416E Backhoe Loader Single Tilt Center Pivot SHA00001-UP (MACHINE) POWER...

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Product:  BACKHOE LOADER

Model:  416E BACKHOE LOADER SHA
Configuration: 416E Backhoe Loader Single Tilt Center Pivot SHA00001-UP (MACHINE) POWERED BY 3054C Engine

Testing and Adjusting

416E, 422E and 428E Backhoe Loaders Hydraulic and Steering System
Media Number -RENR6479-04 Publication Date -01/09/2011 Date Updated -14/09/2011

   
i03311681

Hydraulic Pump - Test and Adjust

SMCS - 5070-025; 5070-081

Sudden movement of the machine or release of oil under pressure can

cause serious injury to persons on or near the machine.

To prevent possible injury, perform the procedure that follows before

testing and adjusting the hydraulic system.

Personal injury or death can result from escaping fluid under pressure.

Escaping fluid under pressure, even a very small pin-hole size leak, can
penetrate body tissue and cause serious injury and possible death. If
fluid is injected into your skin, it must be treated immediately by a
doctor familiar with this type of injury.

Always use a board or cardboard when checking for a leak.

Table 1
Required Tools    
Part Number     Description     Quantity    
6V-4143   Couplers 4

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1U-5793 Pressure Differential Gauge 1

177-7860 Hose Assemblies 2
8T-0856 Pressure Gauges 2
8T-0860 Pressure Gauge 1
6V-3989 Fittings 4    

Illustration 1 g01274096

(1) Hydraulic pump

(2) Flow compensator valve

(3) Pressure compensator valve

(4) Signal pressure tap

Note: Do not adjust the pressure compensator (3) . Any attempt to tamper with the pressure
compensator could result in a valve and a pump failure.

Signal pressure tap (4) is located on hydraulic pump (1) . Flow compensator valve (2) and
pressure compensator valve (3) are also located on hydraulic pump (1) . Access is gained from the
bottom of the machine or access is gained by removing the floorplate.

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Illustration 2 g01274126

(1) Hydraulic pump

(5) System pressure tap

System pressure tap (5) is located at the bottom of pump (1) . Access is gained from the bottom of
the machine.

Prior to making any pump adjustments, perform "Low Pressure Standby Pressure Test", "Margin
Pressure Test" and "High Pressure Stall Test".

Increase the hydraulic oil temperature to the operating temperature by installing the boom lock,
setting the engine to HI IDLE, and stalling the boom down for 60 seconds. Check for leaks.

Assembly of the Hose Assemblies

1. Install one 6V-4143 Coupler to each end of the 177-7860 Hose Assemblies .

2. Install one 6V-3989 Fitting to each pressure gauge.

Low Pressure Standby Pressure Test

1. Start the engine.

2. Lower the work tool on the front of the machine and the stabilizers to the ground. Engage
the parking brake. Stop the engine.

3. Move the hydraulic hand controls to all the positions in order to release system pressure.

4. Remove the floorplate and the floor mat.

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Illustration 3 g00869466

a. Remove two bolts (6) and plate (7) .

Illustration 4 g00869467

b. Remove two bolts (8) and plate (9) . Remove floor mat (10) .

Illustration 5 g00869469

c. Remove six bolts (11) from the perimeter of floorplate (12) . Set floorplate (12) aside.

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5. Install the 8T-0856 Pressure Gauges with a range of 0 to 6000 kPa (0 to 870 psi) to each
hose assembly. Install one hose assembly to pressure tap (5) for system pressure. Install one
hose assembly to signal pressure tap (4) . Refer to Illustration 1 and Illustration 2.

6. Start the engine. Run the engine at HIGH idle. Check for leaks.

Note: Do not move any hydraulic hand controls nor move the steering wheel while the 8T-
0856 Pressure Gauges are installed. The higher pressure that is created by upstroking the
pump will damage the gauges.

7. Lower the engine speed to 1200 RPM.

8. The pressure reading on the gauge that is attached to signal pressure tap (4) should be
approximately 500 kPa to 1600 kPa (70 psi to 230 psi). This pressure is the standby signal
pressure. The standby signal pressure is not adjustable. If the standby signal pressure is in
the range, proceed to Step 10.

Note: The standby signal pressure will vary with each machine.

9. If the standby signal pressure is out of the range, remove the test equipment and cycle the
steering. Then, perform the test again. If the standby signal pressure is out of the range,
there is a possibility of a plugged orifice in the priority spool or in the metering pump.

10. Do not move any hydraulic hand controls nor move the steering wheel. The pressure
reading on the gauge that is attached to pressure tap (5) is the low standby discharge
pressure. The low standby discharge pressure should be approximately 2000 kPa to 3700
kPa (290 psi to 540 psi).

Note: If the standby discharge pressure is not correct perform the "Margin Pressure Test".

11. Stop the engine.

12. Move the hydraulic hand controls to all the positions in order to release system pressure.

13. Remove all test equipment.

Note: Failure to remove the 8T-0856 Pressure Gauges prior to performing the following
tests will cause the gauges to be destroyed, when the pump is upstroked. A 1U-5793
Pressure Differential Gauge should be used in order to perform the "Margin Pressure Test".

Margin Pressure Test

1. A 1U-5793 Pressure Differential Gauge is used in order to perform the margin pressure test.
Attach one 177-7860 Hose As to pressure tap (5) for the pump discharge pressure. Attach
the other end of the hose assembly to the 1U-5793 Pressure Differential Gauge . Install the
other 177-7860 Hose As to signal pressure tap (4) . Connect the other end of the hose
assembly to the 1U-5793 Pressure Differential Gauge .

2. Engage the parking brake. Start the engine. Keep the machine in NEUTRAL.

3. Run the engine at 1200 RPM.

4. Turn the steering to the stops in both directions for three cycles. Turn the steering to the
right to the stop.

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Note: There may be air in the signal network, if there is a hesitation before reaching the
relief pressure. Purge the signal lines of the air.

5. Read the pressure on the differential pressure gauge. This is the margin pressure. The
margin pressure should be 2150 kPa to 2450 kPa (312 psi to 355 psi). If the margin pressure
is out of the specification, then refer to "Flow Compensator Spool Adjustment" in
"Adjustments for the Pump Controller".

6. Return the steering wheel to the centered position.

7. In order to verify the pressure, repeat Step 4 and Step 5.

8. Run the engine at LOW idle. Stop the engine.

Note: Do not make adjustments to the pressure compensator spool.

9. If the margin pressure is correct, proceed to the "High Pressure Stall Test".

High Pressure Stall Test

Table 2
Hydraulic
416E and 422E     428E    
Circuit    

Loader Circuit     19700 kPa to 21700 kPa (2860 psi 21800 kPa to 23800 kPa (3160 psi
to 3150 psi) to 3450 psi)
Backhoe Circuit
  21800 kPa to 23800 kPa (3160 psi to 3450 psi)

High Pressure Stall Test for the Backhoe

1. Remove the 1U-5793 Pressure Differential Gauge that was used in the "Margin Pressure
Test". Connect a 8T-0860 Pressure Gauge with a range of 0 to 40000 kPa (0 to 5800 psi) to
the hose assembly that is connected to pressure tap (5) .

2. Install the swing lock pin and install the boom lock.

3. Ensure that the work tool on the front of the machine and the stabilizers are on the ground.
Engage the parking brake.

4. Start the engine. Run the engine at 1200 RPM.

5. Move the boom control to the boom up in order to initiate a stall condition for the boom.
Note the pressure reading at pressure tap (5) .

6. See Table 2 for the proper pressure readings at pressure port (5) .

Note: There may be air in the signal network, if there is a hesitation before reaching the
relief pressure. Purge the signal lines of the air.

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7. If the pressure is not within the specification, the signal relief valve needs to be adjusted.
Refer to "Adjustment of the Signal Relief Valve For the Backhoe". If the pressure is within
the specification, stop the engine and perform the "High Pressure Stall Test for the Loader".

Adjustment of the Signal Relief Valve For the Backhoe

If the system pressure is out of the specification during the stall test, then adjust the signal relief
valve.

Illustration 6 g01276059

Bank valve for the backhoe

(C) Signal relief valve for the backhoe

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Illustration 7 g01282284

1. Remove plastic cap (13) in order to access the M4 allen screw for adjusting.

2. Rotate M4 allen screw (14) in order to change the setting. Make small rotations at a given
time.

Note: Do not adjust more than a quarter turn.

Note: Rotate adjustment screw (14) clockwise in order to increase the pressure setting.
Rotate adjustment screw (14) counterclockwise in order to decrease the pressure setting.

3. Install plastic cap (13) .

High Pressure Stall Test for the Loader

1. Ensure that the work tool on the front of the machine and the stabilizers are on the ground.
Engage the parking brake.

2. Start the engine. Run the engine at 1200 RPM.

3. Move the tilt control for the loader in order to tilt the bucket. Stall the bucket in a rack
position. Note the pressure reading at pressure tap (5) . See Table 2 for the proper pressure
readings at pressure port (5) .

4. If the pressure is not within the specification, the signal relief valve needs to be adjusted.
Refer to "Adjustment of the Signal Relief Valve For the Loader".

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5. Stop the engine and remove the gauges.

Adjustment of the Signal Relief Valve For the Loader

If the system pressure is out of the specification during the stall test, then adjust the signal relief
valve for the loader.

Illustration 8 g01275889

Bank valve for the loader

(D) Signal relief valve for the loader

The signal relief valve for the loader is located in the inlet cover of the loader valve on the bottom
side. The signal relief valve for the loader is in the same location for single tilt and parallel lift
valves. Also, the signal relief valve for the loader is in the same location for two and three bank
valves.

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Illustration 9 g01276020

(D) Signal relief valve for the loader

(15) Plastic cap

(16) Allen head screw for adjusting

1. Remove plastic cap (15) in order to access adjustment screw (16) .

2. Rotate allen head screw (16) in order to change the setting. Make small rotations at a given
time.

Note: Do not adjust more than a quarter turn.

Note: Rotate adjustment screw (16) clockwise in order to increase the pressure setting.
Rotate adjustment screw (16) counterclockwise in order to decrease the pressure setting.

3. Install plastic cap (15) after adjustment.

Adjustments for the Pump Controller

NOTICE

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When the compensator valve is rebuilt, ensure that the pressure

compensator adjustment and the flow compensator adjustment are
backed out to a low pressure setting before the engine is started. Severe
pump damage and system damage could be the result, or the engine
may not start.

Illustration 10 g01274171

Compensator valve

(17) Flow compensator spool

(18) Set screw

(19) O-ring

(20) Set screw

(21) Adjustment screw

(22) Adjustment screw

(23) O-ring

(24) Pressure compensator spool

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Illustration 11 g01274686

Flow Compensator Spool Adjustment

If the Margin Pressure is not within the specification, then do the following procedure.

1. Lower the work tool on the front of the machine. Engage the parking brake.

2. Stop the engine.

3. Move all the hydraulic hand controls through all of the positions in order to release pressure
in the hydraulic system.

4. Connect one end of the 1U-5793 Pressure Differential Gauge to pressure tap (5) for the
system pressure. Connect the other side of the pressure differential gauge to signal pressure
tap (4) .

5. Repeat the "Margin Pressure Test". If the margin pressure is within specifications, then go
to Step 10.

6. Loosen set screw (20) .

7. Rotate adjustment screw (21) .

Note: Rotate adjustment screw (21) clockwise in order to increase the margin pressure
setting. Rotate adjustment screw (21) counterclockwise in order to decrease the margin
pressure setting.

8. Tighten set screw (20) .

9. Repeat the "Margin Pressure Test" until the margin pressure is within the specification.

10. Lower the implements to the ground. Stop the engine and engage the parking brake.

11. Remove all test equipment.

Copyright 1993 - 2013 Caterpillar Inc.   Fri Nov 8 16:32:10 CST 2013
All Rights Reserved.
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