2 11 666 037 and 11 666 003
6 Adjust the pressure at pos 1, Fig. 43. The pressure

increases when the screw is turned in. One full turn
changes the pressure approx. 10 MPa (1450 psi).
Fig.43 Adjusting shock pressure, forward tilt

1 Pressure limiting valve, shock pressure, for-
ward tilt
9:41
Shock valve, lift function, checking and
adjusting
Op. no. 94523
Tools:
999 3831 Support
999 3723 Nipple
999 3749 Nipple
11 666 003 Pressure gauge
11 666 030 Pump
11 666 037 Hose
14 360 000 Vacuum pump
1 Raise the boom and position the support, release the pres-
sure. Tilt the bucket forward against its end position.
L63130C
1 999 3831
2 Connect the vacuum pump to the hydraulic tank, see

Fig. 45.
NOTE! A condition for using vacuum pump 14 360 000 is
that it is constantly connected and not shut off. Never leave
the machine unattended. The negative pressure in the
hydraulic oil tank must not exceed a maximum of 70 kPa
(10.2 psi) (max. 0.3 bar absolute in the hydraulic tank).
Fig.45 Shutting off hydraulic oil

1 14 360 000
9:42
3 Remove the shock valve for the lift function.
Fig.46
1 Shock valve, lift function
4 Connect the shock valve according to Fig. 47, check the

opening pressure, adjust if needed.
Opening pressure: 32 H0.6 MPa (4640 H87 psi)
5 Refit the shock valve on the control valve, remove the
vacuum pump and lower the boom.
Fig.47 Adjusting shock valve

1 11 666 030
2 11 666 003
3 11 666 037
4 999 3723
5 999 3749
9:43
Back-up valve, opening pressure, checking
Op. no.
Tools:
11 666 018 Pressure gauge, range 0–2.5 MPa
(0–363 psi)
11 666 037 Hose

Engine speed: Low idle speed
IMPORTANT! The bucket must be tilted forward. If the bucket is
tilted back, pressure may increase to maximum working pres-
sure and damage the pressure gauge.
1 Lower the lift arms so that the bucket is positioned flat on
the ground.
2 Connect a pressure gauge to the pressure outlet.
3 Start the engine and let it run at low idle. Tilt forward slowly
so that the machine is raised and read off the pressure.
Opening pressure: 1.0–2.0 MPa (145–290 psi)
NOTE! The valve is not adjustable.
9:44
Customer Support AB
Three-lever system
The three-lever system is based on Volvo BM L70’s working hydraulics. We use it to
show a few common solutions of system design and simultaneous operation of different
functions. The primary purpose is to practise reading and understanding schematics.
Review by filling in the schematic.
Customer Support AB
1. System in neutral position

• Explain the different parts:
- pressure limiting valve
- shock valves
- float mode
- restriction for back-up pressure
- anti-cavitation valve
- lower
• Review the system.

• Connect on the bench.
• Measure the round-pumping pressure.
Customer Support AB
2. The pressure limiting valve

• Set the pressure limiting valve, 80 bar working pressure:
- First let the students fill in the diagram correctly
- then repeat the exercise on the bench.
Customer Support AB
3. Lift and lower

• Let the students fill in and show the lift and lower functions.
• Explain what task the restriction for back-up pressure has.
• Lower, engine off.
• Proposal for measurement on bench:

Pressure difference, in working pressure, at
- lift
- lower
Customer Support AB
4. Events at shock
• Opening of shock valve and anti-cavitation valve.
Review the different methods for setting/checking the shock valves’ opening pressure.
- Check the setting by increasing the working pressure to a higher value than the shock
pressure. NOT recommended as it easily can lead to pump damage or failure of the pump.
- ”Approximate” setting. Lower the pressure on the shock valve until it has a slightly lower
opening pressure than the valve for max. working pressure. Lower the pressure more until
the pressure reduction corresponds the pressure increase that is desired. Note how much
the adjusting screw has to be loosened. Increase the pressure setting to max. working
pressure again and tighten the corresponding number of turns that were required for the
pressure reduction.
- Check-setting with tools. The method that normally is recommended. Where possible,
this is indicated/described in the machine’s service manual.
• Practical exercise:
Let the students try the different methods, where possible.
Customer Support AB
5. Float mode
• Review the purpose and the function of the float mode.
• Practical exercise:
- Measure the round-pumping or circulation pressure with float mode activated.
Customer Support AB
6. Simultaneous operation of different functions

• A common situation of loader hydraulics is simultaneous lowering/tilt in, to finish a loader
cycle. In order for the pump to limit the flow of oil to the function that has the lowest
resistance, that is, the lowering function, the valve has been designed so that the tilt
function restricts the flow from the pump to lift/lower when tilt is affected, while the boom
is lowered by gravity and the minus side is filled with oil from the anti-cavitation valve for
back-up pressure.
Customer Support AB
Variant
Control valve with shock valve on the lift function.
Basic system
A B
P
K1
B
GR
A T P
B
P
A
W BL
G1 G2
3:RD
K2
T B
A
B
K7
K3
A
Tilt
A Y
B R
R/Y
K4 K6
Lift
K5

Customer Support
Servo-controlled Round-pumping system

Fill in:
• working hydraulics in neutral position (round-pumping system)
• the servo system
Review components
Connect the system
Review the functions

• lift
• lower
• shock
Measurement exercise
Basic troubleshooting if time allows

System with 3 functions
A B
P
K1
B
GR
V
A T P
B
P A
A *
B
W BL
G1 G2
3:RD
K2
T B
A
B
K7
K3
A
Tilt
A Y
B R
R/Y
Lift K4 K6
K5

Customer Support

Measurement exercise:
What happens (what should the gauges show) in the following cases
• neutral
• the function is run slowly (just moves)
• the function is run with max. speed
• in end-position
Let the students discuss one measuring point at a time. When they have agreed on what
the gauge should show, tell/check the result with practical measuring on the bench.
System with 4 functions and attachment lock
A B
P *
K1
B
GR
V
A T P
P A
B
W BL
G1 G2 *
3:RD
K2
T
A
B
K7
K3
Tilt
A Y
B R
R/Y
K4 K6
Lift
K5

Customer Support

Basic Machine
A B
P
K1
9
GR
N A T P
B
P A
5 W BL
BRAKE K2
T 3:RD B
A
B
K7
2 K3
A
Tilt
A Y
8
4 B R
R/Y
K4 K6
1 Lift
6
3
K5
1.
2.
3.
4.
5.
7
6.
7.
8.
9.
Customer Support

Volvo Wheel Loaders AB
Service Support L55129B
Control valve
CONTROL VALVE
* *

Customer Support AB
Control valve
Backup valve
1 2 5
7
6

Customer Support AB
Pressure back-up valve

Tilt section

Customer Support AB
Neutral
Control valve, tilt
Tilt in

Customer Support AB
Tilt in
Control valve, tilt
SHOCK/ANTI-CAVITATION FUNCTION
Volvo Construction Equipment L67670B

Customer Support AB
Shock-Anti-cavitation
Function
Shockfunction
1 2 3
6 4

Customer Support AB
Shock valve
Function
Anti cavitation function
1 4
3 2

Customer Support AB
Anti-cavitation
Valve, Function
Servo valve

Customer Support AB
Servo valve
Customer Support AB
Proportional pressure build-up

from servo valve when activated
SERVO PRESSURE RELIEF VALVE
MA 913
24v

Customer Support AB
Reduction valve
Normal servo pressure
SERVO PRESSURE RELIEF VALVE
MA 913
24v

Customer Support AB
Reduction valve
Increased servo pressure
LS-system
These exercises are only to demonstrate certain basic principles in LS-systems, as well as
certain measuring technology for these. It is important to note that to get a fully functional
system, additional components are required such as load holding valves, control valves
with control on the return side, etc. The principal design can be said to adhere to earlier
reviewed systems (Hydraulic valves page 5-8) but with the specific LS-parts added.
T P
A

Customer Support
Connection 1
Use the servo valve (closed centre valve) as control valve. Connect pump, tank as well
as a cylinder. Let students discuss to decide what else is needed. Add non-return valve/
shuttle valve in the line before signal pressure. Review (repeat) the general methodology
before checking/adjusting stand-by pressure and max. pressure, respectively, and then
let the students do this. Stand-by pressure 25 bar, max. pressure 60 bar. (60 bar max.
pressure when the servo valve is used).
After noting that the pump does not return to stand-by pressure with the load in neutral
position:
Discuss possible solutions (restriction, relief valve in the LS-line).
Build in the variable restriction in the LS-line and test to arrive at a suitable setting.
Measure the flow between the pump and control valve
1. in neutral position
2. when the cylinder moves (is run)
3. with the cylinder in end-position
At the same time, measure the pressure in the LS-line and directly after the pump.
Stand-by pressure/max. pressure checking and adjusting.

When checking and adjusting pressure on the hydraulic bench, any previous settings are
to be regarded as unknown. Therefor a suitable first step with regards to safety should also
be to loosen the spring tension completely, both on the flow and pressure compensator.
1. Setting stand-by pressure:

Start the engine, all functions in neutral position. Alternately tension the springs in the
pressure and flow compensator. The pressure compensator shall have slightly higher
tension than the flow compensator. This is to ensure that it really is the flow compensator
that is controlling the stand-by pressure.
2. Setting max. pressure:

To ensure that the pressure compensator’s spring tension is not too high: start by
loosening the spring tension on the pressure compensator so much that the pressure
gauge starts to drop slightly. This shows that the pressure compensator has started to
control the stand-by pressure, which means a known start value for continued setting.
Then, run a function in end-position. End-position corresponds to max. load and thus max.
pressure build-up. In general, a function without shock valve should be chosen. This is so
that any leakage or lower opening pressure does not affect the adjustment.
The max. pressure can be read off and adjusted as long as the function is affected.
NOTE! Always keep safety in mind when working with pressurized systems!
Use pressure gauges with suitable measuring range for stand-by pressure and max.
pressure, respectively. Often one gauge is not enough for both pressures, instead the
gauge must be changed between the checks.
3
T P
A
1 2

Customer Support
Priority of LS-pressure from different functions

Build in another cylinder to the connection from the previous step. Test-run the functions.
Confirm what happens with pressure and flow.
1) One function in neutral position, the other is activated

- under movement
- in end-position (”stalled”)
2) Both functions activated in parallel

- under movement
- in end-position (”stalled”)
3) One function is held in end-position from the start, the other is run
In the connection with this ”control valve” the non-return valves/shuttle valves 2 and 3 will
function as priority valves for the LS-pressure, that is, it is always the highest pressure that
is passed on to the flow compensator. A reference for system application on machine is the
control valve on L110E – L220E.
Some control valves do not lead off the LS-pressure via the non-return valve but instead
through the valve slide itself, for example, L60E – L90E. Then, in order to give priority
to the LS-pressures as well as prevent the LS-pressure from draining to tank, it may be
necessary to install a shuttle valve corresponding to that in position 3.
T P
A

Customer Support
Restriction
To clarify priority of the LS-pressure from the function with different load, and thus different
pressure build-up, a higher load can be simulated by connecting a restriction on the return
side from one of the cylinders.
Adjust the restriction so that a significantly higher pressure build-up is required when the
cylinder is run, compared with running the other.
Then the measurements from the previous task can be repeated, and the differences can
be compared.
T P
A

Customer Support
Pressure limiting valve

If the function with different max. pressure is connected to the same pump, a solution can
be to build in a pressure limiting valve in the LS-line from that function. Due to the pressure
limiting valve, a pressure difference is generated between pump and flow compensator
so it can open and angle off the pump. For example, we can find a practical application
for max. pressure in the central block on the E-series loaders, then in combination with a
pressure reducing function. More of this is reviewed during the machine course.
Circulation flow control
Theory
1. Circulation flow control is a system that is a combination of round-pumping and load-
sensing system.
The slide in the directional valve stands in neutral position and the oil from the pump
circulates through the round-pumping channel to tank. A round-pumping pressure is
created due to the flow resistance in channels and lines.
The round-pumping pressure at the outlet from the directional valve is connected to the
compensator on the pump and controls the flow from the pump. This pressure sets down
the pump flow close to zero.
The pump maintains the set so-called stand-by pressure by delivering a flow that matches
the internal leakage of the pump, at the slide and the flow through the restriction to tank.
2. The operator wants to lift the piston in the hydraulic cylinder and therefore moves the
directional valve’s slide downward to get flow to the piston side.
The round-pumping channel closes and the supply to the pump’s compensator is stopped.
The control line between the directional valve and the pump is drained to tank through the
restriction. The pump increases the flow and the load holding valve opens when the pump
pressure is higher than the pressure on the piston side.
3. The piston moves up and the oil on the piston rod side is drained to tank via the
directional valve.
If the movement stops due to high resistance, the pump will reduce the flow and only
compensate for internal leakage, but maintain max. pressure as long as the lever is
activated.
13
Hydraulic diagram A35D and A40D

Braås: s/n xxxxx -
US: s/n xxxxx -
a T P b
Brazil: s/n xxxxx - 14
C3 C2
SE9102
B Pa 12
10
M1 M2 BVLS5 LD
BVLS1 M4 M5 M6
A L 21 D1 BVLS2
11 a b P6
P4
P3
P2 BV1 OC 4 BVLS4
CHV1 CHV2 T B1-
7 3 1 P1 BV2 3
MA9102
P A1+
M VV2
T2 A-Y 2 BVLS3
5 6 2
BV3 BV4 1 BV5
MTRV1
B-X
VV1 CHV3
22
A L
9 BRAKE R35
B SYSTEM MTRV2
T3 D3 P5 A Y X B T4
Pa M3 M7 M8
16
SE9103
19
SE9104
SE9105 C°
15
17 20 8

Customer Support AB
Hydraulic diagram, A35D and A40D

Cooling fan and brake system
L60E D MA 502 MA 202 PB PR PW LSW
MPR
L70E PFF
L90E
SE502 SE504
N SE 503
MA 501 P
S
PFF
M SP1 S1 S2 SP2 T
P B PS
PPB PA
PB M
T LSF PF LSP LSS
G
L T SP 1 T SP 2
B BR 1 BR 2
M1 M2
Pa
SE 301
SE 501
P3
Rear Front
O
P2 O A D L
A
C
SE 906
G C B M N

Customer Support AB
Hydraulic diagram, L60E-L90E

Fan and brake
Hydraulic diagram, EW160B
A
33
(58-3)Pi
Full Hydraulic Circuit E C240B P T (51-T)

(31-T6)
(12-A2)
32
S H(58-2) (51-P)
1
2
3
Main pump
Main control valve
S wing motor & gear box
51
52
53
Adj. boom selector valve
Adj. boom R CV
Adj. boom valve
4 Travel motor & gear box 54 2nd boom cylinder
3 PG
5 Boom cylinder 55 R otator valve
B C(2-P R 1)
40 (17-G) (9-S 2) 6 Arm cylinder 56 R otator solenoid valve
Pi(43-A) (11-A2) Dr
(53-P)
Dr(21-Td1) (21-Td8) (27-in) 7 Bucket cylinder 57 Check valve for rotator
pw 5 (2-Ps)
PR2 (2-Pi)
(2-Px1) A Pb dr5 PL Py 8 S ervo hydraulic filter 58 Block
50 PR
48 (21-Td7) Po Ps (2-Py) 9 Accumulator block 59 S huttle valve block(A) for X1
P3 P3 (9-PS 1)
2 (2-dr2) 10 Accumulator 60 S huttle valve block(B) for X1
B(back)
Mu(2-R s1)
A(for)
P2 P2 Pg2 270k
Left
dr4 dr3
4
62 64
61 11 S olenoid valve 61 Arm conflux valve
(2-BL4)
(36-P3)Y (21-Td6)
C
Pi Pi 3Pi
17
(2-AL4) (2-AR 3)
12 solenoid valve 62 Logic valve
355 k
(2-ar1)
E G
72
(3-Dr)
13 R emote control valve - left 63 Boom holding valve
(11-A3)
P1 T T P1 (16-S L1)
14 R emote control valve - right
B F
BR 1 65 al1 64 Main relief valve
(2-ar1) 63
(2-BR 3)
38 bl1(16-S R 1) 15 R emote control valve - travel 65 Orifice
or (63-P)
A(back)
BL1 A B 16 S huttle valve block
B(for)
R ight
(21-Td4) 66 S traight travel valve
4
(3-Mu)R s1 AL1 17 Turning joint
(16-BD1) or (63-B) 39 P R 1(40-C) 67 C enter bypass valve
(2-3Pi) ar1 al2(59-2) 18 Hydraulic oil cooler 68 Flow sensing valve
(48-Pi) bl2(59-1) 19 C heck valve(3k)
(16-BU1)br1 69 Port relief valve
AR 1 69 20 C heck valve(4.5k) 70 Arm regenerating valve
BL2
AL2 21 Hydraulic oil tank 71 Arm spool
22 R eturn filter element 72 Boom holding valve
(16-BI1)ar2 70 Pd(33'-A)
23 Bypass valve
(16-BO1)br2 pa(28-3) 73 Arm holding valve
(16-AI1) Pi 49 24 Bypass strainer
BR 2 al3 (58-4)
74 S top valve
66 bl3(16-AO1) 25 S trainer
AR 2
4Pi 6 75 Tilting line
26 Air breather 76 Pattern changer
71 BL3
79 P1 P2 27 Drain filter 77 Boom floating v/v
(15-3)ar3
(15-4)br3 AL3 dr2(2-dr4) 28 Valve block 78 Boom floating sol.
7 al4(15-1) 365k
13 Left 29 Filter connector 79 3-way v/v(grapple)
(17-D)BR 3 bl4(15-2) T1 T2
30 Filter connector 80 3-way v/v(grapple)
(17-F)AR 3
S T7 S T9
Grapple
67 BL4(17-C) (21-Td3) (21-Td3) 31 Valve block

AL4(17-E )
80 67 (2-4Pi) 32 S wing ring gear
(12-A3)a b(12-A2)
or 58 4 1 3 2 4 33 Pilot selector valve
(43-A)X1 2P 68 (33-Pi) 29
68 3 1 AI2 (31-T5)T P(31-P5)
34 Pressure switch
2 AI
(3-S H) (2-al3)AI1 36 Quickfit valve
dr1 AM AO
t5(62-t) R Fr(1-Pi2) Px2 Pi
Pg1 29 Px1 Fl(1-Pi1)
2 (2-Pa)
(2-bl3)AO1
SR 37 R otator pump
(21-Td5) 28 (2-bl1)S R 1
(2-Po) 38 C ap(orifice)
P1 P2 (53-pi) 1 3
(2-al1)S L1 SW SL
BI 14 R ight 39 C ap(check valve)
(2-Ps) P1 T1(21-Td2) 31 (2-ar2)BI1
20 19 30 Psv (43'-P) (43'-T)
Oil leak
4.5k 3k
1
a4 (16-Bu2) (41-P) (41-T) (2-br2)BO1
BO S T7 S T9 40 Option conflux selector valve
P2 T2 (42-T) (3-PG) BD
(14-P)P3 (63-P), (2-ar1)BD1 41 S olenoid valve
a1 a2 T3 (14-T) 51 BU
(1-Dr) 18
(52-P) (52-T) P
(2-br1)BU1 42 R emote control pedal for X1
(15-P) P4 T4 (15-T) (53-C) 1 3 2 4
16 43 S olenoid valve
(13-P)P5 T5(13-T) Pi BU2
t1(36-T) (31-T3)T 29
(3-Dr) 43' S ol. Thumb bucket
t2(55-T) (2-Fl) P6 T6 (33-T) P(31-P3)
In 26 T(33-T) A
27 t3(47-out) Pi1
(12-P1)(12-T)
(33-P) (2-a)
(2-Px1) 44 Hammer pressure switch
Pi2 34 45 Flow control valve
Out
(53-R )t4 (2-b) X1 2P(43-A)
21 (45-A) (2-Fr) A2(2-Py) A3(17-B) (59-6)A1 A2 A3
A1 46 3 way selector valve for X1
(2-Pg2)
T ADD X1 10
(40-T) 22 11 12 15
(11-T) Td1 a3 (45-T) 47 R eturn filter
23
(31-T1)Td2
E ngine 9 G AC (21-Td1) T (31-T6) 2 1 4 3 48 Boom line rupture valve
(49-T1) Td3 24 P1 P2 P3 P2 T (2-bl4) T (2-al4) (2-br3) (2-ar3)
(49-T2)
Td6 Td7 Td8 P1 49 Arm line rupture valve
(48-T)Td4 A3 PS PS 1 P1 29 P2 P3 (31-T4) 29 P
Td5 25 S 3 (45-P) 29 29
29 29 (31-P4) 50 Overload pressure switch
(2-dr5) 37 Out P4 40k 8 S 1 S 2(3-PG) (33'-P)
(43-T) (62-Dr) (55-P) B3 Dr(27-in) (31-P6)
(2-dr1) (2-dr4) (36-PS )
(2-dr3) (46-dr) (33'-T)
Hydraulic diagram, EC240B

Hydraulic Technical

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PROGRAMME

Time Monday Tuesday Wednesday Thursday Friday

Design, single-lever Design, three-lever Basic troubleshooting

Volvo Construction Equipment

Volvo Construction Equipment 1019354

Flow divider, principle

Volvo Construction Equipment 1019355

Pump gives flow, no pressure

Volvo Construction Equipment 1019367

Volvo Construction Equipment 1019502

Volvo Construction Equipment 1019503

This proves Pascal’s law:

Volvo Construction Equipment 1019974

Volvo Construction Equipment 1019357

Volvo Construction Equipment 1019956

Volvo Construction Equipment 1019957

Volvo Construction Equipment 1019958

Volvo Construction Equipment 1019959

30 bar 10 bar 20 bar

Volvo Construction Equipment 1019964

Volvo Construction Equipment 1020414

One variant is to allow the students to draw the symbols as well.

Volvo Construction Equipment L67677A

Direct controlled pressure limiting valve

Explain the different parts:

Volvo Construction Equipment L68084A

Pilot-controlled pressure limiting valve

- Dismantle the valve.

Specifications, L120D, capacities

Fig.1 Hydraulic system, working hydraulics 3rd/4th function

Specifications, L90D, capacities

Specifications, L120D, capacities

Specification L90D, general

Specification L120D, general

Fig.7 Control valve

Fig.8 Control valve, connections for servo pressure

Fig.9 Section of control valve

Fig.10 Control valve, neutral position

Green Atmospheric pressure

Fig.11 Control valve, roll-back (rear tilt)

Fig.12 Back-up valve for return pressure, unaffected position

Red Working pressure

Blue Increased return pressure

Blue Increased return pressure

Fig.15 Anti-cavitation function, L120D

Specification L90D, general

Specification L120D, general

NOTE! To reduce the risk of cavitation damage when start-

Table for Fig. 17 and Fig. 18.

A A A NOTE! 2.1 MPa (304.5 psi) is the highest controlled output

Fig.18 Servo valve

2 Adjust the distance between the lever adjusting screw and

Sensing position at 2.1 MPa (304.5 psi)

3 The sensing position is adjusted using the adjusting screws

Fig.23 Sensing position

Hold (detent) solenoid, bucket leveller, boom kick-out

Fig.26 SW903 Switch, float position

The following applies when checking: