HMK 102 ENERGY WORKSHOP MANUAL

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HYDRAULIC
1
SERVICE
TECHNICAL DATA
THESE DATA ARE VALID FOR BOTH HMK 102B & HMK 102S MODELS.

HYDRAULIC PUMP
MODEL Double pump

ROTATION (VIEWED FROM DRIVESHAFT END) Anti-clockwise

MOUNTING Coupled on the transmission

THEORETICAL DISPLACEMENT cc/rev

PUMP SECTION 1 (mounting flange end) 46
PUMP SECTION 2 23

FLOW AT 2200 rev/min AND SYSTEM PRESSURE

( 95% DISPLACEMENT )
PUMP SECTION 1 (mounting flange end) 81,4 lt /min
PUMP SECTION 2 64,0 lt/ min
MAXIMUM SYSTEM PRESSURE 230 bar ( 3335 PSI )

AUXILARY RELIEF VALVE

RELIEF VALVE OPERATING PRESSURES bar PSI

TELESCOPIC DIPPER RAM HEAD SIDE 210 3045

TELESCOPIC DIPPER RAM ROD SIDE 210 3045
JAW BUCKET RAM HEAD SIDE 248 3600
JAW BUCKET RAM ROD SIDE 248 3600
DIPPER RAM HEAD SIDE 248 3600
DIPPER RAM ROD SIDE 248 3600
SLEWING RAM HEAD SIDE 158 2300
SLEWING RAM ROD SIDE 158 2300
BOOM RAM HEAD SIDE 248 3600
BOOM RAM ROD SIDE 310 4500
SHOVEL CROWD RAM HEAD SIDE 158 2300
SHOVEL CROWD RAM ROD SIDE 248 3600

MAIN RELIEF VALVE 230 3335

HYDRAULIC FILTER ELEMENT

RELIEF VALVE OPERATING PRESSURES
BY-PASS PRESSURE 2 29
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TECHNICAL DATA

LOADER VALVE

ITEM DESCRIPTION
4J ARMS LIFT SERVICE
4K SHOVEL SERVICE
4L CLAM SHOVEL
SERVICE
1H PUMP SECTION 1-
INLET
2H PUMP SECTION 2-
INLET
4A PRESSURE TEST
PORT
4B CLAMSHOVEL
RELIEF VALVE
4F UNLOADER RELIEF
VALVE
4E UNLOADER
SOLENOID
4M AUXILIARY RELIEF
VALVE
4N AUXILIARY RELIEF VALVE
1H+2H CARRY-OVER PORT
1D TANK PORT
P SERVICE PORTS
Y DATA PLATE
4G,4H LOAD HOLD CHECK
VALVES

RELIEF VALVE OPERATING PRESSURES bar PSI

MAIN RELIEF VALVE (1500 rpm) (M.R.V) 227 3300
UNLOADER VALVE 207 3000
CLAM SHOVEL RELIEF VALVE 217 3150
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HYDRAULIC
SERVICE

TECHNICAL DATA

BACKHOE VALVE
ITEM DESCRIPTION ITEM DESCRIPTION
SERVICE PORT Stabilizer left
P1+P2 CARRY OVER from loader valve 10
side, head side
SERVICE PORT Stabilizer right
5C DIPPER 3
side, rod side
SERVICE PORT Dipper arm rod SERVICE PORT Stabilizer right
6 9
side side, head side
SERVICE PORT Dipper arm
12 5G SLEW
head side
5J A.R.V. Dipper arm rod side 5T A.R.V. Bucket crowd ram
5X A.R.V. Dipper arm head side 5S A.R.V. Bucket crowd ram
SERVICE PORT Head side of
5D BUCKET CROWD 2
right ram, rod side of left ram
SERVICE PORT Bucket crowd SERVICE PORT Rod side of right
5 8
ram head side ram, head side of left ram
SERVICE PORT Bucket crowd
11 5H BOOM
ram rod side
5L A.R.V. slew head side 5V A.R.V. Boom head side
5K A.R.V. slew rod side 5U A.R.V. Boom rod side
5E STABILIZER Left side T 1 ,T 2 TANK PORTS
5F STABILIZER Right side 5R, 5Q, 5P, 5O, 5N, 5M
SERVICE PORT Stabilizer left ARE LOAD HOLD CHECK
4
side, rod side VALVES
HYDRAULIC
SERVICE
TECHNICAL DATA

RELIEF VALVE OPERATING PRESSURES Bar PSI

JAW BUCKET RAM HEAD SIDE 248 3600

JAW BUCKET RAM ROD SIDE 248 3600
DIPPER RAM HEAD SIDE 248 3600
DIPPER RAM ROD SIDE 248 3600
SLEWING RAM HEAD SIDE 158 2300
SLEWING RAM ROD SIDE 158 2300
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4 BOOM RAM HEAD SIDE 248 3600
BOOM RAM ROD SIDE 310 4500
SHOVEL CROWD RAM HEAD SIDE 158 2300
SHOVEL CROWD RAM ROD SIDE 248 3600

HYDRAULIC CONTAMINATION

HYDRAULIC FLUID QUALITY

Construction machinery uses different types of fluids in the hydraulic system for
power transmission, equipment lubrication, and rust prevention. Seventy two percent
( 72 %) of the causes of problems in hydraulic equipment are related to the
inadequate maintenance of the quality of the hydraulic fluid therefore, control of the
quality of the hydraulic fluid minimizes hydraulic equipment problems and improves
safety as well as reliability.

EFFECTS OF CONTAMINATION
Contamination greatly effects the performance and the life of the hydraulic
equipment. for example , if there is a contaminant in a hydraulic pump, it develops
internal wear to cause leakage and hence lower delivery output. The particles worn
will cause further deterioration in the performance of the hydraulic system.
Contaminants also enter principal sliding sections of the equipment causing
temporary malfunction, scuffing, rubbing, sticking, chaffing and leakage and can lead
to major problems seriously.

THE CONTAMINANTS ARE CLASSIFIED AS FOLLOWS:

1. SOLID PARTICLES:
Sand, fibres, metallic particles, welding scale, sealing materials and wear
particles.
2.LIQUID:
Usually water and inadequate oils and greases.
3.GASES:
Air, sulphur dioxide etc. that cause corrosive compounds if dissolved in the fluid.

HYDRAULIC
SERVICE
HYDRAULIC CONTAMINATION
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FIGURE: SUDDEN FAILURE FIGURE: BROKEN PUMP

DRIVE SHAFT

Big metal particles are The pump drive shaft is broken by

squeezed in the tooth of the effects of contaminants such
the gear pump. as blocking A. R. V. and leading to
occur of peak pressure.

FIGURE: SCRATCHED RAM

FIGURE : RUST FORMATION
You can see a scratched rod of a ram
damaged by contaminants entering through You can see the results of the
the end cap of the ram. These scratches can hydraulic contamination as rust
cause greater problems by allowing more formation on the samples given.
contaminant in.
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HYDRAULIC
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CONTAMINATION STANDARDS

Contamination that damages the hydraulic system can be seen too small to be
identified visually. The particle is in micron size.

1 MICRON (µ) = 0.001 mm (0.0000394 in)

Listed below are a few typical comparisons:

Red blood cells : 8µ

Human hair : 72 µ
Smallest particle that may be identified visually is 40 microns, normally.
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FILTERS
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7
The filter assembly fitted to HMK 102 B and
HMK 102 S are designed to filter all the
contamination that is rated to the required
level of cleanliness. It must be serviced
according to the requirements given in the
Operation & Maintenance manual. All data
is given in this manual on specifications &
periodical maintenance of the filters.

HYDRAULIC
SERVICE

TROUBLE SHOOTING
The aim of this section is to shoot the trouble when you face with a failure in a faulty
unit such as valves, rams and pumps etc.. If you trace a failure in a faulty unit, refer
to dismantling, inspecting and test instructions given in the following sections in this
manual. It is very important to refer to hydraulic circuit diagrams and relevant
sections to identify the failure.

TO SHOOT THE TROUBLE:

1. READ THE RELEVANT SAFETY INFORMATIONS.

2. MAKE SIMPLE CHECKS AND BEGIN TO FIND THE CAUSE OF FAILURE
FROM SIMPLE TO COMPLEX.
3. MAKE SURE THAT THE HYDRAULIC FLUID IS AT CORRECT OPERATING
TEMPERATURE AND MAKE SURE THAT THE TEMPERATURE IS NOT
OVER 80°C MAXIMUM.
4. CHECK THE CONDITION OF THE HYDRAULIC FLUID AND IF NECESSARY
DRAIN & REPLACE IT.
5. MAKE RELEVANT ELECTRICAL CHECKS BEFORE WORKING ON
HYDRAULICS.
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8 6. REMOVE ALL CONTAMINATION AND IDENTIFY THE ORIGIN OF
CONTAMINATION.
7. REMOVE AND DISCARD ALL SEALS SUCH AS ‘O-RINGS’ AND REPLACE
THEM BY NEW ONES BEFORE ASSEMBLING A HYDRAULIC
COMPONENT.

FAULT 1 : LACK OF POWER IN ALL HYDRAULIC FUNCTIONS

PROBABLE CAUSE ACTION

INSUFFICIENT HYDRAULIC FLUID Check for leaks and top up fluid as required.
LEAKAGE IN HYDRAULIC SYSTEM Check the hoses for leakage.

ENGINE PERFORMANCE Check the engine performance.

MAIN RELIEF VALVE (M.R.V) Check and adjust as required.

SETTING IS INCORRECT

LOW PUMP FLOW Check pump flow, if required replace it.

TANK FILTER BY-PASS VALVE Check the condition of hydraulic filter.

UNLOADER VALVE PRESSURE Check pressure setting of the un-loader

SETTING IS TOO HIGH valve.

HYDRAULIC
SERVICE

FAULT 2: RAMS ARE OPERATING SLOWLY

PROBABLE CAUSE ACTION

LOW PRESSURE LINES ARE BLOCKED, Check pipe lines and replace the
DAMAGED OR LEAKING failed one.

LOW PUMP FLOW Check pump flow

PRIORITY VALVE Check priority valve if it is sticking,

rectify as required.

(M.R.V) SETTING INCORRECT Check and adjust as required

UNLOADER VALVE Check whether un-loader valve sticking

or not.

TANK FILTER BY-PASS VALVE Check condition of hydraulic filter.

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HYDRAULIC TANK BREATHER Check pressure setting of the un-loader 9
valve.

FAULT 3 :ONE HYDRAULIC SERVICE IS OPERATING SLOWLY OR NOT

OPERATING

PROBABLE CAUSE ACTION

SERVICE PIPE LINES ARE BLOCKED Check pipe lines hoses and replace
OR DAMAGED the failed ones. Check ram.

RAM IS LEAKING Identify leak origin and if required

replace the seals.
A.R.V. SETTING IS INCORRECT Check & adjust it.

VALVE BLOCK SECTION IS LEAKING Check for leaks and rectify as required.
Make sure the associated load hold
check valve is operating.
Check the relevant control lever and
linkages. Check whether spool is sticking
or not.
CHECK VALVE IF MALFUNCTIONING Test the check valve.

PISTON ROD IS BENT OR WORK IN Replace piston rod, check A.R.V,

ECCENTRICITY A.R.V. & M.R.V. pressure settings
check the grease in pins.
HYDRAULIC
SERVICE

FAULT 4 : A SPOOL IS STICKING IN LOADER VALVE OR BACKHOE VALVE.

PROBABLE CAUSE ACTION

OIL TEMPERATURE IS TOO HIGH Check for correct fluid. Refer Operation
and Maintenance manual. Check oil cooler
and front grill for blockage.

THE HYDRAULIC FLUID IS Check the hydraulic filter and strainer.

CONTAMINATED If they are clogged badly, draiın and flush
the hydraulic system effectively.
Refill the hydraulic system.

SERVICE PIPE CONNECTIONS Check tightening torque for

AND ADAPTERS over- tightening.

THE VALVE HOUSING IS TWISTED Loosen retaining bolts and tighten to

BOLTS OR RETAINING ARE NOT correct torque value.
WELL TIGHTENED
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PRESSURE IS TOO HIGH Check system pressure.

LINKAGE IS BENT OR BROKEN Renew the failed one.

A SPOOL IS BENT OR SCRATCHED Dismantle and control the valve and

replace the spool.

A RETURN SPRING OR GLAND Remove the end cap, check spring is

MISALIGNED in correct position, dismantle the gland
assy. and check whether there is a failed
part or not.

HYDRAULIC
SERVICE

FAULT 5 : OIL SEALS IN THE CONTROL VALVE ARE LEAKING.

PROBABLE CAUSE ACTION

PAINT OR DIRT ON THE SEAL FACE Remove the seal & clean, if necessary
replace it.

THE BACK PRESSURE IN THE Check circuit pressures and adjust.

VALVE CIRCUIT IS EXCESSIVELY
HIGH

SPOOL IS DAMAGED Dismantle it for inspection. Renew if

necessary.

THE SEAL IS NOT SECURED WELL. Clean the seal and tighten the retaining
bolts to the correct torque.

THE SEAL IS CUT OR DAMAGED Fit a new seal.

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FAULT 6 : RAM IS CREEPING.

PROBABLE CAUSE ACTION

RAM OR PIPE LINES MAY BE Check & rectify as required.

LEAKING.

CHECK VALVE MALFUNCTIONING. Test check valve ,rectify .

VALVE SECTION SPOOLS ARE Check for contamination.

LEAKING.

A.R.V. IS LEAKING. Check for contamination.

HYDRAULIC
SERVICE

FAULT 7: HYDRAULIC OIL BECOMES TOO HOT.

PROBABLE CAUSE ACTION

OIL COOLER OBSTRUCTED Remove debris from cooler

RESTRICTION IN NEUTRAL Check hoses

CIRCUIT LINES

HYDRAULIC FILTER CLOGGED Change hydraulic filter

AND BY-PASS VALVE NOT WORKING

FAULT 8 :THE ENGINE TENDS TO STALL WHEN HYDRAULICS ARE UNDER

LOAD.
PROBABLE CAUSE ACTION

M.R.V. SETTING INCORRECT Check and adjust .

POOR ENGINE PERFORMANCE Check engine performance, see

transmission workshop manual
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UNLOADER VALVE PRESSURE Check pressure setting of the
SETTING IS TOO HIGH un-loader valve.

FAULT 9: STEERING FAILS TO RESPOND SELECTED MODE.

PROBABLE CAUSE ACTION

SELECTOR SWITCH FAULTY Check selector switch

PROXIMITY SWITCHES ARE NOT Check it’s setting, reset or replace

OPERATING PROPERLY.

STEER MODE VALVE IS NOT Check whether spools are sticking or not.
OPERATING PROPERLY. Replace if required.

LEAKS IN THE RELEVANT HOSES OR Check hoses and connections.

COMPONENT CONNECTIONS

ELECTRICAL FAILURE Check relevant electrical connectors, if

problem still persists, check the wiring
continuity on relevant circuits.

HYDRAULIC
SERVICE
HYDRAULIC CIRCUIT DIAGRAM HMK 102 B
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HYDRAULIC
SERVICE
pressure)
1. Hydraulic tank (0.3 bar inlet 1A. Suction strainer
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14 P1+P2. Pump section P1& P2 5D. Control valve, slew
P1A. Pressure test port for P1 5E,5F Control valve, stabilizers
P2A. Pressure test port for P2 5G Control valve, bucket crowd
1H. Pressure line for P1 5H Control valve, boom
2H. Pressure line for P2 5Ii,5J A.R.V. dipper (248 bar)
1H+2H. High pressure carry-over line 5K,5L A.R.V. slew (158 bar)
2. Priority valve 5S,5T A.R.V. bucket crowd (248 bar)
3H. Steering feed line 5U,5V A.R.V. boom
LS. Steering load sensing line (5U:310 bar,5V:248 bar)
1T. pressure test port for aux. val. 6. Throttle valve, return line of
3. Auxiliary valve assy. loader lift
3A. M.R.V. (250 bar),auxiliary valve 7, 8. Rams, loader lift
3D. Auxiliary valve 9,10. Rams, shovel
3B,3C. Relief valve (180 bar for 11,12. rams, clam shovel
breaker) (210 bar for extradig dipper) 13,14.Rams, hydraulic clamps
4. Loader valve block 15. Ram, dipper
4A. Pressure port for hydraulic 16. Ram, bucket crowd
system 17,18. Rams, stabilizers
4B. M.R.V.( 230 bar) 19,20 Cushion valve, slew rams
4C. Check valve 21,22 Rams, slew
4D. Spool, un-loader valve 23. Throttle valve, return line of
4E. H.S.C. solenoid valve boom ram.
4F. Un-loader valve (210 bar) 1D Return line, loader valve
4G,4H,4I Load hold check valves 2D Return line, backhoe valve
4K. Control valve, shovel 24. Ram, boom
4L. Control valve ,clam shovel 4J. Control valve, loader lift
4M,4N A.R.V. shovel 25. Oil cooler, hydraulic fluid.
(4N:248 bar,4M:158 bar) 26. Filter assembly, return line
4O Parallel gallery (bypass valve:2 bar)
5. Backhoe valve block 26A Filter element, return line
5A. Clamping solenoid valve 27. Ram, telescopic dipper
5B. Make-up check valve 28. Hydraulic breaker (optional)
29. Steering ram
30. Steering unit
5C. Control valve, dipper

HYDRAULIC
SERVICE
HYDRAULIC CIRCUIT DIAGRAM HMK 102 S
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FRONT

REAR

HYDRAULIC
SERVICE

1. Hydraulic tank (0.3 bar inlet pressure)

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16 1A. Suction strainer 5D. Control valve, slew
P1+P2. Pump section P1&P2 5E,5F Control valve, stabilizers
5G Control valve, bucket crowd
P1A. Pressure test port for P1 5H Control valve, boom
P2A. Pressure test port for P2 5I,5J A.R.V, dipper (248 bar)
1H. Pressure line for P1 5K,5L A.R.V., slew (158 bar)
2H. Pressure line for P2 5S,5T A.R.V., bucket crowd (248 bar)
2. Priority valve 5U,5V A.R.V, boom
3H. Steering feed line (5U:310 bar,5V:248 bar)
LS. Steering load sensing line 6. Throttle valve, return line of
1T. Pressure test port for aux. val. loader lift
3. Auxiliary valve assy. 7, 8. Rams, loader lift
3A. M.R.V. (250 bar),auxiliary valve 9,10. Rrams, shovel
3D. Auxiliary valve 11,12. Rams, clam shovel
3B,3C. Relief valve 13,14. Rams, hydraulic clamps
(180 bar for breaker) 15. Ram, dipper
(210 bar for telescopic dipper) 16. Ram, bucket crowd
4. Loader valve block 17,18. Rams, stabilizers
4A. Pressure port for hydraulic 19,20 Cushion valve, slew rams
system 21,22 Rams, slew
4B. M.R.V.( 230 bar) 23. Throttle valve, return line of
4C. Check valve boom ram.
4D. Spool, un-loader valve 1D Return line, loader valve
4E. H.S.C. solenoid valve 2D Return line, backhoe valve
4F. Un-loader valve (210 bar) 24. Ram, boom
1H+2H. High pressure carry-over line 25. Oil cooler, hydraulic fluid.
4J. Control valve, loader lift 26. Filter assembly, return line
4K. Control valve, shovel (bypass valve:2 bar)
4L. Control valve ,clam shovel 26A Filter element, return line
4M,4M A.R.V.,shovel 27. Ram, telescopic dipper
(4N:248 bar,4M:158 bar) 28. Hydraulic breaker (optional)
4O parallel gallery 29. Front steering cylinder
4G,4H,4I Load hold check valves 30. Rear steering cylinder
31. Steering solenoid valve
5. Backhoe valve block 32. Steering solenoid valve
5A. Clamping solenoid valve 33. Steering unit
5B. Make-up check valve
5C. Control valve, dipper

HYDRAULIC
SERVICE
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DESCRIPTION OF NEUTRAL CIRCUIT
02
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SERVICE
NEUTRAL CIRCUIT RETURN
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HYDRAULIC 19
SERVICE

DESCRIPTION OF NEUTRAL CIRCUIT

When the hydraulic system of the machine is operated under neutral position, the
hydraulic pump ( tandem, two sections, P1 & P2) receives the hydraulic fluid from the
hydraulic tank and feeds this oil to the hydraulic circuit.

The tandem pump is driven directly by a drive shaft.

The oil fed by pump section P1, is delivered to priority valve 2. Then hydraulic oil
passes to auxiliary valve 3 over priority valve. Since the auxiliary valve is in neutral
position, the hydraulic oil enters loader valve block 4 through auxiliary valve.

Pump section P2, feeds oil directly to loader valve. Thus, the oil fed by P1 & P2
comes together ( confluxes ) in the neutral gallery of the loader valve block and then
passes to backhoe valve 5 block through high pressure carry-over line. Since the
backhoe valve block is neutral position, the hydraulic fluid passes through the neutral
gallery to collector over return line T4.

The oil that is collected in the collector goes to oil cooler thorough pipe 4 and hose 3.
then, after the cooled fluid is strained by return filter, it returns to hydraulic tank via
pipe 6 and hose 8. (refer to page ’NEUTRAL CIRCUIT RETURN’)
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SERVICE

DESCRIPTION OF PUMP

The basic principle of the gear pump depends on the meshing of two spur gears,
one of which is engine–driven while the other is an idler.

Oil is picked up by the gear teeth on the suction side of the pump and carried out
between the teeth and the pump body. As the gears come into mesh, the space
carrying the oil is filled by a gear tooth on the mating gear, forcing the oil out of the
space and through the pump inlet.

PUMP FLOW TESTING

Before removing the pump, it is necessary to determine the source of any problem by
measuring the output flow at system pressure at both of the pump outlet ports.
To check flow it is necessary to fit a flow meter into the output line of each pump
section in turn. Make sure the flow meter is installed with its arrow pointing away from
the pump and, if possible, located between pump and loader valve.

WARNING
HYDRAULIC FLUID AT SYSTEM PRESSURE MAY INJURE YOU. BEFORE
FITTING OR DISCONNECTING HYDRAULIC HOSES, STOP THE ENGINE AND
RELEASE PRESSURE TRAPPED IN THE HOSES BY OPERATING CONTROL
LEVERS A FEW TIMES. TAKE CARE NOT TO START THE ENGINE WHILE THE
HOSE ENDS ARE OPEN WITHOUT ANY PLUG OR CAP.
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SERVICE

FITTING / REMOVING A FLOW METER AND LOAD VALVE

Before removing / fitting a flow meter and load valve, switch off the machine and
operate the loader / excavator control levers a few times to release the system
pressure.

FITTING
1 a. Open the test plug on the pump section P1 line. Fit the flow meter.
b. Open the test plug on the pump section P2 line. Fit the flow meter.

REMOVAL
Removal is the reverse of fitting.

CHECK FLOW
1. Check the setting of the main relief valve (M.R.V.) as described in LOADER
VALVE, PRESSURE TESTING. Adjust if necessary.

2. a. USING A LOAD VALVE: Fit a flow meter and a load valve to each pump
each turn.
Fit a 0-400 bar pressure gauge to the load valve pressure test connector.
b. IF NO LOAD VALVE IS AVAILABLE: Fit a flow meter to each pump output
plugs each turn.

3. START THE ENGINE AND ALLOW TO RAISE THE HYDRAULIC OIL

TEMPERATURE UP TO THE OPERATING TEMPERATURE. SET THE ENGINE
SPEED TO 2000 rpm.

4. a. USING A LOAD VALVE, Adjust the load valve so that pressure gauge
reading is just below the M.R.V. setting.

b. IF NO LOAD VALVE IS AVAILABLE, Raise or lower the loader arms until

the ram’s stroke end. Continue to operate the raise/lower, control so that system
pressure builds up. Observe the flow meter and note its reading at the moment of the
M.R.V. operates.
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LOADER VALVE
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HYDRAULIC 23
SERVICE
LOADER VALVE DESCRIPTION
The loader valve is mounted on the chassis frame, right hand side (when viewed
from rear). Standard equipment includes loader lift spool (4J), shovel spool (4K) and
un-loader valve assembly (4D). Clam shovel spool (4L) is optional. Linkage rods
connect the spool ends to the control levers.

OPERATION
In neutral circuit hydraulic oil from pump section P2 enters the loader valve via a
steering priority valve. On entering the valve block, oil flows around the waist section
of the un-loader valve 3L, past a check valve and joins flow from pump P1.
Oil from pump section P1 enters the loader valve as shown.

Combined oil from P1 and P2 passes the main relief valve (M.R.V.- not shown) and
fills the parallel gallery (1H+2H). From the parallel gallery the oil flows around the
waist central portions of spools 4J, 4K and 4L (all in neutral position) and flows on to
feed the excavator valve via high pressure carry over line 1B.

The exhaust gallery T is connected to the tank return line.

COMPONENT KEY
4 LOADER VALVE BLOCK
4C LIFT RAM SPOOL
4K SHOVEL RAM SPOOL
4L CLAM SHOVEL SPOOL
4D UNLOADER VALVE SPOOL
4F UNLOADER PILOT VALVE

WARNING

MAKE THE MACHINE SAFE BEFORE WORKING UNDERNEATH IT. PARK THE
MACHINE ON LEVEL GROUND, LOWER THE ARMS. APPLY THE PARKING
BRAKE, PUT THE TRANSMISSION IN NEUTRAL AND STOP THE ENGINE.
CHOCK BOTH SIDES OF ALL FOUR WHEELS.
DISCONNECT THE BATTERY, TO PREVENT THE ENGINE BEING STARTED
WHILE YOU ARE BENEATH THE MACHINE.
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SERVICE
LOADER VALVE REMOVAL & INSTALLATION

REMOVAL
1. Operate the valve block levers back and forth to release residual pressure.
2. Remove clevis pins A to disconnect the control levers from the spools of valve
block.
3. Disconnect all hydraulic hoses from the valve block and plug all orifices to
prevent ingress of dirt. Label each hose before disconnecting, this will
ensure correct position when refitting.
4. Loosen and remove nuts and bolts 2, 4 and spacing washers 3.

INSTALLATION
Installation is the reverse of removal sequence.
After installation, check the main relief valve (M.R.V.) and auxiliary relief valve
(A.R.V.) pressure settings.
NOTE:
All hydraulic adapters that are installed together with a sealing washer must also
have sealant applied to the threads of the adapter.
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HYDRAULIC
25
SERVICE

LOADER VALVE CUTOFF VIEW

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SERVICE
ASSEMBLE

1. Lay out valve components on a

clean, flat working surface.
The inlet assembly will include
an O-ring and the spool includes
an O-ring, a load check poppet
and a load check spring. Tools
required for basic valve assembly
include ¾ “ and 11/16” open or
box end wrenches and a torque
wrench with thin wall sockets.

2. Assemble tie rod nuts to one end

of each tie rod with one or two
threads showing. Insert tie rods
through tie rod holes of inlet (larger
tie rod at top). Lay inlet on end with
tie rods up, place O-ring into position.

3. Place first spool section (O-ring side up)

on inlet section, position O-ring and
insert load check poppet (nose down)
and spring (behind poppet) into load
check cavity as shown. Repeat this
procedure for each spool section ;
the load check springs are compressed
by the following sections during assembly.
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HYDRAULIC 27
SERVICE

4. Position end section on last spool section

as shown and hand tighten tie rod nuts.
The end section on picture is a “turn
around” section without ports. Universal
outlet/power beyond section and power
beyond and closed center sections are
also used as end sections.
These end sections do not have O-ring
grooves.

5. Position valve assembly with the mounting pads of the end sections on a flat
surface.
To obtain proper alignment of end
sections relative to the spool sections
apply downward pressure to the end
sections; snug tie rod nuts to about
10 ft.lbs.

Final torque the two 11/16” nuts to

48 ± 5 ft.lbs; final torque the ¾” nut
to 74 ± 8 ft.lbs. Check for proper
spool movement.

6. Install auxiliary valves and plugs and

torque to proper specifications.

General assembly notes:

A. Lever assemblies can be installed on section before or after complete valve
assembly.
B. The load check and spring may be omitted from assembly in certain circuit
conditions.
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28 HYDRAULIC
SERVICE

AUXILIARY RELIEF VALVE

A.R.V.’s are positioned on the excavator valve block in order to relieve excessive
pressure in the services.
1. VALVE AT REST
Below figure shows the service in neutral with no forces acting on the
equipment.
The force of spring D acting through collar C keeps poppet B firmly held on its
seat. Chamber J is connected to exhaust gallery via small drilled holes H, this
means the pressure in the chamber will always be at the exhaust side. The A.R.V.
pressure setting is adjustable by means of spring D and adjusting screw E.
Turning the screw clockwise compresses the spring and therefore increases the
pressure setting. Turning the screw anti-clockwise conversely, releases the spring
which decreases the pressure setting.

2. POPPET OPENS
If the pressure in the service gallery A has reached the setting of the A.R.V.,
the pressure on the service side of the poppet is high enough to overcome the force
of spring D so poppet B lifts off its seat. Oil in chamber J is displaced through small
drilled holes H. Service pressure at A is now released to exhaust gallery K.
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29
SERVICE

OPERATION OF ANTI-CAVITATION

When the service gallery is cavitating, the A.R.V. anti-cavitation operation allows oil
from the exhaust gallery to supplement the cavitating service line.

1. OPERATION 1
When the A.R.V. is subjected to normal operating pressure in service gallery A, the
force of spring F and pressure in the service gallery acting on the bottom face of
anti-cavitation cone G keep the cone held firmly on its seat.

2. OPERATION 2
Whenever the service gallery is cavitating, the pressure in the exhaust gallery K is
sufficient to overcome the force of spring F. The cone and the assembly move down
allowing oil in the exhaust gallery and limit the effects of cavitation.

LOAD HOLD CHECK VALVES

The following text describes how the load hold check valve works on the arms raise
service.

OPERATION 1
The weight of the loaded shovel produces
a higher pressure in service line P than in
parallel gallery 4O. This pressure differential
causes load hold check valve 4G to close,
thus preventing the load from dropping.

OPERATION 2
As the neutral circuit has been blocked by the
central area of the selected spool, the
pressure in parallel gallery 4O increases until it
is greater than that in service line P. At this
point, load hold check valve 4G opens,
allowing oil to flow from the parallel gallery into
service line and operate the lift rams.
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SERVICE
AUXILIARY RELIEF VALVE & LOAD HOLD CHECK VALVE
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SERVICE

AUXILIARY RELIEF VALVE (A.R.V) & LOAD HOLD CHECK VALVE (L.H.C.V.)

DISMANTLING & ASSEMBLY

The numerical sequence shown on the illustration is intended as a guide to
dismantling.
For assembly, the sequence should be reversed.
The following points must be avoided when dismantling and assembling the valve:
CONTAMINATION
DAMAGE TO SPOOL
DAMAGE TO SEAL GROOVES

All or any of the above points may result in possible problems with the valve. The
Aux Relief Valves are identical in design but have different pressure settings.

L.H.C.V., the load hold check valves are also identical.

WHEN DISMANTLING
When removing the O-rings and seals, use an appropriately rounded tool that will
not cause any damage to the seal grooves. Discard all O-rings and back-up rings.
DO NOT use worn or damaged items. Dismantle sub-assembly 14 from item 1 using
a special tool (see service tools) the special spanner locates in cross holes B.
Make sure that small drilling A is not blocked. Ensure good condition of sealing faces
on poppet 18 and on the mating face of the valve block. Inspect the valve
components for scratches, nicks or any other kind of damage, replace with new if
required.

WHEN ASSEMBLING
Renew all O-rings and back-up rings. Coat the parts with hydraulic fluid before
assembling. Make sure that all the parts move freely. Fit back-up ring 13 on the
upper side of O-ring 12. Fit the face of sleeve 9 against shoulder of poppet 10.
Torque tighten item 14 using the special tool (see service tools) until its shoulder
seats firmly against item 1. Pressure test the relief valves using the procedure
described.

TORQUE SETTING

ITEM Nm kgf m
1 65 6,6
3 24 2,5
15 81 8,3
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SERVICE

UNLOADER VALVE ASSEMBLY

Un-loader spool operation avoids overloading the engine if a service is being worked
particularly hard, for example when using the excavator to tear out. It does this by
dumping the oil from pump section P2 to tank, allowing engine power to be applied
fully to the main pump section P1.
The un-loader is operated automatically when the system pressure reaches 210 bar.
The un-loader is operated manually. This is referred to as HYDRAULIC SPEED
CONTROL (HSC).

The main applications for manual operation are:

1. More traction force is made available to the loader end when entering a stock
pile.
2. More power from the engine is made available while traveling on the
highway, providing improved fuel economy.
3. Reduced backhoe speed when placing objects. (sensitivity)
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SERVICE

SYSTEM OPERATION
Pressure in the inlet gallery C rises to the setting of pilot valve 4f via the bore of the
spool 4D. At pressure below the setting of the un-loader valve, both pilot valve 4F
and the spool 4D remain closed.
If the pressure in the inlet gallery C rises to the setting of pilot valve 4F, this valve will
open, allowing oil in spring cavity 3P to escape more quickly than it can be replaced
by oil entering through the small drilling D.
This creates a pressure differential between the spring cavity 3P and gallery C.
Higher pressure in gallery C acts on the face of spool 4D causing the spool to be
moved off its seat. Oil entering the valve block from pump P2 now flows directly to
tank (T).
High pressure in gallery C also holds check valve 4C firmly closed, preventing oil of
pump P1 from being dumped too.
When pressure in the inlet gallery C falls, for example if the excavator has stopped
tearing out, pilot valve 4F will be at the same pressure as oil in gallery C, spring
pressure will move spool 4D back onto its seat, closing pump P2 connection to tank.

HYDRAULIC SPEED CONTROL (HSC)

Solenoid valve 4e is connected between

the un-loader valve chamber 3P and the
return to tank circuit.
When the solenoid is de-energized spring
force acting on the end of the spool keeps
the connection from chamber 3P to tank
closed. When the solenoid is energized by
the switch in the cabin manually, the spool
moves causing a connection from the un-
loader spool chamber 3P to the hydraulic
tank via valve block internal galleries and
service hoses.
Because the un-loader chamber is now
connected to the tank and so at exhaust
pressure, pressure in gallery C acts on
the face of un-loader spool 4D causing
the spool to be moved off its seat. Oil
entering the valve block from pump
section P2 now flows directly to tank.
Therefore, hydraulic oil flow in the system
can be decreased manually whenever
required.
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SERVICE

UNLOADER VALVE ASSEMBLY

HYDRAULIC
SERVICE

DISMANTLING & ASSEMBLY

The numerical sequence given on the
illustration is intended as a guide to
dismantling.
For assembly, the sequence should be
reversed.
The following points must be avoided
when dismantling and assembling the
valve:
CONTAMINATION
DAMAGE TO SPOOL
DAMAGE TO SEAL GROOVES
All or any of the above points may result
in problems with the valve possibly. The
A.R.V.s are identical in design but have
different pressure settings. the L.H.C.V.s
are also identical.

WHEN DISMANTLING
Use an appropriately rounded tool when
removing O-rings and seals that will not
cause any damage to the seal grooves.
Discard all O-rings and back up rings.
Do not use worn or damaged items. Use
a nylon rod to push out spool assembly
item 23 , do not damage spool bore.
Inspect the valve components for
scratches, nicks or any other type of
damage, replace with new if necessary.

WHEN ASSEMBLING
Renew all O-rings and back-up rings.
Coat parts with hydraulic fluid before
assembling. Make sure that all the parts
move freely. Ensure that the small drilling through the centre of item 23 is clean.
Shims 21 are intended to limit the maximum pressure setting the specified pressure
setting is achieved by adjusting cap nut 15. If the specified pressure can not be
 HMK 102 ENERGY WORKSHOP MANUAL
30
achieved under test, it is permissible to add shims as required. There must be at
02
least one hardened shim next to the spring item 22. 35

Check pressure setting after refitting. Check the operation of the ‘Hydraulic Speed
Control’.
WARNING

DO NOT OVERTIGHTEN THE SOLENOID ASSEMBLY, OTHERWISE THE

SOLENOID VALVE CAN BE DAMAGED OR THE OPERATION OF THE SOLENOID
MAY BE EFFECTED, USE OF THE SPANNER FLATS AND TORQUE TIGHTEN TO
FIGURE INDICATED IN THE TABLE BELOW.
Torque settings
ITEM Nm kgf.m
1 6,7 0,7
5 27 2,8
8 81 8,3
12 81 8,3
16 45 4,6
19 34 3,5
HYDRAULIC
SERVICE
STANDARD SPOOL
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SERVICE
DISMANTLING & ASSEMBLY
The numerical sequence given on the illustration is intended as a guide to
dismantling.
For assembly, the sequence should be reversed.
The following points must be avoided when dismantling and assembling the valve:
CONTAMINATION
DAMAGE TO SPOOL
DAMAGE TO SEAL GROOVES
All or any of the above points may result in problems with the valve possibly.

WHEN DISMANTLING
When removing O-ring’ and seals, use an appropriately rounded tool that will not
cause any damage to the seal grooves, for instance item 3 which is a wiper seal and
is a press fit in the counter bore.
Care must be taken to ensure that the spool 8 is not damaged when removing it from
the valve block. Hold the spool in clamp, unscrew bolt 9 and remove spring 12,
spacer 10 and cups 11 and 13.
Check for surface contamination on the under side of the seal plates 2 and 14. Clean
if necessary. Check for the flatness of the seal plate. If found not to be bent-replace
with a new one.

WHEN ASSEMBLING
Renew seal 3 and O-rings 4 and 15. Make sure that the O–rings and wiper seals are
not trapped or damaged.
When fitting bolt 9 , clean the threads through using a cleaning solvent, leave it for 10
minutes then apply a small quantity of lock & seal compound to the threads of the
spool.
Make sure that all the parts move freely, check that item 10 does not interfere with
item 13.
Re-connect lever mechanism to the lever end of the spool.
run the engine and inspect the valve for external leaks.

Torque settings

Item Nm kgf.m
1 5,4 0,6
5 9,5 0,96
9 9,5 0,96
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SERVICE
FLOAT SPOOL
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HYDRAULIC 39
SERVICE
DISMANTLING & ASSEMBLY
The numerical sequence given on the illustration is intended as a guide to
dismantling.
For assembly, the sequence should be reversed.
The following points must be avoided when dismantling and assembling the valve:
CONTAMINATION
DAMAGE TO SPOOL
DAMAGE TO SEAL GROOVES
All or any of the above points may result in problems with the valve possibly.

WHEN DISMANTLING
Use an appropriately rounded tool that will not cause any damage to the seal
grooves when removing O-rings and seals. For instance item 3 which is a wiper seal
and is a press fit in the counter bore.
Care must be taken to ensure that the spool 15 is not damaged when removing it
from the valve block. Remove collar 11 and collect detent balls 12 carefully. Using
tool to hold the spool, remove circlip 18, plug 19, ball 20 and spring 21. Unscrew
detent pin 22 and remove spring 24 and cups 23 and 25.
Check for surface contamination on the under side of the seal plates 2 and 16.
Clean if necessary. Check for the flatness of the seal plate. If found not to be bent-
replace with the new one.

WHEN ASSEMBLING
Renew seal 3 and O-rings 4, 6 and 17. Make sure that the O–rings and wiper seals
are not trapped or damaged.
When fitting detent pin 22, clean the threads through using a cleaning solvent, leave
it for 10 minutes then apply a small quantity of lock & seal compound to the threads
of the spool.
Make sure that all the parts move freely, apply grease balls 12, this will help to hold
the balls in position while assembling.
Re-connect lever mechanism to the lever end of the spool.
Run the engine and inspect the valve for external leaks.

Torque settings

Item Nm kgf.m
1 9,5 0,96
5 9,5 0,96
8 9,5 0,96
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SERVICE
MAIN RELIEF VALVE

1. VALVE AT REST

Main relief valve (M.R.V.) 4B is positioned

in the loader valve block in order to relieve
excessive pressure in the hydraulic system.
When the hydraulic system is in neutral or
under light load and there are no excessive
forces acting on the equipment, hydraulic
system pressure that enters chamber D
through the small drilling e will not be
sufficient to move the main plunger a off its
seat B. The force of spring g is adjustable
to suit the relevant service by means of
adjuster at the top of the valve.
As long as the pressure does not continue
to rise, plunger a will remain on its seat.

2. PILOT VALVE OPENS

as the system pressure increases sufficient

to force the pilot valve f that moves against
spring G, the pressurized oil in chamber D
is allowed to escape into cavity K and to
pass down the sides of sleeve J into the
exhaust gallery H.

3. MAIN VALVE OPENS

as system pressure reaches the setting of

the valve, pressure in chamber D can not
rise because the seat orifice of pilot valve f
is larger than small drilling e and oil is can
not fil the chamber as fast as it is being
exhausted.
Pressure acting on the lower faces of main
plunger A is obviously greater than the combined force of both spring C and the
pressure in chamber D. then, the plunger moves off its seat, allowing pressure to be
vented into the exhaust gallery H.
As the system pressure decreases, the pilot valve can close and pressure in
chamber D helps spring C to push the main plunger a back to its seat.
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SERVICE

LOAD HOLD CHECK VALVES

the following text describes how the load hold

check valve works in the arms raise service.

OPERATION 1
The weight of the loaded shovel produces a
higher pressure in service line P than in
parallel gallery 4O. This pressure differential
causes load hold check valve 4G to close,
thus preventing the load from dropping.

OPERATION 2
As the neutral circuit has been blocked by the
central area of the selected spool, the
pressure in parallel gallery 4O increases until
it is greater than that in service line P. At this
point, load hold check valve 4G opens,
allowing oil to flow from the parallel gallery
into service line and operate the lift rams.
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SERVICE
MAIN RELIEF VALVE
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HYDRAULIC 43
SERVICE

DISMANTLING & ASSEMBLY

The numerical sequence given on the illustration is intended as a guide to
dismantling.
For assembly, the sequence should be reversed.
The following points must be avoided when dismantling and assembling the valve:
· CONTAMINATION
· DAMAGE TO SPOOL
· DAMAGE TO SEAL GROOVES

All or any of the above points may result in problems with the valve possibly.

DISMANTLING
Use an appropriately rounded tool when removing O-rings and seals that will not
cause any damage to the seal grooves.

Discard all ‘o-ring’s and back up rings. do not use worn or damaged items.
Inspect the valve components for scratches, nicks or any other type of damage,
replace with new if required.

ASSEMBLING
Renew all O-rings and back-up rings.
Coat parts with hydraulic fluid before assembling. Make sure that all the parts move
freely.
Make sure that the O-rings and back-up rings are fitted in the correct order, items 10
and 11.

Adjust pressure setting as required.

Torque settings

Item Nm kgf.m lbf.ft

3 5,4 0,6 4
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SERVICE
LOADER VALVE PRESSURE TESTING

MAIN RELIEF VALVE

Make sure that the hydraulic oil is at normal operating temperature, ie.50°C (122° F).
Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine;
operate the control levers to release residual hydraulic pressure.

1. Connect a 0-400 bar ( 0 - 6000 lbf / in2 ) pressure gauge to pressure test
connector A on the loader valve, (see service tools )

2. With the engine running at 1500 revs./min., check M.R.V. pressure by raising
or lowering the loader arms until the rams are fully open or closed and noting the
maximum gauge reading.
CAUTION: Do not select ‘FLOAT’. The maximum pressure should be as stated in
technical data.

NOTE:
The rams must be ‘held’ open or closed when reading gauge.

3. If the pressure is not correct, loosen locknut D and adjust screw C. Turn it
clockwise to increase pressure and anti-clockwise to decrease the pressure.
When the pressure is correct, tighten the locknut.
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SERVICE

UNLOADER VALVE PRESSURE TESTING

Make sure that the hydraulic oil is at normal operating temperature, ie. 50°C (122°F).

Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine;
operate the control levers to release residual hydraulic pressure.

Make sure that the hydraulic speed control facility is not switched on, otherwise the
correct un-loader valve pressure cannot be obtained.

1. Connect a 0-400 bar ( 0 - 6000 lbf/in2 ) pressure gauge to pressure test

connector P2A plug.
2. With the engine running at 1500 revs./min., slowly operate arms raise or lower.

NOTE 1:
The loader lift arms raise or lower service is specified because it has no auxiliary
relief valve (A.R.V.). Selecting this service ensures that the pressure is released
through the un-loader valve and not through an A.R.V.

3. When the service reaches full travel, the gauge reading should rise slowly to
unloading pressure then fall back to zero. The maximum reading should be as
specified in technical data.

4. If the pressure is not correct, slacken locknut E and adjust cap F. Turn it
clockwise to increase pressure and anti-clockwise to decrease the pressure.
When the pressure is correct, tighten the locknut.

If the correct pressure cannot be achieved, add or subtract shims as required, see
un-loader valve assembly - dismantling and assembly.
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SERVICE

UNLOADER VALVE TESTING

HYDRAULIC
SERVICE

HYDRAULIC SPEED CONTROL (H.S.C.) TESTING

 HMK 102 ENERGY WORKSHOP MANUAL
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The following procedure can be used to establish if the hydraulic speed control 47
facility operates correctly.

1. Connect a 0-400 bar (0 - 6000 lbf/in2) pressure gauge to pressure gauge to

pressure test connector P2 A plug.

2. With the engine running at maximum speed, slowly operate lift arms raise,
raise the pressure to 210 bar approximately.

3. Then, the pressure gauge reading should drop to zero, automatically.

4. Repeat the above procedure once more. The pressure gauge reading should
drop to zero again (or near zero).

5. if there is no pressure drop at steps 3 and 4, then check the H.S.C. hydraulic
and electrical circuits for any faults.

HYDRAULIC
SERVICE
REMOVAL & INSTALLATION

WARNING
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48
MAKE THE MACHINE SAFE BEFORE WORKING UNDERNEATH IT. Park the
machine on level ground, lower the arms. apply the parking brake, put the
transmission in neutral and stop the engine. Chock both sides of all four wheels.
Disconnect the battery, to prevent the engine being started while you are beneath the
machine.

Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting
hydraulic hoses, stop the engine and operate the controls to release pressure
trapped in the hoses. Make sure that the engine cannot be started while the hoses
are out without any plugs or caps.

BACKHOE VALVE

CAUTION : This component is heavy. Do not attempt to remove it unless its

weight is held by a sling. Make sure that the sling is attached to a proper
lifting equipment.

REMOVAL

1. Operate the valve block levers back and forth to

release residual pressure.
2. Remove the rear valance.
3. Remove clevis pins a to disconnect the control
levers from the spools of valve block.
4. Disconnect all hydraulic hoses from the valve block
and plug all orifices to prevent ingress of dirt. Label
each hose before disconnecting, this will ensure
correct positioning when refitting.
5. Loosen nuts 3 - do not remove the retaining nuts
completely.
6. Wrap a suitable sling around the valve, make sure that the weight of the valve
is supported by the sling.
7. Remove nuts 2 and lower the valve block to the ground.

INSTALLATION

Installation is the reverse of removal sequence.

Hoses and pipes must be re-connected and phased in same position as removal.
After installation, check the auxiliary relief valve (A.R.V.) pressure settings.
NOTE:
All hydraulic adapters that are installed together with a sealing washer must also
have sealant applied to the threads of the adapter.

HYDRAULIC
SERVICE
BACKHOE VALVE
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49

HYDRAULIC
SERVICE
BACKHOE VALVE DISMANTING AND ASSEMBLY
 102 ENERGY WORKSHOP MANUAL
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50 The numerical sequence shown on the illustration is intended as a guide to
dismantling.
For assembly the sequence should be reversed.

CHECK VALVES
Each of the identical load hold check valves can be removed as shown. Make-up
check valve 5B is smaller in size but otherwise identical.

Ensure good condition of seating faces on poppets 4 and 8 and on the mating faces
in the valve block.

SPOOLS
Spools 5C, 5D, 5E, 5F, 5G are identical but must not be interchanged as they are
matched to their bores. Stabilizer spools 5E and 5F are identical to each other but
different from the excavator spools.
All spools have the same centering and sealing components (items 9 to 21).
Follow the sequence 9 to 21 to dismantle a spool completely. To prevent spool
rotation when turning screw 15, hold a rod through the eye end of the spool.
If only renewing the seals, dismantle as far as cap 14. Then, remove items 15 to 22
as an assembly.
Coat new seals with hydraulic fluid and take care to prevent them from being
damaged by the sharp edges of the spool.
Apply lock and seal compound to threads of screw 15.

RELIEF VALVES

Relief valves 4H to 4P appear identical but have various pressure settings (see
technical data). ensure that they are correctly adjusted and fitted in their specified
positions.
relief valve dismantling and assembly procedures are detailed separately.
NOTE: All hydraulic adapters that are installed together with a bonded sealing
washer must also have sealant applied to the threads of the adapter.

Torque settings

Item Nm kgf.m lbf.ft

1 122 12,4 90
5 80 8,3 60
13 7 0.7 5
15 11 1,1 8
23 95 10,0 70
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51
SERVICE
AUXILIARY RELIEF VALVE
A.R.V.’s are positioned on the excavator
valve block in order to relieve excessive
pressure in the services.
1. VALVE AT REST
Figure shows the service in neutral with
no forces acting on the equipment.
The force of spring D acting through collar C
keeps poppet B firmly held on its seat.
Chamber J is connected to exhaust gallery
via small drilled holes H, this means the
pressure in the chamber will always be at
exhaust.
The A.R.V. pressure setting is adjustable by
means of spring D and adjusting screw E.
Turning the screw clockwise compresses
the spring and therefore increases the
pressure setting. Conversely, turning the
screw anti-clockwise, releases the spring
which decreases the pressure setting.

2. POPPET OPENS
If the pressure in the service gallery A has
reached the setting of the A.R.V., the
pressure on the service side of the poppet is
high enough to overcome the force of spring
D so poppet B lifts off its seat.

ANTI-CAVITATION OPERATION
When the service gallery is cavitating, the A.R.V. anti-cavitation operation allows oil
from the exhaust gallery to supplement the cavitating service line.
OPERATION 1:
When the A.R.V. is subjected to normal operating pressure in service gallery A, the
force of spring f and pressure in the service gallery acting on the bottom face of anti-
cavitation cone G keep the cone held firmly on its seat.
OPERATION 2:
When the service gallery is cavitating, the pressure in exhaust gallery k is sufficient
to overcome the force of spring F. The cone and its assembly move down allowing oil
in the exhaust gallery to enter the service gallery and limit the effects of cavitation.
When the service gallery is no longer cavitating, compressed spring f will return to its
relaxed position and thus bring the anti-cavitation cone back onto its seat.
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SERVICE
AUXILIARY RELIEF VALVES
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HYDRAULIC 53
SERVICE

DISMANTING AND ASSEMBLY

Eight A.R.V’s are fitted at positions 5X TO 5V. These are identical in design but have
various pressure settings (see technical data).

The numerical sequence shown on the illustration is intended as a guide to

dismantling.
For assembly the sequence should be reversed.

DISMANTING
Dismantle sub-assembly 14 from item 1 using a special tool . The special spanner
locates in cross holes B.
Dismantle sub-assembly 14 into its parts. Make sure that small drilling A is not
blocked. discard old and worn ‘o-ring’s and back-up rings.

ASSEMBLING
Renew all O-rings and back-up rings.
Coat O-rings and back-up rings with hydraulic fluid.
Fit back-up ring 13 on the upper side of O-ring 12 as shown in the inset.
Fit flat face of sleeve 9 against shoulder of poppet 10.
Torque tighten item 14 using the special tool see service tools until its shoulder seats
firmly against item 1.
Pressure test the valve using the procedure described in backhoe valve pressure
testing.

Torque settings

Item Nm kgf.m lb.ft

1 65 6.6 48
3 24 2.5 18
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SERVICE

HYDRO-CLAMP OPERATION (SIDESHIFT MACHINES)

When the backhoe is being used for excavation, the kingpost assembly must be
‘clamped’ to the side-shift rear frame.
The hydro-clamp control valve assembly (items G,D and C) is positioned in the inlet
end of the excavator valve block and is connected directly to the parallel gallery B.
The valve operates in conjunction with solenoid valve E housed in the side of the
excavator valve block.

1. CLAMPS PRESSURIZED
When the hydro-clamp control lever is pushed downwards the hydro-clamp valve is
closed. The control lever of jaw bucket is hold steadily until M.R.V. relieves pressure
fully. this situation builds maximum pressure in parallel gallery. In this case, hydro-
clamp check valve opens and let the maximum pressure enter to hydro-clamp piston
when the lever of jaw bucket is released, the hydro-clamp check valve takes its
position and let the oil blocked in pistons. In other words pistons are blocked in
pressurized condition and clamps are pressurized.

2. CLAMPS RELEASED
When hydro-clamp lever is pulled upwards the hydro-clamp valve housing is being
turned clockwise and begin to spin until check valves stand to H. Then, the check
valve takes off its position. In this case, the pressurized oil in hydro-clamp circuit is
released to tank from the clearance that is formed by check valve. This means, the
clamps are released.

3. CLAMPS LOCKED UP
If no service is being operated, pressure in the parallel gallery falls to that of the
neutral circuit and the force of spring G is sufficient to keep the poppet seated.
Therefore, pressure is trapped in the line to the clamps, keeping the excavator end in
a securely clamped condition.
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HYDRO-CLAMP OPERATION (SIDE SHIFT MACHINES)

5 : BACKHOE VALVE BLOCK

5A : HYDRO-CLAMP VALVE
5B : MAKE-UP CHECK VALVE

HYDRO-CLAMP ASSY.
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SIDE SHIFT VALVE – HOSE & PIPES (ISO PATTERN)

1 SERVICE PORT, BOOM RAM, HEAD SIDE

2 SERVICE PORT,BUCKET CROWD RAM, HEAD SIDE
3 SERVICE PORT, STABILIZER, LEFT SIDE, ROD SIDE
4 SERVICE PORT, STABILIZER, RIGHT SIDE, ROD SIDE
5 SERVICE PORT, SLEWING, HEAD SIDE OF RIGHT RAM,
ROD SIDE OF LEFT RAM
6 SERVICE PORT, DIPPER RAM, ROD SIDE
7 SERVICE PORT, BOOM RAM, ROD SIDE
8 SERVICE PORT, BUCKET CROWD RAM, ROD SIDE
9 SERVICE PORT, STABILIZER,LEFT SIDE, HEAD SIDE
10 SERVICE PORT, STABILIZER, RIGHT SIDE, HEAD SIDE
11 SERVICE PORT , SLEWING, ROD SIDE OF RIGHT RAM,
HEAD SIDE OF LEFT RAM
12 SERVICE PORT, DIPPER RAM, HEAD SIDE
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HYDRAULIC TANK

2 TANK
3 HYDRAULIC RETURN FILTER ASSEMBLY
3A ELEMENT, RETURN FILTER
3B CLOGGING & CONTAMINATION INDICATOR
7 FILLER CAP
8 TEMPERATURE& OIL LEVEL INDICATOR
9 SUCTION STRAINER
13 DRANING PLUG
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DESCRIPTION
Hydraulic tank stores hydraulic fluid. There is a special valve in the filler cap 7
mounted on tank that forms a 0.3 bar inlet pressure in the tank to improve pump
suction. The suction strainer in the tank 9 is 90 micron type. The return filter element
fitted on the return line of the tank is 10 micron type.

When the return line filter is clogged, we can only determine it by looking at its
contamination indicator. The by-pass pressure rate of the return line filter is 2 bar.

MAINTENANCE
Hydraulic system oil change interval: 1000 operating hours
Suction strainer flushing interval:1000 operating hours.
Return line filter element change interval: first at 100 operating hours, Then at every
500 operating hours.

NOTE:
If suction strainer is found to be damaged, immediately replace it with a new one.

DIMENSIONS

LOADER RAMS
Diameter Ø mm Stroke mm
LOADER LIFT 90 725
SHOVEL 80 735
SHOVEL CLAM 80 255

EXCAVATOR RAMS
SLEW 115 203
BOOM 115 985
DIPPER 100 820
BUCKET CROWD 90 725
EXTRADIG DIPPER 70 1228
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PRIORITY VALVE

DISMANTLING & ASSEMBLY

TOOLS

1. Open end spanner

2. Nylon pin
3. Hexagon socket spanner
insert 8 mm
4. Torque wrench
5. Socket spanner 22 mm
6. Allen key 8mm
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1. Screw out the pp plug using the

8mm allen key.
Remove the seal ring.(alu.)

2. Loosen the is plug using the 22 mm

open-end spanner

3. Pull out the plug with seal ring (alu.)

and spring
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4. Press out spool using the nylon pin.

5. Dismantled OLS 80
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REASSEMBLY

6. Guide the spool into bore.

Use the nylon pin to centre the spool in the
bore.

7. Put in the PP plug. Remember the seal ring.

8. Guide the spring and LS plug

into the bore. Remember the seal ring.
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9. Tighten the LS-plug with torque wrench

using a 22 socket spanner insert.

10. Tighten the PP plug with a torque wrench

using a 8 mm hexagon socket spanner insert.

Tightening torque: 5+-1 daNm

(442 lbf in ± 88 lbf in)

11. The OLS 80 is now reassembled.

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EXPLODED VIEW OLS 80

1. INTERNAL PP-PLUG
2. O-RING
3. ORIFICE SCREW
5. SPOOL
6. HOUSING
7. SPRING(7 BAR)*
8. INTERNAL LS –PLUG
9. NAME PLATE
10. DRİVE SCREW
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VIEW WITH ADAPTERS

1. PR
IO
RI
TY

VALVE ASSEMBLY
2. PRIORITY VALVE
3. WASHER
4. ADAPTER-S
5. ADAPTER -S
6. WASHER
7. ADAPTER
8. ADAPTER -S
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OPERATING INSTRUCTIONS FOR CAST IRON TYPE

HYDRAULIC GEAR PUMP

1. BEFORE ASSEMBLY OF THE NEW PUMP YOU HAVE TO FOLLOW BELOW

PROCEDURE

a) Discharge hydraulic tank hydraulic oil, main hoses and its connections. As little
and harmful metal particles which comes from old pump can have got into in
your hydraulic components and it causes big problem for your system. Therefore
you must clean it carefully.

b) Disassemble to the valves which are out of order previously in your hydraulic
system. And then check these valves. İf necessary repair it.

c) Discharge all hydraulic oil which is used by hydraulic components from whole
system,

d) Renew connection and old hydraulic hoses in your system. Especially renew
suction hydraulic hoses which lost quality. In order to succeed that touch it and
check to the softness of the hose.

e) Before assembly of the gear pump to the machine you must open to the
pressure relief valve, valve groups. And check to the spring and spool holes.
Renew conic elements spool and faulty or break spring.

f) Adjust set pressure of the pump pressure relief valve to the zero position.

g) Throw out of the old filter which is used in pressure line, suction line and return
line of the system. And then you must use new filter which is suggested by
machine manufacturer .These new filters must have original filtering degree.

h) Disassemble of the suction line strainer and clean it. During this cleaning
operation if necessary disassemble of the connection hoses and then clean and
dry to the tank entirely.

i) Connect to the clean connection hoses and pipe connections. Close valve of the
tank and fill up with proper hydraulic oil till maximum level of the indicator on the
tank.
j) Check drive shaft and coupling which is in the motor and gearbox. Broken or out
of order shafts must be changed. Otherwise pump gears, parallel shaft spline
and shaft bearings can be damaged easily.
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ASSEMBLY OF THE PUMP TO THE MACHINE

a) Install pump shaft to the setting place. Mounting flange must be seat to the
assembling place where on the drive shaft hole. And then mounting flange
connection bolts and nuts must be tightened. These bolts and nuts must have
8.8 quality. Last tightening process must be done with torque-meter. Using
torque-meter equalize axial load on every bolts.

b) Fill up to the suction hoses with hydraulic oil and connect to the suction port
flange with bolts. Hose flange or coupling O-ring must be installed properly.

c) Check pressure line hoses, O- ring and these hoses must be tightened to the
pressure line of the pump. Especially in multiple pumps connection of the
pressure line hoses must be checked. As pressure line hoses can be tightened
wrong pump.

MOST IMPORTANT; Disassemble hoses must be checked because some piece of

clothes can got into disassemble hoses .Therefore these hoses must be checked
manually

d) After completing to the hoses connections and checking to the valve. Tank
valves must be opened and decreasing of the oil level must be observed and
completed.

e) Suction port flange bolts must be loosened slightly. Till hydraulic oil appears .As
soon as hydraulic oil appears these bolts must be tightened again. These
process must be made perfectly. As while operating of the system .Pump musn’t
be sucked air for any reason

3-START UP TO THE HYDRAULIC GEAR PUMP

a) Before starting up to the machine while all valves in neutral position. Revolve
shaft one or more revolution finally start up to the motor which operates to the
pump on neutral and unloading position

b) During operating of the motor. You must listen to the hydraulic equipments and
region where the pump is in .In addition to this new pump must start up
between 10 and 15 minutes

c) During this 10-15 minutes hydraulic oil level in the tank hydraulic hoses must be
checked due to leakage of from hydraulic hoses
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ASSEMBLY OF THE PUMP TO THE MACHINE (cont’d)

d) During above procedure if you didn’t any improper function. Pressure relief
valve of the pump must be adjusted from hydraulic diagram During start up of
the hydraulic equipments (motor,pump,lift etc ) you must not adjust pressure
relief valve because;
e) Pressure relief valve operates when hydraulic components comes to at the end
of the stroke.

f) After you adjust to the pressure relief valve .if your hydraulic circuit contains
shock valve you must adjust shock valve .Shock valve set pressure always set
to the over % 15 of the operating pressure of the system.

g) Check oil level of the hydraulic equipments,

h) Adjust to the level of hydraulic oil in the tank while maximum hydraulic oil out of
the tank

i) Check temperature indicator on the tank .Temperature must not pass to the
85 C. During initial start up of the pump you must check that pump frequently in
first 5 hours manually,

j) If you observe overheated in your system you must check radiator absolutely
your radiator may have dirt .If your radiator contains fan ,Fan motor maybe
breakdown,

k) You don’t start up new pumps on overheated and over operating pressure
Otherwise you faced with some problems like that fire, cutting shaft, bearing
failure and body crack,

4 . In order to do not faced with any problem you must obey to the periodic care
rules which are given to you by machine manufacturer. If you don’t have you must
follow these procedure,

a) You must check hydraulic oil leakage ,hydraulic oil level and dirty-ness condition
of the system once every 50 hours ,
b) You must check hydraulic filters and oil level in the tank once every 250 hours,

c) Renew hydraulic filters once 500 hours ,

d) Change hydraulic oil once 1500-2000 hours. During changing operation of the
hydraulic oil from the tank. Check air ventilation of the tank and Check tightening
of the connection bolts and nuts to the pump

e) You must make maintenance of your hydraulic gear pump every 600 hours,
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PUMP VIEW