SECTION 6 WORK EQUIPMENT

Group 1 Structure and Function ----------------------------------------------------------------------------------- 6-1

Group 2 Operational Checks and Troubleshooting ----------------------------------------------------- 6-35
Group 3 Tests and Adjustments ----------------------------------------------------------------------------------- 6-45
Group 4 Disassembly and Assembly --------------------------------------------------------------------------- 6-60
 SECTION 6 WORK EQUIPMENT
GROUP 1 STRUCTURE AND FUNCTION

1. HYDRAULIC SYSTEM OUTLINE

The loader hydraulic system is a pilot operated, open center system which is supplied with flow from
the fixed displacement main hydraulic pump.
The polit control system is a low pressure, closed center hydraulic system which is supplied with flow
from 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 open center system which routes flow to the boom, bucket or auxiliary
cylinders (not shown) when the respective spools are shifted.
Flow from the steering pump is routed to the pilot supply unit where the steering pump outlet
pressure is reduced to pilot circuit pressure. The pilot supply unit control valve flow to the remote
control valve.
The remote control valve routed flow to either end of each spool valve section in the main control
valve to control spool stroke.
A accumulator mounted on pilot supply unit supplies a secondary pressure source to operated
remote 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 return
filter uses a filter element and a bypass valve. The bypass valve is located in the upside of filter.

6-1
 2. HYDRAULIC CIRCUIT

32
10 11 12 31
FRONT REAR
4
B.D/F B.U IN OUT
Sp

LH RH LH RH
T
34 A B
T
P
1 3 4 2 5 6
18 PS
BL1 BR1 BL2 BR2
3 T
8
T1 P1 T2 P2 3B
3A

5 a3 BOOM UP BOOM DOWN

b3
33

PS
17 17 L FLOATING

27
7 A1 A2
2B
T
19 2A
15
PS

R DUMP ROLL BACK

PS a2 b2
P
P1

T1 T F2
1B
A3 14
16 P 1A

B a1
AUX.
b1
LS
13P2 F1

PS1
PS

19 CF EF U
P 6 P

20 LS
P1 T
P

2 1
30
PS

M1
A
P1 23
30 M2
PS

29 T P
P2 24 21 C
28 25 26
M 22

7409S6WE01

1 Main pump 13 Pilot supply unit 24 Hydraulic tank

2 Fan & brake pump 14 Line filter 25 Return filter
3 Main control valve 15 Safety valve 26 Bypass valve
4 Remote control valve 16 Accumulator 27 Shockless valve
5 Steering unit 17 Accumulator 28 Pump motor (opt)
6 Priority valve 18 Pressure sensor 29 Check valve (opt)
7 Cut off valve 19 Pressure sensor 30 Pressure sensor (opt)
8 Brake valve 20 Line filter 31 Ride control valve (opt)
10 Steering cylinder 21 Oil cooler 32 Accumulator (opt)
11 Bucket cylinder 22 Fan motor 33 Pressure sensor (opt)
12 Boom cylinder 23 Air breather 34 Cushion valve

6-2
3. WORK EQUIPMENT HYDRAULIC CIRCUIT

11 12
4 B.D/F B.U IN OUT

LH RH
3 T T
P
1 3 4 2 5 6
3B

3A
BOOM
a3 BOOM UP DOWN b3
27
FLOATING
15 T

2B

2A P
DUMP ROLL BACK
a2 b2
F2
14
1B

1A
F1
a1
AUX
b1
P2 13

P
P1 T
Priority valve EF port
Steering system
Brake system
1
Return line

23

24
T P

25 26 21 22

Parking brake solenoid

7409S6WE02

1 Main pump 13 Pilot supply unit 23 Air breather

3 Main control valve 14 Line filter 24 Hydraulic tank
4 Remote control valve 15 Safety valve 25 Return filter
11 Bucket cylinder 21 Oil cooler 26 Bypass valve
12 Boom cylinder 22 Fan motor 27 Shockless valve

6-3
1) WHEN THE RCV LEVER IS IN THE RAISE POSITION

11 12
4 B.D/F B.U IN OUT

LH RH
3 T T
P
1 3 4 2 5 6
3B

3A
BOOM
a3 BOOM UP DOWN b3
27
FLOATING
15 T
Load check valve
2B

2A P
DUMP ROLL BACK
a2 b2
F2
14
1B

1A
F1
a1
AUX
b1
P2 13

P
P1 T
Priority valve EF port
Steering system
Brake system
1
Return line

23

24
T P

25 26 22
21

Parking brake solenoid

7409S6WE03

· When the RCV lever (4) is pulled back, the boom spool is moved to raise position by pilot oil
pressure from port 3 of RCV through shockless valve (27).
· The oil from main pump (1) flows into main control valve (3) and then goes to the large chamber of
boom cylinder (12) by pushing the load check valve of the boom spool.
· The oil from the small chamber of boom cylinder (12) returns to hydraulic oil tank (24) through the
boom spool at the same time.
· When this happens, the boom goes up.

6-4
2) WHEN THE RCV LEVER IS IN THE LOWER POSITION

11 12
4 B.D/F B.U IN OUT

3 Check valve T T
LH RH
P
1 3 4 2 5 6
3B

3A
BOOM
a3 BOOM UP DOWN b3
27
FLOATING 39 15 T

2B

2A P
DUMP ROLL BACK
a2 b2
F2
14
1B

1A
F1
a1
AUX
b1
P2 13

P
P1 T
Priority valve EF port
Steering system
Brake system
1
Return line

23

24
T P

25 26 21 22

Parking brake solenoid

7409S6WE04

· When the RCV lever (4) is pushed forward, the boom spool is moved to lower position by pilot
pressure from port 1 of RCV through orifice connector (39).
· The oil from main pump (1) flows into main control valve (3) and then goes to small chamber of
boom cylinder (12) by pushing the load check valve of the boom spool.
· The oil returned from large chamber of boom cylinder (12) returns to hydraulic tank (24) through
the boom spool at the same time.
· When the lowering speed of boom is faster, the return oil from the large chamber of boom cylinder
combines with the oil from the pump through the check valve, and flows into the small chamber of
the cylinder.
This prevents cylinder cavitation by the negative pressure when the pump flow cannot match the
boom down speed.

6-5
3) WHEN THE RCV LEVER IS IN THE FLOAT POSITION

11 12
4 B.D/F B.U IN OUT

LH RH
3 T T
P
1 3 4 2 5 6
3B

3A
a3 BOOM UP b3
27 BOOM DOWN FLOATING
15 T

2B

2A P
DUMP ROLL BACK
a2 b2
F2
14
1B

1A
F1
a1
AUX
b1
P2 13

P
P1 T
Priority valve EF port
Steering system
Brake system
1
Return line

23

24
T P

25 26 21 22

Parking brake solenoid

7409S6WE05

· When the RCV lever (4) is pushed further forward from the lower position, the pilot pressure
reaches to 13~15bar, then the boom spool is moved to floating position.
· The work ports (3A), (3B) and the small chamber and the large chamber are connected to the
return 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 in
accordance with the shape of the ground.

6-6
4) WHEN THE RCV LEVER IS IN THE DUMP POSITION

11 12
4 B.D/F B.U IN OUT

3 T T
LH RH
P
1 3 4 2 5 6
3B

3A
BOOM
a3 BOOM UP DOWN b3
27
FLOATING
15 T

2B

2A P
DUMP ROLL BACK
a2 b2
F2
14
1B

1A
F1
a1
AUX
b1
P2 13

P
P1 T
Priority valve EF port
Steering system
Brake system
1
Return line

23

24
T P

25 26 21 22

Parking brake solenoid

7409S6WE06

· If the RCV lever (4) is pushed right, the bucket spool is moved to dump position by pilot oil pressure
from port 2 of RCV.
· The oil from main pump (1) flows into main control valve (3) and then goes to the small chamber of
bucket cylinder (11) by pushing the load check valve of the bucket spool.
· The oil at the large chamber of bucket cylinder (11) returns to hydraulic tank (24).
· When this happens, the bucket is dumped.
· When the dumping speed of bucket is faster, the oil returned from the large chamber of bucket
cylinder 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 the
bucket dump speed.

6-7
5) WHEN THE RCV LEVER IS IN THE ROLL BACK (retract) POSITION

11 12
4 B.D/F B.U IN OUT

LH RH
3 T T
P
1 3 4 2 5 6
3B

3A
BOOM
a3 BOOM UP DOWN b3
27
FLOATING
15 T

2B

2A P
DUMP ROLL BACK
a2 b2
F2
14
1B

1A
F1
a1
AUX
b1
P2 13

P
P1 T
Priority valve EF port
Steering system
Brake system
1
Return line

23

24
T P

25 26 21 22

Parking brake solenoid

7409S6WE07

· If the RCV lever (4) is pulled left, the bucket spool is moved to roll back position by pilot oil pressure
from port 4 of RCV.
· The oil from main pump (1) flows into main control valve (3) and then goes to the large chamber of
bucket cylinder by pushing the load check valve of the bucket spool.
· The oil at the chamber of bucket cylinder (11) returns to hydraulic tank (24).
· When this happens, the bucket roll back.

6-8
6) WHEN THE RCV LEVER IS IN THE HOLD POSITION

11 12
4 B.D/F B.U IN OUT

LH RH
3 T T
P
1 3 4 2 5 6
3B

3A
BOOM
a3 BOOM UP DOWN b3
27
FLOATING
15 T

2B

2A P
DUMP ROLL BACK
a2 b2
F2
14
1B

1A
F1
a1
AUX
b1
P2 13

P
P1 T
Priority valve EF port
Steering system
Brake system
1
Return line

23

24
T P

25 26 21 22

Parking brake solenoid

7409S6WE08

· The oil from main pump (1) flows into main control valve (3)
· In this time, the bucket spool, the boom spool and the boom float spool are in neutral position, then
the oil supplied to main control valve (3) returns into hydraulic tank (24) through center bypass
circuit of each spool.
· In this condition, each cylinder keeps the neutral position, so the boom and the bucket is holded.

6-9
4. MAIN PUMP
1) STRUCTURE

6 1 2 8 3 4 5 7

10 11,12 13 9 14

15,17 16

P1 P2

Port Port name Port size

P1 Pressure port (to steering valve) 1" split flange
P2 Pressure port (to MCV) 1" split flange
S Suction port 2" split flange
7407B6WE29

1 Cover 7 Driven gear set 13 Square seal

2 Housing 8 Connecting shaft 14 Dowel pin
3 Carrier 9 Thrust plate 15 Washer
4 Housing 10 Lip seal 16 Stud bolt
5 Cover 11 Rubber seal 17 Hexagon bolt
6 Drive gear set 12 Back up seal

6-10
2) OPERATION
The main hydraulic pump is a fixed displacement gear type pump. The pump is driven at engine
speed by the transmission. The pump shafts are supported by lip seal (10), front cover (1), housing
(2, 4) and rear cover (5). The thrust plate (9) are located between the gear surface and front cover
(1), housing (2, 4) and rear cover (5).

As the drive gear (6) turns the driven gears (7), the gear teeth come out of mesh. Oil flows from the
hydraulic tank through the inlet into the cavity between the gear teeth. As the gears continue to
rotate, the oil becomes trapped between the gear teeth and housing (2, 4).
The trapped oil is then carried to the pump outlet. Oil is forced out the outlet to supply the hydraulic
function. As the gears re-mesh, they form a seal to prevent oil from flowing between the gears and
back to the inlet.

The pump uses outlet pressure oil to load the thrust plate (9) against the gear faces. This controls
internal leakage to maintain pump displacement.
Outlet pressure fills the area bounded by the pressure balance moulded seals (13) to force the
thrust plate against the high pressure area or the gear faces.

6-11
5. REMOTE CONTROL VALVE
1) STRUCTURE

38
37
36
33
32
34
35
23
27
26 28
25 30
24 29
19 31
21 20
22 18
17
8
5 16
9 14
12
15
11
10 13
4
7 PF 1/4
49
6
3 47
2 48
UNC 9/16
1,46
39,40,41,42
45

41,42,43,44 7407S6WE28

1 Body 14 Rod seal 27 Nut 40 Rear holder

2 O-ring 15 O-ring 28 Plug 41 Terminal
3 Plug 16 Push rod 29 Nut 42 Seal wire
4 Spring 17 Plate 30 Set screw 43 Housing
5 Spring seat 18 Rod stopper 31 Nut 44 Rear holder
6 Spool 19 Bushing 32 Nut 45 Clip band
7 Spring seat 20 Rod 33 Handle bar 46 Plug
8 Stopper 21 Magnet 34 Nut 47 Connector
9 Spring 22 Plate 35 Boot 48 O-ring
10 Spring seat 23 Joint assy 36 Handle assy 49 O-ring
11 Spring 24 Joint assy 37 Nut
12 Spring seat 25 Plate 38 Spring washer
13 Plug 26 Washer 39 Housing

6-12
2) OPERATION

T P

B.D/F B.U IN OUT

1 34 2
HYDRAULIC CIRCUIT
(3 Electromagnetic locks) 36
38

35

24 20

21

(1) Hydraulic functional principle 16

4
Pilot devices with end position locks operate as
direct operated pressure reducing valves. 9
They basically comprise of handle (36), four
pressure reducing valves, body (1) and locks. 6
Each pressure reducing valve comprises of a
1
control spool (6), a control spring (9), a return
spring (4), push rod (16) and rod (20).
At rest, handle (36) is held in its neutral position by
return springs (4). Ports (1, 2, 3, 4) are connected 7407S6WE27

to tank port T via drilling.

When handle (36) is deflected, rod (20) is pressed against return spring (4) and control spring (9).
Control spring (9) initially moves control spool (6) downwards and closes the connection between
the relevant port and tank port T. At the same time the relevant port is connected to port P via
drilling. The control phase starts as soon as control spool (6) finds its balance between the force
from control spring (9) and the force, which results from the hydraulic pressure in the relevant port
(ports 1, 2, 3 or 4).
Due to the interaction between control spool (6) and control spring (9) the pressure in the relevant
port is proportional to the stroke of rod (20) and hence to the position of handle (36).
This pressure control which is dependent on the position of the handle (36) and the
characteristics of the control spring permits the proportional hydraulic control of the main
directional valves and high response valves for hydraulic pumps.
A rubber boot (35) protects the mechanical components in the housing from contamination.

6-13
(2) End position lock
Only those control ports, for which it is necessary to hold the handle in a deflected position are
equipped with end position locks.
Electromagnetic lock
When this threshold is overcome, a joint assy (24) contacts the magnet (21); if the magnet (21) is
energized, then handle (36) is held in its end position by magnetic force.
This lock is released automatically when the solenoid is deenergized.

6-14
6. MAIN CONTROL VALVE
1) STRUCTURE

20

19 1
39
11 6 40
21-1
4 6-1 38
23 3 34 36
25 35
30
24
21
8
16
5 8
33
18 8 11
1 37 9 29
32
22
21-1 13
8 31
26
2-1 28 13
2 14
40 21 4
12 19
27
12 15
14
4

19

10 20

7407B6WE45

1 Nut 14 Screw 28 Spool

2 Plug 15 Screw 29 Spool
2-1 O-ring 16 Anti void assy 30 Spring
3 O-ring 18 Spool cap 31 Spring
4 O-ring 19 Spool cap 32 Back up ring
5 Cap screw 20 Cap screw 33 Inlet section assy
6 Plug 21 Spool retainer 34 Spool section assy
6-1 O-ring 21-1 Back up ring 35 Spool section assy
8 O-ring 22 Spool retainer 36 Outlet section assy
9 Spring 23 Screw 37 Poppet
10 Main relief valve 24 Washer 38 Tie rod
11 Port relief valve 25 Spacer 39 Tie rod
12 Spring seat 26 Spring 40 Nut
13 Washer 27 Spring

6-15
STRUCTURE

A1 A2 A3
P

B1 B2 B3

3B

3A
BOOM
BOOM UP DOWN
a3 b3

FLOATING

2B

2A
DUMP ROLL BACK
a2 b2

1B

1A
AUX
a1 b1

b1(a1) b2(a2) b3(a3)

P

HYDRAULIC CIRCUIT
7407B6WE20

Port Port name Port size

P From main pump 1 3/16 - 12UN
T To hydraulic tank 1 5/16 - 12UN
A1, B1 To auxiliary cylinder port 1 3/16 - 12UN
A2, B2 To bucket cylinder port 1 3/16 - 12UN
A3, B3 To boom cylinder port 1 3/16 - 12UN
a3, b3 Boom pilot port 9/16 - 18 UNF
a2, b2 Bucket pilot port 9/16 - 18 UNF
a1, b1 Auxiliary pilot port 9/16 - 18 UNF

6-16
 2) BOOM SECTION OPERATION
(1) Spool in neutral

3B

3A

24Mpa BOOM UP BOOM DOWN

a3 b3

FLOATING
24Mpa

2B

2A

24Mpa DUMP ROLL BACK

a2 b2

3A 3B

a3 b3

Low pressure passage

7407B6WE11

If the remote control valve is not operated, the oil supplied from the pump port passes through the
neutral passage to the low pressure passage at the outlet section, and then returns to the tank port.

6-17
 (2) Boom raise position

3B

3A

24Mpa BOOM UP
a3 b3

24Mpa

2B
2A

24Mpa DUMP ROLL BACK

a2 b2

Load check valve(1)

SECTION A-A

3A 3B

A A

a3
b3

Low pressure passage

7407B6WE12

When the pilot pressure from remote control valve is supplied to the pilot port (a3), the spool moves to
the 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
(3A).
The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of
the neutral passage.
The return oil from cylinder port (3B) flows into the tank via the low pressure passage.

6-18
 (3) Boom lower position
Check valve(2)
T

3B

3A

24Mpa BOOM DOWN

a3 b3

24Mpa

2B
2A

24Mpa DUMP ROLL BACK

a2 b2

Load check valve(1)

SECTION A-A

3A 3B

A A

b3
a3

Low pressure passage

7407B6WE13

When the pilot pressure from remote control valve is supplied to the pilot port (b3), the spool moves to
the 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
(3B). The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off
of the neutral passage.
The return oil from cylinder port (3A) 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 cylinder
combines with the oil from the pump through the check valve (2), and flows into the small chamber of
cylinder. This prevents cylinder cavitation by the negative pressure when the pump flow cannot match
the boom lowering speed.

6-19
 (4) Boom float position

3B

3A

24Mpa FLOATING
a3 b3

24Mpa

2B
2A

24Mpa DUMP ROLL BACK

a2 b2

3A 3B

b3
a3

Low pressure passage

7407B6WE14

If the remote control lever pushes further more, the pilot pressure from remote control valve rises over
13-15bar and then the boom lowering spool is pushed to the boom floating position, opening up the
neutral passage to tank and simultaneously (3A), (3B) → T.
In float position the boom drops quickly due to its own weight.
When the bucket touches the ground and the wheeled loader is moving, the bucket raised or lowered
following the unevenness of the ground due to the (3A), (3B) → T connecting.

6-20
3) BUCKET SECTION OPERATION
(1) Spool in neutral

24Mpa

2B

2A

24Mpa DUMP ROLL BACK

a2 b2

21Mpa

2A 2B

a2 b2

Low pressure passage

7407B6WE15

If the remote control valve is not operated, the oil supplied from the pump port passage through the
neutral passage to the low pressure passage at the outlet section, and then return to the tank port.

6-21
 (2) Retract (roll back) position

24Mpa

2B

2A

24Mpa ROLL BACK

a2 b2

Load check valve(1)

21Mpa

SECTION A-A
2A 2B

A A

b2
a2

Low pressure passage

7407B6WE16

When the pilot pressure from remote control valve is supplied to the pilot port (b2), the spool moves to
the left and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve (1) and flow into bucket cylinder port
(2B).
The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of
the neutral passage.
The return oil from cylinder port (2A) flows into the tank via the low pressure passage.

6-22
(3) Dump position

24Mpa

2B

2A

24Mpa DUMP
a2 b2

Load check valve(1)

21Mpa

SECTION A-A
2A 2B

A A

a2
b2

Low pressure passage

7407B6WE17

When the pilot pressure from remote control valve is supplied to the pilot port (a1), the spool
moves to the right and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve (1) and flow into bucket cylinder
port (2A).
The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off
of the neutral passage.
The return oil from cylinder port (2B) flows into the tank via the low pressure passage.

6-23
4) PRESSURE SETTING

A good pressure gage must be installed in Relief valve Check valve Pilot section
poppet(D) poppet(K)
the line which is in communication with the
Pilot poppet(E) Lock nut
work port relief. A load must be applied in
a manner to reach the set pressure of the
relief unit.

(1) Main relief valve

① Loosen lock nut.
② Set adjusting nut to desired pressure Piston poppet(C) Housing O-ring
setting. Piston spring Pilot spring Adjust nut
③ If desired pressure setting cannot be
achieved, add or remove shims as
required. T
④ Tighten lock nut. 210 bar
220bar
⑤ Retest in similar manner as above.
P

7407AWE50

(2) Port relief valve

① Loosen lock nut.
Relief valve Check valve Pilot section
② Set adjusting screw to desired pressure poppet(D) poppet(K)
setting. Pilot poppet(E) Lock nut
③ Tighten lock nut.
④ Retest in similar manner as above.

Piston poppet(C) Pilot spring O-ring

Piston spring Housing Adjust screw

T
240bar

7407AWE51

6-24
5) MAIN RELIEF VALVE
(1) As relief
A D B K
The relief valve is in communication
between the high pressure port HP and
low pressure LP. Oil is admitted through
the hole in poppet C and because of the HP
differential area between diameters A and
B relief valve poppet D and check valve

LP
poppet K are tightly seated as shown in C
the first step.

E
The oil pressure in the high pressure port
Hp has reached the setting of the pilot
poppet spring force and unseats the pilot HP
poppet E and oil flows around the poppet
through the cross drilled holes and to the

LP
low pressure area LP.

D E
The loss of oil behind poppet C, effected
by the opening of pilot poppet E, causes
poppet C to move back and seat against
HP
pilot poppet E. This shuts off the oil flow
to the area behind relief valve poppet D,
LP

and causes a low pressure area internally.

C

D
The imbalance of pressure on the inside
as compared to that of the high pressure
port HP, forces the relief valve poppet D to HP
open and relieve the oil directly to the low
pressure chamber LP in the valve.
LP

7407AWE52

6-25
(2) As anti void

The anti-void unit supplies oil to the high

K G
pressure port HP when cavitation has
occurred. A lower pressure exists in the A
port HP compared to the low pressure
chamber LP. The difference between the HP
effective area of diameter A and G
causes imbalance of the check valve

LP
poppet K which unseats, thus allowing oil
from the low pressure chamber LP to
enter the port HP and fill the void. 7407AWE53

(3) As separate anti void

The anti-void check valve opens when M O-ring

cavitation occurs in the high pressure port
HP and supplies oil from the reservoir LP
to help fill this void. The poppet M is held
A1
A2

on its seat by the port pressure HP, acting HP

on the larger area behind the O-ring.
When pressure HP drops below LP
atmosphere, the tank pressure LP
Spring
operating on the annular area A1-A2 will
overcome the port pressure HP and the 7407AWE54

spring force to open the poppet. When the

void is eliminated the spring will return the
poppet which will then be tightly seated by
the port pressure HP.

6-26
6) PORT RELIEF VALVE
(1) As relief
A D LP B K
The relief valve is in communication
between the high pressure port HP and
low pressure LP. Oil is admitted through
the hole in poppet C and because of the HP
differential area between diameters A and
B relief valve poppet D and check valve
poppet K are tightly seated as shown in LP C
the first step.

LP E
The oil pressure in the high pressure port
Hp has reached the setting of the pilot
poppet spring force and unseats the pilot HP
poppet E and oil flows around the poppet
through the cross drilled holes and to the
low pressure area LP. LP

The loss of oil behind poppet C, effected D LP E

by the opening of pilot poppet E, causes
poppet C to move back and seat against
pilot poppet E. This shuts off the oil flow to HP
the area behind relief valve poppet D, and
causes a low pressure area internally.
LP C

The imbalance of pressure on the inside LP D

as compared to that of the high pressure
port HP, forces the relief valve poppet D to
open and relieve the oil directly to the low HP
pressure chamber LP in the valve.

LP

7407AWE55

6-27
7. PILOT OIL SUPPLY UNIT
1) STRUCTURE

5
1

P
2
U

T
6

P2 2
7607B6WE46

3MPa
Port Port name Port size
U
P1 From steering pump 3/4-16UNF

4.5MPa P2 Pluging 3/4-16UNF

U Supply to RCV lever 9/16-18UNF
P1 T T To hydraulic tank 9/16-18UNF
HYDRAULIC CIRCUIT 7807AWE49

1 Manifold complete 4 Accumulator

2 Reducing valve 5 Gasket
3 Seal kit 6 Relife valve

2) OPERATION
The pilot supply manifold reduces the pressure from the high pressure circuit to a low pressure
circuit in order to supply the remote control valve.
The accumulator satisfies short term peak power demands and is a source of emergency power in
case of main circuit pressure failures.
The unit consists of the housing, the accumulator(4), the relief valve (6), the check valve and the
reducing valve (2).
The flow path is from the high pressure circuit through port P2 to the pressure reducing valve (2).
The pressure is reduced in the reducing valve (2) and oil passes the check valve into the
accumulator (4) and to the port U, which is connected with the remote control valve.
The pressure relief valve (6) protects the pilot circuit in case of the reducing valve (2) failures or
external increase of pressure.

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8. BOOM AND BUCKET CYLINDER
The boom cylinders are two unit and the bucket cylinder is one unit. They use a bolt on rod guide.
The piston (12) threads on to the rod (2) and is retained by a nut (18).
The piston seals against the tube (1) with piston seal (15). Two wear rings (16) are located on each
side of the piston seal.
The gland(3, the rod guide) seals against the tube with an O-ring (10). The cylinder thread seals
against the rod with a lip type buffer ring (7) and a rod seal (5). A dust wiper (8) cleans the rod when
it is retracted.
1) BOOM CYLINDER

8,9 5,6 19 7 10,11 23 22 3 4 1 2 13,14 17 15 16 12 18

20 21 27, 28

24 , 25, 26

7407B6WE46

1 Tube assembly 11 Back up ring 21 Pipe assembly

2 Rod assembly 12 Piston 22 O-ring
3 Gland 13 O-ring 23 Bolt
4 Bushing 14 Back up ring 24 Clamp
5 Rod seal 15 Piston seal 25 Bolt
6 Back up ring 16 Wear ring 26 Spring washer
7 Buffer ring 17 Dust ring 27 Pin bushing
8 Dust wiper 18 Lock nut 28 Dust seal
9 Snap ring 19 Bolt
10 O-ring 20 Pipe assembly

6-29
2) BUCKET CYLINDER

8, 9 5, 6 7 25 24 3 10,11 4 1 2 12 13, 14 17 15 16 19 18

22

27, 26

23
20

7407B6WE47

1 Tube assembly 10 O-ring 19 Set screw

2 Rod assembly 11 Back up ring 20 Bolt
3 Gland 12 Piston 21 Band assembly
4 Bushing 13 O-ring 22 Pipe assembly
5 Rod seal 14 Back up ring 23 Pipe assembly
6 Back up ring 15 Piston seal 24 O-ring
7 Buffer ring 16 Wear ring 25 Bolt
8 Dust wiper 17 Dust ring 26 Pin bushing
9 Snap ring 18 Lock nut 27 Dust seal

6-30
9. HYDRAULIC OIL TANK
1) STRUCTURE
· The oil from the hydraulic tank is sent from the pump through main control valve to the cylinders.
In the return circuit, the oil from various parts merges.
· A part of oil is cooled in the oil cooler, passes through the hydraulic filter and returns to the
hydraulic tank (1).
· If the hydraulic return oil filter becomes clogged, return filter bypass valve (6) acts to allow the oil
to return directly to the hydraulic tank (1). This prevents damage to the hydraulic filter (5). The
bypass valve (6) is also actuated when negative pressure is generated in the circuit.

15 11,13 4 9

1
3

A 7

6
5

SECTION A - A

2,8
15 12,14 10
7409S6WE58

1 Hydraulic tank wa 9 Socket bolt

2 Pipe assembly 10 Bolt
3 Sight gauge 11 Cover
4 Air breather 12 Cover
5 Element assembly 13 O-ring
6 Bypass valve 14 O-ring
7 Spring 15 Bolt
8 O-ring

6-31
2) RETURN OIL FILTER BYPASS VALVE

(1) When the filter is clogged

Bypass valve (1) is opened and the oil
returns directly to the tank without passing 1
through the filter.

·Bypass valve set pressure : 1.36kgf/cm2

(19.3psi)

From MCV
7607B6WE47

6-32
3) AIR BREATHER
The air breather is equipped with the
capacity to perform three functions
simultaneously-as an air filter, breathing
valve, and as a lubrication opening.
(1) Preventing negative pressure inside the
tank Air breather
The tank is a pressurized sealed type, so
negative pressure is formed inside the
hydraulic tank when the oil level drops
during operations. When this happens,
the difference in pressure between the
tank and the outside atmospheric
pressure opens the poppet in the
breather, and air from the outside is let
into the tank or prevent negative pressure.
(2) Preventing excessive pressure inside
the tank
When the hydraulic cylinder is being
used, the oil level in the hydraulic system
increases and as temperature rises. If
the hydraulic pressure rises above the set
pressure, breather is actuated to release
the hydraulic pressure inside the tank. 7409S6WE59

6-33
10. ACCUMULATOR
The accumulator is installed at the pilot oil
supply unit. When the boom is left the
raised position, and the control levers are
operated with the engine stopped the
pressure of the compressed nitrogen gas
inside the accumulator sends pilot pressure
to the control valve to actuate it and allow 1
the boom and bucket to come down under 2
their own weight. 3
Type of gas Nitrogen gas (N2)
Volume of gas 0.75 ℓ (0.2 U.S.gal)
Charging pressure of gas 16 kg/cm2 (228 psi)
Max actuating pressure 128 kg/cm2 (1820 psi)
1 Diaphragm
2 Steel pressure vessel
3 Closure button
7803AWE56

6-34