05液压系统Hydraulic system PDF

Hydraulic system
Table of contents
1.
Hydraulic basic knowledge
z 2.
The introduction of hydraulic components
z 3.
Hydraulic system of excavator
z 4.
The introduction of hydraulic pipe line
z 5.
Pressure test and adjust
z 6.
Troubleshooting
z
1.1
Pascals theorem
1.
Pressure on a confined liquid will

exert the same force in all
directions equally .
Large area
Load
2.
The speed of the load, as it moves,
is in direct proportion to the area of
its cylinder verses the area of the
cylinder F.
3.
Fluid pressure is created by

external load. No load, no pressure.
4.
Conservation of energy
Small area F
Full of oil
FpA
PvF
vqA
F--force p--pressure
A--area
q--flow
P--power v--speed
1.2
Lines and symbols commonly used in hydraulic systems
Lines:
Thick solid lines represent work lines
Broken solid lines represent pilot or drain lines
Double dotted lines represent
combined elements
Intersect lines with small dots
represent connected lines.
Intersecting lines with
small circular offset, represent lines or circuits that do not meet
Symbols
P Pressure oil of pump
AB
The work oil port of cylinder or motor
OTDr Reservoir
1.3
Basic composition of the hydraulic system
4
Hydraulic system consist of 4 parts:
Hydraulic pump: Converts the

mechanical energy to hydraulic energy.
Implement components: Convert the

hydraulic energy to mechanical energy.
For example cylinder, motor and so on.
1.3
Basic composition of the hydraulic system
Control components: Valves. Generally,

there are pressure control valves, flow
control valves, directional control valve.
Auxiliary components: Hydraulic tank,

filters, piping, joints, seals, coolers,
accumulators and so on.
1.4
Symbol of hydraulic components
Hydraulic pump:
One-way, fixed
displacement
Two-way, fixed
displacement
One-way, variable
displacement
1.4
Hydraulic valves :
One-way valve
Relief valve
Shuttle Valve
Pressure
reducing valve
Flow Control Valve
Solenoid valve
Variable Flow
Control Valve
Shut-off valve
1.4
Hydraulic motor:
One-way, fixed
displacement
Two-way, fixed
displacement
Two-way, variable
displacement
1.4
Hydraulic cylinder :
Double-acting
hydraulic cylinder
Single-acting
hydraulic cylinder
1.4
Auxiliary components:
Hydraulic
Reservoir
Cooler
Filter
Accumulator
1.5
Recommended Hydraulic oil
Please contact LiuGong Headquarters for

additional information.
Use of Motor oil is prohibited.

Table of contents
1.
z 2.
z 3.
z 4.
z 5.
z 6.
Troubleshooting
z

Main hydraulic components
Main pump
Travel Motor&Reducer
Main control valve
Swing Motor&Reducer
Pilot valve Travel pilot valve Pilot valve block
2.
2.1 Main pump

2.2 Main control valve
2.3 Swing Motor&Reducer
2.4 Travel Motor&Reducer
2.5 Pilot valve
2.6 Travel pilot valve
2.7 Pilot valve block
2.1 ()
Main pump (description)
This pump is composed of main pump and pilot pump. The main pump is
a variable displacement axial plunger pump. It provides high pressure oil for
the hydraulic system of excavator. The pilot pump is a fixed displacement
gear pump. It supplies oil for the control system. The main pump is driven by
the engine through a coupler. The pilot gear pump is connected directly by the
drive shaft of the main pump at the same rotate speed.
2.1 ()
Main pump (main parameters)
Item
unit
Type
Main pump
923D/925D
Duplex Variable
Axial Piston
Pump
Duplex Variable
Axial Piston
Pump
Displacement
cc
108
115
Flow
L/min
2215
2230
Rated pressure
MPa
34.3
34.3
Gear pump
Gear pump
Type
Pilot pump
920D/922D
Displacement
cc
10
10
Flow
L/min
20
20
Rated pressure
MPa
3.9
3.9
2.1 ()
Main pump (shape)
The port of pilot pressure test
The port of main pressure test
Left pump
Models
920D ()
922D ()
923D ()
925D ()
Port for Leakage
Oil outlet
Right pump
Pilot pump
Pilot pressure
adjust bolt
The adjust bolt

of min. flow
Regulator for
right pump
The adjust bolt of max. flow
Solenoid Proportional
Reducing Valve
Regulator for
right pump
The adjust bolt

of min. flow
2.1 ()
Main pump (Hydraulic schematic )
P1
Regulator for
P1 pump
Reducing Valve
Models
920D ()
922D ()
923D ()
925D () 925D()
P2
Regulator for
P2 pump
Pilot pump
P1 pump
P2 pump
2.
2.1 Main pump

2.5 Pilot valve
2.2 ()
Main control valve (description)
The main control valve is located between the main pump and
actuators(all of the cylinders and motors).It controls the oil direction, pressure,
and flow rate for all of the actuators. Main control valve is pilot control, open
negative flow control, and paralleling monolithic multi-ported directional valve
composed of nine spools. It includes spools for the boomarmbucket
swingtravel and auxiliary devices. Main control valve has the auxiliary
functions for boom raise confluencearm confluencearm regeneration
swing priorityboom anti-driftarm anti-drift and straight travel.
2.2 ()
Main control valve (main parameters)
Item
unit
920D/922D
923D/925D
()
Main relief pressure,
(standard)
Mpa
31.8
32.2
()
Main relief pressure,
(boost)
Mpa
33.3
34.6
Implement circuits
Mpa
25.5
25.5
2.2 ()
Main control valve (Shape)
Port relief valve for arm spool
Models
920D()
922D()
922D()
923D()
925D()925D()
2
2nd arm spool
Lock valve
for boom
Bucket spool
1
1st arm spool
1
1st boom spool
2
2nd boom spool
Port relief valve

for bucket spool
Swing spool
Port relief valve

for boom spool
Main relief valve
Lock valve
for boom
Straight travel valve
Left travel
spool
Right travel
spool
Port relief valve for

option spool
Option spool
Models
2.2 ()
Main control valve (Shape)
C2
/LCo
HV
HV
C1
920D()
922D()
922D()
923D()
925D()925D()
/CCb
/LCa1
CP2
FR
FL
/LCb1
/LCk
/LCa2
CSp
CSp
/CMR1&CMR2
2.2 ()
Main control valve (Hydraulic schematic )
Models
920D()
922D()
922D()
923D()
925D()925D()
2.
2.1 Main pump

2.5 Pilot valve
2.3 ()
Swing motor & reduction gear (description)
The swing motor&reducer consists of a hydraulic motor and a

reduction gear.It rotates the upper structure of excavator.
920D/922D
923D/925D
2.3 ()
Swing motor & reduction gear (shape)
Port for
lubricating oil
Relief valve
Oil dipstick
Models
920D()
922D()
922D()
Port for pressure test
Anti-reversion valve
Port for main pressure
Time-delay valve
for braking
Swing reduction gear
2.3 ()
Swing motor & reduction gear (shape)
Models
923D()
925D()
925D()
Relief valve
Port for
lubricating oil
Oil dipstick
Port for main

pressure
Anti-reversion valve
Swing reduction
gear
2.3 ()
Swing motor & reduction gear (hydraulic schematic)
Models
920D()
922D()
922D()
923D()
925D()925D()
2.
2.1 Main pump

2.5 Pilot valve
2.4 ()
Travel motor & reduction gear (description)
The Travel motor & reducer consists of a hydraulic motor and a

reduction gear. It is used to control the forward, backward, left
turn and right turn operation of the machine.The travel speed can
be controled by travel speed control switch.There are two speed
positons:Low Speed and High Speed. It does not automatically
downshift.
2.4 ()
Travel motor & reduction gear (Shape)
Models
920D()
922D()
922D()
923D()
925D()925D()
Balance valve
Relief valve
/
Pilot Port/control
travel speed
Travel
reduction gear
Relief valve
Port for Leakage
Refill oil
Port for main

pressure
Oil level mark
Port for Leakage
Oil drain plug
Models
2.4 ()
Travel motor & reduction gear (hydraulic schematic )
920D()
922D()
922D()
923D()
925D()925D()
Relief valve
Balance valve
2.
2.1 Main pump

2.5 Pilot valve
2.5 ()
Pilot valve (description)
The pilot control valve is used to control implements speed and

operation. One is installed on the left side of operator seat in the
cab, and another is installed on the right side. The left one
controls swing, arm and horn. The right one controls boom and
bucket and power boost in standard mode.
2.5 ()
Pilot valve (Hydraulic schematic )
2.
2.1 Main pump

2.5 Pilot valve
2.6 ()
Travel pilot valve (Description)
The travel pilot valve supplies pilot oil for the travel spools of the
main control valve to control the forward, backward, left turn and
right turn operation of the machine. It also has hydraulic
dampeners to smooth operation of the travel system.
2.6 ()
Travel pilot valve (Hydraulic schematic )
2.
2.1 Main pump

2.5 Pilot valve
2.7 ()
Pilot valve block (description)
Models
920D()
922D()
922D()
923D()
925D()925D()
Pilot oil goes through the pilot valve block to remote pilot control valve. There
are three solenoid valves which control pilot lock, two speed travel. and power
boost of main relief valve.
Pilot lock
Two speed travel
Power boost
2.7 ()
Pilot valve block (Hydraulic schematic )
Pilot Lock
Two Speed Travel
Power Boost

Table of contents
1.
z 2.
z 3.
z 4.
z 5.
z 6.
Troubleshooting
z
3.
3.1 Hydraulic system parameters

3.2 Drive diagram of hydraulic system
3.3 Hydraulic system schematic
3.3.1 Negative flow control system
3.3.2 Boom raise
3.3.3 Boom lower
3.3.4 Arm out
3.3.5 () Arm In (with regeneration)
3.3.6 () Arm In (without regeneration)
3.3.7 Bucket in
3.3.8 Bucket out
3.3.9 Swing left
3.3.10 Swing right
3.3.11 () Forward travel (high speed)
3.3.12 ( ) Backward travel (low speed)
3.3.13 Straight travel
3.1
Hydraulic system parameters
Item
Unit
920D/922D
923D/925D
Double Variable Axial

Piston Pump
Double Variable Axial

Piston Pump
cc
108
115
Main pump type
Main pump displacement
Main pump total flow
L/min
2215
2230
Relief pressure, main
MPa
31.8
32.2
Relief pressure,
boost
MPa
33.3
34.6
Swing Circuit
pressure
MPa
25.5
25.5
Travel circuit
Pressure
MPa
31.8
31.8
/Boom
Head/Rod Relief Pressure
MPa
36.3/36.3
36.6/36.6
/Arm
MPa
37.2/37.2
36.6/37.2
10
/Bucket
MPa
35.3/36.3
36.6/37.2
11
Option Relief
Pressure
Mpa
19.6
19.6
3.1
Hydraulic system parameters
12
Pilot pump type
Gear pump
Gear pump
13
Pilot pumpdisplacement
cc
10
10
14
Pilot pump flow
L/min
20
20
15
Pilot pressure
MPa
3.9
3.9
16
(
) boom cylinder
(BorerodStroke -Min. Installation
Dimension )
mm
120851187-1794
1259013501950
17
(
) arm cylinder
Dimension )
mm
135951450-2063
1401051610223
5
18
(
) bucket cylinder
Dimension )
mm
120851058-1593
1309010751665
19
(/)hydraulic oil
(tank/system)
230/330
230/330
20
Swing motor gear oil
3.4
4.4
21
Drive motor gear oil
5.5*2
5.5*2
3.2
Drive diagram of hydraulic system
Drive
Control oil
Pilot
pump
Engine
Drive
Work oil
Work
pump
Implement work
Control
Carry out
Driver
Control oil
Work oil
Main valve
Pilot valve
Motor
Work oil
Carry out
Cylinder
SwingTravel
3.3 Hydraulic system schematic

3
3.3.1 Negative Flow Control System
BOOM RAISE
3.3.2 Boom
Raise
BOOM LOWER
3.3.3 Boom
Lower
ARM OUT
3.3.4 Arm Out
ARM IN
WITH REGENERATION
3.3.5 ()Arm In (With Regeneration)
3.3.6 () WITHOUT
ArmARMREGENERATION
InIN(Without Regeneration)
BUCKET IN
3.3.7
Bucket In
3.3.8 BUCKET
Bucket
Out
OUT
SWING LEFT
3.3.9 Swing
Left
3.3.10Swing
SWING RIGHT Right
3.3.11 () Forward
Travel (High Speed)
FORWARD TRAVLE(HIGH SPEED)
3.3.12 () Backward
Travel (Low Speed)
BACKWARD TRAVLE(LOW SPEED)
3.3.13 Straight Travel

STRAIGHT TRAVLE

Table of contents
1.
z 2.
z 3.
z 4.
z 5.
z 6.
Troubleshooting
z
4.1
Main pump piping
Case
Drain hose
Models
920D()
922D()
923D()
925D()925D()
Pressure
sensor
Working hose
Reducing Valve
Oil inlet tube
Sensor for hydraulic

oil temperature
4.2
Swing Motor Piping
Models
920D()
922D()922D()
Working hose
Make up oil
inlet
Swing pressure
test point
Port for
lubricating oil
Case Drain
hose
Swing
relief valve
Oil dipstick
4.2
Swing Motor Piping
Case Drain
hose
Swing
relief valve
Models
923D()
925D()925D()
Make up oil
inlet
Port for
lubricating oil
Oil dipstick
Swing pressure
test point
Working hose
4.3 ()
Models
922D()
Pilot hydraulic pipe line(Pilot valve block)
Accumulator
Pilot relief
valve
Pressure sensor
Pilot pressure
test point
Pilot filter
4.3 ()
Models
Pilot hydraulic pipe line(Pilot valve block)
920D()
922D()
923D()
925D()925D()
Accumulator
Pilot pressure
test point
Pressure sensor
Pilot filter

Table of contents
1.
z 2.
z 3.
z 4.
z 5.
z 6.
Troubleshooting
z
5.1
System pressure test
P2
P1
a2
a1
Models
920D()
922D()
922D()
923D()
925D()925D()
P1P2:(a1a2 ,G1/4)
Port P1P2 pressure test:(pressure test ports a1a2
dimension:G1/4)
1a1a2(
070MPa)
Remove the plug a1/a2 in the illustration with a spanner and
connects with a pressure testing joint and a pressure
gauge(with a range of 0~70MPa);
2505
Start engine, Slowly operate the excavator to raise the

hydraulic oil temoerature to 505;then read the data from
the gauge;
316Nm
Remove pressure gauge and pressure testing joint.Tighten the
plugs to a torque of 16Nm.
5.2
System pressure adjust
Models
920D()
922D()
922D()
923D()
925D()925D()
1
Start the engine, increase its rotating speed slowly to full speed
2
Set the excavator monitor to the function of cheking the left and right pump pressure;
3505
31.8~32.8MPa
33.3~34.3MPa
Turn on the pilot cutoff lever, operate the work implements to let the hydraulic oil temperature
raises to 505, then operate the boom up or arm to extreme position to make the main relief
valve open. At the moment the pressure value should be 31.8~32.8MPa, then press the burst
button located on the right joystick, the pressure value should be 33.3~34.3MPa
4
If the pressure values are not in the arrange above, we need to adjust them as following
procedure:
(1) 30mm3
Loose locknut number 3 with open-end wrench(30mm);
5.2
System pressure adjust
Models
920D()
922D()
922D()
923D()
925D()925D()
(2) 6mm4
33.3-34.3MPa43
Press the burst button located on the right joystick turn number 4 slightly inwards or outwards
slowly with inner hexagon spanner(6mm) and check the pressure value in the monitor.Stop turning
number 4 when the pressure value reaches to 33.3-34.3MPa, then tighten number 3 loose the
burst button located on the right joystick ;
(3)22mm56mm
431.8-32.8MPa45
Loose locknut number 5 with open-end wrench(22mm) in anticlockwise direction.Turn number 4

inwards or outwards slowly with hexagon spanner(6mm) and check the pressure value in the
monitor. Stop turning number 4 and tighten number 5 when the pressure value reaches to
31.8~32.8MPa.
Main relief valve
5.3
Pilot pressure test
Models
920D()
922D()
923D()
925D()925D()
a3G1/4
Pilot pressure test and adjust:(pressure test port a3
dimension:G1/4)
1a3466
(06MPa);
Remove the plug a3number466 in the illustration with
a pressure testing joint and a spanner and connects with a
pressure gauge(with a range of 0~6MPa);
2505
Start engine, Slowly operate the excavator to raise the

hydraulic oil temperature to 505;
a3
The port of pilot pressure test a3
3
3.9~4.1MPa
Set the engine speed to full speed , check the pressure
gauge,the value should be between 3.9~4.1MPa.
5.3
Pilot pressure test
Models
920D()
922D()
922D()
923D()
925D()925D()
124(
06MPa);
Remove the plug number 2 or 4 in the illustration by hand and
connects with a pressure gauge(with a range of 0~6MPa);
2505
Start engine, Slowly operate the excavator to raise the hydraulic

oil temperature to 505;
3
3.9~4.1MPa
Set the engine speed to full speed, check the pressure gauge,the
value should be between 3.9~4.1MPa.
5.4
Pilot pressure adjust
Models
920D()
922D()
923D()
925D()925D()
If the Pilot pressure pressure value is incorrect, adjust

it as following procedure:
(1)22mm312
6mm311
,3.9~4.1MPa
312
Loose locknut 312 with open-end wrench(22mm)as shown
in the illustration. Tighten screw 311 by inner hexagon
spanner(6mm). The pressure will increase when rotate in
clockwise direction and decrease when rotate in
anticlockwise direction. Tighten locknut 312 when the
pressure value reaches to 3.9~4.1MPa. After that,
pressure adjustment is finished.
Pilot pressure
adjust bolt
(2)16Nm
Remove pressure gauge and pressure testing joint.
Tighten the plug to a torque of 16Nm.
5.4
Pilot pressure adjust
Pilot relief valve
Model
922D()
If the Pilot pressure pressure value is incorrect, adjust

it as following procedure:
(1)
,3.9~4.1MPa
Loose locknut that installed on the pilot relief valve as

shown in the illustration. The pressure will increase when
rotate in clockwise direction and decrease when rotate in
anticlockwise direction. Tighten locknut 312 when the
pressure value reaches to 3.9~4.1MPa. After that,
pressure adjustment is finished.
(2)16Nm
Remove pressure gauge and pressure testing joint.
Tighten the plug to a torque of 16Nm.

Table of contents
1.
z 2.
z 3.
z 4.
z 5.
z 6.
Troubleshooting
z
6.1
Hydraulic components works slowly
Cause
Solutions
Low oil level
Add oil to oil tank to the full mark
Cold oil
Run the engine to preheat hydraulic system
Wrong hydraulic oil
Use the correct oil
Slow engine speed
Solve the problem of low engine speed
Pilot oil loops
Check the pilot circuit
Worn pump
Replace or repair worn parts
Restricted pump suction pipe
Check pump suction pipe
6.2
Hydraulic oil over hot
Cause
Solutions
Wrong hydraulic oil
Use the correct oil
Low oil level
Add oil to oil tank to the full mark
Worn pump
Clogged radiator or oil cooler
Clean or rearrange the radiator fins
Oil cooler bypasses
Check one-way valve of the oil return
Relief valve
Check and adjust the relief valve
Unclean oil
Add oil after draining oil
Improper adjustment for the hydraulic

components
Proper adjustment for the hydraulic

components
6.3
Low pressure or no oil pres-sure
Cause
Solutions
Wrong oil
Use the correct oil
Improper adjustment for the

hydraulic components
Proper adjustment for the

hydraulic components
No oil in the hydraulic system
Add the correct oil
Worn cylinder
Relief valve
Check and adjust the relief

valve
6.4
Cylinder can work but can not lift load
Cause
Solutions
Worn pump
Low pressure of main relief valve
Check
and adjust the main relief valve
pressure
Low oil level
Add oil
Clogged the filter
Clean the filter and the system
Pump suction pipeline leaks
Check suction pipeline
6.5
One control lever does not work
Cause
Solutions
Low pressure of the oil port relief

valve
Check
and adjust the oil port relief valve
pressure
Tube or hose damaged
Repair or replace
Hydraulic components loosen
Tighten
O
O
O-ring is damaged when assembled Replace a new O-ring
Pilot valve
Repair or replace worn parts of

pilot valve
Pilot lines
Repair or replace
6.6
One cylinder does not work
Cause
Solutions
Spool of
control valve damaged or polluted by
dust
Replace and repair worn parts of

control valve or cleaning it
Tube or hose damaged
Repair or replace
Hydraulic components loosen
Tighten
O
O
O-ring of hydraulic components damaged Replace a new O-ring
Pilot valve
Pilot pipeline failure
Replace and repair worn parts of hand

pilot valve or clean it
Repair or replace
6.7
One travel motor does not work
Cause
Solutions
Travel motor trouble
Center swivel joint trouble
Check for internal leakage

of center swivel joint
Do not set free brake pedal
Replace and repair brake
Travel pilot valve
Pilot circuit

travel motor or clean it
Repair or replace worn parts of

travel pilot valve or clean it
Repair or replace
6.8
Can not swing
Cause
Solutions
Swing brake release valve
Replace and repair swing brake

release valve
Swing motor

swing motor
Pilot valve

hand pilot valve or clean it

Thank you !
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Hydraulic system

Pressure on a confined liquid will

Fluid pressure is created by

Hydraulic pump: Converts the

Implement components: Convert the

Control components: Valves. Generally,

Auxiliary components: Hydraulic tank,

Flow Control Valve

Please contact LiuGong Headquarters for

Use of Motor oil is prohibited.

Main control valve

Pilot valve Travel pilot valve Pilot valve block

2.1 Main pump

The port of pilot pressure test

The port of main pressure test

Port for Leakage

The adjust bolt

The adjust bolt of max. flow

The adjust bolt

2.1 Main pump

Port relief valve for arm spool

Port relief valve

Port relief valve

Main relief valve

Straight travel valve

Port relief valve for

2.1 Main pump

The swing motor&reducer consists of a hydraulic motor and a

Port for pressure test

Port for main pressure

Swing reduction gear

Port for pressure test

Port for main

Swing motor & reduction gear (hydraulic schematic)

2.1 Main pump

The Travel motor & reducer consists of a hydraulic motor and a

Port for pressure test

Port for Leakage

Port for main

Oil level mark

Port for Leakage

Oil drain plug

2.1 Main pump

The pilot control valve is used to control implements speed and

2.1 Main pump

2.1 Main pump

3.1 Hydraulic system parameters

Double Variable Axial

Double Variable Axial

Main pump type

Main pump displacement

Main pump total flow

Relief pressure, main

Pilot pump type

Pilot pump flow

Swing motor gear oil

Drive motor gear oil

3.3 Hydraulic system schematic

3.3.1 Negative Flow Control System

3.3.4 Arm Out

3.3.5 ()Arm In (With Regeneration)

3.3.13 Straight Travel