04 05 Hydraulic System LG956L

LG56L Training Material
Chapter VI Hydraulic System
CHAPTER VI Hydraulic System
SECTION I WORKING
SECTION II STEERING
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
I. Overview
I. Overview
II. Working pump
II. Loader sensor hydraulic steering system
III. Control valve
1. Overview
1. Main relief valve
2. Steering gear
2. Overload valve of big chamber
3. Priority valve
3.Over load valve of small chamber
III. Common faults and repair of steering
4. Check valve
hydraulic system
IV . Pilot valve
V. Pressure selector valve
VI. Cylinder
VII. Trouble shooting for hydraulic
system
RELIABILITY IN ACTION
SECTION I WORKING
HYDRAULIC SYSTEM
I OVERVIEW
LG956L applied the pilot control
system, to control the high main oil
flow which is high pressured and
mass flowed.
The working hydraulic system is
mainly composed by the working
pump, pressure selector valve,
control valve, lift arm cylinders,
bucket cylinders, oil tank and oil
tubes.
Compared with the machinery
control hydraulic system, this system
has the features as below:
It is portable, flexible and
efficient, which can be controlled
even by a finger.
By using proportional pilot
valve control, it can greatly reduce
the commutation control force.
The relief valve, overflow valve,
oil refill valve and check valve applied
cartridge structure, thus they have
good commonality, and they are easy
to maintenance.
2
SECTION I WORKING
HYDRAULIC SYSTEM
The pilot valve is monolithic
construction, which makes it small in
seize, and easy to place.
When the engine stops, the lift
arm can be lower and the bucket can
be unload by the effect of pressure
selector valve and the pilot valve.
There are electromagnets set
in the lift arm lifting position and
bucket retraction position, it can
realize the limitation of the lift arms
height and the balance of the bucket
at any position. This can simplify the
control process, reduce the labor
intensity and avoid the energy loss
and pressure impact due to the
frequent action of the relief valve.
3
SECTION I WORKING
HYDRAULIC SYSTEM
II WORKING PUMP
The working pump is a gear pump.
The liquid is transmitted due to the
change of the volume formed by the
gears and the pump body. And the
mechanical energy is transferred into
hydraulic energy.
Main parts
1-Pump body
2-Bearing
3-Washer
4-Driven gear
5-Side plate
6-Sealing
7-Bearing
8-Drive gear
4
SECTION I WORKING
HYDRAULIC SYSTEM
Working principle
When the working pump runs, many
volumes formed by the pump body,
the end cover and the gears. When
the gears rotates in the direction of
the picture shown right, the volume of
the oil suck chamber increases
gradually due to the meshing tooth
release little by little. The oil sucked
in will full-fill the volume between the
gears and the pump body. The oil go
with the gears to the oil outlet
chamber. The volume changes to be
smaller because the gears run into
meshing, and the oil will be pushed
out. The oil suck chamber and the oil
outlet chamber are separated by the
gears. As the volume changes, the oil
sucked in and squeeze out constantly.
5
SECTION I WORKING
HYDRAULIC SYSTEM
III .CONTROL VALVE
Compose
The control valve is mainly
composed of valve body, lift arm
valve kit, bucket tilting valve kit,
auxiliary valve kit, over flow valve kit
for big chamber of lift arm cylinder,
over flow valve kit for small chamber
of bucket cylinder, logic valve kit,
check valve etc.
1-Relief valve
2-The third function
3-Bucket tilting valve
4-Lift arm valve
5-Relief valve for small chamber of
bucket tilting cylinders
6-Relief valve for big chamber of
bucket tilting cylinders
7-Valve body
8-End cover
9-Spring
10-Spring seat
11-Spool
6
10
11
SECTION I WORKING
HYDRAULIC SYSTEM
11
1
Oil ports set
1-To small chamber of bucket

cylindersB1
2-To big chamber of bucket cylinders
A1
3-To small chamber of lift arm
cylindersB2
4-To big chamber of lift arm cylinders
A2
5-Oil return portT
6-Oil inlet portP
7&8-To the third function ports
9-Logic valve
10-Check valve
11-To pilot oil
2
8
3
7
4
6
5
11
10
7
SECTION I WORKING
HYDRAULIC SYSTEM
Main function
To control the movement of the lift
arm cylinders and bucket cylinders or
to keep the bucket and lift arm stay at
a position through controlling the
position of the spools, which
determines the direction, the flow and
the pressure of the oil flow. And the
movement of the spools are based
on the pilot oil.
Neutral position
When the pilot lever at the neutral
position, the spools of bucket kit and
lift arm kit stay at the neutral position.
The A1, A2, B1 and B2 chambers are
locked. The oil inlet port is connected
to the oil return port. The oil from
working pump go straight back to the
oil tank through the control valve.
8
SECTION I WORKING
HYDRAULIC SYSTEM
Bucket backward tilting
When the pilot lever at the position of

bucket backward tilting, the pilot oil
come from a1 channel push the
spool to the b1 side. Then the
channel between the P chamber and
the T chamber is cut off. The P
chamber is connected with the A1
chamber and the T chamber
connected with the B1 chamber. The
high pressure oil from P chamber
goes into the big chamber of bucket
cylinders through A1 chamber. The
oil from the small chamber of the
bucket cylinders goes back to the oil
tank through the B1 chamber. Thus
the bucket tilts backward.
a1
b1
9
SECTION I WORKING
HYDRAULIC SYSTEM
Bucket forward tilting (unload)
When the lever is placed at the

bucket forward tilting position, the oil
from channel b1 pushes the spool to
the a1direction, and the spool cut the
channel between P chamber and T
chamber off, and connects the P
chamber and the B1 chamber, and
also connects T chamber and A1
chamber. The pressured oil flows to
the small chamber B1 of the bucket
cylinder. The oil in the big chamber
A1 of the bucket cylinder returns to
the tank through the T chamber. And
the bucket forward tilting (unload)
action can be achieved.
a1
b1
10
SECTION I WORKING
HYDRAULIC SYSTEM
Lift arm lifting
When the lever is placed at the lift

arm lifting position, the oil from a2
channel pushes the spool to the b2
direction. The spool cuts the channel
between the P chamber and T
chamber off, and connects the P
chamber and A2 chamber, and also
connects T chamber and B2
chamber. The pressured oil flows to
the big chamber of the lift arm
cylinder through P chamber. The oil
in the small chamber B2 of the lift
arm cylinder flows to the tank through
T chamber. And the lift arm lifting
action can be achieved.
a2
b2
11
SECTION I WORKING
HYDRAULIC SYSTEM
Lift arm down

position of lift arm down, the oil from
b2 channel pushes the spool to a2
direction. The spool cut the channel
between P chamber and T chamber
off, connect the P chamber and the
B2 chamber, and also connects the T
chamber and A2 chamber. The
pressured oil flows to the small
chamber B2 of the lift arm cylinder
through the P chamber, and the oil in
the big chamber A2 of the lift arm
cylinder flows to oil tank through T
chamber. And the lift arm down
action achieved.
12
SECTION I WORKING
HYDRAULIC SYSTEM
Lift arm float
When the lever is placed at the lift

arm float position, the logic valve
opens, the B2 chamber is connected
with the T chamber. The ports P, A2,
B2 and T are connected, the lift arm
cylinders float under the effect of the
external force.
B2
A2
13
SECTION I WORKING
HYDRAULIC SYSTEM
1
1.Main relief valve
2
The main relief valve is used to
control the pressure of the whole
hydraulic system. The pressure set is
17MPa.
Compose
1-Spring seat
2-Hexagon nut
3-Spring
4-Lock nut
5-Support sleeve
6-Poppet
7-Poppet vale seat
8-Spring
9-Main spool
10-Valve seat
11-Valve body
10
11
14
SECTION I WORKING
HYDRAULIC SYSTEM
Working principle
Chamber C and chamber D are
separated by the control vale body and
the main relief valve body. Chamber C is
connected with oil returning port, and
chamber B is connected with the oil inlet
port. The orifice 1 in chamber B is
connected with the orifice 2 in chamber
C. When the pressure of the oil higher
than the set pressure, the oil flows to
chamber A through orifice 3 and pushes
the poppet to move upward. The
pressured oil flows to chamber B, at this
time the poppet valve seat moves
upward by the force of the spring.
Because of the pressure difference
between the two ends of the orifice, the
main spool is forced to move upward.
And thus chamber C and chamber D are
connected by orifice 4, parts of the oil
return to the oil tank. With the increase
of the oil pressure, the distance the main
spool travels become longer. The size
chamber C to chamber D become larger,
the ability for oil relief is larger. When the
pressure is below the set pressure, the
main spool return by the force of the
spring.
A
C
3
15
SECTION I WORKING
HYDRAULIC SYSTEM
2.Relief valve for big chamber
1
Compose
2
1-Valve seat
3-Spring
5-Spool
2-Hexagon nut
4-Valve seat
3
Working principle
Chamber C is connected with oil
return port, chamber A is connected
with big chamber of bucket cylinder,
chamber B is connected with
chamber C through orifice 7,
chamber D is connected with
chamber C through the orifice in the
spool. When the pressure of the oil in
chamber A higher than the set
pressure, the high pressure pushes
the spool move upward, and
chamber A is connected with
chamber C to drain the oil. When the
pressure decreases below the set
pressure, the spring returns by the
force of the spring.
D
6
5
C
A
16
SECTION I WORKING
HYDRAULIC SYSTEM
1
3.Relief valve for small chamber
2
Compose
3
1-Spring seat 2-Hexagon nut
3-Screw plunger 4-Valve body
5-Spring
6-Spool
4
Working principle
Chamber A is connected with small
chamber of the bucket cylinders, and
chamber B is connected with oil
return port. When the pressure of the
oil in the small chamber is higher
than the set pressure(12MPa),the oil
pushes the spool to move upward.
And chamber A is connected with
chamber B, the oil draining started.
When the oil decreases to below the
set pressure, the spool returns by the
force of the spring.
17
SECTION I WORKING
HYDRAULIC SYSTEM
The function of relief valves
1.When the bucket tilting spool at
the neutral position, both the
chambers of the bucket cylinder are
closed. If some external impact
works on the bucket, the relief valve
can prevent the pressure from been
increased sharply.
2.It can drain the oil automatically at
the process of lift arm up and down.
For example, When the lift arm
reached to a given position, the
piston rod of the bucket cylinder will
be forced out. Thus the pressure of
the oil in the small chamber will rise
sharply. The relief valve can makes
the oil return the oil tank through the
relief valve. And this can prevent the
cylinder and hoses from been broken
by the high pressure.
18
SECTION I WORKING
HYDRAULIC SYSTEM
4.Check vale
There are check valves in every
spool unite of the control valve.
There is a oil refill valve between the
small chamber B1 of the bucket
cylinder and chamber T. This oil refill
valve is a check valve. The main
function is to refill the small chamber
of the bucket cylinder. For example,
when the loader unloading, the
bucket forward tilting fast. When the
barycenter of the bucket passes the
below hinge joint, the bucket
accelerate tilts by the effect of the
gravity. The travelling speed is
limited by the oil volume pumped by
the oil pump. This check valve can
refill the small chamber of the bucket
cylinder, and makes the bucket tilt
fast, strike onto the stop block
realistic.
19
SECTION I WORKING
HYDRAULIC SYSTEM
IV.PILOT VAVLE
Compose
1
The pilot valve is mainly composed of
valve body, electromagnet kit,
metering valve kit, logic valve etc.
The details of the parts in next page.
1-Lever
2-Dust cover
3-Ledge plate
4-Valve body
5-Metering valve
6-Logic valve
3
20
Seat
Dust cover
Ledge plate
Plate
Electromagnet valve
Ledge plate
Spine
Ledge plate
Valve body
Push rod
Seal
Spring seat
Metering spring (internal)
Oil return port
Spring
Spring
Oil return chamber 2C
Logic valve
Oil inlet port
Metering valve seat
Logic valve seat

Metering valve spool
21
SECTION I WORKING
HYDRAULIC SYSTEM
Working positions
The lever is fixed on the pilot valve.
There are 3 positions for the bucket,
like forward tilt position, neutral
position and backward tilt position.
There are 4 positions for the lift arm,
like lifting position, neutral position,
down position and float position.
There are electromagnets at the
lifting, float and backward tilt position.
maximum position of lift arm lifting
position or backward tilt position, the
lever is locked until the lift arm or the
bucket moved to the specific position.
The approach switch works, and the
electromagnet lost its magnetic force.
The lever is forced back to the
neutral position by the force of the
returning spring.
22
SECTION I WORKING
HYDRAULIC SYSTEM
The hose connection
P-Oil inlet port

T-Oil return port
Chamber 2C is connected with K port

in logic valve.
T
P
2C
23
SECTION I WORKING
HYDRAULIC SYSTEM
Working principle

bucket backward tilting position, the
push rod pushes the spring seat, and
the spring is compressed, then the
spool is pushed downward by the
inferior spring seat. The oil inlet
chamber is connected with the pilot
oil chamber through the orifice 1 and
orifice 2 in the spool. The oil flows to
chamber a1 and chamber b1, and
pushes the metering spool upward.
The pilot oil chamber is connected
with the oil return chamber. And the
spool in the control valve moves.
4
5
6
7
8
T
1
3-Spine
4-Push rod
5-Spring seat 6-Metering spring
7-inferior spring seat
8-metering valve spool
24
SECTION I WORKING
HYDRAULIC SYSTEM
Principle of direct ratio control
When the press of the pilot control
chamber equals with the force of the
metering spring(or a little bit bigger),
the oil pushes the spool upward, and
the inferior valve seat pushes the
metering spring. The channel
between oil inlet port and control oil
chamber is cut off, at the same time,
the spool in control valve stop
moving. So the angle the lever
placed determines the movement of
the spool in control valve. And we
can control the working speed by
controlling the angle of the lever
placed.
25
SECTION I WORKING
HYDRAULIC SYSTEM
When the lever is placed at the float
position, the control chamber is
connected with the oil inlet chamber,
the pressured oil flows into the
control chamber of the logic valve,
and pushes the spool upward.
because of the difference of the two
ends of the spool in logic valve,
chamber 2C is connected with the oil
return chamber. The logic valve
works and thus the float action
achieved.
26
V .PRESSURE SELECTOR VALVE

Function
The function of the pressure selector
valve is to supply specific pressured
oil to the pilot valve, and guarantee
the lift arm down when the diesel is
off.
Compose
1-Valve body
2-Check valve
SECTION I WORKING
HYDRAULIC SYSTEM
Port sets
1-P1 port to pilot pump
2-P2 port to pilot valve
3-Pr port to big chamber of the lift
arm cylinder
4-L port to the tank
2
4
28
SECTION I WORKING
HYDRAULIC SYSTEM
Working principle
Pr
When the valve is working , the oil

from pilot pump flows to pilot valve
through P1 port, the orifice in the
spool and P2 port.
P1
29
SECTION I WORKING
HYDRAULIC SYSTEM
When the pressure of P2 port is
higher than 1.5MPa, the spool moves
to the left, and the channel
connecting P1 port and Pr port is cut
off. The check valve in Pr port can
prevent the oil in the big chamber of
the lift arm cylinder from flowing
back.
Pr
P1
30
SECTION I WORKING
HYDRAULIC SYSTEM
When the engine is off, there is no oil
in P1 port, and the spool moves back
to the position when the P1 port and
Pr port are connected. If the working
device is lifted high, and the lever is
placed at the neutral position, the oil
in the big chamber of the lift arm
cylinder is sealed in the chamber.
At this time, just put the lever at the
lift arm down position, and the oil in
the big chamber of the lift arm
cylinder will flow into pressure
selector valve. The high pressured oil
flows to the pilot valve through P2
port and pushes the spool in the
control valve to the lift arm down
position. And then the lift arm can
down to the ground. In this process,
the pressure of the oil to the pilot
valve is controlled by the spool to 1.5
MPa. If the pressure is higher than
1.5 MPa, the spool moves to left, and
the flow will be decreased, vice
versa. And thus the pressure of the
oil can be controlled.
31
SECTION I WORKING
HYDRAULIC SYSTEM
VI.CYLINDER
The cylinder is used to transmit
pressure energy into mechanical
energy. And to drive the working
device to move in line or swing back
and forth.
The cylinders can be divided into
2 types based on the different
working type. There is 1 port in the
single acting cylinder, and the oil can
push the piston out, while it depends
on the force of the spring or the
gravity. There are 2 ports in the
double acting cylinder the movement
of the piston is determined by the oil
pressure.
For this training material, we just
talk about double acting cylinder.
1
1-Cylinder body
2-Piston rod
32
SECTION I WORKING
HYDRAULIC SYSTEM
Compose
1-Bottom 2-Spring ring 3-Ring
4-Clamp ring 5-Piston 6-O-ring
7-Support ring 8-Ring 9-Yx seal
10-Cylinder body 11-Joint
12-Guide sleeve 13-Cylinder cover
14-Dust cover 15-Piston rod
16-pisitioning screw 17-Ring
18-Buffer plunger
Working principle
The cylinder is mainly composed of
the cylinder body 10, piston 5, piston
rod 15, guide sleeve 12 etc. To
simplify, we divide the cylinder into
the small chamber and the big
chamber. The high pressured oil
flows into the cylinder through port A
and pushes the piston to the right.
The oil in the right chamber flows to
the tank through port B.
33
VII.TROUBLE SHOOTING FOR HYDRAULIC SYSTEM

1.Why the gear pump fails? How to prevent?
Reason :
(1)There are scrap iron, gravel or something like that, and this will cause the scratch, wearing to the parts
that moves.
(2)The clearance between the shaft of the pump and the drive shaft is too large to drive the pump.
(3)The friction between the side plate and the gears is too serious.
(4)The oil suck hose jams or leakage, the oil intake shortage and this result in the failure of the pump.
(5)The tightening torque of the bolts used fixe the flange is not equal. Thus cause the failure of the pump.
Prevention measures :
A. Check the drive shaft
B. Check the bear of the drive shaft, there should not be axial float.
C. Check the tightening torque of the bolts used to fix the cover to the pump body. The tightening torque
should be equal.
D. Check the oil sucking hose, prevent the air from flowing into the system.
E. Keep the oil clear.
2. Why the bucket weakness, the bucket tilt forward or backward

automatically?
(1)The sealing rings in the piston fails, and it cause internal leakage.
(2)The scratch or wearing appeared in the spool and the valve body, and it cause the oil leakage in
the control valve.
(3)There are some damages in the conical valve spool or the conical surface of the relief valve, and
thus makes the sealing failure. The leakage in the relief valve appeared.
3. The working pump is easy to burst, and the leakage often appears at
the end cover of the pump, why?
The main reason is the spool of the main relief valve jams, the system stay at the closed station. The
pressure in the system increase rapidly. And this lead to the burst of the pump.
The reasons below can account for the oil leakage:
The long-term bearing of high pressure result in the elongation of the bolts used to fix the cover
to the pump body. And this cause the flexible of the cover. The radial scratch in the cover or the
valve body is another reason that can account for the leakage.
4.What is pulling cylinder? What is the hazard? How to prevent?

(1)Pulling cylinder: the part protruding outward of bucket cylinder piston rod is shortest when the bucket
is at limit position of downward tilting. When the lift arm is lifted to a certain height, the limit point of the
contacts the bottom of the bucket and the bucket can not tilt downward with the lifting of the lift arm. If
the lift arm is lifted continuously, however, relative position of supporting point on two sides of bucket
cylinder can change with continuous lifting of the lift arm, which forces the bucket cylinder piston rod to
extend outward. For small and big chambers of the bucket cylinder are closed when the boom is lifted,
outward extension of the piston rod can lead to rapid pressure increase in the small chamber of the
cylinder. Such phenomenon that outward extension of bucket cylinder piston rod is caused by lifting of
the lift arm when the bucket is dumped fully is called pulling cylinder.
(2) Hazard: bending and deformation of bucket cylinder piston rod; damage of knuckle for bucket
cylinder pine shaft; teeth falling of lock nut for bucket cylinder piston.
(3)solution: retract the bucket and then lift the lift arm after the bucket is dumped.
5.Why does
nodding
(falling first and then rising)occur sometimes when
the lift arm is lifted?
Floating status that oil inlet and outlet are connected with working port will appear at a certain time of
reversing for negative closing is adopted by lift arm control valve of distribution valve. Lower the lift arm
first and then lift it after the negative closing and the floating status of oil inlet and outlet and the working
port end due to the gravity of the lift arm and bucket.
6.Why the bucket is lifted and tilted slowly and powerlessly?

The seals of lifting and tilting bucket cylinders are damaged, resulting in inner leakage of the hydraulic
cylinder, which causes powerless action. Symptom : oil leakage occurs at surface junction, the pressure
drops faster and abnormal sound of oil leakage appears during operation.
7.Failures of control valve.

(1)Dirt in control valve blocks the spool or the pipeline to cause unsmooth oil flow. Symptom : the
resistance when operating control valve is larger, the spool fails to move smoothly and cant be reset
normally.
(2)Excessive wear of control valve and too large fit clearance between the spool and the valve body
result in inner leakage thus to cause insufficient working flow.
(3)The relief valve fails. The relief vale opening pressure is too low. At this time, do not fasten pressureregulating screw of relief valve blindly. It is required to remove and check the relief valve to see if the relief
valve spring is ruptured, guide valve sealing is favorable, the spool is seized and damping hole of spool is
blocked. The opening pressure of the relief valve shall be adjusted if none of the above problems occurs.
(4)Inner leakage of the working pump is large, pump outlet flow is insufficient, loop pressure decreases
and lifting and tilting buckets act powerlessly. Symptom : The hydraulic pump produces large noise when
working and abnormal sound of leakage in the pump can be heard; engine speed raises and the hydraulic
pump produces larger noise; a large amount of copper scales exist in the oil filter and tiny copper scales
also exist in the oil.
(5)The oil suction pipe and the oil filter are blocked or the oil suction pipe is aged, twisted or sealed
improperly, which can result in insufficient flow.
8.Why the machine shivers in the raising or tilting process?

The specific cause and countermeasure for the failure is as below:
(1)The oil is insufficient to cause unstable working pressure. It is necessary to fill up hydraulic oil.
(2)The oil suction rubber pipe nozzle is improperly sealed and air enters in the system to cause unstable
working pressure. It is necessary to check sealing performance.
(3)The oil is invaded by air and the invaded oil is forced to become compressible object due to lots of
tiny bubbles in the oil. It is necessary to eliminate the position which is sealed improperly in the lowpressure oil pipeline and then expel air in the oil.
(4)Hydraulic cylinder piston is loosened to cause runout of the piston rod in the hydraulic cylinder. It is
necessary to dismantle the hydraulic cylinder and trace the cause.
(5)The opening pressure of relief valve is unstable to cause pressure change of high pressure oil thus to
bring about shivering. It is necessary to check pressure-regulating spring of the relief valve and adjust
opening pressure.
(6)The unequal leakage of the two lift arm cylinders result in the flow fluctuation, which brings about
shivering. It is necessary to check the cylinders respectively and repair the broken cylinder.
9.Why the bucket tilts slowly and powerlessly with the lift arm working
normally?
(1)The pressure of two relief valves of the bucket cylinder is abnormal. It is necessary to check the
pressure and adjust it to normal value.
(2)There are particles in the oil and seized the relief valve spool, and the relief valve keep open. It is
necessary to remove sundries and check if the spring is broken or disabled, the sealing ring is aged and
if the fit clearance between the spool and the valve body is suitable(normal fit clearance is 0.0060.012mm).
(3)There is inner leakage in the bucket cylinder. It is necessary to make a check.
10.Why the oil temperature of hydraulic system is too high?

Too high oil temperature is mainly caused by the following cause except for the system:
(1)Wear of pump gear pair, side plate, pump body and seals in the pump result in the reduced efficiency
of pump capacity, which causes too high oil temperature.
(2)Oil brand used fails to meet the requirements, which causes poor clearance of mixed oil deterioration
etc.
Section Steering Hydraulic System
.Overview
Steer Mode
The steering systems function of the
wheel loader is to control the drive
direction of the wheel loader, keep the
wheel loader straight drive stably and
change the drive direction flexible
according to the need. In terms of steering
mode, the wheel loader can fall into
deflection wheel steering, articulated
steering, skid steering.
The working equipment of the
articulated steering wheel loader is
installed on the front frame. When the
frame deflected relatively, the direction
of the work equipment is same with the
direction of the front frame. This type can
makes the work equipment aim at the
work plane quickly, and reduces the
distance and time of operation circulate,
which improves the operate efficiency of
the wheel loader. So the articulated
steering becomes the most popular
steer mode.
Articulated wheel loader
Skid steering wheel loader
Deflection wheel loader
41
.Load sensing full hydraulic system

1.Over view
The steering system of the LG956L
wheel loader mainly consists of priority
valve and coaxial flow amplifying
steering gear.
Composition of the system
This system mainly consists of
steering pump, coaxial flow amplifying
steering gear, steering cylinder,
hydraulic tank, pipelines accessory and
so on.
1.Priority valve
2.Steer pump
3. Oil suction filter
4.Steer Cylinder
5.Steer Gear
6.Hydraulic oil radiator
7.Oil return filter
8.Hydraulic oil tank
42
Features:
The steering system have the
following features:
a. The components structure is
compact, and the size is small.
b. All the components has the function
of self-lubrication, which achieve long
service life.
c. The steer is reliable, and the control
is easy and flexible.
d. Achieve the interflow with working
equipment hydraulic system, reduce
the loss of power, improve the system
efficiency
As steering, the system supplies oil to

the steering hydraulic system. And the
remain oil, interflowed with the
steering system , return to the
hydraulic oil tank through the radiator.
The safety valve is installed on the

priority valve. The set pressure of the
system is 16Mpa.
43
2Steer Gear
The meaning of the steer gear type
Steer Gear BZZ6BZZ6-800
Steer gear
model
Steer gear type
BZZ6
Load sensing flow amplifying full

hydraulic steer gear
Displacement
800ml/r
44
Coaxial flow amplifying symbol

Coaxial flow amplifying typeBZZ6
symbol is labeled at the right picture.
45
The port location

There are 5 ports on the steer gear,
that are inlet port P, return port T, left

turn exhaust oil port L, right turn
exhaust oil port R, feed back port LS,
which are corresponding connected
with exhaust oil port CF of the priority
valve, return oil port of the hydraulic
oil tank, right turn cylinder big cavity,
TExhaust oil
PInlet oil
RRight turn
LLeft Turn
left turn cylinder big cavity and the LS

port of the priority.
LS
T
L
P
R
46
The composition of the steer gear

The structure of BZZ6 type full
hydraulic steer gear is shown in the

picture. It is mainly consists of valve
body, valve core, valve pocket,
universal driving shaft, guide spring,
pin, rotor, stator, rear cover, etc.
1.Connect body 2.Front cover

3.Valve body
4.Spring
5.Pin
6.Valve cover
7.Spool
8.Connected Shaft
9.Rotor
10.End cover
11.Limit Rod
12.Separation disc
13.Stator
14.O-ring
15.Steel ball
16.O-ing
17.X-ring
18.O-ring
47
The steering gear following rotary
valve, which mainly consists of valve

body, valve core and the valve pocket,
controls the direction of the oil flow.
The valve core located inside the
valve pocket is connected with steering

rod directly through the connect block,
and rotated with the steering wheel by
the drive of steer rod. The valve pocket,
located in the valve body, moves in the
valve body by the drive of connected
shaft and the pin.
48

The metering motor, which consists
of rotor and stator, is located at the
lower end of the steering gear. The
stator has 7 teeth, rotor six teeth.
And the stator is stationary, the rotor
rotates around the center of the
stator in the radius of throw of
eccentric.
The shape of metering motor teeth

is Equidistant circular arc epicycloids
tooth. The teeth shape make sure
that every point of the motor curve is
contact point. When rotating, there
are always 7 holes connected with
the valve pocket. The valve pocket
and valve core supply oil to the
metering motor. Then the pressed oil
enters one half teeth cavity, and the
other teeth cavity exhaust oil,
sending the pressure to the steering
cylinder.
1-rotor
2-stator
49

The metering motor, which consists
of rotor and stator, is also called
cyclonical meshing pair. When power
steering, it plays the function of
metering motor to ensure the oil mass
is in proportion to angel of the steering
wheel. When manual steering, it plays
the roles of manipulating fuel pump.
The connect rod and pin are

connected with the rotor and the valve
pocket. When power steering, it can
ensure synchrony between valve
pocket and rotor. When manual
steering, it plays the role of torque
transmission.
1-Connect rod
2-Rotor
3-stator
50
The function of the spring is to

ensure the following rotary remain
the centering position. So the spring
is called centering spring.
1
1.Valve core
2.Spring
3.Valve pocket
51
The one-way valve is installed
between the inlet valve and exhaust

valve. When manual steering, the
one-way valve opens, and the oil in
one of the steering cylinder cavity
return to the inlet port through the
return port. Then the oil passes into
the other cavity of the steering
cylinder by the negative pressure of
1
cyclical meshing pair. Achieve the
function of oil sorting as manual
steering.
1-One-way valve
2-P port(oil inlet port)
3-T port(oil return port)
52
Operation Principle
The Work functional diagram of the
BZZ6 type full hydraulic steering gear
is shown in the picture. The port A
and port B are connected with the
two cavities of the steering cylinder.
The port P is connected with the
exhaust port of the steering pump,
and the port T is connected with the
hydraulic oil tank.
1-connect block
2-front cover
3.valve body
4.spring 5.pin
6.Valve pocket
7.valve core
8.Linkage shaft
9.rotor 17.X-ring
10.End cover
11. limited post
12. separation disc 13.sator

14.16.18.O-ring
15.Steel ball
53
A. The steering wheel doesnt turn.

The valve core 1 and valve pocket 3
stay center position at the function of
the centering spring. The hydraulic
oil from the steering pump 7 enters
inside the valve core through the
small hole located at the end of valve
core and the valve pocket, and return
to the hydraulic oil tank 8 through the
port T.
When the steering wheel doesnt

turn, the centering spring plays role.
As the port A and port B are blocked
by the valve core 1, the oil in the
steering cylinder cant flow in nor out.
The piston cant move, so the wheel
loader runs at the former direction.
54
B. The steering wheel turns left.

The steer wheel drives the valve core
1 rotate counterclockwise. The
centering spring are pressed. As the
biggest rotatio between the valve core
1 and valve pocket 3 is 1030, the
valve core can turn around the valve
pocket.
The oil groove of the valve core is

connected with the inlet port P. The oil
from pump flows through the oil
groove of valve pocket 3, valve core
1,and reflow to stator 4 and rotor 5
driving rotation of the rotor 5 around
stator 4.
55

At the same time, the exhaust oil of
stator and rotor passes into the big
cavity of right steering cylinder
through the port A, making the piston
rod to reach out and making the frame
to drive the wheel turn left.
The oil in the small cavity of the

cylinder passes into he valve pocket 3
through the port B, and return to the
oil return groove through the valve
core 1. In the end, the oil return to the
hydraulic tank through hole of valve
pocket.
During the motion of turning left, the

small cavity of the left steering oil
cylinder (with rod cavity) is connected
with the big cavity of the right steering
oil cylinder. The inlet oil of the small
cavity makes the piston rod to shrink
into the cylinder, driving the frame turn
left.
56

The big cavity of left steering oil
cylinder is connected with the small
cavity of the right steering cylinder.
The oil from the small cavity of right
steering oil cylinder enters into the
port B through the big cavity of the left
steering oil cylinder, and returns to the
oil tank from the oil return hole of the
valve pocket.
When the rotary angle between valve

core and the valve pocket is about
1.5, the oil channel begins to
combine. The rotation of rotor makes
that the oil of steer pump is connected
with oil cylinder. The mass of supply
oil is in direct proportion to the angle
of the steering wheel.
57

When the turn angle of the steering
wheel remains some, the oil from the
steer pump drives the rotor 5 rotate
right because the oil channel above is
open. When the rotary angle of rotor 5
is same with that of steering wheel.
Because the valve pocket 3 is

mechanical jointed with rotor 5
through the linkage shaft , the rotor
drives the valve pocket 3 turn left at
the same time until the centering
spring makes the valve pocket, valve
core to return the center position. The
angle between the stator and the rotor
is same with the rotary angle of the
steering wheel.
58

At this time, the valve pocket 3 and
the valve core 1 stays the position
where they dont have relative rotary
angle. The oil channel, which goes
through rotor and steering cylinder, is
closed. The exhaust oil of the steer
pump enters into the valve pocket
through the port P, and then return to
the hydraulic tank through the return
hole 3 of valve pocket 3 after entering
into the oil return groove of valve core
1. Thus the wheel loader stops
steering.
If the steering wheel continues

rotating, the rotor and the valve
pocket follows to rotate with the
steering wheel until the left turning
position is limited. This is called the
hydraulic feed back function.
59

When the steering speed is low(the
rotary speed of the steering wheel is
below 10r/min), the effective
displacement of the steering gear is
same with the metering displacement.
When the input rotary speed of the
steering wheel increases, the
effective displacement is in direct
proportion to the speed of the
steering wheel.
Part of the oil from oil inlet port P

enters into the stator, rotor parts to
meter, and the others passes into the
oil cylinder through the port A and
port B. So it plays the role of flow
amplifying.
When the input speed of the

steering wheel is above 40 r/min, the
effective displacement of the steering
gear is constant at the rating
displacement.
60
C. The steering wheel turns right

When the steering wheel turns right,
the steering wheel drive the valve

core rotate clockwise. The operation
principle is same with that of turning
left.
61
SECTION 2 STEERING
HYDRAULIC SYSTEM
d.manual steering
In event of sudden flameout of the
engine or the malfunction of steering
pump, rotate the steering wheel with
hand for static steering. While
rotating the steering wheel rightward,
the valve core rotates for a 1030
angle to drive the rotation of valve
sleeve, linkage shaft, and rotor via
shifting pin. In such case, the rotor
and stator are functioned as oil pump.
The rotation of rotor 5 sucks out the
oil from the oil port T and inputs the
oil into the oil inlet chamber of rotor
pump via check valve, valve sleeve,
and valve core. The oil pumping
action during the manual steering
compresses the hydraulic oil sucked
into the steering oil so that the
compressed oil enters into the
rodless chamber of steering cylinder
to extend the piston rod and steer
rightward the loader.
Valve body
Oil return port
Right Oil inlet

Left
Spacer disc
steering steering port
Limit block
Linkage shaft
Valve
core
Bearing
Check valve
Valve sleeve
Return spring
Shifting pin
Stator-rotor pair
Rear cap
62
SECTION 2 STEERING
HYDRAULIC SYSTEM
d.manual steering
The oil in the rod chamber flows
to the oil inlet chamber of rotor
pump from oil port A through valve
sleeve, valve core, valve sleeve,
and check valve and continually
refills into the rodless chamber, in
order to maintain the steering
action.
63
SECTION 2 STEERING
HYDRAULIC SYSTEM
VALVE BLOCK
Valve block is a combined hydraulic
components ,mainly consists of
Check valve, bi-directional buffer
valve (overload valve) and oil refill
valve , etc . It connects between the
steering pump and steering gear,
completes with full hydraulic steering
gear(Usually fixed on the flange of
the steering gear,with the steering
gear make up a whole)
Its use:On the one hand keeps the
steering gear and entire steering
system work normal under the
pressure rated; On the other hand,
can guarantee the steering cylinder
and connecting pipe without damage
in a sudden overload, and can
protect the steering pump.
64
SECTION 2 STEERING
HYDRAULIC SYSTEM
a.CHECK VALVE
Check valve consists of valve seat
1valve core 2 and spring 3,etc.It is
installed in the oil inlet port of the
valve body.The high pressure oil from
the pump flows into the oil inlet port
of the steering gear through the
check valve. Its role is to prevent the
backflow of oi,steering wheel selfdeflection,steering failure.
1-Valve core
2-Spring
3-Valve seat
1
65
SECTION 2 STEERING
HYDRAULIC SYSTEM
b. TWO-WAY DAMPING VALVE
The two-way damping valve
incorporates two constant pressure
direct-acting safety valves composed
of the spring, ball valve seat, and
steel ball. Its installed within the
valve port for connecting the valve
body with the orifices of left and right
chambers of steering cylinder and is
connected with the oil return port, in
order to protect the hydraulic steering
system against impact of over-high
pressure and ensure the safety of oil
lines.
P
1
66
SECTION 2 STEERING
HYDRAULIC SYSTEM
C.REFILL VALVE
The oil refilling valve incorporates two
check valves composed of steel ball
and is installed within the valve port
for connecting the valve body with the
orifices of left and right chambers of
steering cylinder and is connected
with the two-way damping valve.
When the pressure within one
chamber of cylinder is higher than the
pressure setting of damping valve,
the damping valve relieves the load
and the oil refilling valve on the other
chamber of the cylinder refills the oil
to prevent the formation of cavitation
in the system.
1-Valve seat
2-Steel ball
3-Spring
4-Valve core
67
SECTION 2 STEERING
HYDRAULIC SYSTEM
3. Priority valve
FUCTION
The load sensor steering system is
made up of the priority valve and the
BZZ5 steering gear. When you
turning the steering wheel, the
priority valve can ensure the oil flow
demanded by the steering gear and
the rest will flow to the working
hydraulic system.
68
SECTION 2 STEERING
HYDRAULIC SYSTEM
COMPOSITION
The priority valve is mainly
composed of valve body, valve core,
a spring, the relief valve assembly
and parts such as screw. Upper
hydraulic principle diagram for it.
1- The group of relief valve
2-Spring
3-Valve core
4-Valve body
5-Plug screw
69
SECTION 2 STEERING
HYDRAULIC SYSTEM
OIL PORT ARRANGEMENT
Priority valve has five oil port, Oil inlet
P, oil outlet EFCF, feedback oil port
LS and oil return port T, respectively.
The five oil ports respectively
connect with the oil outlet port of
steering gear, the inlet port of
hydraulic oil radiator, the inlet port of
steering gear, the LS port of steering
gear and oil return port of hydraulic
oil tank.
1.P port for oil inlet, connected with
steering pump
2.T port for oil drain, connect with
hydraulic tank
3.EF port connected with the
working equipment(or connected with
the hydraulic oil tank)
4.CF port connected with the inlet
port of steering gear
5.LS port connected with the LS
orifice of the steering gear.
CF
EF
LS
70
SECTION 2 STEERING
HYDRAULIC SYSTEM
working principle
a. When the steering wheel is
stationary, the pressure oil from
the steering pump flows to port
EF from port P through valve core
and enters into the working device
hydraulic system or returns to oil
tank directly.
71
SECTION 2 STEERING
HYDRAULIC SYSTEM
b. When the steering wheel is
rotating, under the joint action of the
spring force and LS pressure, the
valve core moves rightward to
connect the port P with port CF so
that the pressure oil enters into the
steering gear and drives the cylinder
for steering of loader and the
excessive oil diverges into the
working device hydraulic system or
oil tank through port EF.
72
Section III Cause Judgment and Troubleshooting for Common

Malfunctions of Steering Hydraulic System
Heavy steering (analysis and judgment procedure)
Cause
s
y
m
p
to
m
J
u
d
g
e
a
s
p
e
r
m
a
lf
u
n
c
ti
o
n
Yes
Cylinder wriggle, air bubbles in oil, and regular

sound
Check steering
column for flexible
rotation
No
Is the steering heavy

at high speed and
light at low speed?
air from system

Air content in system Bleed
and check oil inlet port
of oil pump for air
leakage
Yes
Heavy steering and no action of

steering cylinder
Measure
Yes
No
Does system pressure
meet requirement?
No
Yes
Check feedback oil

pipe for blockage
Check steel ball for

presence and
blockage
Replace FK
combination valve
Check cylinder for
internal leakage
Failure of manual
steering check valve
Leakage of FK
overload valve
Internal leakage of
cylinder
Damage of steering
column
Repair or replace
Blockage of pipeline
Clean or replace
No
Yes
Adjust the system pressure.

Is there any pressure
change?
Yes
Low system pressure Repair or replace
No
Breakage of priority Adjustment system
pressure
valve spring or
blockage of valve core
Yes
Yes
Is hydraulic oil level

too low?
Shortage of oil
Add hydraulic oil
Blockage of pipeline
Clean or replace
Wear or internal
leakage of steering
pump
Repair or replace
No
Yes
Is oil suction pipe

blocked?
No
No steering end or failure for steering to limit position (analysis and judgment procedure)
No end
After the steering cylinder rotates to limit position,
when the steering wheel is rotated with high force,
the steering wheel can rotate lightly, namely there
is no feeling of end.
Malfunction
cause
Low pressure of
overload valve
Troubleshooting
Appropriately
increase pressure
of overload valve
failure for steering to limit position
The steering cylinder cant be

rotated to the limit position, with
heavy steering
Malfunction
cause
Troubleshooting
Low pressure of
safety valve
Appropriately increase
pressure of safety valve
SECTION 2 STEERING
HYDRAULIC SYSTEM
CAUSE FOR OFF-TRACKING
OF MACHINE
a. Due to leakage towards the
cylinder port when the closed
core steering gear is at neutral
position, the slight off-tracking of
the closed core steering gear is
normal.
b. Check the cylinder connecting
rod for presence of looseness.
c. Internal leakage of cylinder.
d. High pressure difference
between two tires.
e. Unilateral leakage of two-way
overload valve or two-way oil
refilling valve.
f. Air content in oil.
SECTION 2 STEERING
HYDRAULIC SYSTEM
INCORRECT STEERING
a. Air content in system.
b. Loose cylinder pin.
c. Stagnation of priority valve or
shunt valve core.
d. Internal leakage of cylinder.
e. Low pump efficiency, leading to
unstable pressure.
p
Fixed
Pump
Engine
Filter
Reservoir
SECTION 2 STEERING
HYDRAULIC SYSTEM
No rotation or slow rotation of
steering wheels, though the
steering wheel can be rotated
flexibly.
a. Serious internal leakage of twoway overload valve .
b. Serious leakage of cylinder
piston.
77
SECTION 2 STEERING
HYDRAULIC SYSTEM
IDLE TRAVEL OF STEERING

WHEEL
a. Worn or damaged connection
between steering column and
steering gear.
b. Loose nuts of steering wheel
c. Air content in oil.
d. Internal leakage of two-way
overload valve
e. Internal leakage of steering
cylinder
p
Fixed
Pump
Engine
Filter
Reservoir
78
SECTION 2 STEERING
HYDRAULIC SYSTEM
VIBRATION OR AUTOGIRATION
OF STEERING WHEEL
a. Incorrect assembly relationship. At
the time of reassembly after the
disassembly for repair, its required to
align the spline teeth of the linkage
shaft shifting pin slot with the
corresponding inner spline teeth of
rotor.
b. When the oil pumped is connected
to the port R or L, the steering gear
will rotate on its axis like a motor.
79
SECTION 2 STEERING
HYDRAULIC SYSTEM
Bounce of steering wheel.

Cause:
The check valve at oil inlet port of
steering gear is damaged.
Function of check valve:
It prevents the backflow of oil in
steering cylinder under the action of
external force when the pressure is
higher than the pressure at oil inlet
port. If the check valve is damaged,
the backflow of oil will lead to bounce
symptom of steering wheel.
80
THE END
81

04 05 Hydraulic System LG956L

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LG56L Training Material

Chapter VI Hydraulic System

CHAPTER VI Hydraulic System

II. Working pump

II. Loader sensor hydraulic steering system

III. Control valve

1. Main relief valve

2. Overload valve of big chamber

3.Over load valve of small chamber

III. Common faults and repair of steering

Oil ports set

1-To small chamber of bucket

Bucket backward tilting

When the pilot lever at the position of

Bucket forward tilting (unload)

When the lever is placed at the

Lift arm lifting

When the lever is placed at the lift

Lift arm down

When the lever is placed at the

Lift arm float

When the lever is placed at the lift

Oil inlet port

Metering valve seat

Logic valve seat

P-Oil inlet port

Chamber 2C is connected with K port

When the lever is placed at the

V .PRESSURE SELECTOR VALVE

When the valve is working , the oil

VII.TROUBLE SHOOTING FOR HYDRAULIC SYSTEM

2. Why the bucket weakness, the bucket tilt forward or backward

4.What is pulling cylinder? What is the hazard? How to prevent?

6.Why the bucket is lifted and tilted slowly and powerlessly?

7.Failures of control valve.

8.Why the machine shivers in the raising or tilting process?

10.Why the oil temperature of hydraulic system is too high?

Section Steering Hydraulic System

Articulated wheel loader

Skid steering wheel loader

Deflection wheel loader

Section Steering Hydraulic System

.Load sensing full hydraulic system

Section Steering Hydraulic System

As steering, the system supplies oil to

The safety valve is installed on the

Section Steering Hydraulic System

Steer Gear BZZ6BZZ6-800

Steer gear type

Load sensing flow amplifying full

Section Steering Hydraulic System

Coaxial flow amplifying symbol

Section Steering Hydraulic System

The port location

There are 5 ports on the steer gear,

that are inlet port P, return port T, left

left turn cylinder big cavity and the LS

Section Steering Hydraulic System

The composition of the steer gear

The structure of BZZ6 type full

hydraulic steer gear is shown in the

1.Connect body 2.Front cover

Section Steering Hydraulic System