Hydraulic Testing

TLB840R

Issue Date: 27-Oct-2014

Model: TLB840R
Language: English (en)
Revision No. 1.0
Original Instruction
TLB840R Hydraulic Testing

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.
TLB840R Backhoe Loader

TLB840R Mechanical Inloader Valve

The basic steps to follow are:-
1. Check the Main Relief Valve Pressure 250 bar @ 1800rpm.
2. Check the Inloader Valve Pressure @ 1800rpm 207 (-0 +7 bar).
3. Steering at full lock @ 1800rpm 175-180bar.

Unfortunately we do not have any unused ports on the valves to read these pressures.

For main pressure P1 (250bar) you could either T into the P1 inlet port connection, or
the feed to the pressure reducing valve & pilot supply.
For P2 (207bar) you would have to use the P2 inlet.
TLB840R Test Point Locations

Test fitting for inloader

pressure 207bar 7/8 x 16UNF

Test fitting for Steering x 16UNF

Test fitting for main pressure 250bar 7/8 x 16UNF
To test main pressure relief valve.

Connect into the tee connection on the first section of the loader valve.
Install a gauge that is capable of 0-350 bar pressure.
With the pump switch on single pump, operate the bucket cylinder fully.
You should get a reading of 250 bar (-0 +5bar) @ 1800rpm.

If not, this can be adjusted at P1 PRV

All adjustments must be performed with the engine stopped.
Remove outer cap & slacken locknut.
Adjust using flathead screwdriver (screw clockwise/in to raise pressure, anti-
clockwise/out to lower pressure).
Tightening the locknut each time, or damage will occur.
When finished ensure locknut is torqued correctly (18 ft-lbs/25Nm), refit cap &
tighten cap (18 ft-lbs/25Nm).

5
 Add test fitting inline here for inloader
pressure 207bar 7/8 x 16UNF

Add test fitting inline here for main

pressure 250bar 7/8 x 16UNF

P2 PRV 207bar

P1 PRV 250bar
To test the inloader pressure.

Connect into the tee connection on the second section of the loader valve.
Install a gauge that is capable of 0-350 bar pressure.
With the pump switched to twin pump mode, operate the bucket cylinder fully.
You should get a reading of 207 bar (-0 +7bar) @ 1800rpm.

If not, this can be adjusted at P2 PRV

All adjustments must be performed with the engine stopped.
Remove outer cap & slacken locknut.
Adjust using flathead screwdriver (screw clockwise/in to raise pressure, anti-
clockwise/out to lower pressure).
Tightening the locknut each time, or damage will occur.
When finished ensure locknut is torqued correctly (18 ft-lbs/25Nm), refit cap &
tighten cap (18 ft-lbs/25Nm).

7
 Add test fitting inline here for inloader
pressure 207bar 7/8 x 16UNF

Add test fitting inline here for main

pressure 250bar 7/8 x 16UNF

P2 PRV 207bar

P1 PRV 250bar
To test steering pressure.

Connect a tee union into the small union on the steering priority valve.
Attach a 0-300 bar pressure gauge.
Operate the steering orbitrol valve until full lock is reached.
The pressure should be around 180bar (5bar).

If not you need to adjust the steering pressure at the steering orbital valve.

Steering PRV

9
 Hydraulic Cylinders

QTY
CLOSED Rod eye Rod eye Working
PART NUMBER IF (PER Bore ROD STROKE Pin size
CYLINDER CURRENT SPEC MACHIN
LENGTH CUSHIONING (mm)
width diameter pressure
(MM) (MM) (MM) (mm) (mm) (Bar)
(MM)
E)

ARM EXTENSION T105502 1 70 45 1710 1040 No 50 84 90 250

LOADER LIFT 80x50x785 6112580M91 2 80 50 1060 785 No 40/50 65 90 250
LOADER BUCKET TILT CYLINDER T137612 1 95 50 795 472 Yes / HE 40mm from cap 50 83 100 250
STABILISER CM T105504 2 95 60 755 485 No 38.2 73 90 250
BOOM T105506 1 115 60 1250 940 Yes / HE 50 80 110 250
DIPPER T105507 1 115 60 990 680 No 50 80 110 250
SLEW - Potential new spec for 6112582M91 6111073M91GY03 2 90 45 127 225 Yes / HE 55 73 100 250
BUCKET T105503 1 85 60 1065 755 No 50 83 106 250
BUCKET - REAR Potential new spec for T105503 T137614 1 80 55 1065 755 No 50 83 106 250

Flow Requirement of Attachment

Maximum Operating Speed
Setting of Engine (RPM) Ltr/min (Gal/min)

Auxiliary Hydraulic 800

TLB840R
46.0 (12.1)
Flows Rates 900 52.0 (13.7)
1000 58.0 (15.3)
1100 64.0 (16.9)
1200 70.0 (18.5)
1300 75.0 (19.8)
1400 81.0 (21.4)
1500 87.0 (23.0)
Hydraulic Service Speeds

TLB840 Theoretical
Current Competitors TLB 840R Actual Flow Cyl Volume Time
s s s lpm l s
Boom Down (ext) 3.01 3.22 4.44 103 9.76
Boom Up (ret) 3.26 2.46 3.54 103 7.11
Backhoe @1800rpm

Arm In (ext) 3.62 3.38 4.5 103 7.06 4.11

Arm Out (ret) 2.88 2.65 3.34 103 5.14 2.99
Bucket Crowd (ext) 2.33 2.8 2.53 103 3.80 2.21
Bucket Dump (ret) 1.48 1.82 1.63 103 2.00 1.17
Slew (mean) 8.68 2.87 6.22 2.50
Tele out (ext) 2.70 2.12 2.48 103 4.00 2.33
Tele in (ret) 2.70 1.75 2.89 103 2.35 1.37

Loader Lift (ext) 2.82 4.13 3.94 135 7.89 3.51

@2200rpm
Loader

Loader lower (ret) 2.15 2.45 2.46 135 4.81 2.14

Loader Bucket Crowd (ext) 2.13 2.8 1.82 135 3.35 1.49
Loader Bucket Dump (ext) 2.56 1.97 1.48 135 2.42 1.08

Current, competitor & predicted data supplied by Terex

Service times for TLB840R taken from TLB840 Mule machine, current on 27 May 14 (updated pump & cylinders)
Theoretical times do not allow for acceleration or engine lugdown
Typical system flow in neutral vs engine speed:
Terex Construction (Coventry)
ProLogis Park
Coventry
CV6 4BX
www.terex.com

Created by; Clive Oldham