Hydraulic Pressure Testing

TLB890 Backhoe Loaders

Issue Date: 10-Oct-2011

Model: TLB890
Language: English (en)
Revision No. 1.0
Original Instruction
Material Copyright ©
For further information on the subject mater detailed within this training booklet, please refer to Terex
United Kingdom Limited, Maintenance Manuals, Operators Manuals and Product Parts Books.
Alternatively, please contact:
Customer Service Department
Terex United Kingdom Limited
ProLogis Park
Coventry, CV6 4BX
Tel; +44(0) 2476 339 660
Email. [email protected]

The Illustrations, technical information, data and descriptive text in this manual, to the best of our
knowledge, were correct at the time of print. The right to change specifications, equipment and
maintenance instructions at any time without notice, is reserved as part of the Terex United Kingdom
Limited policy of continuous development and improvement of the product.
No part of this publication may be reproduced, transmitted in any form – electronic, mechanical,
photocopying, recording, translating or by any other means without prior permission of Customer
Support Department – Terex United Kingdom Limited.
Please refer to TEREX Specification Sheets or consult Factory Representatives to ensure that
information is current.
TLB890 Backhoe Loader – Hydraulic Testing
A hydraulic pressure test kit is available, part number 6108395M91. This test kit contains adaptors
specifically designed for access to test ports.
WARNING!
Do not work on or around hydraulic systems without wearing safety glasses. Failure to follow
this instruction, may result in personal injury.
CAUTION!
If serious hydraulic pump failure is suspected, do not run the hydraulic pump for longer than is
absolutely necessary to determine its condition. If metal fragments are found in the hydraulic
pump outlet port, suction screen and/or return oil filter. DO NOT restart the hydraulic pump.
Replace the hydraulic suction/return filters, replace the pump, clean the hydraulic reservoir and
complete hydraulic system. Failure to follow this instruction, may result in further damage to
the hydraulic system.
Important Note!

Hydraulic gauges will have a + or - 5% tolerance, testing at 200 bar it is possible to have a 10 bar
discrepancy in the readings. Allow for this if using two separate gauges, use the same gauge for all
tests, if at all possible.
 TLB890 Backhoe Loader
TLB890 Backhoe Loader Hydraulic Test Procedure
The basic testing steps to follow are:-
1. Check the Inlet Compensator Pressure. 18-20 bar @ 1800rpm
2. Check the Main Relief Valve Pressure. 250 bar
3. Check the Unloader Valve Pressure @ 1800rpm. 207 (-0 +7 bar)
4. Steering at full lock @ 1800rpm. 175-180 bar

Reasons or faults that can be found.

1. Points faults related to the Flow Share.
2. Lack of Force in the Hydraulics.
3. Lack of Speed in the Hydraulics.
TLB890 Backhoe Loader
All tests to be carried out with the machine at hydraulic oil operating temperature
approximately 50 – 60 degrees C and the engine set to 1800 rpm.
Inlet Flow Compensating Valve.
Note. Hydraulic gauge to be fitted to the Backhoe Hydraulic Control Valve.
Fit a low pressure hydraulic gauge (0-40 bar) to the 9/16” gauge connection in the
underside of the Backhoe Hydraulic Control Valve.

DO NOT OPERATE ANY HYDRAULIC SERVICE

Start the engine and set @ 1800 rpm with the hydraulic oil at working temperature,
approximately 50–60 degrees C, test the Inlet Compensator Valve pressure.
Select single pump mode. Make sure the indicator light on the rocker pump flow
control switch is illuminated. By selecting single pump mode, the hydraulic system is
not influenced by the outer hydraulic pump or Unloader Valve. If the indicator light is
not illuminated, depress the rocker switch to the right hand side located on the
operators side instrument console.
The Inlet Compensator Valve pressure should be 20 bar (-0 + 1 bar).
Stop the engine and relieve stored hydraulic pressure, before adjusting.
Add or remove shims in the Inlet Compensator as required.
Stop the engine and relieve stored hydraulic pressure, before removing hydraulic
gauges on completion of tests.
Main Pressure Relief Valve
Inlet Compensator Valve
TLB890 Backhoe Loader

The Principle behind Pressure Testing the Inlet Compensator before the Main
Pressure Relief Valve

Inlet Compensator Pressure Relief Valve

Valve
Hydraulic Pressure 20 bar 230 bar
Gauge

Inlet comp. 20 bar + PRV 230 bar = Main Relief Valve 250 bar

If the Inlet Compensator is either higher or lower, then this directly effects the Main Pressure Relief Valve
pressure as both valves are in series.

NOTE: 80 Series machines are the ONLY units to be 250Bar MPRV

 TLB890 Backhoe Loader
Main Pressure Relief Valve.
Replace the hydraulic pressure gauge with a high pressure gauge (0-400 bar) after carrying
out the Inlet Compensator Valve test procedure.
Select single pump mode. Make sure the indicator light single pump is ‘on’ the hydraulic
pumps flow control rocker switch. By selecting single pump mode, the hydraulic system is not
influenced by the outer hydraulic pump or Unloader Valve. If the indicator light is not
illuminated, depress the rocker switch located on the operators side instrument console.

Start the engine and set @ 1800 rpm with the hydraulic oil at working temperature,
approximately 50–60 degrees C, test the hydraulic pressure Main Relief Valve.
Operate the stabiliser legs fully, one at a time, to operate the hydraulic Main
Pressure Relief Valve (Carried out on this service first as the leg spools do not
have separate relief valve / anti cavitation valves in their own section).
The pressure should be 250 bar.
Adjust the main Pressure Relief Valve as required.

Operate every valve control service, one by one, in both directions, to obtain results.
The pressure readings should be 250 bar. Caution if the unit is fitted with auxiliary circuits (extender, hammer etc.) as they may have there
own MPV.
• If you have a pressure difference in one direction only, this could be the Anti Shock Valve in that service. Swap the service Anti
Cavitation Valves / Service Relief Valves over and see if the fault changes direction.

• If it is in both directions the fault is in the Inlet Compensating Valve (Regulating Valve) area.
Stop the engine and relieve stored hydraulic pressure, before adjusting, removing gauges and on completion of tests.
 TLB890 Backhoe Loader
TLB890 Hydraulic Testing – Gear Pump / Mechanical Controls

Unloader Valve Testing

Fit a 9/16” test fitting here.

With this we test the unloader
relief valve 207 bar.
M1
(release one pump back to tank)
The same procedure as current
models, use the bucket or boom
cylinders.

8
 TLB890 Backhoe Loader
Unloader Valve Pressure Testing
With the engine stopped and pressure drained from the hydraulic system.
Remove the pressure test port plug marked M1 on the loader Valve. Install a 9/16” test adapter. Attach a 0 - 400 bar hydraulic pressure gauge.
Select two pump mode. Make sure the indicator light on the two pump flow control rocker switch is not illuminated. This indicates that full flow
from both hydraulic pumps is provided. If the indicator light is illuminated on single pump, depress the rocker switch to the left hand side,
located on the operators side instrument console, to engage two pump mode.
Start the engine and raise the engine speed to 1800rpm.
Also Still using your main pressure relief valve pressure gauge.
Note. Make certain you have plenty of headroom before carrying out this test.
With the backhoe locked in the transport position, open the bucket out until only
approximately 70 - 80mm of cylinder rod is exposed, then continue slowly to open the
bucket. Watch both pressure gauges together.
Open the bucket SLOWLY M1 pressure will increase gradually while the bucket opens
out, until the pressure reaches the setting of the unloader relief valve.
The pressure will slowly increase until at 207bar the pressure is released back to the oil
reservoir by the Unloader Pressure Relief Valve. The maximum pressure indicated on the
pressure gauge, before zero pressure is indicated. The other gauge will continue up to the
main pressure relief valve setting (250bar) is reached.
The unloader pressure reading should be 207 bar (-0 +7 bar). Do this test 2 - 3 times, making sure to reset at 70-80mm of cylinder rod
each time. Take the average pressure reading.
Stop the engine and relieve stored hydraulic pressure, before repair or removing gauges and on completion of tests.
Note: This test can also be carried out using the loader bucket cylinder
 TLB890 Backhoe Loader - SM
Steering Pressure Relief Valve – Gear Pump
Using the ¾” male x female test union adapter connected into the priority
valve on the hydraulic pump.
Attach a 0-400 bar hydraulic pressure gauge.
With the engine set @ 1800 rpm and the hydraulic oil at operating
temperature.
Turn the steering wheel to full left hand lock and record the indicated
hydraulic pressure.
Turn the steering wheel to full right hand lock and record the indicated
hydraulic pressure.
The pressure reading should be 175 ± 7bar .
If the hydraulic pressure reading is not to specification, adjust the pressure
relief valve in the Orbitrol Steering Valve.

Stop the engine and relieve stored hydraulic pressure, before adjusting,
removing gauges and on completion of tests.

Note.
Rexroth Special tool part # E35/:36064 is required to adjust the orbitrol.
+1 turn = +26.6 bar

Steering Pressure Relief Valve

 TLB890 Backhoe Loader - PS
Steering Pressure Relief Valve – Piston Pump
Using a 9/16” test union adapter connected into the Loader valve at position M
on the end.
Attach a 0-400 bar hydraulic pressure gauge.
With the engine set @ 1800 rpm and the hydraulic oil at operating temperature.
Turn the steering wheel to full left hand lock and record the indicated hydraulic
pressure.
Turn the steering wheel to full right hand lock and record the indicated hydraulic
pressure.
The pressure reading should be 175 ± 7bar .
If the hydraulic pressure reading is not to specification, adjust the pressure
relief valve in the Orbitrol Steering Valve.

Stop the engine and relieve stored hydraulic pressure, before adjusting,
removing gauges and on completion of tests.

Note.
Rexroth Special tool part # E35/:36064 is required to adjust the orbitrol.
+1 turn = +26.6 bar

Steering Pressure Relief Valve

TLB890 Backhoe Loader

Notes: Part No.

7/16” Test point union 6195793M91
9/16” Test point union 6195794M91
¾” Union & test point 6195795M91
1 1/16” Union & test point 6195796M91
The unloader relief valve can also be tested on the other hydraulic cylinders, however
as they are fitted with cushioning the reaction is slower to create.

If you have any difficulty contact our Technical Help Desk at

[email protected]
Terex Construction (Coventry)
ProLogis Park
Coventry
CV6 4BX
www.terex.com

Created by; Clive Oldham