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Product: BACKHOE LOADER
Model: 416B BACKHOE LOADER 8SG09251
Configuration: 416B Backhoe Loader 8SG00001-11999 (MACHINE) POWERED BY 3054 Engine
Introduction
Reference: For Specifications with illustrations, make reference to SENR5825, 416B, 426B, 428B,
436B & 438B Backhoe Loaders Hydraulic Systems Specifications. If the Specifications in SENR5825
are not the same as in the Systems Operation and the Testing and Adjusting, look at the printing date
on the cover of each book. Use the Specification in the book with the latest date.
NOTE: This book has been completely changed from the previous issue.
Do not check for leaks with your hands. Pin hole (very small) leaks can
result in a high velocity oil stream that will be invisible close to the hose.
This oil can penetrate the skin and cause personal injury. Use
cardboard or paper to locate pin hole leaks.
1. Move the machine to a smooth horizontal location. Move away from working machines and
personnel and lower the buckets or implements (loader and backhoe) and stabilizers to the ground.
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2. Permit only one operator on the machine. Keep all other personnel either away from the machine or
in view of the operator.
5. Move the hydraulic control levers to all positions to release the pressure in the hydraulic system.
6. Carefully loosen the filler cap on the hydraulic tank to release the pressure in the tank.
7. Make sure all hydraulic pressure is released before any fitting, hose or component is loosened,
tightened, removed or adjusted.
9. The pressure in the system has now been released and lines or components can be removed.
When defining a hydraulic system problem, the following procedure should be followed. First, do
Visual Checks. If, when complete, the problem has not been identified, do Operational Checks. If the
problem is still not fully understood, do Instrument Tests. This procedure will help identify hydraulic
system problems. As soon as the problem is defined, go to Troubleshooting. The Troubleshooting
section will list the probable causes of a known problem. Since there may be more than one cause for
a problem, the Troubleshooting section may suggest specific inspections or instrument tests be done.
These inspections and tests will help identify which of the causes is most probable.
During a diagnosis of the hydraulic system, remember that correct oil flow and pressure are necessary
for correct operation. Oil pressure is caused by resistance to the flow of oil.
Visual Checks
A visual inspection of the hydraulic system and its components is the first step when identifying a
problem. Stop the engine, lower the implements and stabilizers to the ground. To remove the tank
filler cap, slowly turn the filler cap until it is loose. If oil comes out, let the tank pressure lower before
the filler cap is removed. Make the following inspections:
1. Check all backhoe, stabilizer and loader oil line connections for damage and leaks.
2. Follow all backhoe, stabilizer and loader oil lines from the implement connections to valve
connections. Check the lines and connections for damage and leaks.
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3. Check the control valves for leaks. Look around the relief valves and the primary and secondary
resolvers.
5. Follow the pump lines to the tank and valves. Check the lines for damage and leaks.
6. Check the oil cooler and tank for damage and leaks.
8. Use a clear bottle or container to get an oil sample from the tank immediately after the machine is
stopped. Check for air bubbles in the oil sample.
9. Remove the filter element and check for particles removed from the oil by the filter element. A
magnet will separate ferrous particles from nonferrous particles (piston rings, O-rings, seals, etc.).
Performance Tests
1. The temperature of the oil is too hot.
2. Pump makes unusual noise, the cylinders do not move smoothly.
3. Large amount of air in the oil.
4. Pump pressure too low.
5. Pump pressure too high.
6. Pause before pressure is reached in all circuits.
7. Signal pressure not zero (or tank pressure) when all valves in HOLD and steering not used.
8. Any implement moves with control lever in HOLD position.
9. Line reliefs too noisy.
10. Too much implement drift.
11. Implement droops when going from a partially raised position to a raised position.
12. All cycle times too slow.
13. The backhoe boom, bucket or stick cycle times too slow.
14. There is too long of a pause at ground level before raising machine during boom lower
cycle time check.
15. The backhoe boom, bucket or stick cycle times too fast.
16. The loader lift, tilt or clam, or the backhoe extendible stick or auxiliary cycle times are too
slow.
17. The loader lift, tilt or clam, or the backhoe extendible stick or auxiliary cycle times are too
fast.
18. Swing cycle times too slow.
19. Swing cycle times too fast.
20. Stabilizer lower cycle time too fast.
21. Stabilizer cycle times too slow.
22. Stabilizers will not Raise.
23. Stabilizers are unstable (jerky) when raising (lowering the machine).
24. Backhoe bucket slows or stops in mid stroke.
25. Backhoe bucket hits the load (curl) stop hard.
26. The swing cylinders hit the swing stops hard.
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Probable Cause:
Problem 2: Pump makes unusual noise, the cylinder rods do not move smoothly and there are
air bubbles in the oil.
Probable Cause:
Probable Cause:
1. A leak in the oil line between the tank and the pump.
2. Failure to correctly bleed the hydraulic system after assembly, inspection or testing.
3. Relief valve constantly opens and closes.
4. Leakage in and around cylinder seals.
Probable Cause:
1. Flow spool side of compensator valve set wrong (margin pressure low).
2. Flow spool spring broken.
3. Pump not upstroking (swashplate blocked or actuator spring broken).
4. Leak in signal network.
5. Low setting in pressure compensator.
Probable Cause:
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Probable Cause:
Problem 7: Signal pressure is not zero (or tank pressure) when all valves are in HOLD and
steering not used.
Probable Cause:
Probable Cause:
1. The control valve and valve spool have a large amount of wear.
2. A piston seal in a cylinder has a large amount of wear.
3. A leak in a connection between the control valve and the cylinders.
4. Makeup or line relief valves are open.
Probable Cause:
Probable Cause:
1. Leakage in and around the seals on the piston in the cylinder(s) affected.
2. Low setting of line relief.
3. Leakage past a line relief valve or makeup valve for the affected circuit.
4. The spool in the main control valve is not correctly centered. This problem can be caused by
a broken spring or sticky valve spool.
5. If the drift problem is in the stabilizer cylinders, the cause can be any of those above. In
addition, the lock valve in the stabilizer affected may not be seated properly.
Problem 11: Implement droops when going from a partially raised position to a raised position.
Probable Cause:
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Probable Cause:
Problem 13: The backhoe boom, bucket or stick cycle times are too slow.
Probable Cause:
1. The control valve main spool is not fully shifted for the affected circuit.
2. Blocked or partially blocked load signal going to pump compensator valve or leakage in the
signal network.
3. The affected circuit line relief setting is too low.
4. The affected circuit line relief or makeup valve is leaking.
5. Leaking in and around the affected cylinder(s) piston seals.
6. Pump not at full stroke. (Actuator piston stuck or swashplate blocked.)
7. Low pump margin pressure setting.
8. If the backhoe bucket cycle time is too slow it can be any of the above. In addition, the
cylinder snubber orifice may be blocked or partially blocked.
Problem 14: There is too long of a pause at ground level before raising machine during boom
lower cycle time check.
Probable Cause:
The restrictor spool in the backhoe inlet manifold stays open. (Broken restrictor spool spring or
restrictor spool sticking.)
Problem 15: The backhoe boom, bucket or stick cycle times are too fast.
Probable Cause:
Problem 16: The loader lift or tilt, clam, or the backhoe extendible stick or auxiliary cycle times
are too slow.
Probable Cause:
1. The control valve main spool is not fully shifted for the affected circuits.
2. Blocked or partially blocked load signal going to pump compensator valves or leakage in the
signal network.
3. The affected circuit line relief setting is too low.
4. The affected circuit line relief valve is leaking.
5. Leaking in and around the affected cylinder(s) piston seals.
6. Broken flow control spring.
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Problem 17: The loader lift, tilt, clam, or the backhoe extendible stick or auxiliary cycle times
are too fast.
Probable Cause:
Probable Cause:
Probable Cause:
The control valve compensator spool not limiting flow and pressure. Springs broken or fatigued.
Probable Cause:
Probable Cause:
Probable Cause:
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There is a hydraulic lock because the pilot signal passage to the lock valve is blocked.
Problem 23: Stabilizers are unstable (jerky) when raising (lowering machine).
Probable Cause:
The rod end orifice check valves are broken, missing or installed backwards.
Probable Cause:
Broken or missing snap ring on cylinder rod. The snubber piston is not held in place and may now
work anywhere in the stroke.
Problem 25: The swing cylinders hit the swing stops hard.
Probable Cause:
For any pump test, the pump flow, measured in U.S. gpm (liter/min) at 100 psi (690 kPa) will be
larger than the pump flow at 1000 psi (6900 kPa) at the same rpm
The difference between the pump flow of two operating pressures is the flow loss.
Flow loss when expressed as a percent of pump flow is used as a measure of pump performance.
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If the percent of flow loss is more than 10%, pump performance is not good enough.
*
Numbers in examples are for illustration and are not values for any specific pump or pump condition.
See Specifications For 416B, 426B, 428B, 436B, 438B Backhoe Loaders Hydraulic System, Form
SENR5808, for pump flow of a new pump at 100 psi and 1000 psi.
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If the test bench cannot be run at 1000 psi at full pump rpm, run the pump shaft at 1000 rpm. Measure
the pump flow at 100 psi (690 kPa) and at 1000 psi (6900 kPa). Use these values in the top part of
Formula II. For the bottom part of the formula, run the pump shaft at 2000 rpm. Measure the pump
flow at 100 rpm.
Operation Checks
The operation checks can be used to find leakage in the system. They can be used to find a bad valve
or pump. The speed of rod movement when the cylinders operate can be used to check the condition
of the cylinders and the pump.
Lift, lower, dump and tilt back the loader bucket several times.
1. Watch the cylinders as they are extended and retracted. Movement must be smooth and regular.
3. Listen for the sound of the relief valves. They must not open except when the cylinders are fully
extended or retracted, when the bucket is empty.
The loader lift control lever has a detent in the FLOAT position.
The loader bucket tilt control lever has a detent in the TILT BACK position (only when the bucket is
between full dump and the bucket angle to dig).
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The values shown are for an empty bucket. Before measuring drift on the implements, the cylinders
must be extended at least five times. Check the oil temperature.
To check the loader lift circuit, lift the bucket to maximum height and move the lift control lever to
the HOLD position. Measure the distance (and check the time) that the lift cylinders retract. Compare
to the chart.
To check the loader tilt circuit, disconnect the bucket leveler. Lift the bucket to 800 to 1000 mm (31.5
to 39.5 in). Tilt the bucket until it is level. Move the control lever to HOLD. Measure the distance
(and check the time) that the tilt cylinder retracts. Compare to the chart.
To check the backhoe boom, bucket and stick cylinders, position implements in the following manner.
Position stick horizontal (parallel) to ground. Position the bucket so the bottom (cutting edge) is
perpendicular to the ground. If the machine has a factory installed extendible stick, it should be fully
retracted. Raise the boom until it is 200 to 400 mm (8.0 to 15.5 in) from the ground. When correctly
positioned, move implement control levels to HOLD. Measure the distance (and check the time).
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To check stabilizer cylinder drift, position the backhoe loader as in loader circuit and backhoe circuit
drift tests. Lower the stabilizer cylinders and lift the rear wheels about 50 mm (2.0 in) off the ground.
1. Check the makeup valves or line relief valves in the affected control valves.
2. Check the condition of the valve spools in the affected control valves.
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The following tests should be run from a ground level implement to the fully raised position.
The following tests should be run from fully raised implement to ground level implement. During the
tests, the implement may impact the ground heavily. Care should be taken to protect finished ground
surfaces.
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For the final two tests, position the boom at 45° from horizontal. Fully extend the stick and move the
bucket to the fully loaded (closed or curled) position. If the extendible stick has been factory added, it
should be fully retracted. Then move the boom control lever to full boom DOWN. Measure the time
until the bucket hits the ground. To measure boom pause time, keep the control lever in boom DOWN
position and measure the time from when the bucket hits the ground until the rear of the machine
begins to raise.
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2. Check the makeup or line relief valves in the affected control valves.
There are two resolvers per implement control valve. Primary resolver (1) compares rod to head
cylinder pressures. Secondary resolver (2) compares the highest primary signal in its control valve to
the highest primary signal in the next control valve. The secondary resolvers are arranged in series
leading to the pump compensator valve.
The primary and secondary resolvers can be affected by debris, cut or missing seals, bad resolver
seats, or missing balls.
1. Left stabilizer.
2. Right stabilizer.
3. Boom.
4. Swing.
5. Backhoe bucket.
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6. Stick.
7. Extendible stick (if equipped).
8. Loader lift.
9. Loader bucket tilt.
10. Multi-purpose bucket (if equipped).
11. Steering.
Work each implement against a load. Watch the gauge. Maximum system pressure should be seen for
all circuits. By using the gauge, small leakage problems such as cut or missing seals can be detected.
If two or more control valves in series next to each other fail to work normally, the problem may be in
the secondary resolver of the first implement control valve that is closer to pump supply that does
work properly. This control valve's secondary resolver is allowing signal pressure from any control
valve further from pump supply to leak through to either the rod or head end signal passage of that
control valve to tank. This leakage may be caused by a ball not seating against the drain side of its
resolver causing the valve to not function properly.
This holds true unless; the ball is missing; there is debris preventing the ball from seating properly;
the seal is missing or leaking when multiple valves malfunction. Operate the malfunctioning valve
farthest from the pump and at the same time start going through the previously mentioned valve order.
The first valve that makes both of the implements work, is the one with the bad secondary resolver.
What is happening is that the farthest valve is sending a signal and the valve with a bad seal or
missing ball is also sending a signal. When both signals meet at the valve with the bad secondary
resolver the leak has no impact on the signal that now goes to the pump and it has no effect on the
flow control valve.
For valves with a flow control spool, if only one valve section either fails to work in one or both
directions or works slowly in one or both directions, the primary or secondary resolver in that control
valve may be bad. To determine which secondary resolver is bad perform the following check. Stall
an implement further away from the pump than the valve in question. This will force the ball in the
secondary resolver to seat away from the drain side of the resolver. This eliminates the possibility of a
leak on the drain side of the secondary resolver. Now operate the suspect valve while holding the
other implement in stall. If it is still operating slow in one or both directions, then the primary resolver
may be bad.
If the primary resolver is bad, then the pressure bleed off caused by the bad resolver is affecting the
operation of the flow control spool (if so equipped) in the valve body. The effective force (signal
pressure + spring) trying to open up the valve to allow flow to the cylinder is insufficient to meet the
cylinder load requirement so the implement has a slower response.
Normally if an implement is slow in both directions, the problem is usually in the secondary resolver.
If an implement is slow in one direction it is typically caused by a bad primary resolver (caused by
debris or bad seals).
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Other causes of malfunctioning valve sections might be a misadjusted linkage, a broken pressure
reducing valve spring, the flow control spool incorrectly installed or bad line relief and/or makeup
valves.
NOTE: If there is debris in the system. It is recommended that the system be flushed by removing all
the balls in the secondary resolvers and operate the implements. Enough flow will be supplied to flush
the debris to the tank.
Instrument testing on the hydraulic system and its components is the final step when diagnosing a
problem. Test results should verify the status of a component. Adjusting procedures are provided
where needed.
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The hydraulic oil in this system is SAE 10W. If the oil becomes dirty, component failure could result.
Dirty oil can also contribute to overheating.
Start the engine and run at high engine rpm. Actuate all cylinders through at least ten full strokes (do
not use loader float for this procedure). Lower all implements and stabilizers to the ground. Stop the
engine. Move all control levers through all positions to release pressure in the hydraulic system.
Remove the tank filler cap slowly. If oil or pressure is seen or heard coming out, let the tank pressure
lower before the cap is fully removed. Connect a hose assembled to system pressure quick disconnect
(1) in the pump discharge port. Run the free end of the hose into the tank through the fill tube. Make
sure all hydraulic controls are in HOLD. Start the engine and run at low idle.
Draw a 50 mL sample through a tee in the hose assembly. The contaminant level must be equal to or
less than the following:
Hydraulic Pump
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Pump discharge pressures are known values and can be tested during two specific conditions. These
two conditions are low pressure standby and high pressure stall.
2. Install a 0 to 4000 kPa (0 to 580 psi) gauge in pump discharge pressure tap (1).
6. The pressure reading must be about 2200 ± 100 kPa (320 ± 15 psi). Low pressure standby pressure
is equal to margin pressure 2100 ± 100 kPa (305 ± 15 psi) plus the additional pressure needed to keep
the pump swashplate at the angle needed to maintain leakage flow. This is about an additional 10 kPa
(15 psi).
7. Adjustments to pump output should not be made based on the results of this test. Instead, if the
results are not acceptable, the Margin Pressure Test should be run.
2. Stop the engine and move the control levers to all positions to release system pressure.
3. Install a 0 to 25 000 kPa (0 to 3600 psi) gauge in pump discharge pressure tap (1).
5. Move all control levers (one at a time) except boom down in both directions to initiate a stall
condition.
If the pressure readings are all too low or too high, the pressure spool in the compensator valve needs
to be adjusted. See Compensator Valve Adjustment.
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2. Stop the engine and move the control levers to all positions to release system pressure.
3. Install 6V3965 Nipple and 3J1907 Seal to system pressure port (1) and signal pressure port (3).
4. Connect 6V3965 Differential Pressure Gauge to system pressure tap (1) and to signal pressure tap
(3).
5. Start the engine and run at low idle rpm. Check for leaks.
8. Raise the boom control lever to a position between HOLD and FULL RAISE positions. Read the
gauge. This is the margin pressure or the difference between pump discharge and signal pressure from
the pump. the margin pressure should be 2100 ± 100 kPa (305 ± 15 psi).
9. If margin pressure is not correct, see Compensator Valve Adjustments in this section.
NOTE: After performing compensator valve adjustments, recheck the margin pressure.
NOTICE
Pump compensator valve (2) can be tested by running one of the pump discharge tests. The high
pressure stall test will tell if the pressure spool in compensator valve (2) needs adjusted. The margin
pressure test and low pressure standby test will tell if the flow spool in compensator valve (2) needs
adjusted.
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Compensator Valve
(4) Adjusting screw. (5) Locknut. (6) Adjusting screw. (7) Lock nut.
2. Stop the engine and move the control levers to all positions to release system pressure.
3. Remove adjusting screw (6) cap. Loosen locknut (7) and turn the adjusting screw (6) clockwise to
increase the pressure setting and counterclockwise to decrease the setting.
4. Repeat the high pressure stall test to make sure the pressure setting is 20 700 ± 350 kPa (3000 ± 50
psi).
5. When the pressure is adjusted correctly, stop the engine. Tighten locknut (7) and replace cap.
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3. Remove adjusting screw (4) cap. Loosen locknut (5) and turn adjusting screw (4) clockwise to
increase the pressure setting and counterclockwise to decrease the setting.
5. Repeat the margin pressure test to make sure the pressure setting is 2100 ± 100 kPa (305 ± 15 psi).
6. When the pressure is adjusted correctly, stop the engine. Tighten locknut (7) and replace cap.
Relief Valves
There is no main line relief valve. The pressure spool of the compensator valve acts as a main line
relief. It limits system pressure to 20 700 kPa (3000 psi). This can be checked on the machine without
supplemental pump pressure. The boom, head end relief valve, is the only other implement relief that
can be checked on the machine without supplemental pump pressure. All other implement relief
valves are set above the pump compensator spool setting. These all require supplemental pump
pressure to check.
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Bench Test
1. Lower all implements and stabilizers to the ground.
2. Stop the engine and move all the control levers to all positions. This releases system pressure.
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7. Slowly increase pressure. Note the pressure the relief valve opens. Make an adjustment if needed.
On Machine Tests
The boom, head end relief valve can be checked on the machine without supplemental pump pressure.
Use the procedure that follows:
2. Stop the engine and move all the control levers to all positions. This releases system pressure.
4. Install a 0 to 28 000 kPa (0 to 4000 psi) gauge in signal line pressure tap (1).
10. See the chart for correct pressure settings and tolerances.
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Use the following procedure to check all implement relief valves except the boom head end.
The testing location will change for each relief valve circuit. There are two possible fitting sizes used
depending on the circuit being tested.
Adapter Assemblies
(26) 1P2375 Quick Disconnect (male). (27) 5B1309 Coupling. (28) 8T4238 Adapter. (29) 6V8632 1"-14 thd Connector.
(30) 6V8639 13/16"-16 thd Connector. (31) 1P2376 Quick Disconnect [female (not shown)].
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3. Stop the engine and move all control levers to all positions. This releases system pressure.
5. Break the circuit being tested at the cylinder connection. For example, if the boom head end relief
valve is being checked, disconnect the line or tube where it connects to the head end of the cylinder.
Some oil may drain from the line when disconnected.
6. Install the right adapter assembly into the hose or tube that goes back to the control valve. Make
sure the right O-ring is installed correctly. Do not install adapter into the cylinder.
7. The female end of quick disconnect (31) should be connected to 3S6224 Pump Hose.
8. Connect quick disconnect (31) to quick disconnect (26). This now completes the circuit from the
supplemental pump to the control valve.
10. Slowly increase pressure. Note the pressure the relief valve opens at. Check this actual pressure to
the chart.
NOTICE
Pump 3S6224 only has a two gallon reservoir. Pump damage may
result if run with an empty reservoir.
Adjustments
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416B Backhoe Loader 8SG00001-11999 (MACHINE) POWERED BY 3054 Engine(S... Page 30 of 30
3. Turn adjusting screw (34) clockwise for an increase. Turn adjusting screw (34) counterclockwise
for a decrease in the pressure setting of the relief valve.
4. After screw (34) is turned for an adjustment, tighten locknut (33) and re-test the adjustment.
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