GROUP 1 STRUCTURE AND FUNCTION

The loader system components are : Main pump Main control valve Bucket cylinder Boom cylinders Pilot supply unit Remote control valvePilot control valve Safety valve The pilot supply uni

1 HYDRAULIC SYSTEM OUTLINE

The loader hydraulic system is a pilot operated, open center system which is supplied with flow fromthe fixed displacement main hydraulic pump

The pilot control system is a low pressure, closed center hydraulic system which is supplied with flowfrom the first(Steering) pump

The loader system components are :

Main pump

Main control valve

Bucket cylinder

Boom cylinders

Pilot supply unit

Remote control valve(Pilot control valve)

Safety valve

The pilot supply unit consists of the pressure reducing valve, relief valve and accumulator

Flow from the main hydraulic pump not used by the steering system leaves the priority valve EF port

It flows to the inlet port plate of four blocks type main control valve

The main control valve is a tandem version spool type, open center valve which routes flow to theboom, bucket or auxiliary cylinders(Not shown) when the respective spools are shifted

Flow from the steering pump(The first pump) is routed to the pilot supply unit where the steeringpump outlet pressure is reduced to pilot circuit pressure The pilot supply unit flow to the remotecontrol valve

The remote control valve routed flow to either end of each spool valve section in the main controlvalve to control spool stroke

A accumulator mounted on pilot supply unit supplies a secondary pressure source to operatedremote control valve so the boom can be lowered if the engine is off

The return circuit for the main hydraulic system have return filter inside the hydraulic tank The returnfilter uses a filter element and a bypass valve The bypass valve is located in the upside of filter

SECTION 6 WORK EQUIPMENT

GROUP 1 STRUCTURE AND FUNCTION

A B C

P2 T

P1

U 3MPa

F1 F2

T P

T P

1B 1A

a1

P 21MPa Dump Roll back

Boom up Boom down

3

9 8

2 Main control valve

3 Remote control valve

3 WORK EQUIPMENT HYDRAULIC CIRCUIT

CF EF

P

A B C

P2 T

P1

U 3MPa

F1 F2

T

P

T P

B.D/F B.U IN OUT

a2 2B 2A

1B 1A

a1

P 21MPa Dump Roll back

Boom up Boom down

2 Main control valve

3 Remote control valve

WHEN THE RCV LEVER IS IN THE RAISE POSITION

When the RCV lever(3) is pulled back, the boom spool on the second block is moved to raiseposition by pilot oil pressure from port 3 of RCV

The oil from main pump(1) flows into main control valve(2) and then goes to the large chamber ofboom cylinder(9) by pushing the load check valve of the boom spool through center bypass circuit

of the bucket spool

The oil from the small chamber of boom cylinder(9) returns to hydraulic oil tank(19) through theboom spool at the same time

When this happens, the boom goes up

CF EF

P

A B

P2 T

P1

U 3MPa

F1 F2

T

P

T P

B.D/F B.U IN OUT

a2 2B 2A

1B 1A

a1

P 21MPa Dump Roll back

Boom up Boom down

WHEN THE RCV LEVER IS IN THE LOWER POSITION

When the RCV lever(3) is pushed forward, the boom spool on the second block is moved to lowerposition by pilot pressure from port 1 of RCV

The oil from main pump(1) flows into main control valve and then goes to small chamber of boomcylinder(9) by pushing the load check valve of the boom spool through center bypass circuit of thebucket spool

The oil returned from large chamber of boom cylinder(9) returns to hydraulic tank(19) through theboom spool at the same time

When the lowering speed of boom is faster, the return oil from the large chamber of boom cylindercombines with the oil from the pump through the check valve, and flows into the small chamber ofthe cylinder

This prevents cylinder cavitation by the negative pressure when the pump flow cannot match theboom down speed

CF EF

P

A B

P2 T

P1

U 3MPa

F1 F2

T

P

T P

a2 2B 2A

1B 1A

a1

P 21MPa Dump Roll back

Boom up Boom down

10

12

11Check valve

2)

A 1st pump

B 2nd pump

WHEN THE RCV LEVER IS IN THE FLOAT POSITION

When the RCV lever(3) is pushed further forward from the lower position, the pilot pressurereaches to 13-15 bar, then the boom spool on the second block is moved to floating position.The work ports(2A), (2B) and the small chamber and the large chamber are connected to thereturn passage, so the boom will be lowered due to it's own weight

In this condition, when the bucket is in contact with the ground, it can be move up and down inaccordance with the shape of the ground

CF EF

P

A B

P2 T

P1

U 3MPa

F1 F2

T

P

T P

B.D/F B.U IN OUT

a2 2B 2A

1B 1A

a1

P 21MPa Dump Roll back

Boom up Boom down

WHEN THE RCV LEVER IS IN THE DUMP POSITION

If the RCV lever(3) is pushed right, the bucket spool on the first block is moved to dump position bypilot oil pressure from port 2 of RCV

The oil from main pump(1) flows into main control valve(2) and then goes to the small chamber ofbucket cylinder(8) by pushing the load check valve of the bucket spool

The oil at the large chamber of bucket cylinder(8) returns to hydraulic tank(19) through the bucketspool

When this happens, the bucket is dumped

When the dumping speed of bucket is faster, the oil returned from the large chamber of bucketcylinder combines with the oil from the pump, and flows into the small chamber of the cylinder.This prevents cylinder cavitation by the negative pressure when the pump flow cannot match thebucket dump speed

CF EF

P

A B

P2 T

P1

U 3MPa

F1 F2

T

P

T P

B.D/F B.U IN OUT

a2 2B 2A

1B 1A

a1

P 21MPa

Dump Roll back

Boom up Boom down

WHEN THE RCV LEVER IS IN THE ROLL BACK(Retract) POSITION

If the RCV lever(3) is pulled left, the bucket spool on the first block is moved to roll back position bypilot oil pressure from port 4 of RCV

The oil from main pump(1) flows into main control valve(2) and then goes to the large chamber ofbucket cylinder by pushing the load check valve of the bucket spool

The oil at the chamber of bucket cylinder(8) returns to hydraulic tank(19) through the bucket spool.When this happens, the bucket roll back

When the rolling speed of bucket is faster, the return oil from the small chamber of bucket cylindercombines with the oil from the pump, and flows into the large chamber of the cylinder

This prevents cylinder cavitation by the negative pressure when the pump flow cannot match the

CF EF

P

A B

P2 T

P1

U 3MPa

F1 F2

T

P

T P

B.D/F B.U IN OUT

a2 2B 2A

1B 1A

a1

P 21MPa Dump Roll back

Boom up Boom down

WHEN THE RCV LEVER IS IN THE HOLD POSITION

The oil from main pump(1) flows into main control valve(2)

In this time, the bucket spool and the boom spool are in neutral position, then the oil supplied tomain control valve(2) returns into hydraulic tank(19) through center bypass circuit of each spool

In this condition, each cylinder keeps the neutral position, so the boom and the bucket is holded

CF EF

P

A B C

P2 T

P1

U 3MPa

F1 F2

T

P

T P

B.D/F B.U IN OUT

a2 2B 2A

1B 1A

a1

P 21MPa Dump Roll back

Boom up Boom down

3 MAIN PUMP OPERATION

STRUCTURE

4 5 6 7 14

15

7 6 5 16

13

12

11

5 6 7

8

9

7 6 5 4

3

2 1 20

As the drive gear(9) and (15) turns the driven gears(8, 14), the gear teeth come out of mesh Oilflows from the hydraulic tank through the inlet into the cavity between the gear teeth As the gearscontinue to rotate, the oil becomes trapped between the gear teeth and the balance plates(7).The trapped oil is then carried to the pump outlet Oil is forced out the outlet to supply the hydraulicfunction As the gears re-mesh, they form a seal to prevent oil from flowing between the gears andback to the inlet.

The pump uses outlet pressure oil to load the balance plates(7) against the gear faces Thiscontrols internal leakage to maintain pump displacement

Outlet pressure fills the area bounded by the seals(5, 6) to force the pressure plate against the highpressure area or the gear faces Pump shaft lubrication is achieved by routing outlet pressure oilinto the area between the gear shafts and the balance plates The oil is collected at the end of theshafts in the hollow areas in the port and flange plates and routed back to return

4 REMOTE CONTROL VALVE

STRUCTURE

A

17

29 28

21 26

27

1 4

B

12 13 6 23 7 1

3

1 4 5

1 4

25 24

30

20

A

15 16 10

18 15 11

19 14 9

HYDRAULIC OPERATION

2526

242322212019

1716151418

21

45

6

7

10

89

Boom downBucket dumpBoom raiseBucket crowdSupply pressureTank

1/4 BSPP1/4 BSPP1/4 BSPP1/4 BSPP1/4 BSPP1/4 BSPPHydraulic circuit

10 Pressure reducing v/v housing

Neutral position

12

The spring pack subassembly contains the pressure reducing piston(1) which has a center holemachined from the service port end This center hole links with a cross hole which in the normalcondition, that is with the lever not selected, connects the service port to the spring chamber(2) Thisspring chamber(2) is in turn connected to tank and as such the pilot can on the MCV, to which this valve

is connected, would be connected to tank and the MCV spool would therefore be in the neutral position

(1)

Metering position

4

1

23

The lever housing is selected and this in turn operates the spindle(1) which in turn depresses theoperating spindle This operating spindle now compresses the return spring(2) and starts to select thecharacteristic spring As there is currently no resistance, the pressure reducing valve piston(3) movesfurther down in its bore As this pressure reducing piston moves lower in its bore this service portconnection to tank, through the cross holes, is initially cut off as the cross hole pass under the land Asthe pressure reducing piston moves further then the cross holes open into the pressure chamber(4),which is connected to the 30 bar supply, and so at that point the 30 bar supply is connected to theservice port This also connects to the pilot end cap on the MCV and so spool movement in the MCVoccurs

(2)

End of metering

1

As the pressure builds up in the RCV service port and MCV pilot can, this same pressure acts on theend of the pressure reducing valve piston(1), which was initially moved by a force applied to the top ofthe characteristic spring As this pressure increases it starts to react to the force in the characteristicspring The piston begins to move back in its bore, and at some point a force balance will occur Whenthis happens, and the hydraulic force on the service port end of the piston just starts to exceed thespring force on the opposite end then the pressure reducing piston moves back in its bore until the crosshole moves back under the land and so the 30 bar supply to the port is cut off

(3)

Fully selected

12

If the operating lever is now selected further then the force balance on the pressure reducing valvepiston(1) is upset and supply pressure is once again connected to the service port, until a force balance

is restored

Similarly, if the operating lever is moved back towards neutral then the force balance is once againupset, this time in the opposite direction and the service port hydraulic force now being greater than thecharacteristic spring force, the pressure reducing valve piston moves such that the cross holes openinto the spring chamber(2) and some pressure is lost until the balance is once again restored when thecross hole moves back under the land

In this way pressure supplied to the MCV pilot can, and so spool movement, is proportional to the levermovement of the RCV

There is a point in the stroke of some of the RCV assemblies where progressive movement of the MCVspool is no longer necessary due to the spool position and flow/pressure characteristics and thepressure reducing valve piston is mechanically forced into a position where the cross holes areconstantly held open to the pressure chamber This happens when the pin fitted to the operatingspindle contacts the top of the pressure reducing valve piston and this mechanical force overrides anyhydraulic balancing forces

The ports controlling boom up and down and bucket roll back are also fitted with a magnetic detentsand/or prefeel ramps

The port controlling the power down function also controls the boom float function A prefeel ramp isfitted at the point on the pilot valve stroke which controls the spool on the MCV to its power lowerposition Moving the lever beyond this prefeel ramp position and to the end of its stroke gives an outputpressure from the RCV which drives the spool in the MCV into a float position Details on prefeel rampscan be seen in the next page

(4)

MECHANICAL OPERATION

The Bucket roll back and boom up and

down functions are fitted with a magnetic

detent

To prevent accidental engagement of this

magnetic detent each of these detent has

a prefeel position just before the armature

plate engages with the hold coil The right

figure shows the major components in this

assembly

As the lever is operated the prefeel

spindle and armature plate are depressed

in the bore and towards the end of the

stroke, the prefeel ball, loaded by the

prefeel spring, contacts the ramp on the

prefeel spindle This provides a physical

restriction to further lever movement as a

step increase in force is required to

overcome the preload of the prefeel

mechanism

At this point there is still a gap between

the armature plate and the hold coil,

therefore the valve can be operated

without accidentally engaging magnetic

detent

If an extra amount of force is applied to

the operating lever the force of the prefeel

mechanism can be overcome and

magnetic detent engaged This allows

the function to remain fully selected

without further operator demand The

lever automatically returns to neutral

when the electric current is switched off

due to the position of the loader reaching

proximity sensors Manual override from

magnetic detent is always possible

Armature plateHold coil(Magnet)Prefeel spindlePrefeel springPrefeel ballPrefeel cage assy

3)

(1)

(2)

(3)

5 MAIN CONTROL VALVE

6162

1

2, 3

223958

4 5

63

61

60 59

73 72 71 69 70 68 73

72 71 74 75 76 77 70 68

1B

1A

2B 2A

43

24 40 41 42 24 38

25 65 21

23 25 26 24

STRUCTURE(2/2)

79 78 80 81

44

44 57 45 50

48 52

25 64

66

28 54

68 77 76 75 71 73 72 74

70

1B

1A

2B 2A

24 27 37 46

49 47

51

53

56 55

30 31

24 27 37 28 29 34

33 32

35

36 25

9 8 12 11 13 18 17 14 15 16 19

Floating

a2 2B 2A

1B 1A

a1

P

b1 b2

T

b2

b1 a1

To bucket cylinder port

To boom cylinder portBucket pilot portBoom pilot port

1 1/16UNF

1 5/16UNF

1 1/16UNF

1 1/16UNF7/16UNF7/16UNF

BOOM SECTION OPERATION

1B 1A

a1

b1

b2 BOOM UP BOOM DOWN

DUMP ROLL BACK

Boom raise position

When the pilot pressure from remote control valve is supplied to the pilot port(a2), the spool moves tothe right and the neutral passage is closed

The oil supplied from the pump pushes up the load check valve(1) and flow into boom cylinder port(2A).The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of theneutral passage

The return oil from cylinder port(2B) flows into the tank via the low pressure passage

1B 1A

When the pilot pressure from remote control valve is supplied to the pilot port(b2), the spool moves tothe left and the neutral passage is closed.

The oil supplied from the pump pushes up the load check valve(1) and flow into boom cylinder port(2B).The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of theneutral passage

The return oil from cylinder port(2A) flows into the tank via the low pressure passage

When the lowering speed of boom is faster, the return oil from the large chamber of boom cylindercombines with the oil from the pump through the check valve(2), and flows into the small chamber of

Boom lower position

(3)

b1

b2

DUMP ROLL BACK

BOOM UP BOOM DOWN

FLOATING

a2 2B 2A

1B 1A