Guide To The EJC 65 Hydraulic System: General

Guide to the EJC 65 Hydraulic System
General
This section contains functional descriptions and repair instructions for the major components of.
the steering, park brake, and bucket (implement) circuits. Repair instructions include: removal,
disassembly, cleaning, inspection, reassembly, and installation procedures. Checks and
adjustment procedures for the hydraulic circuits/components are also included.
Preventative maintenance procedures are provided in this manual. Whenever feasible, the
component manufacturer's service information is provided as a supplement to the service
information.
NOTE: The information in this section covers the standard hydraulic system. Refer to the Parts
Manual identified with the machine serial number of your machine for a detailed
breakdown.
Park Brake System
Description
The park brake system consists of:
• an accumulator;
• an accumulator charge valve;
• an enclosed dry disc brake;
• a solenoid valve;
• a pressure reducing valve; and
• a manifold with brake pressure switches.
When energized, the solenoid valve directs pressure from the accumulator to the dry disc brake to
release the park brake. When the solenoid is de-energized, it stops pressure from going to the dry
disc brake and allows the oil to return to the tank. The pressure reducing valve limits the amount
of pressure to the park brake to that required to release the brake, 200 psi (14 Bar). The
accumulator charge valve directs the pump flow to the accumulator until the accumulator is
charged to 1500 psi (100 Bar). When the accumulator is fully charged, accumulator charge valve
redirects pressure to the steer circuit. The brake pressure switches monitor pressure in the brake
circuit and de-energize the solonoid valve to apply the park brake when the pressure drops below
150 psi (10 Bar).
Dry Disc Brake Maintenance
The new dry disc park/emergency brake is essentially wear-free and maintenance-free. Wear and
damage can only occur if the brake is used improperly.
HYD-083/05/08 1
The supplier defines improper use as operating the brake at an extremely low oil pressure or at an
extremely high operating temperature.
Excessive wear can also occur if the dry disc park/emergency brake is used in a dynamic braking
application (i.e. emergency braking). Although the brake is designed to function under this type
of condition, a complete inspection of the dry disc park/emergency brake is required.
! WARNING!
The dry disc park/emergency brake will seize if the plates inside exceed the wear limit.
NOTE: Plates must be replaced and installed as a set.
Checking Park Brake Circuit Pressure

NOTE: This procedure also checks the maximum pressure setting of the pressure reducing valve.
Replace the valve if pressure exceeds 200 psi (14 Bar).
! WARNING!
Pressure must be relieved from the accumulator before disconnecting any lines.
1. Lower the bucket and stop the engine. Block the wheels. Release the oil pressure in the
accumulator by moving the park brake button from the PARK position to the RELEASE
position ten (10) times with the engine stopped and the ignition switch in the RUN position.
Slightly loosen the hydraulic line to the accumulator until no pressure exists.
2. Connect a pressure test gauge at the test port.
3. Start the motor and observe the gauge. The indicator should gradually increase to 200 psi
(14 Bar).
4. Stop the motor and release the accumulator pressure (see step 1 above).
5. Disconnect the test gauge from the test port.
Steering System
System Description
The steering system consists of:
• a steering/brake pump;
• an accumulator charge valve in the park brake circuit; and
• a control valve and a steering cylinder.
The pump used for the steering/park brake circuit is mounted on and driven by the hydrostatic
pump. It operates whenever the engine is running. The pump delivers oil through the
accumulator charge valve to the steering control valve and the park brake accumulator. Whenever
HYD-083/05/08 2
the accumulator pressures reaches 1500 psi (10.3 MPa), the accumulator charge valve will
automatically stop flow to the accumulator and direct flow to the steering control valve.
When making a right-hand turn, the steering valve directs oil to the cylinder base rod. This exerts
hydraulic pressure on the piston and turns the machine to the right. Oil displaced in the cylinder
by the piston is returned through the steering valve and back to the hydraulic tank. If at any time
during the cycle, oil pressure in the WORKING PRESSURE LINES should exceed 2200 psi (152
MPa), the relief valve will direct the flow to the hydraulic tank. The port relief valves in the
control valve protect the steering system from overloads and shock when the control spool is in
the neutral position.
During a left-hand turn, oil flows from the steering valve to the rod end of the steering cylinder.
This causes the rod to retract, articulating the machine to the left. Oil displaced in the cylinder by
the piston stroking is returned through the steering valve to the hydraulic tank. The oil pressure is
controlled the same way as explained for a right-hand turn.
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Cylinder Description
The steering cylinder is a double acting cylinder. It consists of:
• a cylinder body;
• a piston assembly; and
• a retainer assembly.
Hydraulic oil pressure applied to one of the cylinder ports acts against the piston, causing piston
and rod movement. As one end of the cylinder fills, the opposite end dumps oil. Oil is prevented
from internally transferring from one side of the piston to the other, by two nonmetal seal sets,
each consisting of two guide/locking rings and a five-piece seal ring set.
The cylinder would complete its stroke when the piston reaches the end of the cylinder, however,
the center pivot stop blocks contact, stopping cylinder travel. At this time, hydraulic pressure
increases causing the main relief valve to direct the oil back to the tank.
CAUTION: Worn or damaged steering stop blocks may cause steering cylinder or driveline
damage.
HYD-083/05/08 4
CONTROL VALVE
2500 PSI
STEERING
CYLINDER
2200 PSI
SUPPLY FROM RETURN

PARK BRAKE TO TANK
MANIFOLD
STEER CYLINDER
REF.
STEER CONTROL GROUP

REF.
PUMP GROUP
REF.
STEER CYLINDER
REF.
HYDRAULIC TANK GROUP

REF.
Figure 2 : Steering Hydraulic System
HYD-083/05/08 5
Cylinder Removal
! WARNING!
Do not disconnect any line without first releasing all hydraulic oil pressure and load on the
cylinder.
1. Pivot the machine to the right to allow access to the steering cylinder. Block all wheels.
Turn the engine off and remove the hydraulic pressure by moving the steering, lever back
and forth until steering circuit pressure is depleted (zero hydraulic pressure).
NOTE: The steering cylinder may be disassembled and repaired on the machine, depending on
the service required.
2. Disconnect and cap the two lines to the cylinder.
3. Remove the rod end cylinder pin. If necessary, rotate the pin to work it out.
4. If repairs are to be made with the base end of the cylinder attached to the machine, remove
the four capscrews from the retainer, then remove the rod assembly.
5. If the cylinder is to be removed from the machine, remove the pin from the base end of the
cylinder.
Cylinder Disassembly
1. Remove the cap screws that secure the retainer.
2. Pull the rod from the tube assembly, along with the piston and live end.
3. Remove the self-locking nut from the rod assembly.
4. Slide the piston off the rod assembly.
5. Slide the live end off the rod assembly.
6. Remove and discard all O-rings, seals and wipers
Cleaning and Inspection
1. Wash all parts thoroughly in solvent. Blow dry with compressed air.
2. Inspect all parts for scoring, deep scratches and abnormal wear.
3. Inspect the cylinder pins and bushings for excessive wear and replace if necessary.
4. Replace all defective parts.
Cylinder Reassembly
NOTE: Refer to the Parts Manual for the correct replacement seal kits. If the loaded lip seal is
assembled with a black o-ring, replace it with the high temperature o-ring included in the
kit.
CAUTION: Lubricate all parts with hydraulic oil during reassembly to avoid damaging o-ring,
seals, etc.
1. Install a new wiper seal into the groove of the live end. The lip of the wiper points toward
the rod bearing end.
HYD-083/05/08 6
2. Install the wear ring (bearing) and loaded lip seal inside live end.
3. Install an O-ring (facing the pressure side) and a back-up ring in the groove around the outer
periphery of the live end.
4. Slide the rod into the live end.
5. Install a new O-ring in the groove in the piston bore.
6. Install on the piston two sets of "Vee Seals," one set facing each direction with the lips
facing the pressure side.
7. Slide the piston onto the rod. Secure the piston with a lock nut and torque to 660 foot-
pounds (895 Nm).
8. Carefully insert the piston and rod assembly into the tube assembly.
9. Secure the live end to the tube with four cap screws. Torque the screws to 65 foot-pounds
(88 Nm).
Cylinder Installation
1. Set the cylinder in place with the rod end toward the front of the machine.
2. Connect the cylinder to the machine at both ends. The use of new bearings is recommended.
CAUTION: If any of the cylinder mounting pins are scored, galled or pitted, replace the pin.
3. Secure, the pins with 1/2 UNC cap screws. Tighten the cap screws to 55 foot-pounds (75
Nm) of torque.
4. Install the two steering cylinder hoses and tighten.
5. Start the engine and check for leaks.
HYD-083/05/08 7
Figure 3 : Steering Cylinder Assembly
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Control Valve Description

1. When the fixed displacement pump is started, oil enters the valve assembly at "P" on the
inlet body (1).
2. The load sense passage (6) is vented to tank whenever the flow control spools are centered
in the work section.
3. The pump's flow is bypassed at the bypass spring (3) pressure of 200 psi to the "T" port.
4. A load sense signal causes the bypass spool (2) to close until the supply of oil reaches a
pressure equal to the load sense pressure plus 200 psi from the bypass spring (3).
5. When the load sense pressure rises to the main relief cartridge's (4) setting, the load sense
signal is relieved, allowing the bypass spool (2) to shift open, unloading the pump.
6. The standard VPL section (7) is actuated by energizing the Pulsar (10). The flow control
spool (8) shifts, allowing proportional control.
7. The individual compensation spool (11) maintains a constant pressure drop across the
meter-in land, independent of supply or load pressure variations.
8. The direct acting mechanical override linkage (9) can provide pressure compensated
directional proportional flow control for a manual control station or emergency override.
9. The VPL body with work port options and dual individual pressure limiters (12) provides
these features in a compact package.
10. The pressure of the load sense passage (17) is limited by the C2 port pressure limiter (13) or
the C1 port pressure limiter (14), depending on which work port is pressurized.
11. The relief with the anti-cavitation check cartridge (15) protects the C2 work port and the
anti-cavitation check (16), which also provides make-up oil to the work port.
12. Flow limiters (18) are standard on all work sections, providing maximum flow limitation,
independently for each work port.
HYD-083/05/08 9
1. BYPASS INLET BODY

2. BYPASS SPOOL
3. BYPASS SPRING
4. RELIEF CARTRIDGE
5. PILOT REDUCING CARTRIDGE
6. LOAD SENSE PASSAGE
7. VPL BODY (STANDARD, NO OPTION)
8. FLOW CONTROL SPOOL ASSEMBLY
9. MECHANICAL OVERRIDE
10. PULSAR TMSOLENOID
11. SEGMENT COMPENSATION SPOOL
12. VPL BODY WITH WORK PORT OPTIONS AND
PRESSURE LIMITERS
13. PRESSURE LIMITER ADJUSTMENT, C2 PORT
15. WORK PORT RELIEF WITH ANTI-CAVITATION
CHECK CARTRIDGE
16. WORK PORT ANTI-CAVITATION CHECK
Figure 4 : Steer Control Valve
HYD-083/05/08 10
Control Valve Removal
! WARNING!
Do not disconnect any hydraulic line or fitting without first releasing all hydraulic oil
pressure.
1. Lower the bucket flat on the ground. Block the wheels or install a frame lock bar, turn off
the engine, then move the steering lever back and forth to remove oil pressure in the lines.
2. Remove the valve cover from the frame.
NOTE: Prepare for the lines to drain residual oil when disconnecting them from the steering
control valve.
3. At the steering control valve, disconnect the supply pressure lines, two steering cylinder
lines, and a return to tank line. Put caps on the lines and the valve ports.
4. Remove the three capscrews that secure the valve to the machine frame.
5. Remove the valve from the machine.
Repairs
Refer to the maintenance instructions at the end of this section for repair procedures.
Installation of Steering Valve
1. Secure the valve to the machine frame
2. Reconnect all lines back to the valve.
4. Check the main relief pressure and adjust if needed. Install access cover.
Adjusting the Main Relief Valve
1. Remove the access cover. Connect a T-fitting and a 3000 psi (20.7 MPa) gauge to the
control valve in the SUPPLY line.
2. Start the engine and operate the hydraulic system until the oil temperature is 130° F to 150°
F (54° C to 65° C).
CAUTION: Hold steering controls in the actuated position only long enough to observe the
pressure reading or to make a quick adjustment to prevent excessive heat build up.
3. Move the steering lever until the machine is in a full turn against the stops. Operate engine
at high idle. The pressure must be 2200 psi (152 MPa).
4. If the machine has an old style relief valve, remove or add shims to obtain the correct
pressure. If the machine has a new style relief valve, turn the adjusting screw to obtain the
correct pressure.
5. Remove the gauge and T-fitting. Connect the supply line to the control valve and install the
access cover.
HYD-083/05/08 11
Bucket (Implement) System
Description
The bucket hydraulic system consists primarily of;
• an implement pump;
• a bucket control valve;
• two bucket lift cylinders; and
• a bucket dump cylinder
The implement pump is mounted on and driven by the hydrostatic pump. The inlet side of the
pump is connected to the suction strainer inside the hydraulic tank.
The control valve is mounted on the rear frame to the right of the operator's seat. Six hydraulic
lines are attached to the bucket control valve;
• a SUPPLY line from the implement pump;
• a RETURN line back to the hydraulic tank; and
• four WORKING PRESSURE lines, two to the lift cylinders and two to the bucket
cylinder.
Oil flows from the valve through the oil cooler and through the return filter into the hydraulic
tank.
Two lift cylinders are mounted under the lift arms and are connected on the rod end to the lift arm
assembly and on the piston end to the front frame of the machine. The bucket cylinder is mounted
between the lift arms and is connected on the rod end to the bucket lever and on the piston end to
the front frame assembly. On each cylinder, one hydraulic line connects the cylinder housing at
the rod end to its respective bucket control valve spool and the cylinder housing at the piston end
to the opposite side of the bucket control valve at that spool.
NOTE: Since there are two lift cylinders, crossover manifolds are used to distribute oil from the
valve to each end of the cylinders.
These are the WORKING PRESSURE lines referred to in paragraph 3.
System Operation
1. Oil necessary for the operation of the bucket hydraulic circuit is drawn from the hydraulic
tank by the implement pump. The pump delivers oil to the bucket control valve. All return
oil from the bucket valve flows through the oil cooler and return filter into the hydraulic
tank.
2. The main relief valve cartridge, located on the inlet side of the bucket control valve, by-
passes oil into the return circuit whenever the oil pressure exceeds 2200 psi (15.2 MPa).
The system pressure must not exceed the relief valve setting of 2200 psi (15.2 MPa). A
cylinder relief valve cartridge, located in the raise and rollback circuits of the bucket control
valve, protects the circuit from overload or shocks when the control valve spool is in the
centered position (lever in HOLD position). There are also anti-cavitation valves to prevent
HYD-083/05/08 12
a vacuum in the cylinder circuits. Each bucket valve section has a load check valve to
prevent reverse oil flow from a work port back to the inlet port until sufficient pressure is
accumulated from the pump.
3. When the bucket dump lever is moved, oil is metered through the bucket control valve to the
bucket cylinder. The oil pressure exerts the necessary force on the piston to move the
bucket. Oil at the opposite end of the cylinder is forced back through the control valve to
the return circuits while the cylinder rod is being stroked.
HYD-083/05/08 13
BUCKET LIFT PUSH PLATE

CYLINDER CYLINDERS CYLINDER
OPTIONAL
BUCKET CONTROL VALVE
RETURN TO TANK
FROM TANK
FOR RRC ONLY

REMOVE FOR STANDARD
INSTALL PLUG VNPK1
TO TUBES IN
FRONT FRAME
TO BRACKET ON
FRONT FRAME
TO PUMP GROUP
MOUNT TO INSIDE FACE

OF R.H. SIDE PLATE
FOR RRC ONLY

REMOVE FOR STANDARD AND
INSTALL PLUG VNPK1
TO OIL COOLER
Figure 5 : Bucket Hydraulic System
HYD-083/05/08 14
4. The lift circuit is similar to the bucket dump circuit in operation. However, the lift circuit
has a "float" function. When the hoist lever is pushed completely forward, both ends of the
lift cylinders are hydraulically connected to the return circuits to allow oil to move freely
from either end of the lift cylinders.
5. The optional ejector bucket requires a bucket control valve with three (instead of two)
spools. The circuit makes use of the main relief valve and a cylinder relief valve cartridge
as do the lift and bucket dump circuits.
Lift Cylinder Description
The lift cylinders are double-acting cylinders consisting of:
• a tube assembly;
• a piston and rod assembly; and
• a live end.
Hydraulic oil pressure is applied to either side of the piston to extend or retract the rod. As one
end of the cylinder fills, the opposite end empties. When the piston reaches the end of the
cylinder, hydraulic pressure increases causing the main relief valve to divert oil back to the
hydraulic tank.
Removal of Lift Cylinders
1. Block up the front frame. Remove the front wheels. Extend the lift cylinders until the
bucket is approximately four feet (approximately 1 meter) off the floor. Block the bucket
and lift arms in this position.
! WARNING!
Release trapped oil pressure and remove all load on the cylinders before disconnecting hoses
or fittings.
2. Release the oil pressure in the hydraulic tank. Work the control levers to release pressure to
the cylinders
3. Disconnect, cap, and tag the lines from the cylinder to be removed.
4. Attach a lifting device to the cylinder, and with the cylinder secure, remove the pin retaining
devices. Drive out the pins and remove the cylinder.
Disassembly of Lift Cylinder
1. Drain the oil from both ends of the cylinder.
2. Remove the cap screw from the live end.
3. Pull the rod from the tube assembly, along with the piston and the live end.
4. Remove the self-locking nut from the rod assembly.
5. Remove the piston from the rod.
6. Remove the live end from the rod.
7. Discard all seals, O-rings and wipers.
HYD-083/05/08 15
Cleaning and inspection

1. Wash all parts thoroughly in solvent. Blow dry with compressed air.
2. Inspect all parts for scoring, deep scratches, and abnormal wear.
3. Inspect the pins and bushings for excessive wear and replace if necessary.
4. Replace all parts, seals, and O-rings provided in the seal kit.
Reassembly of Lift Cylinder
assembled with a black o-ring, replace it with the high temperature o-ring (gray) included
in the kit.
CAUTION: Lubricate all parts with hydraulic oil during reassembly to avoid damaging o-ring,
seals, etc.
1. Install a new wiper seal and loaded seal in the retainer. The wiper seal lip points outward to
keep dirt out. Install sealing rings and a loaded lip seal. Install a new O-ring and back-up
ring around the outer diameter of the live end.
2. Slide the rod into the live end, being careful not to damage the seals.
3. Install two sets of "Vee Seals” on the piston, one set facing each direction with the lips
facing the pressure side. Also install a new O-ring in the groove in the bore of the piston.
4. Slide the piston onto the rod. Secure the piston with the self-locking nut. Torque the nut to
660 foot-pounds (895 Nm).
5. Insert the piston and rod assembly into the cylinder tube.
6. Secure the live end to the tube and tighten the cap screws to 220 foot-pounds/298 Nm (dry).
lnstallation
1. With a suitable lifting device, lift the cylinder into place and install the two pins. Secure
pins with their retaining devices.
2. Connect the hydraulic lines.
4. When the hydraulic oil is warm, check the oil level and fill as necessary.
HYD-083/05/08 16
1. BEARING
2. SPACER RING
3. LIVE END
4. SEAL KIT
5. WEAR RINGS
6. ROD ASSEMBLY
7. CYLINDER BODY
8. PISTON
9. SELF-LOCKING NUT
10. SNAP RING
11. PIN ANCHOR
12. PIN
13. GREASE FITTING
14. CYLINDER ASSEMBLY
Figure 6 : Lift Cylinder Assembly
HYD-083/05/08 17
Bucket Cylinder Description

The bucket cylinder is a double-acting cylinder consisting of;
• a live end.
end of the cylinder fills, the opposite end empties. When the piston reaches the end of the
cylinder or when the bucket stop blocks make contact, hydraulic pressure increases, causing the
main relief valve to divert oil back to the hydraulic tank.
CAUTION: Worn or damaged stop blocks may cause cylinder damage.
Removal of Bucket Cylinder

1. With the lift arms completely lowered, extend the bucket cylinder until the bucket lays flat
on the floor.
! WARNING!
Release trapped oil pressure and remove all load on the cylinder before disconnecting hoses
or fittings.
2. Release the air pressure in the hydraulic tank and work the bucket control levers to release
pressure to the cylinder.
3. Disconnect, cap, and tag the hoses from the cylinder to be removed.
4. Attach a lifting device to the cylinder, and with the cylinder secure, remove the pin retaining
Disassembly, Cleaning and Inspection
The bucket cylinder is similar in construction to the lift cylinder.
Reassembly of Bucket Cylinder
in the kit.
CAUTION: Lubricate all parts with hydraulic oil during reassembly to avoid damaging the o-ring,
seals, etc.
1. Install a new wiper seal in the seal retainer, and new sealing rings and a loaded lip seal in the
live end. The wiper seal lip points outward to keep dirt out and the loaded lip seal notch
points inward to keep oil in. Install a now O-ring around the outer diameter of the live end.
2. Slide the rod into the live end.
3. lnstall two sets of "Vee Seals" on the piston, one set facing each direction with lips facing
the pressure side. Also install a new O-ring in the groove in the bore of the piston.
HYD-083/05/08 18
4. Secure the piston to the rod with the four socket head cap screws. Tighten the cap screws to
480 to 495 foot-pounds/550 to 670 Nm (lubed). Lock wire the cap screws.
5. Carefully insert the piston and rod assembly into the cylinder tube.
6. Secure the live end to the tube and tighten the cap screws to 250 foot-pounds/339 Nm (dry).
Lock wire the cap screws.
Installation of Bucket Cylinder
1. With a suitable lifting device, lift the cylinder into place and install the two pins. Secure the
pins with their retaining devices.
2. Connect the hydraulic lines.
4. When the hydraulic oil is warm, check the oil level and fill as necessary.
HYD-083/05/08 19
1. GREASE FITTING
2. SNAP RING
3. BEARING 9. HARDENED WASHER
4. LIVE END 10. CAPSCREW AND
5. SEAL KIT LOCKWIRE
6. ROD ASSEMBLY 11. PIN
7. PISTON 12. CYLINDER ASSEMBLY
8. CYLINDER BODY
Figure 7 : Bucket Cylinder Assembly
HYD-083/05/08 20
Push-Plate Cylinder Description

The push-plate cylinder (used only with the push-plate bucket) is a double-acting cylinder
consisting of:
• a live end.
end of the cylinder fills, the opposite end dumps oil. When the piston reaches the end of the
cylinder, hydraulic pressure increases, causing the main relief valve to divert oil back to the
hydraulic tank.
Removal of Push Plate Cylinder
1. Set the bucket completely on the floor and retract the push-plate. Secure the pushplate so
that it will not move when a cylinder is disconnected.
! WARNING!
Release trapped oil pressure and remove all load on the cylinder before disconnecting hoses
or fittings.
2. Relieve the hydraulic tank of air pressure by pushing the button in the center of the filler
cap.
3. Disconnect and tag the hydraulic hoses from the cylinder.
4. Attach a lifting device to the cylinder and, with the cylinder secure, remove the pin retaining
Disassembly, Cleaning and Inspection
The push-plate cylinder is similar in construction to the lift cylinder.
Reassembly of Push-Plate Cylinder
NOTE: Refer to the Parts Manual for the correct replacement seal kits if the loaded lip seal is
in the kit.
CAUTION: Lubricate all parts with hydraulic oil during reassembly to avoid damaging the o-ring,
seals, etc.
1. Install a new wiper seal, o-ring, and back-up rings. The wiper seal lip points outward to
keep dirt out and the o-ring points inward to keep oil in. Install a new o-ring around the
outer diameter of the live end.
2. Place the rod into the live end.
3. Install the piston rings (if they were removed) and o-ring with the piston seal on the piston.
4. Secure the piston to the rod with the rod end nut and install the roll pin.
HYD-083/05/08 21
NOTE: Tighten the rod end as much as possible (torque specification for nut is approximately 600
foot-pounds/801 Nm), and then tighten more until the roll pin hole lines up. Do not loosen
the nut to install the roll pin.
5. Insert the piston and rod assembly into the cylinder tube.
CAUTION: Do not allow the piston ring joints to pass under the port openings during assembly.
6. Secure the live end to the tube and tighten the cap screws to 200 foot-pounds (271 Nm).
Lock wire the cap screws.
Installation of Push-Plate Cylinder
1. With a suitable lifting device, set the cylinder in place with the rod end up.
2. Connect the cylinder to the machine at both ends. The use of new bearings is recommended.
CAUTION: If a cylinder mounting pin is scored, galled, or pitted, the pin must be replaced.
3. Secure each pin with its appropriate pin retention device.
4. Connect all hydraulic lines and securely tighten.
5. Pressurize the hydraulic tank.
HYD-083/05/08 22
1. CYLINDER 8. CAP SCREW

2. PIN 9. LOCK WASHER
3. PIN 10. LOCK NUT
4. KEEPER PLATE 11. COLLAR
5. LOCKING PLATE 12. GREASE FITTING
6. CAP SCREW 13. 0-RING
7. CAP SCREW 14. HYDRAULIC MANIFOLD
Figure 8 : Push-Plate Cylinder Assembly
HYD-083/05/08 23
Bucket Control Valve Description

The bucket control valve is an open-centered valve. Oil flows freely from the bucket pump to the
hydraulic tank when all the spools are in the centered position. The control valve consists of:
• a main relief valve assembly;
• a bucket circuit spool;
• lift circuit spools;
• an optional push-plate circuit spool;
• two combinetion port relief/anti-cavitation/load check valves;
• a combination port relief/load check valve; and
• a combination anti-cavitation/load check valve.
Passages within the valve body connect the spool bores with SUPPLY, RETURN, and
CYLINDER ports in the control valve. Actuating the spools connects these passages in
appropriate combinations to obtain the desired hydraulic flow patterns. If the lift spool is
retracted to the RAISE position, the pressurized oil flows to the piston end of the lift cylinders and
allows oil in the rod end of the cylinders to return to the hydraulic tank. The bucket spool controls
the bucket cylinder.
The load check valve prevents back-flow from the cylinder(s) to the hydraulic pump before the
pressure increases enough to move the load. The anti-cavitation check valve allows cavitating
work ports to refill from the return chamber of the valve to supplement pump flow when needed.
The port relief valve limits the maximum pressure at the cylinder ports when the spool is in the
NEUTRAL position. The main relief valve limits the system relief pressure to 2200 psi (15.2
MPa).
HYD-083/05/08 24
1. BYPASS INLET BODY

2. BYPASS SPOOL
3. BYPASS SPRING
4. RELIEF CARTRIDGE
5. PILOT REDUCING CARTRIDGE
7. VPL BODY (STANDARD, NO OPTION)
8. FLOW CONTROL SPOOL ASSEMBLY
9. MECHANICAL OVERRIDE
10. PULSAR TMSOLENOID
11. SEGMENT COMPENSATION SPOOL
12. VPL BODY WITH WORK PORT OPTIONS AND
PRESSURE LIMITERS
15. WORK PORT RELIEF WITH ANTI-CAVITATION
CHECK CARTRIDGE
16. WORK PORT ANTI-CAVITATION CHECK
Figure 9 : Bucket Control Valve
Control Valve Removal
! WARNING!
Do not disconnect any hydraulic line or fitting without first releasing all hydraulic oil
pressure.
1. Lower the bucket flat on the ground. Block the wheels and turn off the engine.
2. Move the control levers back and forth to remove oil pressure in the lines.
3. Remove the valve access cover.
NOTE: Be prepared for the lines to drain residual oil when disconnecting them from the bucket
control valve.
4. At the bucket control valve, disconnect the supply pressure line, four lines to the cylinders
and a return to tank line. Put caps on the lines and the valve ports.
HYD-083/05/08 25
5. Remove the three capscrews that secure the valve to the machines frame.
6. Remove the valve from machine.
Repairs
Refer to the Gresen Maintenance instructions at the end of this section.
Installation of Bucket Valve
1. Mount the valve to the machine frame.
2. Reconnect all lines back to the valve.
4. Check pressure and adjust if needed. Install access cover.
Adjusting the Main Relief Valve
1. Connect a T-Fitting and a 3000 psi (20.7 MPa) gauge in the SUPPLY line to the control
valve.
2. Start the engine and operate the hydraulic system until the oil is 130° F to 150° F (54° C to
65° C)
CAUTION: Hold bucket controls in the actuated position only long enough to observe the pressure
reading or to make a quick adjustment to prevent excessive heat.
3. Hold the dump lever in the ROLLBACK position with the bucket retracted and the engine at
high idle. The pressure must be 2200 psi (15.2 MPa).
4. If the valve has an old style relief valve, remove or add shims to obtain the correct pressure.
If valve has a new style relief valve, turn the adjusting screw to obtain the correct pressure.
5. Remove the gauge and T-Fitting. Connect the supply line to the control valve. Install the
access cover.
Adjusting the Port Relief Valve
1. Connect a T-Fitting and a 3000 psi (20.7 MPa) gauge in the SUPPLY line to the control
valve.
2. Start the engine and operate the hydraulic system until the oil is 130° F to 150° F (54° C to
65° C)
CAUTION: Hold bucket controls in the actuated position only long enough to observe the pressure
reading or to make a quick adjustment to prevent excessive heat.
3. Set the main relief valve to 2800 psi (19.3 MPa).
4. Move the lever slowly to the position of the port relief function being tested. Keep the
engine speed as low as possible without stalling the engine. The port relief pressure should
be at 2500 psi (172 MPa).
5. Remove or add shims to obtain the correct pressure.
6. Reset the main relief valve to 2200 psi (15.2 MPa).
7. Remove the gauge and T-fitting. Connect the supply line to the control valve. Install the
access cover.
HYD-083/05/08 26
Testing for Lift Cylinder Leakage

1. Position the lift arms with the lift cylinders approximately half extended. Place blocking
under the lift arms to prevent the arms from falling more than a short distance. Do not
position the blocking so that it is contacting the lift arms at the start of the test.
2. Shut the engine off and observe the bucket hydraulic system for several minutes, looking for
leaking fittings, hoses, or components.
3. Cylinder creepage could indicate internal leakage in the cylinders or in the bucket control
valve. The leakage could be caused by one or more of the following:
• Defective sealing rings around the piston or a scored cylinder wall allowing oil to leak
from one end of the cylinder to the other,
• Defective or dirty cylinder port relief valve.
Testing for Bucket Cylinder Leakage
1. Place a load approximately one-half of the rated capacity in the bucket, then raise the lift
arms sufficiently to allow full swing of the bucket when the bucket dump lever is actuated.
2. Block the lift arms to completely prevent their movement and half-extend the bucket
cylinder.
3. Shut the engine off and observe the bucket hydraulic system for several minutes, looking for
leaking fittings, hoses, or components.
4. Cylinder creepage could indicate internal leakage in the cylinder or the bucket control valve.
This leakage could be caused by one or more of the following:
• Defective sealing rings around the piston or a scored cylinder allowing oil to leak from
one end of the cylinder to the other
• Worn bucket control valve spool or housing
• Defective or dirty cylinder port relief valve
! WARNING!
Further testing for determining the exact cause of the problem should be performed by a
person with a thorough understanding of hydraulic principles, the complete hydraulic
system, and the safety aspects involved. Before disconnecting any hydraulic hoses, fittings,
or valve, remove all load from the bucket and move the controls back and forth.
HYD-083/05/08 27
Hydraulic Tank
Description
The hydrostatic transmission, bucket, park brake, and steering circuits all draw oil from the same
hydraulic tank. The hydraulic tank assembly consists primarily of:
• the tank;
• a filler assembly;
• a suction strainer;
• a hydraulic return filter; and
• a transmission suction filter.
The relief valve is located in the filler cap and opens at approximately 7 psi (48 kPa) to allow
excess pressure to escape. Hydraulic tank air pressure may be released by pushing the button on
the filler cap.
The return flow from the steering and bucket hydraulic systems connect into the return filter
assembly. The supply flow for the hydrostatic transmission goes through the suction filter
assembly.
Inspection
1. Drain the tank by removing the plugs from the front and rear sections at the bottom of the
tank.
2. Remove the filler assembly and access plate.
3. Remove the magnetic suction strainer from inside the tank.
4. Remove the hydraulic oil filter assemblies and replace the filter elements.
5. Make sure the tank is clean and free of rust, dirt, or other foreign matter. Clean the tank with
diesel fuel or solvent if necessary.
6. Disassemble and clean the magnetic suction strainer thoroughly and then reinstall it.
7. Reinstall the hydraulic filter assemblies.
8. Clean and inspect the filler cap/ strainer assembly. Replace if necessary.
9. Install the access plate and filler assembly.
Filling the Tank
1. Fill the tank to the sight glass.
2. Loosen the inlet connections at the pumps until all the air is removed (oil flow does not
contain any air bubbles), then tighten the inlet connections. Check the oil level and add oil
if needed. Install the filler cap.
3. Start the engine and check the system for leaks. Re-check the oil level when the system is at
normal operating temperature.
HYD-083/05/08 28
DASH INDICATOR SWITCH
RETURN FROM OIL

COOLER
RETURN FROM
PARK BRAKE
MANIFOLD
XMSN DRAIN
HYDRAULIC TANK
TO IMPLEMENT
PUMPS
MAGNETIC STRAINER
DRAIN FROM
XMSN VALVE
TRANSMISSION
SUCTION FILTER
ASSEMBLY
FILLER
ASSEMBLY
O-RING
BY-PASS
VALVE
FILTER
ELEMENT
MAGNETIC
SUCTION
STRAINER
RETURN FILTER
ASSEMBLY
Figure 10 : Hydraulic Tank Arrangement
HYD-083/05/08 29
Hydraulic Pumps
Description
There are two pump assemblies:
• the implement pump (steering, brake, bucket); and
• the hydrostatic transmission pump.
The implement pump is mounted to the hydrostatic pump. The hydrostatic pump is mounted to
the engine flywheel housing.
Removal
! WARNING!
Do not disconnect pressure outlet lines without first releasing all hydraulic pressure from
the circuits.
1. Lower the bucket flat on the ground and stop the engine. Move the bucket control levers
back and forth several times.
2. Release the oil pressure in the accumulator by moving the park brake control knob from the
PARK position to the RELEASE position ten (10) times with the engine stopped and the
ignition switch in the RUN position. Slightly loosen the hydraulic line to the accumulator if
needed. Release the pressure in the hydraulic tank by pushing the button on the top of the
filler cap.
3. Drain the hydraulic tank.
4. Remove the batteries and other components as necessary to make removal of the pumps
easy.
NOTE: Prepare to drain large amounts of oil from the hoses when they are disconnected from
pumps.
5. Disconnect the suction and pressure lines from the pumps. Put protective covers on the ends
of the lines and plug the pump ports.
! WARNING!
Pumps are heavy. They should be lifted from the machine with a lifting device.
6. Attach a lifting device to the pump being removed and remove the cap screws from the
mounting flange. Pull pumps straight outward from the flywheel housing.
Disassembly, Inspection and Reassembly
Refer to the manufacturer's information included in this section.
HYD-083/05/08 30
Installation
CAUTION: Torque all capscrews to the torque specified in section 1 unless specified below.
To install the hydrostatic transmission pump, proceed as follows:
1. Coat the splined shaft of the pump and coupling adapter with grease.
2. With the aid of a suitable lifting device, position the pump for installation.
3. Install new lockwashers on the mounting capscrews. Torque to 150 foot-pounds (203 Nm)
and lockwire.
4. Connect the hydraulic lines. Use a lockwasher on capscrews for split flange so capscrew
does not bottom out.
5. Replace oil and filters.
CAUTION: The hydraulic oil and filter must be changed whenever the transmission has been
repaired.
6. Loosen inlet connection and expel air.
To install the implement pump, proceed as follows:
NOTE: It is not necessary to coat the pump shaft with grease because the shaft is lubed by
hydrostatic return oil.
1. Place a new gasket between the implement pump flange and the hydrostatic pump.
2. Slide the pump into the coupling adapter.
3. Install new lockwashers on the mounting capscrews. Torque the capscrews to 100 foot-
pounds (135 Nm).
4. Replace oil and filters.
5. Loosen inlet connection and expel air. Tighten connection.
HYD-083/05/08 31
MOUNTING
DRIVE
HYDROSTATIC
TOWIN
UNDERSIDE G
HIGH
IMPLEMENT
PUMP
TO PORT
HORSEPOWER LIMITER
CARTRIDGE (DO NOT
ADJUST)
TIMING
CHARGE PRESSURE
RELIEF OVERRIDE
Figure 11 : Pump Installation Arrangement
HYD-083/05/08 32
Hydraulic System Maintenance
Maintenance of the System

The amount of maintenance a system receives will be related to the downtime and repair costs of
operation. An hydraulic system, like a fuel or lubrication system, will give many hours of reliable
service if properly maintained.
There are three general sources for contaminants:
• Contaminants are built-in to the system during manufacturing.
• Contaminants are generated into the system during operation.
• Contaminants are introduced from external sources present at the mine sites.
Built-in Contaminant
During manufacturing and shipment, components are exposed to grinding, welding, and plating.
These processes create harmful particles that are so small they cannot be seen by the naked eye.
Needless to say, they cannot be removed from the system by a wiping cloth, blast of air, or other
common cleaning methods.
Replacement parts put into the hydraulic system are a source of contamination if they are allowed
to sit on skids and shovels without being properly sealed. Dust from sweeping can settle within
the component itself as well as sweepings that get kicked into component openings. Cast parts of
the components machining burrs and welding scale all become part of the contamination.
Generated Contaminant
Contaminants are generated by the system itself as it operates. Moving components such as
pumps and cylinders gradually wear themselves in. During the first few hours of operation these
components are actually doing their final machining.
Seals and metal parts of cylinders are continuously wearing during operation. Particles from cast
housings are torn loose by shock loads that occur within the system. High fluid flows tend to
erode sharp edges in various components, thus generating additional debris.
Contaminant Added
This would be the most common and easily prevented form of contamination. Whenever fluid is
added, or the system is opened for repair, contaminates are allowed to enter. An unclean
container used to replenish fluid, or a hose replaced after falling into dirt without being flushed
and blown out, are common entry points for this type of contamination.
Other Contaminants
Other forms of contamination that are harmful to the hydraulic system come from the oil itself.
The break down of additives in the oil cannot be completely controlled by preventative
maintenance. For example, the formation of soluble and insoluble contaminates is caused by the
breakdown of these additives. This type of contamination is accelerated when the system
becomes overheated. However, even under the most careful maintenance, contamination due to
oxidation, condensation, and the formation of acids causes the oil to become harmful. Most
authorities agree and recommend that all hydraulic oil should be drained from the system
HYD-083/05/08 33
regularly. How often a system should be changed depends on many factors. It is always a good
idea to rely on the manufacturer's recommendations and on suggestions offered by the oil
company supplying the products being used.
Servicing Filters and Strainers
The hydraulic return filter has a mechanical indicator. As the filter becomes clogged with foreign
contamination, the indicator will show the restriction. Recommended changes are based on the
indicator reading. Change filters only when the indicator says to.
CAUTION: Whenever component failures occur, it is recommended that the filter elements be
changed.
Most hydraulic filter assemblies are equipped with a by-pass valve which allows the oil to by-pass
a clogged filter element. This ensures a continuous flow of hydraulic fluid to the system. Without
such a by-pass arrangement, oil being forced into the filter under pressure could blow a clogged
filter to pieces. The small particles would then flow through the system. Because of the presence
of the by-pass valve, more and more hydraulic oil will by-pass around the filter elements as it fills
up with dirt. Thus, the filtration of the oil is being left to the suction filter only.
It is difficult to establish a time schedule for servicing hydraulic system filters that will apply in
all cases. The reason is that the rate of contamination accumulation in a system is affected by six
factors:
1. The cleanliness of the hydraulic oil when first placed in the system and the cleanliness of the
make-up oil which has been added.
2. The amount of dirt entering the system due to carelessness when adding make-up oil.
3. The dirt and dust conditions encountered by the equipment on the job.
4. The condition of the hydraulic cylinder seals.
5. The amount of moisture, due to condensation, in the oil.
6. Overheating of the system.
Inspection
Remove and inspect the hydraulic filter element from time to time. If close inspection reveals that
there is a thin but definite film of dirt covering the outside of the element, dirt is starting to work
its way through. If dirt is just beginning to show at the root of each pleat, the element will soon
need to be changed. An element in this condition is still capable of trapping more dirt, but it will
soon commence to restrict the oil flow to the extent that a great deal of oil will by-pass the filter
uncleaned. Then contaminates will be deposited on the components of the hydraulic system,
causing them to wear rapidly, or malfunction.
Changing Oil in the Hydraulic System
1. Steam clean the unit thoroughly, especially in areas where the circuit will be opened.
2. Operate the hydraulic system until it reaches normal system temperature, this will ensure the
greatest quantity of contamination being carried away.
3. Shut down the motor.
4. Remove the filler cap and the return filter elements.
5. Place a large container under the tank drain plug.
HYD-083/05/08 34
6. Remove the tank drain plug and allow the oil to drain completely.
7. Remove the suction filter and thoroughly clean all parts.
8. Clean the inside of the tank completely, and flush it with a mixture of five parts fuel oil to
one part clean lubricating oil. Pay particular attention to the bottom and corners of the tank.
Make sure that all flushing materials are removed.
9. Disconnect and drain all hoses that might trap oil, pump suction lines, etc.
10. Drain any oil that might be trapped in the hydraulic control valve bodies by shifting the
levers through the various positions.
11. Reassemble all components removed from the tank and install new filter elements.
12. Reconnect all hoses previously disconnected.
13. Ensure that the tank drain plug and cover plates are replaced securely and form an effective
seal.
14. Refill the tank to the recommended level.
15. Make sure that all control levers are in the neutral position and start the motor allowing it to
run for a few minutes.
CAUTION: Keep all personnel away from the unit when operating hydraulic functions.
16. Operate the hydraulic circuits through their complete cycle several times to bleed any
trapped air from the system. Repeat this until foaming has ceased in the tank.
17. Add sufficient hydraulic oil to the tank to bring the level up to the recommended mark.
18. Carefully check all connections in the hydraulic system for leaks.
If a component has failed (causing metal particles to circulate within the system), or heavy
contamination exists, more extensive cleaning must be done. In addition to draining and cleaning
the tank and filters, the following steps are recommended:
• Disconnect all hoses from components, flush with clean hydraulic oil, and blow out
with compressed air.
• Remove pumps, cylinders, control valves, and other hydraulic components.
Disassemble, clean, and carefully inspect for other damage.
• Thoroughly clean and flush hydraulic components.
• Assemble and install hydraulic components.
• Refill the system with clean hydraulic oil.
• Start the unit and bleed the system. Run the unit through several cycles to further flush
out the system.
• Drain the entire system again.
• Once again clean all screen and strainers, flush out the tank and replace all hydraulic
filter elements with new ones.
• Fill the hydraulic system with new hydraulic oil and bleed the air as described
previously.
HYD-083/05/08 35
Operation
A few simple operating and maintenance procedures will assist in keeping hydraulic systems
operating at peak efficiency with a minimum of downtime. They will also help exted the effective
life of the units. Several points are listed which are well worth careful attention.
Starting New Pumps
• Make certain that the entire hydraulic system is clean.
• Fill the hydraulic tank to the proper level with the recommended grade of hydraulic fluid.
• A new pump and system should not be started and immediately operated at full speed. The
recommended procedure is to gradually speed up to approximately one-half operational
speed, or a minimum of 1000 rpm at minimum pressure. Preliminary circuit checks for air
entrapment, leaks, etc., may be made at this time.
• When the recommended operation viscosity and temperature has been achieved, load may be
alternatively applied up to the relief valve setting to check for satisfactory operation of all
circuit components.
Cylinder Removal
To remove the hydraulic cylinders from the equipment, proceed as follows:
1. Lock or position the unit which receives its motion from the hydraulic cylinder(s) so that no
force or weight is placed on the piston assembly.
2. Disconnect the hydraulic lines leading to and from the cylinder(s), and drain the hydraulic
oil into a suitable container.
3. Plug the oil ports in the cylinder(s) and cap the lines to prevent dirt from getting in.
4. Before removing the cylinder, attach a suitable lifting device to support its weight.
5. Remove the pins mounting the cylinder to the equipment.
6. Lift the cylinder assembly from the equipment.
Cleaning
Thoroughly wash all of the parts of the cylinder assembly in a suitable solvent. Dry with a clean,
lint free cloth or with compressed air.
Inspection
Carefully inspect the inside of the cylinder and the condition of the piston.
When assembling the cylinder, use new seals, back-up rings. O-ring, and wiper ring. Replace
any part which may be worn or damaged.
NOTE: Refer to the Parts Manual for the correct replacement seal kits.
Installation
To install the hydraulic cylinders, reverse the procedure for removal. Check the hydraulic
cylinder(s) for leaks during operation.
External leaks which occur on the intake side of the pump are much more difficult to detect.
However, you can usually suspect intake leaks in the system if any of the five following
conditions are evident:
HYD-083/05/08 36
• Air bubbles in the hydraulic oil.

• Erratic or jerky hydraulic system action.
• Overheating.
• Excessive pressure in the tank.
• Excessive pump noise.
If any of these conditions exist, your best bet is to first check all intake fittings and connections
for leaks.
Over-tightening of the hose fittings can be even more troublesome than under-tightening.
Some mechanics have a tendency to give the wrench just one more twist "for the road". However,
that last extra effort to prevent leaks may just be what it takes to distort the fitting and cause leaks.
Here again, manufacturer's recommendations should be used as a guide. The number of foot-
pounds recommended for tightening a particular swivel nut, for example, will ensure a tight seal
and yet not be so tight as to result in distortion of one or both members.
Leaks in the intake side of the system can usually be detected by adding oil to the area of the
connection. If the pump noise caused by aeration discontinues, you then know that you have
found the connection where air is being taken into the system.
Internal Leaks
As the various components of a hydraulic system wear, internal leakage within the components
becomes more and more evident. A slight amount of internal leakage can be tolerated. However,
as leakage increases, overheating will become a problem. When this happens, other components
or the entire hydraulic system will begin to fail. Therefore, it is important that the hydraulic
system be kept in good working order.
HYD-083/05/08 37
Troubleshooting Tables
Park Brake Circuit

TROUBLE PROBABLE CAUSE CORRECTIVE ACTION
Park brake not releasing Oil level low in hydraulic tank. Check and fill.
Pump not functioning. Repair or replace pump.
Broken or leaking suction hose, Check and repair, or replace
pressure hose or fitting. parts.
Charging cycle repeats Accumulator precharge Fill accumulator with nitrogen
frequently when the park pressure too low. to 900 psi (6.2 MPa).
brake is released.
Accumulator leaking. Repair or replace accumulator.
Accumulator charge valve not Repair or replace accumulator
functioning. charge valve.
Operating pressure Defective or worn pump (does Rebuild or replace pump.
insufficient not deliver full flow at system
pressure).
Pressure reducing is not Reset to correct pressure.
functioning correctly. Replace if needed.
Steering Circuit
Spool does not shift Contaminated oil. Clean valves, drain and flush
system, replace oil.
Foreign body in valve or Clean valves and deburr spool,
damaged spool. or replace.
Spring broken. Replace spring.
Valve jams due to temperature. Maintain permissible
temperature range.
Valve distorted during Remove cause.
mounting.
System pressure too low. Defective pump. Repair or replace pump.
HYD-083/05/08 38
Relief valve in steering valve Repair or replace.

stuck open.
Unloading valve stuck open. Repair or replace.
Pressure fluctuates Air in fluid. Bleed system.
Contaminated fluid. Clean valve, drain, flush and
replace fluid.
Viscosity of fluid too high or Follow the fluid
too low. recommendations.
Differential pressure sensing Repair or replace.
valve sticking.
External leak Sealing rings fail. Replace seals, if necessary,
remove and clean valve.
Damaged or porous valve body. Replace valve body. Establish
cause.
Boom/Bucket Circuit
Lift arm fails to lower or Defective cylinder. Repair or replace cylinder.

will not lower completely
(no load)
Structural warpage, clearances Check lift arm alignment and
too close, lack of lubricant, bushings. Repair, adjust and
defective lift arm bushings. lubricate as necessary.
Excessive cylinder creep Pressure line leaks Check all lines and fittings.
rate Replace or tighten as necessary.
Cylinder leaks. Replace seals and check for
cause of seal damage. Repair as
necessary. If damage was
caused by contaminated oil,
flush the system, change the
filters, and fill the system with
hydraulic oil as specified.
Bucket control valve defective. Repair or replace as necessary.
HYD-083/05/08 39
No motion of bucket No oil or insufficient oil being No hydraulic actions.

cylinder supplied to cylinder.
Load greater than rated Reduce load.
capacity.
Slow or uneven action of Insufficient oil being supplied Check bucket circuit, for: "no
the bucket cylinder to cylinder. motion of lift cylinder" in
trouble column.
Defective cylinder seal. Replace and check for cause of
seal damage. Repair as
necessary. If damage was
caused by contaminated oil,
flush the system, change the
filter, and fill the system with
hydraulic oil as specified.
System resistance. Check for hot points in system
(fittings too small etc.). Repair
or replace as necessary.
Main relief or cylinder relief Check relief pressure. Adjust
valve out of adjustment. or replace relief valve as
necessary.
Spongy or jerky action of Air in system. Check oil level in the hydraulic
the boom/bucket cylinder tank. Check for air leaks at
fittings, lines, and cylinder
seals. Fill the hydraulic tank or
repair leaks as necessary.
Bend rod, deformed cylinder, or Disassemble, check and repair
scored piston. cylinder assembly.
No hydraulic actions Oil level in hydraulic tank. Check and fill.
Main relief valve improperly Check and readjust. Replace
adjusted or defective. valve if defective.
Hydraulic pump inoperative. Check pump for proper
operation. Repair or replace.
Cable Reel Circuit
HYD-083/05/08 40
Cable reel will not reel Defective hydraulic supply Repair or replace the pump.
cable in or out. pump.
Leaking hydraulic lines. Repair or replace the lines.
Plugged hydraulic oil cooler. Remove obstruction or replace
the cooler.
Defective reel shifter valve Replace spool and valve
spool. housing.
Defective low or high pressure Replace relief valve cartridge.
relief valve.
Defective cable reel drive Repair or replace the motor.
motor.
Drive chain broken or Repair, readjust or replace the
disconnected. drive chain.
Cable reel spool jammed or Remove obstruction. Repair or
damaged. replace the spool.
Low oil level in hydraulic tank. Check oil level, fill tank as
necessary.
Hydrostatic Transmission Circuit
1. TRANSMISSION DOES NOT DRIVE WITH THE PRIME MOVER RUNNING.

1.1 Is there oil in the reservoir? No Fill reservoir.
Yes Proceed to step 1.2
1.2 Is engine clutch engaged? No Engage clutch.
1.3 Is the hydraulic piping in No Correct the piping.
accordance with the hydraulic
circuit?
1.4 Is the pump direction of rotation No Fit pump having the correct
correct? direction of rotation.
1.5 Is there a broken pipe, loose No Proceed to step 1.6
fitting or burst hose?
HYD-083/05/08 41
Yes Repair the fault

1.6 Are the brakes released? No Check brake release circuit or
mechanism.
Charge pump and relief valve:
1.7 Is there any charge pressure at No Proceed to step 1.10
port G?
1.8 Is the charge pressure at least No Proceed to step 1.9
320 psi while the pump is
running at normal operating
speed?
1.9 Can the charge pressure be No Proceed to step 1.10
adjusted at the charge pressure
relief valve.
Yes Adjust charge pressure to 320 psi
and proceed to step 1.19
NOTE . If flushing valve is used in circuit, it should be set at 25 psi less than charge pump
relief. refer to data sheet on flushing valve for information and setting procedure.
1.10 Is suction line shut-off valve No Open valve.
open?
1.11 Is the charge pump suction No Proceed to step 1.12
pressure within recommended
limits? )-3.2 psi or 6.5 in. Hg
vacuum.
1.12 Is suction filter element No Proceed to step 1.13
plugged?
Yes Replace filter element.
1.13 Does the reservoir design ensure No Correct the reservoir design
that suction pipe is always
covered with oil?
HYD-083/05/08 42
1.14 Is the suction pipe size adequate No Run at lower speed and return to
for the flow? point 1.7, or rework suction piping.
1.15 Is the reservoir air breather No Proceed to step 1.16
blocked or undersized?
Yes Clean or replace air breather.
1.16 Remove charge pressure relief No Refit cartridge and proceed to step
valve cartridge and inspect. Is it 1.17
damaged?
Yes Fit a new cartridge and return to step
1.7
1.17 Remove and inspect charge No Proceed to step 1.18
pump assembly. Is it damaged?
Yes Repair or replace damaged
components and return to step 1.7
NOTE . Replace charge pump as
complete unit.
1.18 Is the charge pump installed for No Refit charge pump by rotating pump
correct direction of rotation? housing 180_. Return to step 1.7
Yes With proper charge pressure and
transmission still does not operate,
proceed to step 1.19
Pump Control
1.19 Is control medium connected to No Connect appropriate medium and
pump control? HD-pilot pressure check that control signal is actually
HW-mechanical cable or linkage being applied to the control valve.
El 12 or 24 volts DC, electrical
current
1.20 If variable displacement motors No Select maximum displacement.
are installed, is maximum
displacement selected? (If not
done automatically).
1.21 Actuate the control in both No Proceed to step 1.22
directions. Does pump stroke?
HYD-083/05/08 43
Yes operate the transmission.

1.22 Stroke the pump in both No Remove control module and replace
directions. Do the pressures at with new unit. Repeat step 1.21
X3 and X4 alternate between 30
and 250 psi during cycle?
1.23 Is the pressure at port R less than No Repipe pump case drain line so that
21 psi? case pressure at port R is less than
21 psi. Return to step 1.21.
1.24 Stroke pump in both directions. No Verify that loading on the pump will
Does any pressure greater than cause system pressure to increase
350 psi alternate between ports above charge pressure. Proceed to
MA and MB? step 1.19

1.25 Is it possible to adjust high No Replace high pressure relief valve
pressure relief valves using the cartridges and return to step 1.21
0-10000 psi gauges at MA and
MB to monitor pressure (refer to
relief valve adjustment)
Yes Adjust high pressure relief valves to
required or design pressure. Proceed
to step 1.26
1.26 Actuate control in both No Check if motor sizing is adequate for
directions. Does transmission application. Check for mechanical
run? fault in the drive beyond the motor
shaft.
Yes Operate the transmission.
2. TRANSMISSION DRIVE IS SLUGGISH OR ERRATIC
2.1 Is the control medium in good No Rectify the control fault. HD-bleed
condition? For example. control pilot lines HW-lubricate or free the
medium in not in good condition cable or linkage.
of. HD control-air in pilot lines EL-check control current.
HW control-sticking cable or
linkage EL control-fluctuating
control current.
HYD-083/05/08 44
2.2 Are the brakes fully released? No Check brake release circuit or
mechanism.
2.3 Are the stroking time orifices No remove the plugs in ports X1 and X2
correctly sized for the and remove control orifices with
application? screwdriver. Try various sizes until
desired pump stroking rate is
attained.
2.4 With HD control, is the control No Change spring to suit. AA4V pump-
curve of remote pilot valve curve 05 or 06 of 4TH7 pilot
correctly matched to the pump? operator.
2.5 Does the charge pressure No Proceed to 2.9
fluctuate more than 30 psi when
stroking the pump?
2.6 If the charge pump output is used No Proceed to step 2.8
to operate auxiliary functions, do
these other functions cause
fluctuations in charge pressure?
2.7 Isolate the auxiliary function and No Proceed to step 2.8
run the transmission. Are the
charge pressure fluctuations
reduced or eliminated?
Yes Operate transmission and return to
step 2.1
2.8 Are there system pressure No Proceed to step 2
fluctuations which are
synchronous with the charge
pressure fluctuations?
Yes Determine the cause of system
pressure fluctuations.
HYD-083/05/08 45
2.9 If variable displacement motor is No Add motor stroking time adjustment

used, is motor stroking time valve to the variable motor or
correct for the application? modify the control circuit to provide
desired stroking time.
3. TRANSMISSION DRIVES IN ONE DIRECTION ONLY
3.1 With control lines switched does No Proceed to step 3.2
pump drive in the opposite
direction only?
Yes Control signal from one side does
not work properly. Repair as
necessary.
3.2 With control lines still switched No Proceed to step 3.3
does pump drive in initial
direction only?
Yes Problem is in one side of control
module or the pump. Proceed to
step 3.3
3.3 Is there control pressure or No Correct control signal problem.
current from both control lines?
3.4 Check flushing valve (if No (not installed) Proceed to step 3.5
installed) is shuttle spool stuck
in one position?
Yes Remove flushing valve and clean or
replace.
3.5 Switch relief valves. Does No Proceed to step 3.6
transmission drive in the other
direction only?
Yes Repair or replace relief valve on
non-driving side.
3.6 Replace control module and No Replace or repair pump
reconnect control lines. Does
pump operate properly?
Yes Operate transmission
4. TRANSMISSION DRIVES IN THE WRONG DIRECTION
HYD-083/05/08 46
4.1 Pump with HD control Switch control lines on ports Y1 &

Y2
4.2 Pump with El control. Switch electrical connectors on

solenoids A & B.
4.3 Pump with HW control. Rework linkage or cable to give
correct drive direction
5. PUMP DOES NOT FIND OR HOLD NEUTRAL
5.1 Does pump return to neutral with No Proceed to step 5.2
control lines removed?
Yes Check control for electrical signal
problem (EL control), or back
pressure in the pilot lines (HD
control).
5.2 Check mechanical centering of No Repair or replace pump
pump and control per pages 16
& 17. Does pump return to
neutral with control lines
removed?
Yes Replace control module if needed.
Operate transmission.
6. TRANSMISSION DRIVES AT A HIGH NOISE LEVEL
6.1 Are the drive gear boxes filled No Fill gearbox with correct grade of oil
with correct grade of oil? to the prescribed level.
6.2 Is the drive coupling correctly No Install coupling per manufacturer's
installed and aligned? instructions and tolerances.
6.3 Is rigid piping connected to the No Proceed to step 6.4
pump?
Yes Install short length of hose between
pressure ports of the pump and the
system piping.
6.4 Is the suction pressure at the No Return to step 1.7
charge pump inlet within
recommended limits?
HYD-083/05/08 47
6.5 Is there air in the hydraulic oil? No Proceed to step 6.6

This may be indicated by
foaming or milky coloured oil.
Yes Derate the oil and inspect system for
cause of air induction.
6.6 Is the hydraulic motor operating Yes Check motor sizing in relation to
at excessive speed? available oil floe from the pump.
7. TRANSMISSION OPERATES AT A HIGHER THAN NORMAL TEMPERATURE
7.1 Is the operating temperature No 195_F is the upper limit. If
above 195_F? temperature is close to 195_, the oil
cooler may need to be cleaned.
7.2 Is the hydraulic motor stalling No Proceed to 7.3
intermittently?
Yes Hydraulic oil is being heated
through system relief valves. Shut
down system and rectify cause of the
motor stall.
7.3 Does temperature remain above No Operate transmission. Check oil
195_F after cleaning oil cooler? cooler more often.
7.4 Check differential pressure No Proceed to step 7.5
across oil cooler as compared to
the manufacturer's specs at
charge pump flow.
Yes Check piping from oil cooler to the
reservoir.
Check for plugged or damaged
cooler.
Is case pressure higher than it should be?
NOTE . Max. case pressure is 30 psi

7.5 Disconnect pump case drain No Refer to charge pump remove and
from oil cooler and check flow inspection procedure.
from charge pump. Is flow
normal?
Yes Check oil cooler location
HYD-083/05/08 48
8. PUMP DOES NOT DEVELOP MAXIMUM HORSEPOWER
(FLOW & PRESSURE)
8.1 Is the charge pressure at least No Return to 1.9
320 psi measured at port G?
Yes Proceed to 8.2
8.2 Is the case pressure less than 30 No Check sizing on return lines from T
psi? port of pump and the cooler sizing
related to flow.
Yes Proceed to 8.3
8.3 Are the high pressure relief No Adjust or replace relief valve
valves adjusted to the required cartridge.
pressure so that they do not by-
pass?
Yes Replace the pump.
NOTE . If pressure override valve is fitted to pump, check that pressure setting is sufficient for
the application.
Notes

Guide To The EJC 65 Hydraulic System: General

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Guide To The EJC 65 Hydraulic System: General

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Guide to the EJC 65 Hydraulic System

Park Brake System

Checking Park Brake Circuit Pressure

SUPPLY FROM RETURN

STEER CONTROL GROUP

HYDRAULIC TANK GROUP

Figure 2 : Steering Hydraulic System

Figure 3 : Steering Cylinder Assembly

Control Valve Description

1. BYPASS INLET BODY

Figure 4 : Steer Control Valve

Control Valve Removal

Bucket (Implement) System

BUCKET LIFT PUSH PLATE

BUCKET CONTROL VALVE

FOR RRC ONLY

MOUNT TO INSIDE FACE

FOR RRC ONLY

Figure 5 : Bucket Hydraulic System

Cleaning and inspection

Figure 6 : Lift Cylinder Assembly

Bucket Cylinder Description

Removal of Bucket Cylinder

Figure 7 : Bucket Cylinder Assembly

Push-Plate Cylinder Description

1. CYLINDER 8. CAP SCREW

Figure 8 : Push-Plate Cylinder Assembly

Bucket Control Valve Description

1. BYPASS INLET BODY

Figure 9 : Bucket Control Valve

Control Valve Removal

Testing for Lift Cylinder Leakage

DASH INDICATOR SWITCH

RETURN FROM OIL

Figure 10 : Hydraulic Tank Arrangement

Figure 11 : Pump Installation Arrangement

Hydraulic System Maintenance

Maintenance of the System

• Air bubbles in the hydraulic oil.

Park Brake Circuit

TROUBLE PROBABLE CAUSE CORRECTIVE ACTION

Relief valve in steering valve Repair or replace.

TROUBLE PROBABLE CAUSE CORRECTIVE ACTION

Lift arm fails to lower or Defective cylinder. Repair or replace cylinder.

No motion of bucket No oil or insufficient oil being No hydraulic actions.

Cable Reel Circuit

TROUBLE PROBABLE CAUSE CORRECTIVE ACTION

Hydrostatic Transmission Circuit

1. TRANSMISSION DOES NOT DRIVE WITH THE PRIME MOVER RUNNING.

Yes Repair the fault

Yes operate the transmission.

Yes Proceed to step 1.25

2.9 If variable displacement motor is No Add motor stroking time adjustment

4.1 Pump with HD control Switch control lines on ports Y1 &

4.2 Pump with El control. Switch electrical connectors on

6.5 Is there air in the hydraulic oil? No Proceed to step 6.6

NOTE . Max. case pressure is 30 psi

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