EJC 145

GUIDE TO EJC 145

HYDRAULIC SYSTEM
© 2001 EJC Loaders
Technical Publications Department
4445 Fairview Street
Burlington, Ontario
Canada L7L 2A4
Tel: (905) 632-4940
Fax: (905) 632-2172
E-mail: tech.pubs@sandvik.com
 Table of Contents
EJC 145 Hydraulic System Specifications ............................1-1
Hydraulic Circuits ....................................................................2-1
Introduction ................................................................................................................ 2-1
Pilot Circuit ................................................................................................................. 2-2
Radio Remote Control (Optional) .............................................................................. 2-5
Boom/Bucket Circuit .................................................................................................. 2-7
Steer Circuit ............................................................................................................. 2-10
Eject Circuit (Optional) ............................................................................................. 2-12
Brake Circuit ............................................................................................................ 2-13
Brake Release Circuit .............................................................................................. 2-20
Brake Cooling Circuit ............................................................................................... 2-22
Major Components ..................................................................3-1
Introduction ................................................................................................................ 3-1
Location of Major Components .................................................................................. 3-1
Hydraulic Oil .............................................................................................................. 3-6
Hydraulic Tank ........................................................................................................... 3-9
Implement Pumps .................................................................................................... 3-14
Brake Release Pump ............................................................................................... 3-17
High Pressure Filter ................................................................................................. 3-19
Brake Cooling Filter ................................................................................................. 3-20
Accumulator Charging Valve ................................................................................... 3-21
Accumulators ........................................................................................................... 3-23
Auto Brake Solenoid Valve ...................................................................................... 3-25
Auto Bleed Down Solenoid Valve ............................................................................ 3-26
Pressure Switch - Park/Emergency Brake Light ...................................................... 3-27
Pressure Switch - Auto Brake .................................................................................. 3-28
Pressure Switch - Brake Impending Light/Brake Fault Light ................................... 3-29
Pressure Reducing Valve (PRV) .............................................................................. 3-30
Front and Rear Brake Solenoid Valves .................................................................... 3-31
Pressure Differential Switch ..................................................................................... 3-32
Brake Pedal Valve ................................................................................................... 3-33
Steer Pilot Valve ....................................................................................................... 3-34
Eject Pilot Valve (Optional) ...................................................................................... 3-35
Steer Valve ............................................................................................................... 3-36
Boom/Bucket Pilot Valve .......................................................................................... 3-39
Boom/Bucket Valve .................................................................................................. 3-41
Radio Remote Control Manifold (Optional) .............................................................. 3-43
Test Port Manifold .................................................................................................... 3-45
Hoses and Tubing .................................................................................................... 3-47
Cylinders .................................................................................................................. 3-48
Axles ........................................................................................................................ 3-49
Brake Cooling Relief Valve ...................................................................................... 3-51

HYD-068/01/02 0-1
 Table of Contents

Troubleshooting ......................................................................4-1
No Pressure In System .............................................................................................. 4-1
Insufficient System Pressure ..................................................................................... 4-1
Excessive Pump Noise .............................................................................................. 4-1
System Excessively Hot ............................................................................................ 4-2
Brakes Will Not Release ............................................................................................ 4-2
Brakes Release But Brake Circuit Pressure Low ...................................................... 4-3
Accumulator Charging Cycle Repeats Frequently When Brakes Are Not Used ........ 4-3
Accumulator Charging Time Too Long ....................................................................... 4-3
Control Lever Sticks ................................................................................................... 4-4
Poor Control ............................................................................................................... 4-4
Pressure Fluctuates in System .................................................................................. 4-4
Excessive External Leakage From Steer Valve ......................................................... 4-4
No Steering ................................................................................................................ 4-5
Boom Cylinders Will Not Move .................................................................................. 4-5
Boom Cylinders Move Slowly .................................................................................... 4-5
Boom/Bucket Cylinders “Creep” (Retract Slowly When Bearing a Load) .................. 4-6
Bucket Cylinder Moves Slowly ................................................................................... 4-6
Spongy or Jerky Action Of Bucket Cylinder ............................................................... 4-7
No Hydraulic Action ................................................................................................... 4-7

S15001/06/00 0-2
 EJC 145 Hydraulic System Specifications

NOTE: SAE standard hose sizes are indicated on hydraulic schematics. Hose lengths are listed in
the parts manual.

ITEM SPECIFICATION
MAIN HYDRAULIC SCHEMATIC 64544503 REV 00

BRAKE CIRCUIT SCHEMATIC 64545402 REV. 00

ELECTRICAL SCHEMATIC (REFERENCE) 64264836 REV. 03

HYDRAULIC OIL SEE “FUEL AND LUBRICANT SPECIFICATIONS” IN

SECTION 1 OF SERVICE MANUAL

HYDRAULIC TANK CAPACITY 73 U.S. GALLONS (276 LITERS)

STRAINER BASKET 100 MESH FILTRATION

SUCTION STRAINER 3 PSI BY-PASS

NOTE: FILTRATION SPECIFICATION NOT AVAILABLE
AT TIME OF PUBLICATION.

RETURN FILTER 22 PSI BY-PASS

(BOOM/BUCKET CIRCUIT) 10 MICRON FILTRATION

BOOM/BUCKET PUMP 39 GPM (BASED ON 2100 ENGINE RPM)

STEER PUMP 17 GPM (BASED ON 2100 ENGINE RPM)

PILOT/BRAKE PUMP 6 GPM (BASED ON 2100 ENGINE RPM)

BRAKE RELEASE PUMP MAX. PRESSURE 1800 PSI

PILOT PRESSURE REDUCING VALVE 450 PSI

ACCUMULATORS, BLADDER TYPE 800 PSI DRY NITROGEN PRE-CHARGE

(2) BRAKE-1 GALLON CAPACITY EACH

ACCUMULATOR CHARGING VALVE LOW (“CUT-IN”) 1850-1950 PSI

HIGH (“CUT OUT”) 2275-2325 PSI
RELIEF SET AT 2800 PSI
CHARGING RATE 2.03-3.2 GPM AT 2100 ENGINE RPM

BRAKE COOLING CHECK VALVE 50 PSI

BRAKE PRESSURE DIFFERENTIAL 300-450 PSI

SWITCH

BOOM/BUCKET MAIN RELIEF 2300 PSI

BOOM PORT RELIEFS 2500 PSI

BUCKET PORT RELIEFS 2500 PSI ROLLBACK

800 PSI DUMP

HYD-068/01/02 1-1
 EJC 145 Hydraulic System Specifications

ITEM SPECIFICATION
STEER MAIN RELIEF 2500 PSI

STEER PORT RELIEFS 2700 PSI

EJECTOR PORT RELIEFS (OPTIONAL) 2700 PSI

BOOM CYLINDERS BORE 6.50 INCHES

ROD 3.00 INCHES
STROKE 23.30 INCHES

BUCKET CYLINDER(S) BORE 6.50 INCHES

ROD 3.00 INCHES
STROKE 31.25 INCHES

STEER CYLINDERS BORE 3.50 INCHES

ROD 2.00 INCHES
STROKE 16.00 INCHES

EJECTOR CYLINDERS (OPTIONAL) BORE 3.50 INCHES

ROD 2.00 INCHES
STROKE 16.00 INCHES

BRAKE PEDAL VALVE 1700-0 PSI REVERSE MODULATING

BRAKE FAULT/BRAKE IMPENDING 1600 PSI (1 Form C contact)

WARNING LIGHT PRESSURE SWITCH

PARK BRAKE ON LIGHT PRESSURE 1400 PSI (1 Form C contact)

SWITCH

PARK BRAKE APPLICATION PRESSURE 1400 PSI (1 Form C contact)

SWITCH

HYD-068/01/02 1-2
 Hydraulic Circuits

Introduction
This portion of the guide discusses the oil flow of each hydraulic circuit. Hydraulic schematics
printed on “B size” (11” x 17”) paper are included in this section of the service manual for handy
reference.
NOTE: The position of components on the hydraulic schematics indicates the approximate
physical location of the components on the machine. All components are shown in neutral
position.
This hydraulic system contains the following major circuits:
• pilot circuit;
• radio remote control (optional);
• boom/bucket circuit;
• eject circuit (optional);
• steer circuit;
• brake circuit;
• brake release circuit;
• brake cooling circuit.

! WARNING!

Do not attempt to service hydraulic components while the circuit is under pressure. do not
attempt to service any component while the machine is moving.

! WARNING!

Before servicing any hydraulic component, make sure that accumulator pressure is at zero
psi.

HYD-068/01/02 2-1
 Hydraulic Circuits

Pilot Circuit
Oil flows from the hydraulic tank through a suction strainer to the pilot/brake pump. The pilot/
brake pump is installed in tandem with the boom/bucket pump on the torque converter.

Figure 1: Hydraulic Tank

1. Suction Strainer
2. To Boom/Bucket Pump and Pilot/Brake Pump

2 3

5 6

Figure 2 : Pumps
1. From Hydraulic Tank
2. Boom/Bucket Pump
3. Pilot/Brake Pump
4. To Test Port Manifold
5. To Boom/Bucket Valve
6. To Accumulator Charging Valve (Pilot/Brake Circuit)

HYD-068/01/02 2-2
 Hydraulic Circuits

From the pilot/brake pump, oil flows through a high pressure filter to the inlet port of the
accumulator charging valve. If brake circuit pressure is above the relief setting, oil is directed
through the relief valve to the tank port. If brake circuit pressure is below the relief setting, oil
exits the accumulator charging valve through port “A”.

1
5

Figure 3 : Accumulator Charging Valve

1. Inlet Port
2. Relief Valve
3. Outlet Port
4. Tank Port
5. “A” Port
Oil flows from port “A” of the accumulator charging valve to the pressure reducing valve (PRV).

2 3

Figure 4 : Pressure Reducing Valve (PRV)

1. From PRV Interrupt Valve
2. To Pilot Valves
3. To Hydraulic Tank

HYD-068/01/02 2-3
 Hydraulic Circuits

The pressure reducing valve supplies low pressure oil to the steer pilot valve and boom/bucket
pilot valve.
NOTE: If the machine is equipped with an optional ejector circuit, there is also an ejector pilot
valve and an ejector spool in the steer valve.
Moving a control lever on the dashboard causes the appropriate pilot valve to meter oil to the
appropriate spool in the steer valve, or the boom/bucket valve. The oil pressure applied to the
spool causes it to shift. In the shifted position, the spool allows oil to flow to the cylinders (not
shown), which in turn move to perform the selected function.

12

5 8 9 10
6
4 1 2 3
7

11

Figure 5 : Pilot Valves

1. Steer Pilot Valve
2. Boom/Bucket Pilot Valve
3. Eject Pilot Valve (Optional)
4. Steer Left
5. Steer Right
6. Boom Down
7. Boom Up
8. Roll Back Bucket
9. Dump Bucket
10. To Hydraulic Tank
11. To Radio Remote Control Manifold (Optional)
12. Pressure Reducing Valve (PRV)

HYD-068/01/02 2-4
 Hydraulic Circuits

Radio Remote Control (Optional)

Introduction
Extra solenoid valves and shuttle valves are plumbed into the pilot circuit to allow the machine to
be operated manually from the operator’s compartment or by radio remote control, depending on
the position of the radio/manual switch on the instrument panel.
Hydraulic Circuit
Downstream of the pressure reducing valve, the circuit branches. One branch goes to two (or
three if equipped with optional eject) manually operated pilot valves.
The other branch goes to the remote control manifold. The remote control manifold is equipped
with six solenoid valves and six shuttle valves. The purpose of the shuttle valves is to direct flow
to and from either the manually operated pilot valves or the solenoid valves.

1
4

1
2
5

3
6

Figure 6 : Radio Remote Control Manifold

1. Dump Solenoid
2. Boom Down Solenoid
3. Steer Right Solenoid
4. Rollback Bucket Solenoid
5. Boom Up Solenoid
6. Steer Left Solenoid

HYD-068/01/02 2-5
 Hydraulic Circuits

Manual Mode
1. When the manual/radio switch on the instrument panel is turned to the “MANUAL”
position, the solenoid valves are de-energized.
2. In the de-energized position, the solenoid valves are closed.
3. Pressure from the manually operated pilot valves shift the shuttle valves to shut off flow
from the solenoid valves.
4. Shuttle valves direct oil from the manually operated pilot valves to the control valves.
5. The spools in the control valves shift according to the position of the manually operated
pilot valves. The cylinders extend or retract according to the movement of the spools in the
control valves.
Radio Remote Control Mode
1. When the manual/radio switch on the instrument panel is turned to the “RADIO” position,
the solenoid valves energize or de-energize according to the position of the control levers
(joysticks) on the transmitter.
2. The spools in the control valves shift according to the energized or de-energized state of the
solenoid valves. The cylinders extend or retract according to the movement of the spools in
the control valves.

HYD-068/01/02 2-6
 Hydraulic Circuits

Boom/Bucket Circuit

Neutral
Oil flows from the hydraulic tank through a suction strainer to the boom/bucket pump. The steer
pump supplements the boom/bucket pump when the steer valve is in neutral position.

Figure 1: Hydraulic Tank

1. Suction Strainer
2. To Boom/Bucket Pump and Pilot/Brake Pump

2 3

5 6 7

Figure 2 : Pumps
1. From Hydraulic Tank
2. Boom/Bucket Pump
3. Pilot/Brake Pump
4. To Test Port Manifold
5. To Boom/Bucket Valve
6. From Steer Pump (if Steer Valve in Neutral Position)
7. To Accumulator Charging Valve (Pilot/Brake Circuit)

HYD-068/01/02 2-7
 Hydraulic Circuits

From the boom/bucket pump, oil flows to the boom/bucket valve. The boom/bucket valve is open
when the boom/bucket function is not used.

Figure 3 : Boom/Bucket Valve

1. From Boom/Bucket Pump
2. To Hydraulic Tank
Oil flowing through the open boom/bucket valve returns to the hydraulic tank through the return
filter.

Figure 1: Hydraulic Tank

1. Return Filter

HYD-068/01/02 2-8
 Hydraulic Circuits

Cylinders Actuated
When the operator moves the boom/bucket control lever (bucket/boom pilot valve), oil flows
from the appropriate spool in the boom/bucket valve to move the boom cylinders or the bucket
cylinder.
The boom/bucket valve is equipped with a main relief valve and port relief valves for both the
boom spool and the bucket spool.
If oil pressure exceeds a relief setting, the relief valve allows oil to drain to the hydraulic tank
through the return filter until oil pressure drops below the relief setting.

1 3

Figure 2 : Boom/Bucket Valve

1. From Boom/Bucket Pump
2. To Hydraulic Tank
3. Main Relief Valve
4. Boom Spool
5. Bucket Spool
6. Port Relief Valve
7. Bucket Cylinder
8. Boom Cylinders

HYD-068/01/02 2-9
 Hydraulic Circuits

Steer Circuit
Oil flows from the hydraulic tank through a suction strainer to the steer pump.

Figure 1: Hydraulic Tank

1. Suction Strainer
2. To Steer Pump

Figure 2 : Steer Pump

1. From Hydraulic Tank
2. To Test Port Manifold
3. To Steer Valve

From the steer pump, oil flows through the steer valve, which is open when the steer function is
not used.
From the steer valve, oil flows into the boom/bucket circuit to combine with the flow from the
boom/bucket pump. The steer valve is equipped with a main relief valve and port relief valves for
the steer spool.
NOTE: See illustration on the following page.

HYD-068/01/02 2-10
 Hydraulic Circuits

8 2

A2 B2

PA2 PB2
7

5
A1 B1

PA1 PB1
6

Figure 3 : Steer Valve

1. From Steer Pump
2. To Hydraulic Tank
3. To Boom/Bucket Pump
4. Main Relief Valve
5. Port Relief Valve
6. Steer Spool
7. Eject Spool (Optional)
8. Check Valve
When the operator moves the steer control lever (steer pilot valve), oil flows from the steer spool
to move the steer cylinders.
One cylinder extends as the other retracts to turn the machine in the selected direction.

Figure 4 : Steer Cylinders

HYD-068/01/02 2-11
 Hydraulic Circuits

Eject Circuit (Optional)

Introduction
The eject circuit operates a push plate installed inside the bucket. As the eject cylinders extend,
the push plate forces the load out of the bucket. When the eject cylinders are fully retracted, the
bucket is ready to be loaded again.
Hydraulic Circuit
From the steer pump, oil flows through the open center steer valve through the steer spool to the
eject spool.
NOTE: See steer circuit.
When the operator moves the ejector plate control lever (eject pilot valve), oil flows from the eject
spool in the steer valve to move the eject cylinders.

Figure 5 : Eject Pilot Valve

Figure 6 : Eject Cylinders

HYD-068/01/02 2-12
 Hydraulic Circuits

Brake Circuit
NOTE: The brakes are spring applied and hydraulically released.
Engine On, Brakes Released
1. Oil flows from the hydraulic tank through a suction strainer to the pilot/brake pump.

Figure 1: Hydraulic Tank

1. Suction Strainer
2. To Boom/Bucket Pump and Pilot/Brake Pump

2 3

5 6

Figure 2 : Pumps
1. From Hydraulic Tank
2. Boom/Bucket Pump
3. Pilot/Brake Pump
4. To Test Port Manifold
5. To Boom/Bucket Valve
6. To Accumulator Charging Valve (Pilot/Brake Circuit)

HYD-068/01/02 2-13
 Hydraulic Circuits

From the pilot/brake pump, oil flows through the accumulator charging valve.
If brake circuit pressure is below the relief setting, the accumulator charging valve directs oil to
the brake circuit through port “ACC”. If brake circuit pressure is above the relief setting, the
accumulator charging valve directs oil to the hydraulic tank.

6 1

Figure 3 : Accumulator Charging Valve

1. Inlet Port
2. Relief Valve
3. Outlet Port
4. Tank Port
5. “A” Port
6. “ACC” Port

HYD-068/01/02 2-14
 Hydraulic Circuits

From the accumulator charging valve, oil flows through the pressure switch manifold to charge
the brake accumulators.

3 3 8

10

9
7

Figure 4 : Pressure Switch Manifold

1. From Accumulator Charging Valve

2. Pressure Switch Manifold
3. Accumulator
4. Auto Bleed Down Valve
5. To Port “P” of Auto Brake Valve
6. Hydraulic Tank*
7. Pressure Switch, 1600 psi
8. Pressure Switch, 1400 psi
9. From Tank Port “T” of Pressure Reducing Valve
10. To Hydraulic Tank
*Tank passage open only if accumulator drain valve is de-energized as shown

HYD-068/01/02 2-15
 Hydraulic Circuits

Accumulators are fluid pressure storage chambers in which hydraulic oil under pressure is stored
against the compressible force of pressurized nitrogen gas. The pressurized oil is readily available
when needed in the brake circuit.

Figure 5 : Brake Accumulators

The auto bleed down valve prevents the accumulators from draining back to the hydraulic tank
through the return filter.
Two pressure switches mounted on the manifold monitor accumulator pressure. If pressure drops
to 1600 psi, pressure switch 2 closes to illuminate the brake impending light and brake fault light.
If pressure drops to 1400 psi, pressure switch 1 closes to illuminate the park brake light.

1
3
2

Figure 6 : Pressure Switch Manifold

1. Pressure Switch, 1400 psi, (Form C contact)
2. Pressure Switch, 1600 psi, (Form C contact)
3. Auto Bleed Down Valve

Another pressure switch monitors brake circuit pressure downstream of the energized auto brake
solenoid valve. If pressure drops to 1400 psi, the pressure switch opens to de-energize the auto
brake solenoid valve. The brakes apply.

HYD-068/01/02 2-16
 Hydraulic Circuits

Figure 7 : Auto Brake Solenoid Valve

1. Pressure Switch, 1400 psi, (Form C contact)
2. Auto Brake Solenoid Valve (4 Way, 2 Position, Electrically Actuated)
Oil flows from the auto brake solenoid valve to port “P” on the brake pedal valve. Oil flows
through port “P” of the brake pedal to the front brake solenoid valve and rear brake solenoid
valve. The brake solenoid valves are open to the wheel ends in the energized position.

5
6
3 4

Figure 8 : Brake Pedal Valve and Brake Solenoid Valves

1. From Auto Brake Valve
2. Brake Pedal Valve
3. Front Brake Solenoid Valve
4. Rear Brake Solenoid Valve
5. To Front Brakes and Differential Pressure Switch
6. To Rear Brakes and Differential Pressure Switch

HYD-068/01/02 2-17
 Hydraulic Circuits

The differential pressure switch monitors the difference in pressure between the front brakes and
the rear brakes. If the difference is 300 psi or greater, the differential pressure switch causes the
brake solenoids to de-energize (open to tank) and apply the brakes.

4 5

Figure 9 : Differential Pressure Switch

1. Differential Pressure Switch
2. From Front Brake Solenoid Valve
3. From Rear Brake Solenoid Valve
4. To Front Brakes
5. To Rear Brakes
The pressure supplied to the wheel ends keeps the brakes released.

Figure 10 : Axle

HYD-068/01/02 2-18
 Hydraulic Circuits

Engine On, Brakes Applied with Brake Pedal Valve

NOTE: The brakes may be applied by pressing the brake pedal valve, or by pressing in the park/
emergency brake button. The amount of foot pressure applied to the brake pedal valve is
proportional to braking action.
1. When the operator presses the brake pedal valve, the spool shifts slightly and drains some
oil from the front and rear brakes to the hydraulic tank. The loss of oil pressure in the brakes
causes them to apply.
Engine On, Brakes Applied with Park/Emergency Brake Button
1. When the operator presses in the park/emergency brake button, the auto brake solenoid
valve, front brake solenoid valve and rear brake solenoid valve de-energize.
2. In the de-energized position, the valves prevents oil from entering the front and rear brakes.
3. The valves also open a tank passage.
4. Oil drains from the front and rear brakes to the hydraulic tank. The loss of pressure causes
the brakes to apply.
Engine Off, Brakes Applied
1. When the engine is off, the pilot/brake pump stops supplying the pilot/brake circuit with oil.
2. The auto brake solenoid valve, front brake solenoid valve, rear brake solenoid valve, and the
auto bleed down solenoid valve de-energize.
3. In the de-energized position, the auto brake solenoid valve, front brake solenoid valve, rear
brake solenoid valve prevent oil from entering the front and rear brakes.
4. The valves also open a tank passage.
5. Oil drains from the front and rear brakes to the hydraulic tank. The loss of pressure causes
the brakes to apply.
6. Oil drains from the accumulators through the auto bleed down valve to the hydraulic tank.
Pressure in the pilot/brake circuit drops to zero psi. The loss of pressure in the pilot circuit
renders the controls inoperative.

HYD-068/01/02 2-19
 Hydraulic Circuits

Brake Release Circuit

The brake release circuit allows the brakes to be released if no engine power is available and the
machine must be towed.
NOTE: The brake release circuit will not function if the electrical system is not functioning.

! WARNING!

Use only under the strict supervision of the maintenance supervisor. Precautions must be
taken to ensure that the machine does not run away. Follow towing procedures carefully.
Press the brake pedal to apply the brakes again.
The outlet of the brake release pump installs into the pressure line of the brake pedal valve.

1
2
3

Figure 11 : Brake Release Pump

1. Brake Release Pump
2. Gauge
3. Quick Connect Fitting

Pulling out the tow light/button on the instrument panel energizes the front brake solenoid valve,
and the rear brake solenoid valve. In the energized position, the valves are open to the wheel ends
and closed to tank. See illustration on the following page.
NOTE: The tow light/button functions only if electrical power is available and the ignition switch
is turned to the “OFF” position.
Operating the brake release pump draws oil from the hydraulic tank, and circulates it through
brake solenoid valves into the wheel ends. Approximately 1400 psi of pressure in the wheel ends
causes the brakes to release.

! WARNING!

Maximum pressure is 1800 psi.

HYD-068/01/02 2-20
 Hydraulic Circuits

5
6
3 4

Figure 12 : Brake Pedal Valve and Brake Solenoid Valves

1. From Brake Release Pump

2. Brake Pedal Valve
3. Front Brake Solenoid Valve
4. Rear Brake Solenoid Valve
5. To Front Brakes and Differential Pressure Switch
6. To Rear Brakes and Differential Pressure Switch

HYD-068/01/02 2-21
 Hydraulic Circuits

Brake Cooling Circuit

1. Oil flows from the hydraulic tank through a suction strainer (1) to the pilot/brake pump (2).

Figure 1: Hydraulic Tank

Figure 2 : Pilot/Brake Pump

2. From the pilot/brake pump, oil flows to the inlet port (3) of the accumulator charge valve
(4).

Figure 3 : Accumulator Charging Valve

HYD-068/01/02 2-22
 Hydraulic Circuits

3. Oil flows out of the outlet port (5) of the accumulator charge valve (4) to the front and rear
axles (6).

Figure 4 : Accumulator Charge Valve

4. The oil enters the axle (6) through pressure line (7), cools brake components, then returns to
the hydraulic tank via a check valve (8).

TANK

8
6

Figure 5 : Front Axle

HYD-068/01/02 2-23
 Hydraulic Circuits

NOTE: The return line of this circuit is equipped with a filter which is not shown on brake
hydraulic schematic 64544502 Rev. 00.
5. If pressure in the brake cooling circuit is 50 psi or more, a relief valve (9) downstream of the
accumulator charge valve (4) opens and directs oil to the hydraulic tank (not shown) via the
tank port (10).

10

4
9

Figure 6 : Accumulator Charge Valve and Relief Valve

HYD-068/01/02 2-24
 Major Components

Introduction
This section of the guide contains a description and schematic of major components. Service
information is also included where available.
NOTE: See Parts Manual for parts lists and illustrations.

Location of Major Components

1 2 3 4

Figure 1 : Front Frame - Side View

1. Boom/Bucket Valve
2. Boom Cylinders
3. Bucket Cylinder
4. Front Axle

HYD-068/01/02 3-1
 Major Components

1 2 3 4 5 6 7

Figure 2 : Rear Frame - Side View

1. Brake Safety Valve
2. Instrument Panel
3. Steer Cylinder
4. Steer Valve
5. Accumulator Charging Valve
6. Implement Pumps
7. Pressure Switch Manifold
8. Rear Axle

HYD-068/01/02 3-2
 Major Components

1 2 3

8 4 9 7 5 6

Figure 3 : Rear Frame - Top View

1. Hydraulic Tank
2. Steer Valve
3. Accumulator Charging Valve
4. Steer Cylinder
5. Accumulator Assembly (See “Accumulator Assembly” on page 3-3)
6. Pressure Switch Manifold (See “Pressure Switch Manifold” on page 3-4)
7. Rear Axle
8. Manual Brake Release Pump
9. Manual Brake Release Pump Handle (Storage Position)

HYD-068/01/02 3-3
 Major Components

3 1 4 2

3 5

Figure 4 : Accumulator Assembly

1. Accumulators (ACC 1 and ACC 2)

2. Pressure Reducing Valve (PRV)
3. Auto Brake Solenoid Valve
4. Pressure Switch
5. Pressure Switch Manifold
6. Auto Bleed Down Solenoid Valve

HYD-068/01/02 3-4
 Major Components

Figure 5 : Operator’s Compartment

1. Steer Pilot Valve
4. Brake Pedal Valve
5. Boom/Bucket Pilot Valve
NOTE: If fitted, optional eject pilot valve is located to the right of the boom/bucket pilot valve.

HYD-068/01/02 3-5
 Major Components

Hydraulic Oil

Keep It Clean
Hydraulic oil is the most important component in the hydraulic system. It allows the machine to
perform work, and lubricates and cools hydraulic components while the machine is working. If
the hydraulic oil is contaminated or does not conform to specification, then the entire hydraulic
system is affected.
During the initial period of operation, pumps, valves and cylinders generate particles which
become suspended in the flow of hydraulic oil. These particles are normally trapped in strainers
and filters as the oil circulates.
Contaminants accumulate in filters, strainers and on other parts according to:
• cleanliness of the hydraulic tank
• cleanliness of oil added to hydraulic tank
• amount of contamination entering the system due to carelessness when oil is added to
hydraulic tank
• condition of hydraulic cylinder seals
Oil can become exposed to three types of contaminants:
1. Dirt
• Dirt includes dust, lint, rust and scale. Dirt attacks hydraulic oil from the outside. Most
dirt is abrasive, and when it works its way into the hydraulic system, it causes friction,
excessive heat and rapid wear of components. Dirty oil may also cause oil and air leaks.
2. Air
• Air mixing with hydraulic oil causes foam. Small bubbles form which accumulate in
various parts of the system. When oil foams, it overheats. This is because the air in the
oil increases in temperature when the oil is compressed. In turn, the hot air bubbles heat
the surrounding oil.
3. Soluble and insoluble products which form when oil additives deteriorate
• Hydraulic oil additives deteriorate more rapidly when the hydraulic system overheats.
This type of contamination cannot be completely controlled through preventive
maintenance. Control contamination due to oxidation, condensation and formation of
acids by completely draining and replacing hydraulic oil on a regular basis.

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Oil Storage and Handling

Do not allow contaminants of any kind to enter stored oil or oil in the hydraulic system. To keep
oil clean:
1. Store oil drums on their sides and under a protective cover.
2. Before opening an oil drum, clean the top carefully so that dirt will not fall into the oil.
3. Inspect and keep clean all containers and equipment used for storage or dispensing of
hydraulic oil.
Changing the Oil
To drain and replace the hydraulic oil:
1. Thoroughly steam clean the machine, especially in areas where the hydraulic circuits will be
exposed.
2. Turn on the machine. Perform all inspection/safety checks, including park and service brake
tests.
3. Bring the hydraulic system to operating temperature. At this temperature, the greatest
quantity of contamination will be suspended in the oil and provide a more efficient flushing
of the hydraulic system.
4. Fully lower the boom/bucket.
5. Apply the park brake.
6. Shut down the engine.
7. Remove filler cap.
8. Remove access covers to the suction filter and return filter from the hydraulic tank.
9. Place a large container under the drain plug of the hydraulic tank. It may be helpful to place
a funnel under the reservoir to guide to the oil into the container.
10. Remove the access cover from the front of the hydraulic tank.
11. Completely drain all cylinders by removing the cylinder hoses at their lowest points.
12. Remove the suction strainer from the hydraulic tank and thoroughly clean all parts.
13. Check the breather on the hydraulic tank and make sure it is clean and functioning properly.
14. Clean the inside of the hydraulic tank completely. Wash it with a mixture of five parts diesel
fuel to one part clean lubricating oil. Pay particular attention to the bottom and corners of
the tank. Make sure all washing materials are removed.
15. Disconnect and drain all hoses that might trap oil.
16. Move the control levers. Drain any oil that might be trapped in the steer and boom/bucket
valves.
17. Re-assemble all components removed from the hydraulic tank assembly and install a new
element in the return filter.
18. Reconnect all hoses that were previously disconnected.
19. Make sure that:
• hydraulic tank drain plug and covers are replaced securely
• o-rings form an effective seal

HYD-068/01/02 3-7
 Major Components

20. Refill the hydraulic tank with clean oil of proper viscosity to the top of the liquid level sight
gauge. Use oil from a filtered filling station if possible.
21. Make sure that the control levers are in the neutral position.
22. Start the engine and allow it to run at idle speed for a few minutes.
23. Raise and lower the boom and roll back the bucket several times to bleed trapped air from
the circuit.
24. Steer the machine right and left several times to bleed trapped air in the circuit.
25. Operate the steer and boom/bucket functions until the oil in the hydraulic tank stops
foaming.
26. If a component has failed or if the system is highly contaminated, also perform the
following steps when changing the oil:
• Disconnect all hoses from components.
• Flush hoses with clean hydraulic oil and blow out with compressed air.
• Remove pumps, cylinders, control valves, and other hydraulic components.
• Disassemble, thoroughly clean and inspect for damage.
• Thoroughly clean and inspect hydraulic tank.
• Start the machine and bleed the system.
• Raise and lower the boom and roll back the bucket several times to bleed trapped air from
the circuit.
• Steer the machine right and left several times to bleed trapped air in the circuit.
• Re-drain the entire system.
• Clean/replace filters and strainers.
• Flush out hydraulic tank and install filters/strainers.

HYD-068/01/02 3-8
 Major Components

Hydraulic Tank
The hydraulic tank is equipped with an MSHA-approved filler cap. A strainer in the filler neck
prevents large particles of contaminants from entering the hydraulic tank. Make sure the strainer
is in place before adding oil. Periodically remove and inspect the filler cap and filler neck strainer.
Clean strainer and replace o-ring seal as necessary.
Two access covers on top of the tank allow easy servicing of the suction strainer and the return
filter. An access cover on the side allows the interior of the tank to be inspected and cleaned. A
breather prevents pressure from building inside the tank.

1 3

2 4

Figure 6 : Hydraulic Tank - Top

1. Breather
2. Access to Suction Strainer
3. Access to Return Filter
4. Filler Cap

3 2

Figure 7 : Hydraulic Tank - Schematic

1. Breather
2. Suction Strainer
3. Return Filter

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 Major Components

The filler neck strainer prevents coarse contaminants from entering the hydraulic tank during
filling.

Figure 8 : Filler Cap

1. Filler Neck Strainer

A sight glass installed on the side of the hydraulic tank displays the oil level. Always make sure
the oil level is correct (at the FULL mark) before putting the machine to work. Too much oil in the
tank may cause potentially hazardous spillage through the breather. Too little oil may damage
components and cause the machine to perform below its normal capacity.

Figure 9 : Sight Glass

HYD-068/01/02 3-10
 Major Components

Servicing the Suction Strainer

1. Remove drain plug with 3/4” allen key and box end wrench. Carefully and thoroughly drain
the hydraulic tank as described in “Changing the Oil”.
CAUTION: Be prepared to drain large amounts of oil.

Figure 10 : Drain Plug

2. Remove 1/2” bolts from access cover. Remove access cover and pull out suction strainer.

Figure 11 : Remove Suction Strainer

3. Visually inspect the suction strainer for damage. Remove 7/16” bolts, handle and brackets.

Figure 12 : Inspect Suction Strainer

HYD-068/01/02 3-11
 Major Components

4. Slide retaining bands until magnets are exposed. A standard screwdriver or other flat edge
may be helpful.

Figure 13 : Expose Magnets

5. Remove five (5) magnets.

Figure 14 : Remove Magnets

6. Carefully wash and wipe down magnets with clean shop cloths.

! WARNING!

Wear gloves to avoid metal slivers.

7. If the strainer basket appears dirty, then clean it in a solvent solution. Blow dry with
regulated air pressure of 25 to 35 psi.

HYD-068/01/02 3-12
 Major Components

8. Test the by-pass check valve on top of the strainer basket by pushing down on the plate
inside the valve.
9. Reassemble suction strainer and reinstall in hydraulic tank.
Replacing the Return Filter
1. Remove 1/2” bolts from access cover.
2. Remove access cover and pull out return filter assembly.
3. Discard used return filter element and install new one.

Figure 15 : Return Filter

4. Make sure the tank is clean and free of rust, dirt, or other contaminants.
5. Install the access cover. Use a new gasket.
Removing the Hydraulic Tank

! WARNING!

Connect the frame lock between the front and rear sections of the machine before working
on the hydraulic tank.
1. Remove the drain plug.
2. Drain the tank.
3. Disconnect all the lines to the tank.
4. Support the tank with a floor jack, lift truck or overhead crane.
5. Remove the mounting capscrews from the main frame and fender.
6. Pull the tank straight away from the machine.

HYD-068/01/02 3-13
 Major Components

Implement Pumps

Description
Hydraulic gear pumps are mounted on and powered by the torque converter. The boom/bucket
pump and the pilot/brake pump are mounted in a tandem assembly.

2
4

3
5

Figure 16 : Implement Pumps

1. Torque Converter
2. Steer Pump
3. Charge Pump
4. Boom/Bucket Pump
5. Pilot/Brake Pump
NOTE: The charge pump supplies oil to the transmission.

2 3

Figure 17 : Schematic
1. Steer Pump
2. Boom/Bucket Pump
3. Pilot/Brake Pump

HYD-068/01/02 3-14
 Major Components

Service Information
Removing Pumps
1. Attach a lifting device to the pump being removed and remove the cap screws from the
mounting flange, mounting bracket or adapter.

! WARNING!

Pumps are heavy. Lift pumps with a lifting device.

2. Pull the pump straight outward from the torque converter.
3. Lift the pump out of the machine.
4. Put the pump in a clean, safe work area.
Servicing Pumps
See pump manufacturer's service information in this section of the service manual.
Installing Pumps
1. Coat the pump shaft and coupling adapter with grease.
2. Place a new gasket between the pump and torque converter (boom/bucket pump) and
between pump and adapter and adapter torque converter (pilot/brake pump).
3. Slide the coupling adapter on to the pump shaft.
4. With the aid of a lifting device, position the pump for installation. Coat the mounting
capscrews with loc-tite 271 or equivalent and install capscrews with correct torque.
5. If the pump is being repaired or replaced because of a failure, clean the suction, then drain
and refill hydraulic tank with new oil. Also replace all hydraulic oil filter elements.
NOTE: Tighten capscrews to torque specified in “Torque Values for Standard Hardware”.
Starting New Pumps
1. Make sure the entire hydraulic system is clean, and suction lines are full of oil to avoid
cavitation.
2. Fill hydraulic tank to recommended level of hydraulic oil.
3. Start new pump. Gradually increase engine speed to approximately 1000 rpm.
4. Check for leaks and trapped air.
Checking for Internal Leaks
1. Run the pump at normal operating speed.
2. Apply load up to the recommended relief valve setting.
3. Make sure all components are functioning properly.
4. Check for air bubbles in hydraulic oil, erratic or jerky hydraulic system action, excessive
pressure in hydraulic tank, and/or excessive pump noise.

HYD-068/01/02 3-15
 Major Components

5. If any of the above appear, check all intake fittings and connections for leaks and correct.
See Troubleshooting Guide.
Starting Pumps in Cold Conditions
When starting in cold conditions, do not load pumps until oil has achieved the minimum viscosity
requirements to prevent damage from cavitation. Introducing hot oil into cold pumps may cause
them to seize due to unequal expansion rates. Oil temperature must not be more than 22° C above
the surface temperature of the pump when oil enters the pump.

HYD-068/01/02 3-16
 Major Components

Brake Release Pump

Description
This manually-operated pump is used to release the brakes when no engine power is available and
the machine must be towed.
NOTE: The electrical system must be in working order. The brake release pump will not function
if the electrical power is not available, or if the ignition switch is not in the “OFF”
position.

! WARNING!

Use only under the strict supervision of the maintenance supervisor. Precautions must be
taken to ensure that the machine does not run away. Follow towing procedures carefully.
NOTE: The brakes may still be re-applied with the brake pedal while the brake release circuit is
installed.
Service Information
See document entitled “Enerpac Instruction Sheet for Hydraulic Hand Pump”.

3
2

Figure 18 : Brake Release Pump

1. Brake Release Pump
2. Steer Cylinder
3. Transmission Oil Dipstick

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 Major Components

Figure 19 : Brake Release Pump Handle

1. Brake Release Pump Handle
2. Steer Cylinder
3. Instrument Panel

3
4

1 2

Figure 20 : Accumulator Assembly

1. Quick Connect Fitting
2. Brake Release Pump Outlet
3. Brake Pedal Valve Pressure Line
4. Hose End Cap

HYD-068/01/02 3-18
 Major Components

High Pressure Filter

Description
This filter is installed downstream of the pilot/brake pump. The filter element removes
contaminants as oil passes through it. When the filter element is clogged, oil will by-pass the filter
element through the integral check valve.
All hydraulic filters should be renewed after the initial 50 hours of operation, and every 250 hours
thereafter. See Parker filter service information.

Figure 21 : High Pressure Filter

1. Accumulator Charging Valve
2. Brake Cooling Relief Valve
3. High Pressure Filter

OUT

1 2

IN

Figure 22 : Schematic
1. Filter Element
2. Check Valve

HYD-068/01/02 3-19
 Major Components

Brake Cooling Filter

Description
The filter element removes contaminants as oil passes through it. When the filter element is
clogged, oil will by-pass the filter element through the integral check valve.
All hydraulic filters should be renewed after the initial 50 hours of operation, and every 250 hours
thereafter. See Parker filter service information.
NOTE: This filter is part of the brake cooling circuit. It is not included on brake hydraulic
schematic 64545402 rev. 0.

1 2

Figure 23 : Brake Cooling Filter

1. Brake Cooling Filter
2. Steer Control Valve

OUT

1 2

IN

Figure 24 : Schematic
1. Filter Element
2. Check Valve

HYD-068/01/02 3-20
 Major Components

Accumulator Charging Valve

Description
The accumulator charging valve regulates pressure in the pilot/brake circuit and charges the brake
accumulators.
Service Information
See “Mico 463 Series 30 GPM Single Charging Valve With Relief Valve Service Instructions” in
this section of the service manual.

5
1

Figure 25 : Accumulator Charging Valve - Component

1. Test Port
2. Tank Port
3. Port “ACC”
4. Inlet
5. Port “A”
6. Outlet

HYD-068/01/02 3-21
 Major Components

Operation
1. Valve 1 (1) senses pressures in the pilot/brake circuit.
2. When pressure in the circuit rises to between 2275 and 2325 psi, valve 1 (1) causes the spool
inside valve 2 (2) to shift. This directs pump flow back to the hydraulic tank through the
tank port (5).
3. When pressure drops to between 1850 and 1950 psi, the spool in valve 2 (2) springs back to
its original position. This allows pressure in the circuit to build again and ensures that
correct pressure is maintained in the circuit.
4. A relief valve (6) diverts oil entering the inlet port (8) to the hydraulic tank if pressure in the
circuit exceeds 2800 psi.
5. A filter (4) cleans the oil as it flows through the accumulator charging valve. Replace this
filter every 1000 hours of service, or more frequently if necessary.
6. Port “ACC” (3) goes to the pressure switch manifold in the brake circuit.
7. Port “A” (7) goes to the PRV interrupt valve in the pilot circuit.

1 5

3
4

8 9

Figure 26 : Schematic
1. Valve 1
2. Valve 2
3. Port “ACC”
4. Filter
5. Tank
6. Relief Valve
7. Port “A”
8. Inlet
9. Outlet

HYD-068/01/02 3-22
 Major Components

Accumulators

Description
Accumulators are fluid pressure storage chambers in which hydraulic oil under pressure is stored
against the compressible force of pressurized nitrogen gas. The pressurized oil is readily available
when needed in the brake circuit.
Accumulators are pre-charged (filled with dry nitrogen) to a pressure determined by the system
operating pressure and load as the hydraulic pump forces oil into the accumulator fluid chambers.
The gas inside the accumulators compresses until the gas pressure is equal to the hydraulic oil
pressure.
Accumulators are used to supply oil to a system during temporary demands greater than the pump
can supply, or they can supply make-up oil for holding system pressure.

1
1

Figure 27 : Accumulator Assembly

1. Accumulator

Figure 28 : Schematic

HYD-068/01/02 3-23
 Major Components

Service Information
NOTE: See accumulator manufacturer’s service documents for more information.
NOTE: The accumulators remain charged even when the engine is off.

! WARNING!

Open accumulator drain valve and allow pressure in the circuit to drop to zero psi before
servicing any hydraulic component. Make sure accumulator drain valve is closed before
resuming normal operations.
Inspection
Check the pre-charge pressure at least once during the initial week of service. To check the pre-
charge pressure, fill accumulator using pump until maximum oil pressure is reached. Switch off
pump and open accumulator drain valve to let oil flow out of accumulator slowly. As soon as the
pre-charge pressure is reached, the oil pressure should drop abruptly.

! WARNING!

Never use compressed air or oxygen to pre-charge accumulators - risk of explosion!

! WARNING!

Do not attempt to weld or solder accumulator body.

HYD-068/01/02 3-24
 Major Components

Auto Brake Solenoid Valve

Description
The auto brake solenoid valve regulates oil flow to the wheel ends in the brake circuit.
Operation
1. The auto brake solenoid valve is energized if the engine running, and brake circuit pressure
is above 1400 psi, and/or the park/emergency brake button is fully pulled out. In the
energized position, port P (from pressure switch manifold) is open to port B (to front and
rear brake solenoid valves).
2. When the engine is off, the auto brake solenoid is de-energized. In the de-energized
position, port P is blocked by a test port installed on port A.. Oil from the front and rear
brake solenoids enters port B and flows back to the hydraulic tank through port T.

Figure 29 : Accumulator Assembly

Figure 30 : Hydraulic Schematic

HYD-068/01/02 3-25
 Major Components

Auto Bleed Down Solenoid Valve

The auto bleed down solenoid valve (1) is mounted on the pressure switch manifold (2). The
solenoid is energized (valve closed to tank) when engine oil pressure is 7 psi or above (engine
running).
When the solenoid is de-energized (valve open to tank), the accumulators drain and brake circuit
pressure drops to zero psi.

Figure 31 : Pressure Switch Manifold

Figure 32 : Auto Bleed Down Solenoid Valve - Schematic

HYD-068/01/02 3-26
 Major Components

Pressure Switch - Park/Emergency Brake Light

Figure 33 : Accumulator Assembly

1. Pressure Switches
2. Auto Brake Solenoid Valve
Operation
The pressure switch closes when pressure in the brake circuit rises above 1400 psi. When the
pressure switch is closed, the park/emergency brake light/button illuminates.

Figure 34 : Auto Brake Solenoid Valve - Schematic

1. Pressure Switch (1400 psi, Form C contact)
2. Auto Brake Solenoid Valve

HYD-068/01/02 3-27
 Major Components

Pressure Switch - Auto Brake

Description
This normally closed pressure switch is mounted on the accumulator assembly.

Figure 35 : Accumulator Assembly

1. Pressure Switches

Figure 36 : Pressure Switch Manifold

Operation
1. The pressure switch is set at 1400 psi and is open when there is no pressure in the system.
2. During normal operations, pressure rises above 1400 psi and closes the pressure switch.
3. If brake circuit pressure falls to or below 1400 psi, the pressure switch opens and cuts the
circuit which energizes the auto brake solenoid.
4. In the de-energized position, the auto brake solenoid drains the oil in the brake circuit and
causes the brakes to apply.

HYD-068/01/02 3-28
 Major Components

Pressure Switch - Brake Impending Light/Brake Fault Light

Description
This pressure switch is mounted on the accumulator assembly.

Figure 37 : Accumulator Assembly

1. Pressure Switches

Figure 38 : Pressure Switch Manifold

Operation
1. During normal operations, brake circuit pressure rises above 1600 psi and opens the
pressure switch.
2. If brake circuit pressure falls to or below 1600 psi, the pressure switch closes and completes
the circuit which illuminates the auto brake impending light and the brake fault light on the
instrument panel.

HYD-068/01/02 3-29
 Major Components

Pressure Reducing Valve (PRV)

Description
The pressure reducing valve (PRV) regulates oil pressure to the pilot valves.
Operation
Oil enters the PRV through port “P” and also applies pressure to the valve spool.
Pressure exceeding 450 psi forces the spool down to create a path from port “RP” to port “T”. Oil
exits the circuit and returns to the hydraulic tank until pressure drops below 450 psi.

Figure 39 : Pressure Reducing Valve

1. Pressure Reducing Valve
2. Accumulator Assembly Mounting Bracket

Figure 40 : Pressure Reducing Valve

HYD-068/01/02 3-30
 Major Components

Front and Rear Brake Solenoid Valves

Description
The front and rear solenoid valves are mounted beside the accumulator assembly. The valves are
energized (open to the wheel ends) when the brakes are released, and de-energized (open to tank)
when the brakes are applied with the park/emergency brake light/button, brakes are applied auto-
matically.
NOTE: To release the brakes using the manual brake release pump when the engine is off, the
solenoid valves must be energized by pulling out the tow light/button on the instrument
panel.

Figure 41 : Front and Rear Brake Solenoid Valves

1. Front Brake Solenoid Valve
2. Rear Brake Solenoid Valve
3. Pressure Reducing Valve (Reference)

1 2

Figure 42 : Schematic

HYD-068/01/02 3-31
 Major Components

Pressure Differential Switch

The pressure differential switch senses the difference in pressure between the front brakes and the
rear brakes. If the difference is too great, it de-energizes the front brake solenoid valve, rear brake
solenoid valve and auto brake solenoid valve. This causes the brakes to automatically apply.

Figure 43 : Pressure Differential Switch

Figure 44 : Schematic

HYD-068/01/02 3-32
 Major Components

Brake Pedal Valve

Service Information
See “Mico Pedal Actuated Reverse Modulating Hydraulic Power Brake Valve” in this section of
the service manual.

Figure 45 : Brake Pedal Assembly, 64280314 Revision 01

Figure 46 : Schematic

HYD-068/01/02 3-33
 Major Components

Steer Pilot Valve

Service Information
See “Joystick Type Oil Hydraulic Remote Controller” in this section of the service manual.

2
4
3

Figure 47 : Steer Pilot Valve - Component

1. Steer Control Lever
2. Port “B” (Steer Right)
3. Port “P”
4. Port “A” (Steer Left)

Figure 48 : Schematic

HYD-068/01/02 3-34
 Major Components

Eject Pilot Valve (Optional)

Service Information
The eject pilot valve has the same part number as the steer valve. See “Joystick Type Oil
Hydraulic Remote Controller” in this section of the service manual.

2
4
3

Figure 49 : Optional Eject Pilot Valve - Component

1. Eject Control Lever
2. Port “B” (To Port PB2” on Steer Valve)
3. Port “P”
4. Port “A” (To Port “PA2” on Steer Valve)

Figure 50 : Schematic

HYD-068/01/02 3-35
 Major Components

Steer Valve

Service Information
See “Commercial Hydraulic Service Manual KA10/18” in this section of the service manual.
The steer valve may be equipped with an optional ejector spool. For service information, see
“Commercial KA18 Banking Instructions” in this section of the service manual.
Operation
The steer valve directs oil to the steer cylinders when the operator moves the steer pilot valve.
Pilot pressure from the steer pilot valve shifts the spool inside the steer valve to allow oil to flow
to the steer cylinders.
The spool in the steer valve is spring-centered to the neutral position. It is equipped with two port
relief valves to protect the steer cylinders when the steer spool is in the neutral position. Excessive
pressure is relieved by venting oil from one work port to the other via a specially drilled passage
in the valve section.
If the machine is equipped with an optional eject circuit, the steer valve is fitted with an eject
spool, which is also open centered. Pilot pressure from the eject pilot valve shifts the spool inside
the steer valve to allow oil to flow to the eject cylinders.

5
5
A2 B2
2
PA2 PB2

4 4
A1 B1

PA1 PB1
1

Figure 51 : Schematic With Optional Eject Spool

1. Steer Spool
2. Optional Eject Spool
3. Main Relief
4. Steer Port Reliefs
5. Optional Eject Port Reliefs
6. Check Valve

HYD-068/01/02 3-36
 Major Components

1 3

2 4

7 8

9
5

Figure 52 : Steer Valve Without Optional Eject Spool

1. Steer Pilot Left
2. Steer Left Port Relief
3. Steer Pilot Right
4. Steer Right Port Relief
5. Check Valve
6. From Steer Pump
7. To/From Steer Cylinder
8. To/From Steer Cylinder
9. To Hydraulic Tank

HYD-068/01/02 3-37
 Major Components

1 3

4 4

Figure 53 : Steer Valve With Optional Eject Spool

1. Steer Left Port Relief
2. Main Relief
3. Steer Right Port Relief
4. Eject Port Relief
5. Check Valve
6. From Steer Pump

HYD-068/01/02 3-38
 Major Components

Boom/Bucket Pilot Valve

Service Information
See “Pilot Valve” in this section of the service manual.

2 5

3 6

4 7

Figure 54 : Boom/Bucket Pilot Valve - Component

1. Boom/Bucket Control Lever
2. Port “A1” to Port “PA1” on Boom/Bucket Valve (Boom Down)
3. Port “P” (from Pressure Reducing Valve)
4. Port “B2” to Port “PB2” on Boom/Bucket Valve (Dump Bucket)
5. Port “B1” to Port “PA2” on Boom/Bucket Valve (Roll Back Bucket)
6. Port “T” (to Hydraulic Tank)
7. Port “A2” to Port “PB1” on Boom/Bucket Valve (Boom Up)

HYD-068/01/02 3-39
 Major Components

2 4
1
3

Figure 55 : Schematic
1. Boom Down
2. Boom Up
3. Roll Back Bucket
4. Dump Bucket

HYD-068/01/02 3-40
 Major Components

Boom/Bucket Valve

Service Information
See “Commercial VA 20/35 VG 20/35 Directional Control Valve Service Instructions” in this
section of the service manual. The model is VA 35.
Operation
The boom/bucket valve directs oil to the boom and bucket cylinders when the operator moves the
boom/bucket pilot valve. Pilot pressure from the boom/bucket pilot valve shifts the spools inside
the boom/bucket valve to allow oil to flow to the boom/bucket cylinders.
The spools in the boom/bucket valve are spring-centered to the neutral position. Each spool is
equipped with two port relief valves to protect the cylinders when the spool is in the neutral
position. Excessive pressure is relieved by venting oil from one work port to the other via a
specially drilled passage in the valve section.

2 4

3 5

Figure 56 : Boom/Bucket Valve - Component

1. Main Relief
2. Dump Bucket Pilot
3. Raise Boom Pilot
4. Rollback Bucket Pilot
5. Lower Boom Pilot
6. Port Relief

HYD-068/01/02 3-41
 Major Components

5 5

3 3

Figure 57 : Schematic
1. Main Relief
2. Boom Spool
3. Boom Port Reliefs
4. Bucket Spool
5. Bucket Port Reliefs
6. Bucket Cylinder
7. Boom Cylinders

HYD-068/01/02 3-42
 Major Components

Radio Remote Control Manifold (Optional)

This manifold is equipped with eight solenoid valves and eight shuttle valves. The solenoid valves
operate the steer and boom/bucket valves while the Manual/Radio Button on the instrument panel
is turned to the “RADIO” position.
When the Manual/Radio Button on the instrument panel is turned to the “MANUAL” position,
the shuttle valves direct flow from the boom/bucket and steer pilot valves to the boom/bucket and
steer valves.

Figure 58 : Radio Remote Control Lines, 64542439 Revision 00

1. Radio Remote Control Manifold
2. Steer Pilot Valve
3. Boom/Bucket Pilot Valve
4. Boom/Bucket Valve
5. Steer Valve

HYD-068/01/02 3-43
 Major Components

1
4

1
2
5

3
6

Figure 59 : Radio Remote Control Manifold

1. Dump Solenoid
2. Boom Down Solenoid
3. Steer Right Solenoid
4. Rollback Bucket Solenoid
5. Boom Up Solenoid
6. Steer Left Solenoid

HYD-068/01/02 3-44
 Major Components

Test Port Manifold

Description
The test port manifold allows service personnel to test several hydraulic pressures at one
convenient location in the center hinge area.

1 2

Figure 60 : Center Hinge Area

1. Test Port Manifold
2. Operator’s Compartment (Reference)

Safety Precautions

! WARNING!

The following safety standard should be adhered to while conducting hydraulic pressure
tests.
1. Park the machine in a safe location, clear of mine traffic flow.
2. Apply the park/emergency brake light/button and ensure the light is activated.
3. Install safety blocks on both sides of each wheel.
4. Install frame lock unless testing steer pressure.
5. The operator should remain in the operator's compartment for the duration of the test.
NOTE: For an accurate pressure test of boom/bucket functions, read the gauge when the boom/
bucket is fully raised and fully lowered.

HYD-068/01/02 3-45
 Major Components

Required Tools for Pressure Tests

1. 3000 psi pressure gauge
2. Quick-couple connector
3. High pressure hose
NOTE: If only the operator is conducting the test, the high pressure hose must be long enough for
the operator to read the gauge while seated in the operator's compartment. The operator
must remain in the operator's compartment for the duration of the test.

Figure 61 : Test Port Manifold

1. Brake Pressure
2. Pressure Reducing Valve (PRV) Pressure
3. Dump/Hoist (Boom/Bucket) Valve Pressure
4. Steer Valve Pressure
5. Torque Converter/Clutch Pressure

HYD-068/01/02 3-46
 Major Components

Hoses and Tubing

NOTE: SAE standard hose sizes are indicated on hydraulic schematics. Hose lengths are listed in
the parts manual.
When servicing hoses and tubing:
1. Replace hoses and tubing in their original position. New hoses and tubing should be the
same length as the original hoses and tubing.
2. Avoid sharp bends. Avoid bending the hose to a radius smaller than 10 times the outside
diameter of the hose. Sharp bends in hydraulic lines may restrict the flow of oil and cause
overheating.
3. If the hose normally flexes during operation, avoid bending the hose to a radius smaller than
2.5 to 3 times the outside diameter.
4. Keep lines as short as possible. The longer the line, the more resistance.
5. Tighten swivel nuts firmly, but do not overtighten. Overtightening can damage swivel nuts
and sealing surfaces.
6. NEVER use pipe wrenches to service hoses or tubing. Use flare wrenches or open end
wrenches of correct size.
7. After a hose or tubing has been disconnected, cap or plug the hose line and the fitting from
which it was removed. This prevents contamination from entering the hydraulic system.
8. NEVER use rags or waste material to plug lines or other components. Rags or waste
material may contaminate the hydraulic system.

HYD-068/01/02 3-47
Cylinders

Maintenance
Remove, clean, inspect, repair and replace hydraulic cylinders according to preventive
maintenance schedule.
Removal
To remove a hydraulic cylinder:
1. Lock or position the implement which receives its motion from the hydraulic cylinder so
that no force or weight is placed on the piston assembly.
2. Disconnect the hydraulic lines leading to and from the hydraulic cylinder. Drain the oil into
a suitable container.
3. Plug the oil ports in the cylinder and cap the lines to prevent dirt from entering.
4. Securely attach a suitable lifting device to the cylinder.
5. Remove the pins mounting the hydraulic cylinder to the unit.
6. Lift the cylinder assembly from the machine.
Cleaning
Thoroughly wash all of the parts of the cylinder assembly in a suitable solvent. Dry with a clean,
lintless cloth or with compressed air.
Inspection
Carefully inspect the inside surface of the hydraulic cylinder and the condition of the pistons.
Repair/Replacement
Re-assemble the hydraulic cylinder using new packing, back-up rings, o-ring, and wiper ring.
Also replace any part that is worn or damaged.
Re-install the hydraulic cylinder on the unit, reversing the procedure for removal.
Operate the cylinder. Check the cylinder for leaks. If oil is leaking from the piston rod, tighten the
packing capscrews.
 Major Components

Axles
NOTE: For more information, see Clark axle and brake manuals.
Front Axle
NOTE: There is no drawing at this time for front axle assembly.

2
1
3

Figure 62 : 64542855 Forced Brake Cooling - Front

1. Brake Cooling Pressure

2. Brake Cooling Return
3. To Vent
4. Brake Lines (Reference)
5. Bulkhead Plate (Reference - Front Frame)

HYD-068/01/02 3-49
 Major Components

Rear Axle

5 1

2
3

Figure 63 : 64543689 Rear Axle Assembly

1. Brake Port
2. Cooling Outlet Port
3. Cooling Inlet Port
4. Torque to 2000 +- 100 ft. lbs.
5. Bolster Assembly

Figure 64 : 64543989 Rear Axle Assembly - Top View

6. Tube assembly mounts to stud on rear axle. Torque to 130 ft. lb.

HYD-068/01/02 3-50
Brake Cooling Relief Valve

Figure 65 : 64543819 Brake Cooling Rear Frame

1. Brake Cooling Relief Valve

Figure 66 : 64117439 Brake Cooling Relief Valve

2. To Tank Port on Accumulator Charge Valve
3. To “O” Port on Accumulator Charge Valve
4. To Front Axle Brake Cooling Pressure
5. To Rear Axle Brake Cooling Pressure
Notes
 Troubleshooting

No Pressure In System

PROBABLE CAUSE REMEDY

Intake restricted. Check suction strainer and clean if necessary.

Low oil level. Add oil to hydraulic tank. Do not over fill.

Worn out pump. Repair or replace.

Air leak in intake line. Check tightness or connections and condition of suction
hose.

Oil viscosity too low. Drain system and refill with clean oil with proper viscosity.

Relief valve constantly by-passing. Check for flow through tank port. If necessary, remove
contaminant or replace relief valve.

Insufficient System Pressure

PROBABLE CAUSE REMEDY

System relief valve set too low. Re-adjust to specified pressure.

Cold oil. Warm up system.

Defective or worn pump (does not deliver full Rebuild or replace pump.
flow at system pressure).

Excessive Pump Noise

PROBABLE CAUSE REMEDY

Cavitation (vacuum on the intake side of the pump Check for restricted air intake line, clogged strainers or
due to too little oil) filters, plugged air vent in hydraulic tank, and oil of too high
viscosity. Make necessary repairs.

Low oil level. Add oil to hydraulic tank. Do not over fill.

Oil viscosity too low. Drain system and refill with clean oil with proper viscosity.

Air leak in intake line. Check tightness of connections and condition of suction
hose.

HYD-067/06/01 4-1
 Troubleshooting

System Excessively Hot

PROBABLE CAUSE REMEDY

Restricted open circuit. Check for:
-collapsed hose lines
-replaced, undersized hoses
-damaged tubing

Low oil level. Add oil to hydraulic tank. Do not over fill.

Brakes Will Not Release

PROBABLE CAUSE REMEDY

Electrical malfunction. Check electrical circuits
-engine oil pressure switch
-transmission oil pressure switch
-brake pressure switches
-emergency brake relay
-auto brake solenoid
-tripped circuit breaker

Blocked orifices. Check orifices and remove contamination.

Faulty brake pressure switch. Check for loose connections. Check for voltage at pressure
switch when unit is operational with correct pressure of
component.
Test with gauge. Check voltage to switch in a normally
closed position. Check that when park brake button is in a
pull and reset position, switch directs current to emergency
brake relay.

Faulty emergency brake relay. Check for voltage to emergency brake relay coil.
Check for voltage at emergency brake relay contacts.

Faulty auto brake solenoid. Check for proper voltage at solenoid coil. To test solenoid:
1. Remove solenoid and measure its resistance (should
be 28 ohms).
2. Directly apply 24VDC to the coil and verify that the
spool shifts.

Excessive leakage in brake circuit. Isolate and check the following components:
-accumulator drain valve
-auto brake solenoid valve
-brake pedal valve
-safety valve
Check for damage or loose hose connections. Repair and
replace accordingly.

HYD-067/06/01 4-2
 Troubleshooting

PROBABLE CAUSE REMEDY

Hydraulic malfunction. Isolate and check engine oil pressure, transmission oil
pressure and brake circuit pressure.

Brakes Release But Brake Circuit Pressure Low

PROBABLE CAUSE REMEDY

Low accumulator pressure. With machine on level ground and wheels chocked, bleed
down accumulators. Make sure accumulators are charged to
800 psi dry nitrogen.
Also check the filter inside the accumulator charging valve.
Replace the filter, o-ring and poppet if the filter is dirty or
clogged.

Contamination. Clean seized or jammed spool as required.

Plugged hydraulic lines. Check pressure at each component. Adjust as required.

Accumulator drain valve open. Close accumulator drain valve.

Accumulator Charging Cycle Repeats Frequently When

Brakes Are Not Used

PROBABLE CAUSE REMEDY

Accumulators precharge pressure too low. Precharge accumulators with nitrogen to 800 psi (5.5MPa)

Check valve leaking. Clean or replace check valve.

Accumulator Charging Time Too Long

PROBABLE CAUSE REMEDY

Defective or worn pump doesn't deliver full flow Rebuild or replace pump.
at system pressure.

Leaking hose or component. Visually check, then disconnect return lines from
components to determine leakage.

HYD-067/06/01 4-3
 Troubleshooting

Control Lever Sticks

PROBABLE CAUSE REMEDY

Spool jammed. Loosen tie bolts and torque to 29 ft. lbs. (39Nm)

Contaminated oil. Clean valves, drain and flush system, replace oil.

Foreign body in valve or damaged spool. Clean valve and deburr spool, or replace.
Replace spring.

Spring broken. Replace spring.

Valve jams due to incorrect operating temperature. Maintain permissible temperature range.

Poor Control

PROBABLE CAUSE REMEDY

Pressure reducing valve out of adjustment. Adjust pressure. Check steer circuit pressure.

Pressure Fluctuates in System

PROBABLE CAUSE REMEDY

Relief valve damaged. Replace relief valve.

Air in fluid. Bleed system.

Contaminated fluid. Clean relief valve, drain system, flush and fill with clean
fluid.

Viscosity of fluid too high or too low. Drain fluid and replace with clean hydraulic oil which
conforms to specification.

Excessive External Leakage From Steer Valve

PROBABLE CAUSE REMEDY

Sealing rings have failed. Replace seals. If necessary remove and clean valve.

Tie bolts are loose. Re-tighten with torque wrench to 20 ft. lbs. (39Nm)

Tie bolts stretched. Replace tie bolts.

Damaged or porous valve body. Replace valve body. Establish cause of damage.

HYD-067/06/01 4-4
 Troubleshooting

No Steering

PROBABLE CAUSE REMEDY

Oil level low in hydraulic tank. Check oil level and fill hydraulic tank as required.

Pump not functioning. Repair or replace pump.

Broken, or leaking suction hose, pressure hose or Check and repair or replace parts.
fitting.

Boom Cylinders Will Not Move

PROBABLE CAUSE REMEDY

Insufficient or no pilot pressure. Check pressure in pilot circuit. Adjust or replace pressure
reducing valve as required. Check pilot valve.

No oil or insufficient oil being supplied to See “No Hydraulic Action”. Repair or replace as necessary.
cylinders.

Load greater than rated capacity. Reduce load.

Boom Cylinders Move Slowly

PROBABLE CAUSE REMEDY

Insufficient oil being supplied to cylinders. See “No Hydraulic Action”.

Defective cylinder seal. Replace seal and check for cause of seal damage. Repair as
necessary. If damage was caused by contaminated oil, drain
all hydraulic oil, change filters, clean strainers, and fill the
system with hydraulic oil.

Pressure reducing valve in pilot circuit not Adjust pressure reducing valve to proper setting (see
working properly. Hydraulic System Specifications.)

Structural warpage, not enough clearance, lack of Check alignment of boom and bushings. Repair, adjust and
lubrication, defective arm bushing. lubricate as necessary.

System resistance. Check for hot points in system (too small a fitting, etc.).
Repair or replace as necessary.

Main relief or cylinder relief valve out of Check relief pressure. Adjust or replace relief valves as
adjustment. necessary.

Load greater than rated capacity. Reduce load.

HYD-067/06/01 4-5
 Troubleshooting

PROBABLE CAUSE REMEDY

Air in system. Check oil level in hydraulic tank. Check for air leaks at
fittings, lines, and cylinder seals. Fill the tank or repair leaks
as necessary.

Bent rod, deformed cylinder or scored piston. Disassemble, check and repair cylinder assembly.

Defective cylinder(s). Repair or replace cylinders.

Structural warpage, not enough clearance, lack of Check boom alignment and bushings. Repair, adjust and
lubrication, defective boom bushings. lubricate as necessary.

Boom/Bucket Cylinders “Creep” (Retract Slowly When

Bearing a Load)

PROBABLE CAUSE REMEDY

Pressure line leaks. Check all lines and fittings. 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, drain all hydraulic oil, change
filters, clean strainers, and fill the system with hydraulic oil.

Boom/bucket valve defective. Repair or replace as necessary.

Bucket Cylinder Moves Slowly

PROBABLE CAUSE REMEDY

Insufficient oil supplied to See “No Hydraulic Action”.
cylinder.

Defective cylinder seal. Replace and check for cause of seal damage. Repair as necessary. If damage
was caused by contaminated oil, drain all hydraulic oil, change filters, clean
strainers, and fill the system with hydraulic oil.

System resistance. Check for hot points in system (too small a fitting, etc.). Repair or replace as
necessary.

Pressure reducing valve in pilot Adjust pressure reducing valve. See “Hydraulic System Specifications”.
circuit not adjusted properly.

HYD-067/06/01 4-6
 Troubleshooting

Spongy or Jerky Action Of Bucket Cylinder

PROBABLE CAUSE REMEDY

Air in system. Check oil level in the hydraulic tank. Check for air leaks at fitting, lines and
cylinder seals. Fill the hydraulic tank or repair leaks as necessary.

Bend rod, deformed cylinder, or Disassemble, check and repair cylinder assembly.
scored piston.

No Hydraulic Action

PROBABLE CAUSE REMEDY

Oil level low in hydraulic tank. Check level and fill as necessary.

Main relief valve improperly Check and re-adjust. Replace valve if defective.
adjusted or defective.

Hydraulic pump inoperative. Check pump for proper operation. Repair or replace as required.

Malfunctioning or maladjusted Adjust or replace valve.

pressure reducing valve in pilot
circuit.

HYD-067/06/01 4-7
 Troubleshooting

Notes

HYD-067/06/01 4-8
Tamrock Loaders Inc. Telephone: (905) 632-4940
EJC Loaders Division Fax: (905) 632-2172
4445 Fairview Street
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it ion

Burlington, Ontario Canada L7L 2A4

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