Loader Hydraulic Training Courseware 2011

Loader Hydraulic Training Courseware
2011
Main Content
Suitable Group
Training Objectives
Contents
Evaluation Topics
19/05/2015
Suitable Group
This course is suitable for domestic and foreign intermediate and

above technical service personnel
It also applies to…
19/05/2015
Main Content
Suitable Group
Training Objectives
Contents
Evaluation Topics
19/05/2015
Training Objectives
1. This training course is expected to have 12 hours.

2. After training of this course, students should master the following main
knowledge points:
（1）Basic knowledge of hydraulic system
（2）Structure and principle of LG hydraulic system
（3）Common failure and troubleshooting of systems and components
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Contents
Basic Knowledge of
1 1 Hydraulic
Transmission
Hydraulic
2 System Introduction of LG
Loader
2015/5/19 19/05/2015
Part 1 Basic Knowledge of Hydraulic
Transmission
Basic Principle of Hydraulic Transmission
1
2 Composition of Hydraulic Transmission System
1
3 Advantages of Hydraulic Transmission System
Disadvantages of Hydraulic Transmission

4 System
5 Hydraulic Medium
6 Hydraulic Power Components
7 Hydraulic Control Components

8
Hydraulic Actuating Components
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Ⅰ. Basic Principle of Hydraulic Transmission
● A machine is basically made up of four parts, including prime motor,

transmission device, working mechanism, and assistant mechanism.
The purpose of prime motor is to change various forms of energy into

mechanical energy, which is power supply of the machine. Working
mechanism works outside with mechanical energy. Transmission device
between prime motor and working mechanism transfers power and
controls.
There are many transmission types. Transmission can be divided into

mechanical transmission, power transmission, pneumatic transmission and
liquid transmission by parts or working medium.
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Ⅰ. Basic Principle of Hydraulic Transmission
● Transferring and controlling energy with liquid as working medium is

called liquid transmission.
It can be divided into hydraulic pressure transmission and hydraulic

transmission by principle. Hydraulic pressure transmission mainly
delivers power with liquid pressure. Hydraulic transmission mainly
transfers power with kinetic energy of liquid.
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Ⅰ. Basic Principle of
Hydraulic Transmission
● Take hydraulic jack for example to
illustrate principle and features of
hydraulic transmission.
1. Force transmission follows Pascal's
Principle
1）
）Thrust on piston equals oil pressure times
piston area.
2）
）P, oil pressure, depends on external load. Figure 1-1 Working Principle of Oil Jack
2. Loading speed transfers according to the 1-oil tank 2-control valve 3,6-cylinder 4,7-plunger 5-lever
8,9-one-way valve 10,11-pipelines
principle of equal liquid volume after
changes. Its speed depends on quantity Pressure：：P=F1/A1=F2/A2；；(Pascal's Principle)
Quantity of flow：
：Q=A1V1=A2V2; (V=S/t)
of flow. Ignoring loss, hydraulic
(the Principle of Continuity )；
；
transmission force is irrelevant with
Power：
：P＝
＝V1F1=V2F2=PQ ；
speed.
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Ⅱ. Composition of Hydraulic Transmission System
1. Hydraulic Power Supply
Components converting mechanical energy into liquid pressure. Typical
component is hydraulic pump.
2. Control Components
Control force, movement speed and direction actuating components by
controlling pressure, flow quantity and direction of fluid. Pressure, flow
quantity and direction usually control hydraulic valve.
3. Actuating Components
Components converting liquid pressure into mechanical energy,
including hydraulic cylinder moving in a straight line and hydraulic
motor with rotation movement.
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Ⅱ. Composition of Hydraulic Transmission System
4. Assistant Components
Other devices besides the above three components to guarantee
normal operation of the system in the system have delivering, storage,
heating, cooling, filtration, measurement and other functions, such as
pipeline, connector, fuel tank, radiator, filter, etc.
5. Working Medium
Deliver energy and signal with it.
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Ⅲ. Advantages of Hydraulic Transmission System
1. Unit power is light in weight, which means large force and torque can be obtained with
lighter equipment weight.
2. Small inertia, fast starting and braking due to its small volume and light weight.
3. Stepless speed regulation is easy during operating process with a large speed regulation
range.
4. Linear reciprocating motion can be easily achieved with the help of hydraulic cylinder with
simple structure.
5. Easy to realize automation
6. Easy to achieve overload protection. Work is safe and reliable.
7. Hydraulic transmission can layout transmission mechanism flexibly.
8. Liquid working medium with elasticity and vibration absorbing ability makes hydraulic
transmission smooth and reliable.
It can be lubricated by itself during operation. Easy heat dissipation and long service life.
9. Easy to realize standardization, serialization and universalization. Easy to design,
manufacture and market.
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Ⅳ. Disadvantages of Hydraulic Transmission System
1. Low transmission efficiency (75% ~ 80%). Leakage and environmental pollution.
2. Largely influenced by temperature change during operation.
3. Reliability of hydraulic system is still not as good as that of power transmission and
mechanical transmission.
4. Hydraulic components have high requirements to manufacturing accuracy and high
manufacturing cost. Use and maintenance require a certain professional knowledge and
a higher level of skill.
5. Acquisition and transfer of hydraulic energy is not as convenient as that of electricity.
Due to pressure loss and other reasons, hydraulic energy should not be transmitted
over a long distance.
6. Components, accessories and working medium in the hydraulic system work in a
closed system. Failures are difficult to discover in time. Failure causes are difficult to
determine.
7. Hydraulic transmission is sensitive to pollution of hydraulic oil and easy to have
failures.
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Ⅴ. Hydraulic Transmission Medium
1. Functions of Hydraulic Medium
• Energy and signal transmission;

• Lubricate hydraulic components, and reduce friction and wear;
• Heat dissipation;
• Corrosion prevention;
• Sealing of clearance in hydraulic components to prevent dual friction;
• Transmission, separation and precipitation of non-soluble
contaminants; and
• Provide diagnosis information for component and system failure.
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2. Types of Hydraulic Medium
• One is flammable hydrocarbon hydraulic oil (mineral oil type and

synthetic hydrocarbon type);
• Another is nonflammable (or fire resistant) hydraulic fluid.
• Nonflammable fluid includes aqueous (such as HFA, HFB and HFC)
and non-aqueous synthetic fluid（
（HFD）
）.
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3. Main Performance of Hydraulic Medium
1）
）Viscosity
2）
）Abrasion resistance
3）
）Oxidation stability and thermal stability
4）
）Demulsibility and hydrolytic stability
5）
）Defoaming
6）
）Anti-corrosion
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3. Main Performance of Hydraulic Medium （Continued）
）
7）
） Shear stability
8）
） Material compatibility
9）
） Filtering property
10）
） Other performance requirements
Other requirements include flame resistance, resistance to low temperature,
radiation resistance (radioresistant) stability, nonpoisonous and tasteless,
harmless to human body, easy processing of waste fluid and other
performance.
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4. Classification and Features of Hydraulic Oil of Mineral Oil Type
• HH Hydraulic Oil. HH Oil is refined mineral oil without any additives.
• HL Hydraulic Oil. HL Oil is made from neutral base oil with high refined depth,
and antioxidant and anti-rust . It is anti-corrosive and anti-oxidative type.
• HM Hydraulic Oil. HM Oil is developed from HL anti-corrosive and anti-oxidative
oil.
• HR Hydraulic Oil. HR Oil is HL Oil added with viscosity index additive, which
makes oil viscosity decrease with temperature change.
• HG Hydraulic Oil. HG Oil is HM Oil added with anti-sticking agent (oiliness
solvent or antifriction agent)
• HV and HS Oil. HV and HS Oil are both low-temperature hydraulic oil used over
wide range of temperature variation according to ISO Standard. HV Oil is mainly
used in cold area. HS Oil is mainly used in freezing area.
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5. Reasonable Use and Maintenance of Hydraulic Medium
● Key Points of Reasonable Use
1）
）Identify variety and mark of oil;
2）
）Hydraulic system should be thoroughly cleaned before
liquid filling;
3）
）New oil must be filtered before use;
4）
）Oil cannot be mixed optionally;
5）
）Pollution should be strictly controlled to prevent moisture,
air and solid impurities from entering hydraulic system.
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● Monitoring of hydraulic oil of mineral oil type
Due to mechanical, chemical and physical effect, additive in oil will be
gradually consumed during use and oil will decay. Its performance will
gradually deteriorate, which is characterized by:
1）
）Changes of oil state, such as odor, color and appearance;
2）
）Point of flammability decreases. other oil may be mixed;
3）
）Mechanical impurities increase;
4）
）Viscosity changes；
；
5）
）Acid value increases;
6）
）Demulsibility becomes bad; and
7）
）Defoaming becomes bad.
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● Replacing of hydraulic oil of mineral oil type
• For some main performance parameters of oil should be monitored periodically
and frequently. When deterioration reaches a certain degree, oil must be
replaced. At present, there are generally 3 methods to determine the oil
replacing period.
1) Specify fixed oil replacing period
Specify fixed oil replacing period according to equipment, condition and type of
oil and oil injection quantity, such as half a year, one year or operation of 1000
to 2000h;
2）
）Determine whether to replace oil according to experience and observation of oil
sample; and
3）
）Specify oil drainage index. Determine whether to replace oil according to test
result of oil sample;
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6. Pollution and Protection of Hydraulic Oil
● Pollution of hydraulic oil is mainly caused by the following reasons.
1）
）If sand, scraps, abrasive materials, welding slag, rust slice, dust and other dirt in
pipelines of hydraulic system and hydraulic components are not removed in
washing before use, these dirt will enter hydraulic oil when hydraulic system
works.
2）
）External dust and sand, and oil lead flowing back into the tank pass the
repeatedly stretching piston rod during operation of hydraulic system and enter
hydraulic oil. In addition, dust, cotton lint and other things may enter hydraulic oil
during maintenance due to carelessness.
3）
）Hydraulic system itself also constantly produces dirt, which will directly enter
hydraulic oil, such as wear particles of metal and seal materials, particles
dropping form filter materials, jelly generated due to oxidative deterioration of
fiber and oil caused by oil temperature increase, etc.
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● Harms of oil pollution

Serious hydraulic oil pollution will directly influence work performance of
hydraulic system, cause frequent failure of hydraulic system , and shorten
service life of hydraulic components. Main reason causing these risks are
particles in dirt. For hydraulic components, if these solid particles enter
components, wear of sliding parts of components will be intensified, orifice and
damping hole in hydraulic components may be blocked, or spool will be stuck,
causing hydraulic system failure. Water and air mixing will reduce lubrication
capacity of hydraulic oil reduction, accelerate oxidative deterioration, cause
corrosion, accelerate corrosion of hydraulic components, and make hydraulic
system vibrate or craw.
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● Pollution prevention measures

1）
）Keep hydraulic oil clean before use;
2）
）Keep hydraulic system clean after assembling and before operation;
3）
）Keep hydraulic oil clean during operation;
4）
）Use appropriate oil filter;
5）
）Regularly replace hydraulic oil; and
6）
）Control working temperature of hydraulic oil.
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Ⅵ. Hydraulic Transmission Components
1. Working Principle of Hydraulic Pump
Hydraulic power components provide power supply for the system. They are
indispensable core components of the system. Hydraulic pump is the power
component providing the system with certain flow quantity and pressure.
Hydraulic pump works on the principle of

seal volume change, so it is generally
called volumetric hydraulic pump.
The operation principle is explained with
Figure and gear pump.
Figure
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2. Features of Hydraulic Pump
1）
）With several seals and can periodically change space;
2）
）Absolute pressure of liquid in the tank must be identical to or greater than
the atmospheric pressure, which is the external condition for volumetric
hydraulic pump to absorb oil.
3）
）Have corresponding assignment mechanism to separate oil absorption
cavity from liquid discharge cavity.
Ensure regular and continuous absorption and discharge of liquid of
hydraulic pump . Hydraulic pumps with different structure principle have
different assignment mechanism.
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3. Main Performance Parameters of Hydraulic Pump
1）
）Pressure
Working pressure, rated pressure and maximum permissible pressure.
2）
）Discharge and flow
Theoretical flow, rated flow, and actual flow
3）
）Power and efficiency
● Power loss of hydraulic pump includes volume loss and mechanical
loss.
● Power of hydraulic pump: input power and output power
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4. Type of Hydraulic Pump
1）
）By structure: Gear pump, vane pump, plunger pump, screw pump, etc.
① Gear pump: Inner gearing gear pump and outer gearing gear pump;
② Vane pump: Single acting vane pump and double acting vane pump;
③ Plunger pump: Axial plunger pump, radial plunger pump and valve oil
distributing valve plunger pump;
2）
）By function: Constant delivery pump and variable pump
gear pump axial plunger pump radial plunger pump
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Ⅶ. Control Components (Hydraulic Valve)
1. Concept
Hydraulic transmission control and regulating components are also

called control valve, valve for short. They are used to control
direction of flow and adjust pressure and flow of fluid of, in order to
satisfy start, stop, redirection, speed regulation, voltage
stabilization, unloading, pressurization, decompression and other
operational needs of actuating components.
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2. Common Features
1）
） In structure, all valves consist of valve body, valve spool (turn valve or
slide valve) and components of driven valve spool movements (such as
spring and electromagnet).
2）
） In working principle, relationship among opening size, pressure
difference between inlet and outlet of valve and flow through valve of all
valves comforts to orifice flow formula, but different valves have
different control parameters.
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3. Performance Parameters and Basic Requirements of
Hydraulic Control Valve
● Performance Parameters
① Nominal pressure Maximum working pressure allowed by long-term reliable
work of hydraulic control valve , which is limited by intensity of valve. Actual
permissible maximum working pressure is also related to other factors, such
as reversing reliability of reversing valve and pressure regulating scope of
pressure valve.
② Nominal diameter Unit of nominal diameter of hydraulic control valve is mm. A
certain nominal diameter represents a certain of flow capacity, which is
permissible maximum flow (nominal flow). It should be pointed out that, valves
with the same nominal diameter may have different nominal flow because of
their different functions.
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3. Performance Parameters and Basic Requirements of
Hydraulic Control Valve
● Performance requirements
a. High action sensitivity. Reliable to use. Small impact and vibration during
operation. Low noise.
b. When valve port is closed, sealing should be good. When valve port is opened,
direction valve should have small fluid flow pressure loss, direction valve
should have good core stability.
c. Controlled parameters (pressure or flow) should have high precision and
small fluctuation when influenced by outside interference.
d. Compact structure. Convenient to install, debug and maintain. High
universality.
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4. Classification of Hydraulic Control Valve
There are many varieties of control valves used in hydraulic transmission, which can
be classified by characteristics. It is the most common to classify by purpose of
control valves.
（1）
）Directional control valve (such as one-way valve and reversing valve);
（2）
）Pressure control valve (such as overflow valve, pressure reducing valve and
sequence valve);
（3）
）Flow control valve（
（such as throttling valve, flow speed control valve and flow
distributing and collecting valve );
They can also be classified by structure, operation mode, connection mode, control
mode, adjustability of output parameters, etc. Different combination valves can be
composed according to needs.
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5. Pressure Control Valve
• Concept：
：Valve used to control fluid flow pressure in the hydraulic system
or control.
• Common Points：
：Work in the principle of balanced liquid pressure and
spring force on valve core.
• Classification：
：
Overflow valve－
－safety valve and constant pressure valve;
Pressure reducing valve－
－fixed pressure reducing valve, fixed
differential reducing valve and proportional pressure reducing valve;
Sequence valve－
－ sequence valve, unloading valve, back pressure
valve, balanced valve, hydraulic switch, etc.
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1）
） Overflow valve
● Main purpose of overflow valve is pressure leveling (constant pressure valve) or
security protection (safety valve) of hydraulic system.
Almost all the hydraulic systems need to use it. Its performance has very big effect on
normal operation of the whole hydraulic system.
● System figure illustrates the role of overflow valve. Overflow Valve 2 in the left figure
is constant pressure valve. Overflow Valve 2 in the right figure is safety valve.
constant pressure safety valve

valve
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1）
） Overflow valve（
（Continued）
）
● Structure type: can be divided into directly
operated type and pilot operated type by form
of structure and basic action mode.
① Directly operated overflow valve（
（see figure）
）
Directly operated overflow valve controls on-off

movement with pressure oil in the system directly
acting on valve core which is balanced with spring
force. Figure of Low-pressure Directly Operated Overflow Valve
1-nut 2-pressure adjusting spring 3-top cover 4-valve core 5-
valve body
Limited by structure and control precision, directly
operated overflow valve is commonly used in little Function Symbol
traffic system with low pressure (less than 2.5 MPa). Map
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Ⅶ. Control Components
(Hydraulic Valve) Remote
Control
1) Overflow valve（
（Continued）
）
② Pilot operated overflow valve （see figure
for operating principle）
）
● Consist of main valve and pilot valve;
● Damping hole has small diameter (0.6-1.2);
Easy to block. Will not operate normally.
● Advantages in performance (pressure
adjusting range, on-off characteristic, Pilot Overflow Valve
1-spring of main valve 2-main valve core 3-damper hole
dynamic performance, remote control, etc.). 4-valve core of pilot valve 5-sping of pilot valve
Suitable for system with high pressure and

Principle
big flow. Demo
Function
Symbol Map
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2）
）Pressure reducing valve
Pressure reducing valve is a pressure control valve

which makes outlet pressure (secondary pressure)
below inlet pressure (primary pressure). Its function
is to provide two or several different pressure
output with one oil source.
In addition, when oil pressure is unstable, a stable
low pressure can be obtained by putting a pressure
Pressure Reducing Valve
reducing valve in the return circuit. 1-main valve core 2-damper hole 3-vavle core of pilot valve V-flow speed
of valve port
It can be divided into fixed pressure reducing valve, L-outside leakage port
fixed differential reducing valve and proportional

pressure reducing valve by pressure controlled by
Function
pressure reducing valve.
Symbol Map
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2) Pressure reducing valve
As in the picture above, working principle of fixed pressure reducing valve can be considered according to
that of pilot operated overflow valve .
Compare pilot operated pressure reducing value and pilot operated overflow valve. They have the
following differences.
a. Pressure reducing valve keeps outlet pressure basically unchanged, and overflow valve keeps inlet
pressure basically unchanged.
b. When not working, inlet opening and outlet opening of pressure reducing valve are connected. Inlet
opening and outlet opening of overflow are not connected.
c. To ensure pressure setting value of outlet of pressure reducing valve is constant, its spring cavity of
pilot valve needs to be connected to external oil tank separately through drain port. Outlet of overflow
valve is connected to oil tank, so its spring cavity and oil leakage of pilot valve can be connected to
outlet through pass on the valve. It doesn’t need to be connected to external oil tank separately.
★ Other types of pressure reducing valves will not be described.
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Remote
3）
）Sequence valve Control
● Sequence valve is a pressure valve which allows

actuating components to act successively with
pressure. See figure for working principle.
● Sequence valve includes directly operated type
and pilot operated type. The former is generally
used in low pressure system. The latter is used in
middle or high pressure system. Pilot Sequence Valve
● Sequence valve and overflow valve have similar

structure. Compare pilot operated sequence valve
Function Symbol
and pilot operated overflow valve. They have the
following differences.
Map
directly operated external pilot operated
control sequence valve sequence valve
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Remote
3）
）Sequence valve Control
① Inlet pressure of overflow valve is basically unchanged

under through-flow condition. Inlet pressure of
sequence valve is determined by outlet pressure under
through-flow condition. If outlet pressure p2 is much
lower than inlet pressure p1, p1 will be basically
unchanged. When p2 increases to a certain degree, p1
will also increase. p1 = p2 + ∆ p. ∆ p is pressure loss
Pilot Sequence Valve
on sequence valve.
② Overflow valve has internal leakage and sequence
Function Symbol Map

valve needs to separately draw out leakage path,
which is external leakage.
③ Outlet of overflow valve has to return to the oil tank.
pilot operated
Outlet of sequence valve can be connected to load. directly operated external
control sequence valve sequence valve
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4) Pressure switch（
（hydraulic switch）
）
Pressure switch is a electrohydraulic control

component converting oil pressure signal into
electrical signal. When oil pressure reaches setting
pressure of pressure switch, electrical signal will
be sent out to control movements of electromagnet,
electromagnetic clutch, relay and other
components, so as to realize sequential actions of
oil-way pressure relief, reversing and actuating 1—Plunger 2—Lever
components, or close electromotor to stop 3—Spring 4—Switch
operation of system for safe protection, etc.
Structure
Chart
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6. Directional control valve
Concept: Function of directional control valve is to control flow direction of fluid. It

realizes connection or disconnection of pathways with relative motion between valve
core and valve body, to meet requirements of the system.
Type: Directional control valve includes one-way valve and reversing valve.
Left position of three-position

Right position of three-position
four-joint reversing valve

four-joint reversing valve
Reversing Valve（
（2-position
One-way
figure）
）
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1）
）One-way valve
● Classification of one-way valve
① By function: Common one-way valve and hydraulic controlled one-way valve.

② By structure: Tubular (direct connection) and plate (right angle)
Oil Inlet Oil Outlet

P1 P2
Oil Inlet P1 Oil Outlet P2
Tubular Plate
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① Common One-way Valve
● Principle and performance: One-way valve only allows fluid flow to flow in one direction, but not reverse
flow. It can be used for outlet of hydraulic pump, to prevent system oil from flowing back; it can be used
to separate the connection between oil channels, to prevent oil from mutual interference; it also can be
used as the bypass valve to connect parallelly with sequence valve, pressure reducing valve, throttling
valve and speed control valve, so as to assemble into one-way sequence valve, one-way pressure
reducing valve, one-way throttling valve one-way speed control valve, etc.
● Opening pressure: Oil Inlet P1

Oil Outlet
P2
Generally 0.04～
～0.1MPa; Mode
opening pressure of back Oil Inlet P1 Oil Outlet P2
pressure valve is 0.2～
～ Mode
0.6 MPa
Oil Inlet P1 Oil Outlet P2
● Structural form and
(d) Symbol
function symbol: Mode
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● Application:
①Reverse protection of ②Separate oil channels prevent
hydraulic pump interference
On one hand, prevent
system pressure from
influencing normal
operation of pump. On
the other hand, prevent
the liquid from flowing
back to oil tank through
pump when stopped.
③Comprise combination ④Installed in outlet oil line to

valve produce back pressure
One-way valve
can comprise
one-way
combination
valve with
other valves
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②Hydraulic Controlled One-way Valve
● Principle and performance: When the hydraulic controlled port K doesn’t connect pressure oil,
its function is same to common one-way valve. When the hydraulic controlled mouth
connects oil, valve can flow freely in two ways. The figure explains the working principle.
● Structure: Hydraulic controlled piston, plunger, valve, spring etc.
● Application：：Hydraulic controlled one-way valve has characteristics of common one-way
valve. It can also allow forward and reverse fluid flow to go through freely under certain
conditions. Therefore, it is commonly used in pressure maintaining, locking and balanced
circuit of hydraulic system.
symbol P1 P2
K
Structure
Chart
Function Symbol
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2）
）Reversing Valve
Change flow direction and connect or cut off oil channels by relative motion of valve core in
valve body, so as to control reversing, start or stop of actuating components.
● Classification of reversing valve
① By motion mode of valve core relative to valve body:

Steering valve type, sliding valve type, ball valve type, etc.
Reversing
Manual
Valve
② By control method:
Manual, engine driven, electromagnetic, hydraulic, electric
hydraulic, etc;
③ By working position of valve core on valve body:
Two-position valve and three-position valve
Electromagnetic
④ By number of main oil port on valve body:
Reversing
Valve
Two-port valve, three-port valve, four-port valve and five-port
valve.
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● Control mode symbols of commonly used sliding
reversing valve
Engine Drive (Roller

Manual Type) Electric Spring
Hydraulic Pilot Electromagnetic-Hydraulic Pilot

Hydraulic Control Control
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●Working principle of sliding reversing valve
Valve Body Valve Core
Position of Valve Core Valve Port State Piston State
Middle Port A and Port B don’t connect oil Stop
Left P A Right
Right P B Left
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●Station and pathway symbols of main structure of reversing
valve（
（see figure）
）
Big Box Valve body
Small Station
Box
Crossover point of arrow line in the small box or┴
symbol and bounding
Oil port
Oil channels connected （not

always flow direction）
）
┴ Oil channels
disconnected
Head of Normal position（
（valve core without
symbol force);
A, B Oil ports connected to the oil tank；
； Functional chart of three-
position four-port
P, O Oil inlet and return opening reversing valve
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● Principle and type symbols of main structure of reversing valve
Name Structure and Principle Chart Symbol
A
Two-position
two-port
P
A B
Two-position
three-port
P
A B
Two-position
four-port
P O
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● Principle and type symbols of main structure of reversing valve （continued）
）
Name Structure and Principle Chart Symbol
A B
Two-position five-
port O1 P O2
A B
Three-position
four-port
PO
AB
Three-position five-
port O1 P O2
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● The most commonly used six median functions of
three-position reversing valve
Function Median Symbols State, Features and Application of Median
Model Symbols
Port P, A, B and O are all closed；

； Hydraulic
cylinder is locked. Hydraulic pump doesn’t
O
unload.
Port P, A, B and O are Hydraulic pump ; Piston

of hydraulic cylinder is floating. Hydraulic
H
pump unloads.
Port P is closed. Port A, B and O are

connected. Piston of hydraulic cylinder is
Y
floating. Hydraulic pump doesn’t unload.
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● The most commonly used six median functions of three-
position reversing valve（
（continued）
）
Function State, Features and Application of Median
Median Symbols
Model Symbols
Port P, A and B are connected. Port O is

closed. Pump and hydraulic cylinder are
P
connected, which can comprise differential
motion and connect inlet.
Port P and Port O are connected. Port A and

Port B are closed. Piston of hydraulic cylinder
M
is locked. Hydraulic pump unloads.
Port P, A and B are connected. Port O is

closed. Piston of is locked. Hydraulic pump
K
unloads.
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● Several Commonly Used Reversing Valves
① Electromagnetic reversing valve
Valve
Body
Coil
Armature
Valve
Core
Function
Symbol
Three-position four-port Two-position four-port

electromagnetic reversing valve electromagnetic reversing valve
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★ Performance of electromagnetic reversing
valve
◆ AC power type: Convenient to use. Big starting force. Big reversing
impact. Noisy. Low frequency (about 30 times/min). Coil is easy to burn
out when valve is locked or voltage is low.
◆ DC power type: Small reversing impact. High tolerance level of

reversing frequency. Due to constant current, coil is not easy to burn out.
Working reliability is high, but structure is complicated.
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② Hydraulic reversing valve
Hydraulic
controlled Hydraulic
pressure controlled
port pressure
port
Hydraulic three-position four-port

reversing valve
Function
Symbol
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★ Performance of hydraulic reversing valve
Hydraulic reversing valve changes position of valve core with oil pressure. It has
big starting force. When flow of hydraulic controlled oil is big, reversing impact is
big. To control movement speed of valve core and reduce impact, one-way
throttling device (called damper regulator) is usually installed in front of
hydraulic controlled pressure port.
Damper Regulator
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③ Electro-hydraulic reversing valve
Main valve
Pilot valve
（electromagnetic
（electromagn
etic valve）） valve）
）
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★ Principle drawing of electro-hydraulic reversing valve
Control oil
channel
Main oil
channel
Simplified Function
Symbol
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★ Performance of electro-hydraulic reversing
valve
Electro-hydraulic reversing valve is combination of electromagnetic reversing
valve (pilot valve) and hydraulic reversing valve (main valve). Therefore, it can
control the high-power main valve with small-power electromagnet. Oil source and
return oil of pilot electromagnetic reversing valve can be established separately. It
can also be shared with main oil channel.
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④ Engine driven reversing valve（
（motion valve）
）
Oil Inlet
Roller Push Back-moving

Rod Valve Core Oil Outlet Spring
Lift type, two-port, Lift type, two-port,

Roller type, three-
normally closed normally opened
port
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★ Performance of electro-hydraulic engine driven
reversing valve
Purpose of engine driven reversing valve is to move valve core with cam-action
strokedog installed on actuating mechanism, in order to control on-off of oil
channels and control stroke.
Appropriate reversing speed is obtained and reversing impact is reduced by

changing appearance of cam.
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⑤ Manual reversing valve
Self-restoring Mechanical
Type Positioning Type
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★ Performance of manual reversing valve
Manual reversing valve is convenient to use. It is applicable to

occasion with small flow and longer interval.
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◆ Student practice: draw out symbols of
the following reversing valves
1. Two-position two-port electromagnetic reversing valve (normally
closed);
2. Three-position four-port manual reversing valve（
（Median function：
：
H);
3. Three-position four-port hydraulic
hydraulic（（with damper
damper）） reversing valve
（Median function：：P）；
）；
Figure 1 Figure 2 Figure 3
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7. Flow Control Valve
● Overview: Movement speed of actuating components in the hydraulic

system is determined by oil flow entering actuating components. Flow
control valve is a hydraulic valve controlling the flow by changing flow
area of port (local resistance of throttling port) or length of channels.
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7. Flow Control Valve (Continued)
● Classification: Common throttling valve, pressure compensation speed control valve,

overflow throttling valve, temperature compensation speed control valve, flow
distributing and collecting valve, etc. Functional chart of all kinds of valves is shown
as below. Working principle of each flow control valve will not be described. See
teaching material.
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Ⅷ. Hydraulic Actuating Components
• Function：
：Convert pressure of liquid into mechanical energy. Make linear,
swinging and rotating with motion drive working mechanism.
• Type: Hydraulic cylinder and motor.
1. Hydraulic Cylinder
1）
）Type of Hydraulic Cylinder
Hydraulic cylinder has the following types by structure and function.
● Single-acting hydraulic cylinder ● Double-acting hydraulic cylinder
● Swinging hydraulic cylinder ● Combination hydraulic cylinder
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2）
）Single-rod Piston Cylinder
The piston only has piston rod at one end.
There are cylinder fixed type and piston
rod fixed type. Single-rod piston cylinder
is a commonly used oil cylinder type. Sketch Map of Single-rod
Piston Cylinder
2. Motor
1）
）Features of Motor
Hydraulic motor is a device converting fluid pressure into mechanical energy. In
principle, hydraulic pump can be used as hydraulic motor, and hydraulic motor
can be also used as hydraulic pump. In fact the same type of hydraulic pump
and hydraulic motor have similar structure, but by the two have different work
situation, which makes the two different in structure. Main differences are as
follows:
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1）
）Features of Motor
• Hydraulic motor generally needs forward and reversing rotating, so it should

have symmetry in the inside structure. Hydraulic pump usually rotates in single
direction. It doesn’t have this requirement.
• In order to reduce oil absorption resistance and radial force, inlet port of
hydraulic pump is generally larger than outlet port. Pressure in low-pressure
cavity of hydraulic motor is slightly above atmospheric pressure, so it doesn’t
have the above requirement.
• Hydraulic motor is required to operate normally at a wide speed range. Therefore,
we should adopt hydraulic bearing or hydrostatic bearing. Because when motor
is at low speed, if hydraulic bearing is used, it is not easy to formed lubrication
film.
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1）
）Features of Motor (Continued)
• Vane pump rotates at high speed with blades to generate centrifugal force, so that
blades always adhere to the inner surface of stator to seal the oil and form working
volume. If it is used as motor, spring must be installed on root of blades of hydraulic
motor, in order to ensure that blades always adhere to the inner surface of stator and
motor can normally start.
• Hydraulic pump should have self-priming capacity in structure , and hydraulic motor
doesn’t have this requirement.
• Hydraulic motor must have large starting torque. Starting torque is the torque that
can be output by motor axle when motor starts from static state. The torque is
generally larger than that under operation condition under the same operating
differential pressure. Therefore, in order to make the starting torque near to torque
under operation condition, it is required that motor torque has small pulsation and
small internal friction.
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2）
）Type of Motor
Hydraulic motor can also be divided into gear type, vane type, piston
type and other types by structure types.
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3）
）Axial Piston Motor
Structure of axial piston motor is basically
same to that of axial piston pump, so its
varieties are same to those of axial piston
pump. It can be also divided into straight axial
piston motor and bent axial piston motor. See
figure for working principle (see textbook for
content).
F1=p*A*tanγ Torque force of cylinder Working Principle of

generated by piston Swash-plate Axial Piston
Motor
T1=F*r=F*R*conφ Torque of cylinder
=p*A*R*tanγ*conφ generated by piston
Total torque actually output

T=ηm*∆p*V/2π by motor
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Contents of Training
Courseware
Basic Knowledge of Hydraulic

1 1
Transmission
Hydraulic
2 System Introduction of LG
Loader
2015/5/19 19/05/2015
Part 2 LG Hydraulic
System Introduction
Working Device Hydraulic
1 System
1
Steering Hydraulic
2
System
3 Case Analysis
2015/5/19 19/05/2015
Ⅰ. Working Hydraulic System
1. Type
Loader working device hydraulic system has two types by control method of
multiple unit valve .
1) Manual (Flexible Axle) Control Working Hydraulic System;

918, 933, 936, 40F, 952, 953, 956 and other types of our company
use this type.
2) Hydraulic Pilot Control Working Hydraulic System;

Exported 918, 936, 938, 958, 959, 968, 969, 979 and other types of our
company use this type.
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2. Principle of Working Hydraulic Working and Steering
System Hydraulic System Demo
Manual manipulation of flexible axel makes swing

arm slide valve and rotating bucket slide valve of
multiple unit valve do reciprocating movement,
connects ports of oil inlet and slide valve of multiple
unit valve, changes flow direction of hydraulic oil,
and realizes different actions of working device.
①When flexible axel and rotating bucket reversing

valve of multiple unit valve are in the middle position,
flexible axel and bucket remain in the original
position. At this time, hydraulic oil in working oil
pump directly returns to oil tank through middle Principle Drawing of Working
channel of multiple unit valve. Hydraulic System
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2. Principle of Working Hydraulic System
(Continued)
② Swing arm can lift, descent or float by controlling reversing slide valve on
swing arm.
③ Bucket can turn forward and backward back controlling rotating bucket
reversing valve. Double-acting safety valves are installed on oil channels in
front and back cavity of rotating bucket oil cylinder to protect from
overloading of big and small cavity of rotating bucket cylinder caused by
rotating bucket link mechanism.
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3. Composition of
Working Hydraulic
System
● Gear pump（
（working
pump））
● Multiple unit valve
● Oil cylinder (swing arm
cylinder and rotating
bucket cylinder））
● Oil tank（
（shared with
steering system））
● Pipe, filter and other
accessories
Describe the components
according to system
principle drawing
System Principle Drawing
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Gear Pump（
（Working Pump）
）
● Main parameters（
（take LG953 and CBGj3166 for example）
）
1）
）Rated pressure （18MPa）
）
2）
）Rated rotate speed（
（2200r/min）
）
3）
）Displacement（166ml/r）
）
★ Liquid volume discharged per round of hydraulic pump
4）
）Flow（
（265 l/min)
★ Flow= Displacement×Rotate speed
★ Module of transfer gear with 42 gear teeth, working pump spindle

with 42 gear teeth and steering pump gear with 48 gear teeth are all 4.
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● Working Principle of Gear Pump
Gear pump is a hydraulic pump widely used in hydraulic system. It is generally made into quantitative
pump. By structure, gear pump can be divided into outer gearing gear pump and inner gearing gear pump.
Outer gearing gear pump is most widely used. working principle of outer gearing gear pump will be
explained with outer gearing gear pump.
It generally has separate three-piece structure. Three-piece

means front and back pump cover and pump body. A pair of gear
are installed in the pump body. They have the same number of
gear teeth and gear into each other. Their width are close to that
of pump body. This pair of gear form a seal chamber with covers
at two ends and pump body. Tooth point of gear and gearing line
divide the seal chamber into two parts, which are oil absorption
cavity and oil pressure chamber. Two gears are respectively
Demo
fixed on driving axle and driven axle supported by needle roller Map
bearing with keys. Driving axle is driven by power machine.
Figure of Outer Gearing Gear
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● Working Principle of Gear Pump (Continued)
When driving gear of the pump rotates according to direction of arrow as shown in the figure,
teeth on the right of gear (oil absorption cavity) will throw out of gear and gear teeth will exit
tooth space, so that sealing volume will increase and partial vacuum will be formed. Under
the action of external atmospheres, oil in the oil tank will enter tooth space through oil
absorption channels and oil absorption cavity. With gear rotating, inhaled tooth between oil
was brought to the other side, into the pressure oil chamber. Then rotation of gear, oil
absorbed into tooth space will be brought to the other side and enter oil pressure cavity. At
this time, gear teeth are engaged each other, so that sealing volume will decrease and some
oil in the gear will be squeezed out, which forms oil pressure process of gear pump. During
gear engagement, tooth contact line will separate oil absorption cavity and oil pressure
cavity for oil distributing. When driving gear of gear pump is driven by power machine, the
gear meshing side, withdraw because sealing capacity greaten is constantly from tank in oil
absorption, gear meshing side, the side of teeth throwing out of gear will continually absorb
oil from oil tank because sealing volume increases. The side with gear engagement will
continually discharge oil because sealing volume decreases. This is the working principle of
gear pump.
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● Common fault analysis of loader gear pump
No. Failure Reason Troubleshooting Method
Hydraulic oil decreases. Transmission Test pressure. Change working

1 Oil seal is broken
oil increases. pump (or steering pump)
Hydraulic oil increases. Transmission Test pressure. Change working
2 Oil seal is broken
oil decreases. pump (or steering pump)
Oil leakage on joint surface of pump

3 O ring or bolt is loose Change O ring or fasten bolt
body
4 Oil leakage of pump body Pump body cracks Test pressure. Change pump
Overwear of spline shaft Change spline shaft or pump
Overwear of side plate Change side plate or pump
5 Abnormal sound of pump Poor size of spline shaft. Change spline shaft or pump
Push the shaft.
Change bearing or pump
Bearing is broken
Internal leakage caused

Insufficient flow of pump causes weak
6 by overwear of gear or Change pump (or broken parts)
and slow lifting
side plate
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Multiple Unit Valve
1）
）Type
● Double-joint multiple unit valve-used in loader with common
functions
● Multiple unit valve-used in loader of multifunctional working device
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Multiple Unit Valve
2）
） Composition and Functions
● Double-joint valve: Consisting of rotating bucket reversing slide valve, swing
arm reversing slide valve, safety valve, overload supplement valve, valve body,
etc.
● Rotating bucket reversing slide valve is three-position valve. It controls middle
standing, front tilting and back tilting of bucket.
● Swing arm reversing slide valve is four-position valve. It controls middle
standing, lifting, dropping and floating of swing arm.
● Reversing action of slide valve is realized by manual control of flexible axle (or
pilot oil pressure). Rotating bucket slide valve returns to the middle position with
spring. Swing arm slide valve returns to the middle position by manual control
and ball locking.
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Piping Map of Working Device Hydraulic System
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Profile Map of Double-joint Multiple Unit Valve（
（DF32）
）
Action
Demo
supravergence
Turn below
Seal off
1 Swing arm slide
valve
2 Turning slide
Seal off
Descend
Lifting
Float
valve
3 Turn cylinder
small cavity
overload valve
4 Turn cylinder big
cavity overload
valve
5 Safety valve
6 Valve body
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Safety Valve
1）
）Safety valve of multiple unit reversing valve is between oil inlet cavity and returning
cavity. When system pressure is greater than setting pressure, safety valve will open
and overflow, so that working pressure of the system will be within the scope limited
by the setting pressure for safeguard of system. See structure chart for working
principle of safety valve.
2）
）Pressure control: realized by adjusting pressure adjusting screw to change spring
preload.
3）
）Setting pressure of safety valve
of different types of LG Loader
★ LG956 and LG953 Loader
System setting pressure is 18MPa;
★ LG952 Loader
System setting pressure is 16MPa；
；
★ LG933 and LG936 Loader
System setting pressure is 16MPa. Structure Chart Demo Map of
of Safety Valve Safety Valve
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Overload Supplemental Valve
Overload supplemental valve (also called safety valve) is the combination of pilot type
overflow valve and on-way valve. It is installed on multiple unit reversing valve through
bolt. Two ports are respectively connected to oil channels in big and small cavity of turn
cylinder in multiple unit reversing valve . The other two ports are connected to oil-
returning circuit.
Profile Map of Overload

Supplemental Valve
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Overload Supplemental Valve (Continued)
1）
）Functions of Overload Supplemental Valve
● When turn reversing valve is in the middle position, front and back
cavity of turn cylinder are closed. At this time, if the bucket is affected by
external impact load, sharp rise of partial pressure can be effectively
prevented.
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● When swing arm lifts or drops, oil drainage and oil supplementation will be automatically
completed. If swing arm lifts to a certain position, piston rod of turn cylinder will be pulled
out, which will cause pressure rise in front cavity of turn oil cylinder. When the pressure
increases to a certain degree, hydraulic oil cylinder or hydraulic pipelines may be
destroyed. Due to double-acting safety valve, oil trapped in front cavity of hydraulic oil
cylinder can return to hydraulic oil tank through safety valve. When volume of front cavity
of oil cylinder reduces, volume of back cavity will increase, forming partial vacuum.
Supplemental valve of double-acting safety valve will be opened to supplement hydraulic
oil for back cavity of turn oil cylinder and eliminate partial vacuum.
● During unloading of loader, the bucket can quickly turn down by its weight. When the
bucket quickly turns down, after gravity center of the bucket goes over lower hinge point,
the bucket will turn faster by gravity, but movement speed of turn oil cylinder will be limited
by insufficient oil supple of oil pump. Because supplemental valve of double-acting safety
valve supplements oil timely for front cavity of turn oil cylinder, bucket can quickly turn
down, hit stop block, and realize unloading.
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2）
）Setting Pressure of Overload Supplemental Valve
• Setting pressure of overload valve in big cavity of turn cylinder of LG953, LG956
and LG958 Loader is 21MPa. Setting pressure of small cavity is 12MPa.
• Setting pressure of overload valve in big cavity of turn cylinder of LG952, LG936
and LG933 Loader is 19 MPa. Setting pressure of small cavity is 12MPa.
• Setting pressure of overload valve in big cavity of turn cylinder of LG918 Loader
is 20 MPa. Setting pressure of small cavity is 12.5MPa.
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Basic Failure and Troubleshooting of Multiple Unit Valve (DF)
No. Reason Failure Troubleshooting Method
Pressure setting of safety valve is Adjust pressure of safety valve
low
1
Slide valve of safety valve is locked Take apart, clean and reassemble
Insufficient Pressure adjusting spring is Change new spring
working pressure broken
Pressure loss in system pipelines Change pipelines or adjust
is too large pressure of overflow valve within
permissible pressure scope
Oil supply of system is not enough Check oil source

Port opening is not enough Adjust control mechanism
2 Oil temperature is too high. Take measures to reduce oil
Insufficient Viscosity drops temperature
working flow
Improper selection of oil Change oil
Fit clearance between slide valve Change slide valve or assembly
and valve body is too big according to proper clearance
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(Continued)
No. Reason Failure Troubleshooting Method
Restoring spring is broken or deforms Change spring or assembly

3 Reset failure
Restoring parts are not in the same axle, Change broken parts or
pulled, etc. assembly
Seal ring is broken Change to new parts

Oil temperature is too high. Viscosity Take measures to reduce oil
4 Outside leakage
drops temperature
Flange face installed on port is not well Check fastening and sealing
sealed. of corresponding parts
Fastening screws on joint surfaces are Fasten corresponding parts

blocked or cap of pressure adjusting
screw is loose
5 Big deflection of Clearance between valve body and Change valve rod or
swing arm valve rod of multiple unit valve assembly
increases
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(Continued)
No. Reason Reason Troubleshooting Method
Inner leakage of overload supplemental Disassemble, clean,

6 Bucket drops valve in big cavity of turn cylinder (dirt reassemble or replace
blocked and broken)
Wear and clearance between valve Change valve rod or
body and valve rod of multiple unit assembly
valve increases
7 Bucket is put away Inner leakage of overload supplemental Change supplemental valve.
valve in small cavity of turn cylinder Low pressure
(dirt blocked and broken)
Front tire cannot Setting pressure of overload valve in Increase pressure of
8 support small cavity of rotating bucketis low overload valve in small
cavity
Large amount of leakage in small cavity Change slide valve
of rotating bucket according to proper
clearance
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Oil Cylinder
• Type：
：Hydraulic cylinder used in loader is single-rod piston double-acting oil cylinder.
• Classification: Swing arm oil cylinder, turn oil cylinder and steering oil cylinder.
• Composition：
：Piston double-acting hydro-cylinder generally consists of oil cylinder
body, piston, piston rod guide sleeve, etc.
• Comments：
：In order to analyze the problem, oil cylinder is usually divided into cavity
with rod (or small cavity, the side with piston rod) and cavity without rod (or big cavity).
Pressure oil enters left cavity of hydraulic cylinder from Port A and pushes piston to the
right. Hydraulic oil in the right cavity is discharged through Port B.
Structure of Oil Cylinder
1. Back cylinder cover
2. Stop collar
3. Lantern ring
4. Snap ring
5. Piston 6. O Ring
7. Back-up ring 8. Stop dog
9. Ax seal ring
10. Oil cylinder body
11. Port stand
12. Guide sleeve
13. Cylinder end
14. Dust ring
15. Piton rod
Buffer Plunger 16. 16. Screw
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Hydraulic Pilot Control Working Hydraulic System
1）
）Features of the System
Working hydraulic system of LG918, LG933, LG936, LG956L, LG958L and other loaders, which
are export products of our company, uses pilot control working hydraulic system. main oil
channels with high pressure and big flow are controlled by pilot oil channels with low pressure
and small flow. Compared with mechanical control hydraulic system, this working hydraulic
system has the following features:
● Pilot control is light, flexible and efficient. Finger control can be realized.
● By pressure-relief type proportional pilot valve control, stroke of valve rod of main valve is in
proportion to control angle of pilot value handle, which means proportional pilot control to
work of main valve is realized.
● Safety valve, overload valve, supplemental valve and one-way valve use insert type structure.
With good generality, it is convenient to maintain.
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）Features of the System (Continued)
1）
● Pilot valve uses overall structure. With a small volume it is convenient to arrange.
● When engine shuts down, drop of swing arm and forward tilting of bucket can be realized
by pressure selecting valve and pilot valve.
● Pilot valve has orientation with electromagnetic iron at lifting position of swing arm and
backward tilting position of bucket. Vertical limit of lifting height of swing arm and automatic
leveling control of bucket at any position can be realized, which simplifies operating
procedures, reduces labor intensity, and avoids energy loss and pressure shock caused by
frequent movement of safety valve.
）System Composition
2）
Composition of pilot control working hydraulic system:
Consists of Working pump, pilot pump. Pilot valve, multiple unit valve, pressure selecting
valve, swing arm cylinder, rotating bucket cylinder, oil tank, pipelines filter and other
accessories. See principle chart of hydraulic system.
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Principe of Hydraulic Pilot
Control System
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Pilot Valve
Pilot valve is equipped with control rod. Rotating bucket control has
forward tilting, middle standing and backward titling positions. Swing
arm control has lifting, neutral, middle standing, dropping and floating
positions. Pilot valve has orientation with electromagnetic iron at lifting,
floating and backward titling position. See figure.
Structure of Pilot Valve
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● Working principle of pilot valve（proportional pilot
control and automatic control of electromagnet)

When pulling the control rod to dropping position, pressure pin will push down pressure
lever. Measurement spring will push down measurement valve core, cut off the channel
between control cavity and oil returning chamber, connect oil inlet cavity to control oil cavity,
guide pressure oil to the end of multiple unit valve, push multiple unit valve to move, and
corresponding reversing action. Meanwhile, oil pressure of control cavity will act on lower
end of measurement valve core, and balance with the force of measurement spring. When
control rod remains in one position, the spring force and control cavity pressure will be fixed,
which is similar to action process of fixed pressure reducing valve. Spring force will change
with pivot angle of control rod. The bigger pivot angle is, the bigger spring force will be and
the higher control cavity pressure will be. Thrust on valve core of multiple unit valve will
increase accordingly, which means stroke of main valve core is in proportion to pivot angle
of control rod of pilot valve, so as to achieve proportional pilot control.
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● Working principle of pilot valve（proportional pilot
control and automatic control of electromagnet)
When control rod is pulled from dropping position to floating position, because this
position has electromagnet positioning, pilot valve will be locked. At this time, oil pressure
at control port will increase. Sequence valve in pilot valve will open. Hydraulic oil in Drain
Hole K of multiple unit valve will enter oil tank through Drain Hole 2C in pilot valve.
Supplemental valve in small cavity of swing arm oil cylinder will open. Port P, A2, B2 and T
will be connected. Swing arm floating will be realized. When pilot valve is pulled out of
floating position and loosen, restoring spring will push up pressure lever. Control rod will
return to the middle position.
When control rod of pilot valve is pulled from whole lifting or bucket collecting position,
control rod will be locked and positioned. When swing arm or bucket reaches limited lifting
height or limited bucket angle, which is close to switch action, magnetic coil will shut off
and lose its magnetism. Control rod will automatically go back to the middle position under
the action of restoring spring.
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Multiple Unit Valve (D32)
• The function of multiple unit valve is changing flow direction of working oil,
realizing different movement direction of turn oil cylinder and swing arm oil
cylinder, and completing corresponding different action of working device,
by different open direction of slide valve under the action of pilot control oil.
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Multiple Unit Valve (D32 Continued)
• There are two-joint multiple unit valve and three-joint multiple unit valve.
Two-joint valve is used for common loader. Three-joint valve is used for
multifunctional work device of loader. As shown in the following profile
structure chart, two-joint multiple unit valve is hydraulic multiple unit valve
with overall structure. It is mainly consists of rotating bucket reversing valve,
swing arm reversing valve, overload valve, supplemental valve and one-way
valve.
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• Rotating bucket reversing valve is three-position valve. It can control middle
standing, forward titling and backward titling action of bucket. Swing arm
reversing valve is four-position valve. It can control middle standing, lifting,
dropping and floating action of swing arm. Movement of slide valve relies on
action of pilot control oil. It restores by spring. Two reversing valves are
connected to oil channels by series-parallel connection. They are at a certain
position under the pressure of pilot hydraulic oil and action of spring.
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● Automatic control of lifting height of swing arm
When swing arm automatically controls lifting
position, work position of slide valve of
multiple unit valve is exactly the same to lifting
position of swing arm. Because control rod of
pilot valve is pulled to whole lifting position,
control rod is locked and positioned at this
time. When swing arm reaches lifting height
limit, and stator fixed on swing arm is close to
switch action, magnetic coil will disconnect
and lose magnetic force. Control rod will move
to the middle position under the action of
restoring spring. Multiple unit valve will lose
control of pilot oil. Lifting of swing arm will Structure of Multiple
Unit Valve
automatically end.
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● Floating of swing arm
When swing arm is at floating position, work position of slide valve of multiple
unit valve is exactly the same to dropping position of swing arm. Because
control rod of pilot valve is at floating position and this position doesn’t have
electromagnet, sequence valve in pilot valve will open. Hydraulic oil in Drain
Hole K of multiple unit valve will enter oil tank through Drain Hole 2C in pilot
valve. Supplemental valve in small cavity of swing arm oil cylinder will open.
Port P, A2, B2 and T will be connected. At this time, piston rod of swing arm oil
cylinder will freely float under the action of external force. When control rod of
pilot valve is pulled out of floating position and returns to the middle position,
floating of swing arm will end.
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● Automatic leveling of bucket

When bucket is at automatic leveling position, work position of multiple unit
valve is exactly the same to backward titling position of bucket. Because
control rod of pilot valve is pulled to whole bucket collecting position, control
rod is locked and positioned at this time. When bucket reaches limited bucket
collecting angle, and stator fixed on turn oil cylinder is close to switch action,
magnetic coil will disconnect and lose magnetic force. Control rod will move to
the middle position under the action of restoring spring. Multiple unit valve will
lose control of pilot oil. Backward titling of swing arm will automatically end.
With this function, at any unloading height, when swing arm drops to ground
shoveling position of bucket, undersurface of bucket will be parallel with
ground.
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Pressure Selecting Valve
● Function: Purpose of pressure selecting valve

is to provide a certain pressure of control oil to One-way
valve
pilot valve, and ensure swing arm on the ground
position when diesel engine shuts off.
● Structure: Pressure selecting valve is installed

in pilot oil channel. Control valve of pressure
selecting valve mainly consists of valve body,
valve core, spring, etc. Port P1 is connected to
One-way
pilot pump. Port Pr is connected to big cavity of valve
swing arm oil cylinder. Port P2 is oil outlet,
which is connected to pilot valve. L is oil
returning port. See structure chart. Structure and Principle of
Pressure Selecting Valve
19/05/2015
● Working Principle
During operation, oil in pilot pump enters Port P1, and flows to pilot valve through valve
centre hole and oil outlet P2. When pressure of oil outlet P2 is greater than 1.5 MPa, valve
core will move left. Port P1 and Port Pr mouth will stagger to close the oil in lower cavity of
swing arm oil cylinder. Port Pr is equipped with one-way valve, in order to prevent reverse
flow of oil.
When diesel engine shuts off, Port P1 doesn’t have oil supple of pilot pump. Pressure will
drop. Under the action of control spring, valve core will return to the connection position of
Port Pr and Port P2. If swing arm in at lifting condition and control rod is at the middle
position at this time , hydraulic oil in big cavity of swing arm oil cylinder will be sealed. At
this time as long as control rod is pulled to dropping position of swing arm, under the
gravity hydraulic oil in big cavity of swing arm oil cylinder will enter pilot valve through Port
Pr and Port P2. Pilot valve controls multiple unit reversing valve, so that valve core of swing
arm is at dropping position. Swing arm can be put down. In this process, valve core of
pressure selecting valve also controls pressure from Port Pr to pilot valve of about 1.5 MPa.
If pressure of oil outlet P2 rises, valve core will move left, throttling damping will be
increased, flow of Port Pr will be reduced, and pressure of oil outlet P2 will be reduced,
which will realize pilot pressure control.
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Ⅱ. Steering System
• Function: Wheel loader steering system is used to control driving direction of
loader. It can make loader run straight steadily and change driving direction
flexibly according to requirements.
• Classification: By steering method, wheel loader can be divided into deflection

wheel steering, skid steering and articulated steering.
• Advantages of articulated steering: Work device is installed on front frame.

When the frame deflects relatively, direction of work device will be always same
to that of front frame, which can help work device to quickly aim at working
plane, reduce distance and time of work cycle, and improve working efficiency
of the loader. Therefore, articulated steering becomes the most widely used
steering method of modern loader.
19/05/2015
●Type of Steering System
Steering system has many varieties. Different types of steering system
respectively represent development level of different hydraulic technique.
At present wheel loader uses the following types of steering system.
① Whole hydraulic steering system consisting of single stable valve and

open center non-reaction steering gear;
② Load sensing whole hydraulic steering system consisting of priority valve
and load sensing steering gear;
③ Load sensing whole hydraulic steering system consisting of priority valve
and coaxial flow amplifying steering gear;
④ Flow amplifying steering system
19/05/2015
1. Whole Hydraulic Steering System Controlled by
Solenoid Valve
1) Composition of System
Whole hydraulic steering system controlled by solenoid valve
mainly consists of hydraulic pump, one-way steady flow
divider valve, BZZ1 (open center non-reaction) whole hydraulic
steering gear, steering oil cylinder, pipelines, etc. See principle
chart of the system.
2)Steering Gear
BZZ Whole Hydraulic Steering Gear is a cycloid
rotary valve whole hydraulic steering gear consisting of servo
valve and pin wheel gear pair. It is current widely used steering
component at home and aboard. It is flexible to operate, energy
saving, compact in structure, reliable, and convenient to install.
Manual steering can be realized after engine shuts off.
System Principle
19/05/2015
●Type of Whole Hydraulic Steering Gear
There are the following major types of
BZZ Whole Hydraulic Steering Gear.
Open center non-reaction （BZZ1）；
）；
Open center reaction （BZZ2）；
）；
Closed center non-reaction（
（BZZ3）；
）；
Load sensing （BZZ5）；
）；
Coaxial flow-amplifying（
（BZZ6）；
）；
and other structural styles
Function symbols are shown in the
figure.
Type Symbol of BZZ
19/05/2015
Structure of BZZ Whole Hydraulic Steering Gear
It is mainly consists of valve body, valve core,

valve pocket, universal driving shaft, guide
spring, pin, rotor, stator, rear cover, etc.
Working principle of steering gear
Structure of Whole Hydraulic

Middle position Steering position Steering Gear
19/05/2015
Correspondence of valve core, valve
pocket , stator and rotor
High
HHigh
H igh Pressure
igh Pressure
PPressure
Pressure
ressure Low
Low
Low
Low
LowPressure
Pressure
P
Pressure
ressure Oil
Oil
OO
Oil
ilOilTrap
Trap
ilTrap
Trap
Trap
19/05/2015
3) Combined Valve Block
Combined valve block is a combined hydraulic component. Connected between
steering oil pump and steering gear, it forms a complete set with whole hydraulic
steering gear. It is generally installed directly on flange of valve body, and makes a
whole with steering gear.
Functions：On one hand, ensure that steering gear and the whole steering system
Functions：
works normally and smoothly under pressure rated; On the other hand, ensure that
steering cylinder and connected pipelines will not be damaged during sudden
overload, and protect steering pump. So valve block is an indispensable hydraulic
component in hydraulic steering system.
19/05/2015
3) Combined Valve Block
Composition of Combined Valve Block：
：
According to different requirements of
steering system, combined types of valve
block are different. Valve block generally
consists of one-way valve, overflow valve
(safety valve), two-way buffer overload
valve, supplementary valve, etc. (but some
valve blocks are only equipped with two-
way buffer valve and one-way valve, and
some only have overflow valve and one-way
valve). Structure of valve block is shown in
figure.
Composition of existing steering gear valve
Structure Chart
block: one-way valve, overflow valve (safety of Valve Block
valve), and two-way buffer overload valve.

Functional Chart
of Valve Block
19/05/2015
4) Single stable Valve
Single-channel stable flow divider valve (single stable valve for short) mainly works with BZZ
series of whole hydraulic steering gear. It is used in whole hydraulic steering system. When oil
supply of steering oil pump and system load change, stable flow required by steering gear is
ensured by single stable valve, to satisfy hydraulic steering requirement of loader.
Single-channel stable flow divider valve mainly consists of valve body, valve core, spring,
safety valve, damping plug and other parts. It has shunt type and constant-current type. See
figure.
Single stable valve is used in

independent system. Oil from steering is
supplied to the system. The rest oil and
oil overflowing when safety valve opens
unloading will flow back to the oil tank
through Port T.
★ Safety valve is on the valve Structure and

block now！！ Principle Chart
19/05/2015
2. Load Sensing Whole Hydraulic Steering System
1）
）Composition of System
Mainly consisting of priority valve, BZZ5 load sensing

steering gear (or BZZ6 coaxial flow amplifying steering
gear), steering oil cylinder, pipelines, radiator, oil tank,
etc.
Priority valve can realize combination and distributing

with working hydraulic steering system, improve
efficiency, and reduce loss. This type is widely used at
present. LG933, LG936, LG953, LG956 and other types
of our company all use this type.
System Principle
Chart
19/05/2015
2. Load Sensing Whole Hydraulic Steering System
1）
）Composition of System（
（Continued）
）
If LG953 steering hydraulic system is independent load

sensing hydraulic system steering, this system will
preferentially supply oil to steering hydraulic system.
The residual oil will return to oil tank after combining
with returning oil of steering system through radiator.
Safety valve is on priority valve. The system setting
pressure is 16MPa. See system principle chart.
System Principle
Chart
19/05/2015
Load Dynamic Sensor System
19/05/2015
2）
）Pipeline Direction of Load Sensing Whole
Hydraulic Steering System
19/05/2015
3) BZZ5 Load Sensing Whole Hydraulic Steering
Gear
Structure of BZZ5 Load Sensing Whole Hydraulic Steering Gear is similar to that of BZZ1
Whole Hydraulic Steering Gear. It is mainly consists of rotary valve and measurement motor.
The valve body has 4 ports, respectively connected to oil inlet, oil outlet and two cavities of oil
cylinder. Load Feedback Port Ls is connected to priority valve. See the following photo for
position of ports of steering gear.
Following
Rotary Valve
Measurement
Motor
Ports of Steering
3D Profile of Structure Gear
19/05/2015
T：
：oil return
P：
：oil inlet
R：
：right
steering
L：
：left steering
T
LS L
P
R
Position of ports on
steering gear
19/05/2015
Main Components
of Steering Gear
Core components of whole hydraulic

steering gear:
• Metering mechanism---stator and rotor
• Servo proportional control valve ---valve
core/valve pocket pair
19/05/2015
● Working Principle（
（BZZ5）
）
When following rotary valve is at the middle
position (steering wheel doesn’t move), valve
Combin
package and valve core are in the middle es or
returns
under the action of positioning spring, and to oil
tank
channels connected to tooth cavity of rotor
and stator and two cavity of steering cylinder
are closed, only a small amount of pressure
oil pumped from steering pass through Pump
Diesel
Engine
inside of steering gear, and most oil will be
Hydraul
ic oil
distributed by Port EF of priority valve tank
(combined to working hydraulic system or

flows back to oil tank). Oil in two cavity of
steering cylinder will be closed, piston
cannot move, and loader will run in original
direction.
System Sketch Map
19/05/2015
● Working Principle（
（BZZ5 Continued）
）
When steering wheel turns, priority valve will preferentially satisfy steering needs.
Oil in steering pump will go to measurement motor through priority valve and
following rotary valve, and turn in the direction of steering wheel with rotor.
Working oil will be delivered to a cavity of steering cylinder and realize steering.
Oil in the other cavity of steering cylinder will return to oil tank with following
rotary valve. When steering wheel turns fast, a large amount of oil will reach
steering cylinder through measurement motor. Steering will be fast.
19/05/2015
4) Priority Valve
This valve works together with BZZ5 Steering
Gear (or BZZ6 Steering Gear) and forms load
sensing steering system. When rotate speed of
steering wheel changes, flow required by
steering gear can be ensured preferentially.
The red oil will enter working device hydraulic
system or flow back to oil tank.
Structure and
Principle Chart of
Priority Valve
19/05/2015
4) Priority Valve (Continued)
● When steering wheel doesn’t move, pressure oil from steering pump will enter working
device hydraulic system or directly flow back to oil tank through Port P, valve core and
Port EF.
● When steering wheel turns, valve core will move right under the action of spring force and
LS pressure. Port P will be connected to Port CF. Pressure oil will enter steering gear and
push oil cylinder to realize loader steering. The rest oil will be distributed by Port EF, enter
working device hydraulic system or flow back to oil tank. Therefore, when priority valve
preferentially satisfies steering, the rest power oil will be distributed by Port EF and
applied to other working hydraulic system, which will reduce system power loss and save
energy.
19/05/2015
5）
）Coaxial Flow Amplifying Steering Gear
Coaxial Flow Amplifying Steering Gear (BZZ6 and TLF) and BZZ5 type are all load
sensing steering gear. With the same displacement, two steering gears can replace
each other. But displacement of coaxial flow amplifying steering gear changes with
input turning speed of steering wheel.
19/05/2015
5）
）Coaxial Flow Amplifying Steering Gear
(Continued)
In low-speed steering (turning speed of steering wheel is under 10 rpm), effective
displacement and measurement displacement of steering gear are identical; When input
turning speed of steering wheel increases (turning speed of steering wheel is 10 ~ 40 rpm),
the effective displacement is in proportion to turning speed of steering wheel. At this time
only part of oil in oil inlet P will enter stator and rotor pair for measurement. The rest oil will
directly enter oil cylinder through Port A or Port B, so it has flow amplifying function at this
stage. When input turning speed of steering wheel is above 40rpm, effective displacement of
steering gear will be its calibrated equivalent displacement.
Coaxial Flow Amplifying Steering Gear has good relative performance. It has high pressure
loss (about 0.5MPa higher than the first two kinds), good sealing and small leakage.) At
present, LG953 Loader uses BZZ6 (or TLF) Coaxial Flow Amplifying Whole Hydraulic Steering
Gear to replace BZZ5 Load Sensing Steering Gear.
19/05/2015
3. Flow Amplifying Steering System (Flow
Amplifying Valve)
• Flow amplifying system mainly consists of hydraulic pump, flow
amplifying valve, limit valve, steering gear (BZZ3) , steering cylinder, etc.
Oil channels are divided into pilot oil channel and main oil channel. oil
amount change of pilot oil channel is in proportion to flow change of
steering cylinder in main oil channels. High pressure and big flow is
controlled by low pressure and small flow, so that steering control is
convenient and flexible. Because flow amplifying valve has pressure
compensation device, flow doesn’t change with load, which improves
performance and has certain energy-saving effect. Therefore, it has small
power consumption, reduces system heating, and improves flow
adjusting property.
19/05/2015
3. Flow Amplifying Steering System（
（Continued）
）
• Besides functions of common flow amplifying valve, priority flow

amplifying valve can combine with working hydraulic system by priority
valve. It has characteristics of load sensing steering system.
• For example, LG958 Flow Amplifying Steering System mainly consists of

double pump, steering gear, flow amplifying valve, unloading valve,
steering cylinder, hydraulic oil tank, pipeline accessories, etc. See the
following figure for system principle.
19/05/2015
1－
－Oil returning filter
2－
－Radiator
3－
－Hydraulic oil tank
4－
－Working pump
5－
－Pressure selecting
valve
6－
－Steering gear
7－
－Steering cylinder
8－
－Flow amplifying valve
9－
－Air change filter
10－
－Steering pump
11－
－Unloading valve
12－
－Oil absorption filter
core
Principle Chart of Flow Amplifying System
19/05/2015
1）
）Flow Amplifying Valve Structure and working principle of priority flow amplifying valve:
1 front door 2 amplifying valve core 3 valve body 4 adjusting washer 5 steering valve spring
6 back door 7 pressure adjusting screw 8 pilot valve spring 9 cone valve 10 flow divider valve
spring 11 adjusting shim 12 flow divider valve core 13 shuttle valve
19/05/2015
1）
）Flow Amplifying Valve（
（Continued）
）
● Middle Position
When steering wheel stops turning or turns to extreme position, pilot oil will be
cut off. Steering valve spring (5) will make amplify valve spool (2) keep in
middle position. Oil in steering pump will push distributing valve core (12) right.
19/05/2015
1）
）Flow Amplifying Valve（
（Continued）
）
Flowing into working system from Port PF, oil in steering pump is fully utilized,
so as to reduce displacement of working pump. Because amplifying valve core (2)
is at the middle position, hydraulic oil in p cavity will not be connected to
hydraulic oil in A and B cavity of left and right steering cylinder, so that loader
will run in the direction when steering wheel loader stops turning. Hydraulic oil
sealed in A and B cavity of left and right steering port will act on cone valve (9) of
safety valve through internal channel. When steering wheel carries external
resistance, pressure in A (or B) cavity will increase, until cone valve (9) is opened,
in order to protect steering cylinder and other hydraulic components from
damage.
19/05/2015
● Right Steering Position
When steering wheel turns right, pilot oil will flow into spring chamber from pilot oil port
along direction b. As pressure in spring cavity of steering valve spring (5) increases,
amplifying valve core (2) will be pushed left. Then P cavity will be connected to right
steering port (B). Left steering port (A) will be connected to oil returning port (T1).
Hydraulic oil will enter oil cylinder of right turning port and realize right turning. When
right turning is preferentially met, the rest oil will be distributed to working system
through Port PF.
Movement amount of valve core is controlled by turning speed of steering wheel. The
faster steering wheel turns, the larger pilot oil flow is, the greater valve core displacement
is, and the higher steering speed is. Conversely, if steering wheel turns slow, valve core
displacement will be small and steering speed will be low (Note: Two ends of valve core
are connected to orifice on the oil channels. The hydraulic damping realizes this function).
19/05/2015
● Right Steering Position (Continued)
When pressure oil flows into right turning port (B), because of load feedback effect,
pressure difference of two ends of distributing valve (12) remain unchanged, so as to
ensure that flow in steering cylinder only relates to displacement of valve core , and
doesn’t related to load pressure. Oil pressure acts on core valve (9) and distributing
valve core (12) through shuttle valve (13) , which automatically controls flow. If
pressure continues to rise and goes beyond the setting pressure of safety valve,
cone valve (9) will open, distributing valve core (12) will move right, and flow will go
to working system. Oil returning in oil channels at middle position will have
protection function. When load is eliminated, pressure will reduce, distributing valve
core (12) will go back to its normal position, and cone valve (9)will be closed.
Left steering is similar to right steering.
19/05/2015
Ⅲ. Failure Case Analysis
1. Failure Case Analysis of Working Hydraulic System
1）
）Weak lifting of swing arm
2）
）Slow and weak bucket
3）
）Bucket turns over or shakes during lifting operation
4）
）Hydraulic oil temperature is too high
19/05/2015
Ⅲ. Failure Case Analysis
2. Failure Case Analysis of Steering Hydraulic System
1）
）Heavy steering
2）
）No terminal point for steering
3）
）Reason for vehicle deflection
4）
）Inaccurate steering
5）
）Steering wheel rotates freely. Steering doesn’t move or slow.
6）
）Blanking stroke of steering wheel
7）
）Steering wheel shakes or rotates
8）
）Steering wheel rebounds
19/05/2015
1. Failure Case Analysis of Working Hydraulic System
1）
）Weak lifting of swing arm （analysis and Reason Measures
judgment process）） 1. Valve rod is blocked

2. Positioning steel ball of
1. Check valve rod,
steel ball, positioning
Yes valve rod becomes invalid spring of valve rod or

due to wear. Positioning change valve
spring becomes invalid 2. Check control
3. Control mechanism mechanism
No
Check whether Check whether doesn’t control well Add hydraulic oil to
stroke of multiple hydraulic oil Hydraulic oil amount is not specified mark
No Yes
unit valve rod is in amount meets enough
place standard Check whether oil Check whether
Measure when Remove dirt or change
absorption tube of pump driving axle
Action stroke of 918 swing When bucket is flat on the pressure is zero or Yes No Yes Dirt or rubber dropping of rubber tubes
working pump is is broken or falls
arm valve is 7mm. Action ground, oil position is low
blocked tubes makes pump unable to Change pump axle
stroke of rotating bucket between 6 and 10 on mark
valve is 8.1mm. Action of hydraulic oil tank absorb oil
stroke of the two valve Yes Pump axle is broken or Set to system pressure
rods of other types are all drops. Working pump cannot value
16mm. Pressure doesn’t
Test pressure is Pressure changes change after absorb oil
below requirement Yes after adjustment No adjustment Yes Setting pressure of main Wash or change spring
Check whether safety valve is low
working device Adjust pressure of main safety valve. 933, 936 and 952 are 16MPa. 918 is 17.5MPa.
Yes Spring in main safety valve Change gear pump or
hydraulic system is 953, 956 and 958 are 18MPa.
normal is broken or valve core is repair
Pressure increases
with engine throttle, blocked Repair of change oil
When big arm lifts to extreme
position and control rod of swing but doesn’t reach Yes Working gear pump wears or cylinder
arm is at lifting position, rotating setting pressure
is broken Repair or change
of engine will gradually increase Internal leakage of swing multiple unit valve
Yes
to not less than 2200r/min. And
Meets setting arm cylinder Check pedal and cable.
than measure Check whether
requirement of swing arm cylinder 1. Leakage of swing arm Adjust rotating speed
working system Yes Check whether
has internal leakage slide valve to specified value
pressure No multiple valve leaks Yes 2. Internal leakage of main Change filter screen
safety valve
Accelerator pedal or cable
When stroke of valve rod is in
place and hydraulic oil amount cause low rotating speed
meets standard, check whether No Oil absorption channels are
rotating speed of engine meets blocked
standard
Measure with tachymeter
to check whether rated
Yes
rotating speed of engine
reaches 2200r/min
19/05/2015
2）
）Slow and weak bucket （analysis and judgment
process）
）
Reason Measures
Broken seal ring causes Change seal ring

Yes
internal leakage and bucket
dropping
Check whether setting
Check whether pressure of two Check whether broken Scratching or wear on valve
rotating bucket overload valves in rotating bucket slide
No Yes Yes rod or valve hole of rotating Repair or change
cylinder has internal rotating bucket valve causes internal
leakage cylinder is normal leakage bucket makes leakage of
hydraulic oil large
Pressure in big cavity of 933, 936,
938 and 952 is from 18 to 1. Main valve core of
18.5MPa. Pressure in big cavity overload valve has dust 1. Wash main valve
of 918, 953 and 956 is from 20 to Check whether
20.5MPa. Pressure in big cavity overload valve has particles, which makes core and remove
of 958 and 968 is 21.5MPa. No Yes
internal leakage overload valve open impurities
Pressure in big cavity of 40F is
15.5MPa. Pressure in small 2. Aging of seal ring 2. Change seal ring
cavity of all types is from 12 to 3. Improper clearance 3. Change overload
12.5MPa.
No between valve core and valve
valve body
1. Low pressure of overload
valve causes bucket 1. Adjust pressure to
dropping or floating specified value
Check whether
pressure of overload 2. Spring of overload valve 2. Repair or change
Yes
valve is low is broken or invalid
19/05/2015
3）
）Bucket turns over or shakes during lifting operation
（analysis and judgment process）） Reason Measures
No Oil amount is not Add hydraulic oil to

enough specified mark
Change or repair
Check whether Test pressure of Check pressure Working gear pump
oil amount working device increases with
Yes Yes wears or is broken Check setting
meets standard hydraulic system increase of engine
throttle Unstable starting pressure of valve, and
Check whether pressure of safety whether spring

Oil position is When big arm rises to
between 6 and 10 extreme position and No starting pressure of valve changes deforms. Adjust
Yes
on mark of control rod of swing arm safety valve is
stable pressure of hydraulic starting pressure
hydraulic oil tank is at lifting position,
Check whether oil Repair or change
rotating speed of engine
indicator of
will gradually increase to No
pressure gage Caused by aging and
not less than 2200r/min.
swings foaming of inlayer of
And then measure. 933,
intensively Check whether oil
936 and 952 are 16MPa.
channels are Yes rubber tubes, or
918 is 17.5MPa. 953, 956
No blocked or flat
and 958 are 18MPa. blocking of transiting
valve block and joint Repair or change
Check whether oil
Air entering system
absorption rubber Yes
tubes are well makes working Repair or change
When system pressure and sealed
hydraulic oil amount are pressure unstable
normal, check whether leakage
Different leakage
amount of rotating bucket
No
cylinder and swing arm amount causes flow Repair or change
cylinder are same
fluctuation and
shaking
Yes
Loosen piston makes
When system pressure and piston rod move in

hydraulic oil amount are No hydraulic cylinder
normal, check whether pistons
in rotating bucket cylinder and
swing arm cylinder are loosen
19/05/2015
4）
）Hydraulic oil temperature is too high
（analysis and judgment process ） Reason Measures
Check whether position of hydraulic oil is too Insufficient hydraulic oil Add hydraulic oil to specified mark
low Yes
makes working pump absorb
No air Change or filter hydraulic oil
Hydraulic components are
Check whether hydraulic oil is too dirty or goes Yes
bad blocked, causing throttling
and temperature rise of Clean with high pressure gun
No
Too much grease causes poor
Check whether there is too much grease heat dissipation Repair or change
Yes
between blades of cooling fin in water box
Blocking in radiator or other
reasons cause poor heat
No
dissipation Repair or change
When system pressure is set
Check whether hydraulic radiator has
Yes too high, overflow valve
problem
cannot overflow and reduce
pressure normally, internal
No leakage will increase, oil
temperature of system will
rise. When oil returning filter
Check whether improper pressure setting
causes high temperature of hydraulic oil Yes core is blocked or oil
returning channels become
old and delaminate, back
pressure will be high and oil Repair or change
No temperature will rise.
Serious internal leakage of
hydraulic components will
cause temperature rise of Repair or change
Check whether cylinder, pump and valve have Yes
leakage system
Low volumetric efficiency will
No
cause temperature rise of
Check whether gear pump, gear pair, side plate hydraulic oil
or pump body have wear Yes
19/05/2015
2. Failure Case Analysis of Steering Hydraulic System
1）
）Heavy steering（
（analysis and judgment process）
）
Reason Measures
Air in system Remove air in system.
Cylinder crawls. Foam in oil. Regular Yes Check whether oil inlet of
Decide according to fault
sound oil pump leaks.

-One-way valve -Check whether steel ball
phenomenon
failure of manual exists and whether it is

Heavy steering. Steering cylinder Yes steering blocked
doesn’t move. -Leakage of FK -Change FK combination
overload valve valve
-Internal leakage of -Check whether oil cylinder
Check whether oil cylinder has internal leakage
steering pillar is Yes
flexible Repair or change
No
Check whether Steering pillar is
Whether system No feedback oil Yes
No pressure meets broken Clean or change
channels are
the needs unblocked Pipelines are
No
Yes blocked Repair or change
Is fast steering Adjust system Yes
heavy and slow press. Does the Low system
steering light? pressure change? pressure Adjust system pressure
Spring of priority
No
valve is broken.
Yes
Shuttle valve is
blocked Supplement hydraulic oil
Is surface of Yes Lack oil Clean or change
hydraulic oil low?
Pipelines are
No
blocked Repair or change
Is oil sucking pipe Yes
blocked? Wear and internal
leakage of steering
No
pump
19/05/2015
2）
）No terminal point for steering or limit position
cannot be reached （analysis and judgment process)
No terminal
point Failure Reason Troubleshooting
Method
After steering cylinder turns to extreme Low overload Increase overload
position, turning the steering wheel, valve pressure valve pressure

steering wheel can turn lightly, which properly
means no sense of terminal point.
Steering cylinder cannot

turn to extreme position
Failure Reason Troubleshooting Method
Low safety valve Increase safety valve

Steering cylinder cannot turn to pressure pressure properly
extreme position. Steering
response is heavy.
19/05/2015
3）
）Reason for Vehicle Deflection
① Leakage at cylinder port when closed center steering gear is at middle
position. It is normal for closed center steering gear system to have
slight deflection.
② Check whether connecting rod of oil cylinder is loosen.
③ Leakage in oil cylinder
④ Pressure of two tires has big difference.
⑤ Leakage on two-way overload valve or two-way supplemental valve.
⑥ Air in oil
19/05/2015
4）
）Inaccurate Steering
① Air in system;
② Pin of oil cylinder is loosen;
③ Priority valve or main valve of L R
T P
flow divider valve is blocked;
④ Oil cylinder has leakage;
p
⑤ Low efficiency of pump causes Fixed
Engine
unstable pressure. Filter
Pump
Reservoir
19/05/2015
5）
）Steering wheel rotates freely. Steering doesn’t
move or slow.
① Serious leakage in two-way
overload valve
② Serious leakage in piston of oil

cylinder
19/05/2015
6）
）Blanking Stroke of Steering Wheel
① Connection of steering pillar and steering gear
wears or is broken
② Nut on steering wheel

moves
L R
T P
③ Air in oil
p
④ Leakage in two-way Fixed

Fixed
Pump
Pump Engine
Engine
overload valve
Filter
⑤ Leakage in steering Reservoir
cylinder
19/05/2015
7）
）Steering wheel shakes or rotates
① Assembly relation mistake. During overhaul

and reassemble, it is required that spine gear
corresponding to pin groove of universal
driving shaft engages with internal spine
gear corresponding to gear groove of rotor
② When oil in pump is connected to Port R or

L, steering gear will rotate like motor.
19/05/2015
8）
）Steering wheel rebounds
Reason：
：One-way valve at oil inlet of
steering gear is broken.
Function of one-way valve:

Prevent backflow of oil when pressure of
steering oil cylinder under external force is
higher than that of oil inlet. If one-way valve
is damaged and oil backflows, steering
wheel will rebound.
19/05/2015
Reliability
bears great
trust!
19/05/2015

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Loader Hydraulic Training Courseware 2011

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Loader Hydraulic Training Courseware

This course is suitable for domestic and foreign intermediate and

1. This training course is expected to have 12 hours.

Disadvantages of Hydraulic Transmission

6 Hydraulic Power Components

7 Hydraulic Control Components

● A machine is basically made up of four parts, including prime motor,

The purpose of prime motor is to change various forms of energy into

There are many transmission types. Transmission can be divided into

● Transferring and controlling energy with liquid as working medium is

It can be divided into hydraulic pressure transmission and hydraulic

• Energy and signal transmission;

• One is flammable hydrocarbon hydraulic oil (mineral oil type and

● Harms of oil pollution

● Pollution prevention measures

Hydraulic pump works on the principle of

gear pump axial plunger pump radial plunger pump

Hydraulic transmission control and regulating components are also

constant pressure safety valve

Directly operated overflow valve controls on-off

Suitable for system with high pressure and

Pressure reducing valve is a pressure control valve

fixed differential reducing valve and proportional

● Sequence valve is a pressure valve which allows

● Sequence valve and overflow valve have similar

① Inlet pressure of overflow valve is basically unchanged

Function Symbol Map

Pressure switch is a electrohydraulic control

Concept: Function of directional control valve is to control flow direction of fluid. It

Left position of three-position

four-joint reversing valve

● Classification of one-way valve

① By function: Common one-way valve and hydraulic controlled one-way valve.

Oil Inlet Oil Outlet

● Opening pressure: Oil Inlet P1

③Comprise combination ④Installed in outlet oil line to

● Classification of reversing valve

① By motion mode of valve core relative to valve body:

Engine Drive (Roller

Hydraulic Pilot Electromagnetic-Hydraulic Pilot

Valve Body Valve Core

Position of Valve Core Valve Port State Piston State

Middle Port A and Port B don’t connect oil Stop

Oil channels connected （not

Name Structure and Principle Chart Symbol

Name Structure and Principle Chart Symbol

Port P, A, B and O are all closed；

Port P, A, B and O are Hydraulic pump ; Piston

Port P is closed. Port A, B and O are

Port P, A and B are connected. Port O is

Port P and Port O are connected. Port A and

Port P, A and B are connected. Port O is

Three-position four-port Two-position four-port

◆ DC power type: Small reversing impact. High tolerance level of

Hydraulic three-position four-port

Roller Push Back-moving

Lift type, two-port, Lift type, two-port,

Appropriate reversing speed is obtained and reversing impact is reduced by

Manual reversing valve is convenient to use. It is applicable to

Figure 1 Figure 2 Figure 3

● Overview: Movement speed of actuating components in the hydraulic

● Classification: Common throttling valve, pressure compensation speed control valve,

Hydraulic cylinder has the following types by structure and function.

F1=pAtanγ Torque force of cylinder Working Principle of

judgment process）） 1. Valve rod is blocked