PDF Service Manual Hyundai HX480L HX520L Excavator - 4 MB

This is the complete 2023 service manual for the Hyundai HX480L and HX520L hydraulic excavators.

It provides comprehensive, factory-authorized procedures for every aspect of repair and maintenance.

Inside you'll find detailed specifications, troubleshooting charts, and step-by-step instructions.

This manual is designed for professional technicians to perform everything from minor adjustments to a complete overhaul.

Rely on this guide to service your Hyundai excavator to the highest standards.

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--- Page 1 ---
CONTENTS

SECTION 1 GENERAL

  Group 1 Safety Hints ------------------------------------------------------------------------------------------------------ 1-1
  Group 2 Specifications --------------------------------------------------------------------------------------------------- 1-10

SECTION 2 STRUCTURE AND FUNCTION

  Group 1 Pump Device ---------------------------------------------------------------------------------------------------- 2-1
  Group 2 Main Control Valve ------------------------------------------------------------------------------------------- 2-20
  Group 3 Swing Device ---------------------------------------------------------------------------------------------------- 2-60
  Group 4 Travel Device ---------------------------------------------------------------------------------------------------- 2-71
  Group 5 RCV Lever -------------------------------------------------------------------------------------------------------- 2-85
  Group 6 RCV Pedal -------------------------------------------------------------------------------------------------------- 2-92

SECTION 3 HYDRAULIC SYSTEM

  Group 1 Hydraulic Circuit ----------------------------------------------------------------------------------------------- 3-1
  Group 2 Main Circuit ------------------------------------------------------------------------------------------------------- 3-2
  Group 3 Pilot Circuit -------------------------------------------------------------------------------------------------------- 3-5
  Group 4 Single Operation ---------------------------------------------------------------------------------------------- 3-14
  Group 5 Combined Operation --------------------------------------------------------------------------------------- 3-24

SECTION 4 ELECTRICAL SYSTEM

  Group 1 Component Location --------------------------------------------------------------------------------------- 4-1
  Group 2 Electric Circuit -------------------------------------------------------------------------------------------------- 4-3
  Group 3 Electrical Component Specification --------------------------------------------------------------- 4-23
  Group 4 Connectors ------------------------------------------------------------------------------------------------------- 4-32

SECTION 5 MECHATRONICS SYSTEM

  Group 1 Outline --------------------------------------------------------------------------------------------------------------- 5-1
  Group 2 Mode selection System ----------------------------------------------------------------------------------- 5-3
  Group 3 Automatic Deceleration System --------------------------------------------------------------------- 5-6
  Group 4 Power Boost System --------------------------------------------------------------------------------------- 5-7
  Group 5 Travel Speed Control System ------------------------------------------------------------------------- 5-8
  Group 6 Automatic Warming Up Function -------------------------------------------------------------------- 5-9
  Group 7 Engine Overheat Prevention Function ----------------------------------------------------------- 5-10
  Group 8 Variable Power Control System ---------------------------------------------------------------------- 5-11

--- Page 3 ---
TEMPERATURE
Fahrenheit-Centigrade Conversion.
A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse
is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.

   ˚C                ˚F       ˚C                ˚F          ˚C             ˚F       ˚C                 ˚F
  -40.4    -40      -40.0    -11.7     11      51.8          7.8   46     114.8    27.2      81      117.8
  -37.2    -35      -31.0    -11.1     12      53.6          8.3   47     116.6    27.8      82      179.6
  -34.4    -30      -22.0    -10.6     13      55.4          8.9   48     118.4    28.3      83      181.4
  -31.7    -25      -13.0    -10.0     14      57.2          9.4   49     120.2    28.9      84      183.2
  -28.9    -20       -4.0     -9.4     15      59.0         10.0   50     122.0    29.4      85      185.0

  -28.3    -19      -2.2     -8.9      16      60.8         10.6   51     123.8    30.0      86      186.8
  -27.8    -18      -0.4     -8.3      17      62.6         11.1   52     125.6    30.6      87      188.6
  -27.2    -17       1.4     -7.8      18      64.4         11.7   53     127.4    31.1      88      190.4
  -26.7    -16       3.2     -6.7      20      68.0         12.8   55     131.0    32.2      90      194.0
  -26.1    -15       5.0     -6.7      20      68.0         12.8   55     131.0    32.2      90      194.0

  -25.6    -14       6.8     -6.1      21      69.8         13.3   56     132.8    32.8      91      195.8
  -25.0    -13       8.6     -5.6      22      71.6         13.9   57     134.6    33.3      92      197.6
  -24.4    -12      10.4     -5.0      23      73.4         14.4   58     136.4    33.9      93      199.4
  -23.9    -11      12.2     -4.4      24      75.2         15.0   59     138.2    34.4      94      201.2
  -23.3    -10      14.0     -3.9      25      77.0         15.6   60     140.0    35.0      95      203.0

  -22.8     -9      15.8     -3.3      26      78.8         16.1   61     141.8    35.6      96      204.8
  -22.2     -8      17.6     -2.8      27      80.6         16.7   62     143.6    36.1      97      206.6
  -21.7     -7      19.4     -2.2      28      82.4         17.2   63     145.4    36.7      98      208.4
  -21.1     -6      21.2     -1.7      29      84.2         17.8   64     147.2    37.2      99      210.2
  -20.6     -5      23.0     -1.1      35      95.0         21.1   70     158.0    51.7      125     257.0

  -20.0     -4      24.8     -0.6      31      87.8         18.9   66     150.8    40.6      105     221.0
  -19.4     -3      26.6      0        32      89.6         19.4   67     152.6    43.3      110     230.0
  -18.9     -2      28.4     0.6       33      91.4         20.0   68     154.4    46.1      115     239.0
  -18.3     -1      30.2     1.1       34      93.2         20.6   69     156.2    48.9      120     248.0
  -17.8     0       32.0     1.7       35      95.0         21.1   70     158.0    51.7      125     257.0

  -17.2     1       33.8      2.2      36       96.8        21.7   71     159.8    54.4      130     266.0
  -16.7     2       35.6      2.8      37       98.6        22.2   72     161.6    57.2      135     275.0
  -16.1     3       37.4      3.3      38      100.4        22.8   73     163.4    60.0      140     284.0
  -15.6     4       39.2      3.9      39      102.2        23.3   74     165.2    62.7      145     293.0
  -15.0     5       41.0      4.4      40      104.0        23.9   75     167.0    65.6      150     302.0

  -14.4     6       42.8      5.0      41      105.8        24.4   76     168.8    68.3      155     311.0
  -13.9     7       44.6      5.6      42      107.6        25.0   77     170.6    71.1      160     320.0
  -13.3     8       46.4      6.1      43      109.4        25.6   78     172.4    73.9      165     329.0
  -12.8     9       48.2      6.7      44      111.2        26.1   79     174.2    76.7      170     338.0
  -12.2     10      50.0      7.2      45      113.0        26.7   80     176.0    79.4      172     347.0


                                                      0-8

--- Page 4 ---
DISPOSE OF FLUIDS PROPERLY
Improperly disposing of fluids can harm the
environment and ecology. Before draining any
fluids, find out the proper way to dispose of
waste from your local environmental agency.
Use proper containers when draining fluids. Do
not use food or beverage containers that may
mislead someone into drinking from them.
DO NOT pour oil into the ground, down a drain,
or into a stream, pond, or lake. Observe                   13031GE24
relevant environmental protection regulations
when disposing of oil, fuel, coolant, brake fluid,
filters, batteries, and other harmful waste.


REPLACE SAFETY SIGNS
Replace missing or damaged safety signs.
See the machine operator's manual for correct
safety sign placement.


                                                           13031GE25


LIVE WITH SAFETY
Before returning machine to customer, make
sure machine is functioning properly, especially
the safety systems. Install all guards and
shields.


                                                     1-9

--- Page 5 ---
9) HX520 L
    余7.06 m (23' 2") BOOM, 2.40 m (7' 10") ARM


                                                                                             480F2SP03


                      Description                      Unit            Specification
Operating weight                                      kg (lb)        52160 (114990)
Bucket capacity (SAE heaped), standard                m3 (yd3)         2.20 (2.88)
Overall length                            A                           12510 (41' 1")
Overall width, with 600 mm shoe
                                          B                      2980/3540 (9' 10"/11' 7")
(transport position / working position)
Overall height                            C                           4070 (13' 4")
Superstructure width                      D                           2980 ( 9' 9")
Overall height of cab                     E                           3340 (10' 11")
Ground clearance of counterweight         F                           1445 ( 4' 9")
Engine cover height                       G                           3030 ( 9' 11")
Overall height of handrail                G'                          3595 (11' 8")
Minimum ground clearance                  H       mm (ft-in)           770 ( 2' 6")
Rear-end distance                         I                           3885 (12' 9")
Rear-end swing radius                     I'                          3940 (12' 11")
Distance between tumblers                 J                           4470 (14' 8")
Undercarriage length                      K                           5405 (17' 7")
Undercarriage width
                                          L                      2990/3540 (9' 10"/11' 7")
(transport position / working position)
Track gauge
                                          M                      2380/2940 (7' 10"/9' 8")
(transport position / working position)
Track shoe width, standard                N                             600 (24")
Travel speed (low/high)                          km/hr (mph)         3.3/5.3 (2.1/3.3)
Swing speed                                             rpm                8.6
Gradeability                                     Degree (%)              35 (70)
Ground pressure (600 mm shoe)                    kgf/cm2 (psi)         0.91 (12.94)
Max traction force                                    kg (lb)        34100 (75180)


                                               1-19

--- Page 6 ---
5) HX520 L
    余6.55 m (21' 6") BOOM
                                                     A
                                                     A'
                                                                 F


                            D
                            B'    E
                            C
                            B


                                                          8ft
                                                                                           480F2SP05


            Description                    2.40 m (7' 10") Arm        2.90 m (9' 6") Arm
Max digging reach                     A    10690 mm (35' 1")         11130 mm (36' 6")
Max digging reach on ground           A'   10430 mm (34' 3")         10870 mm (35' 8")
Max digging depth                     B     6240 mm (20' 6")          6740 mm (22' 1")
Max digging depth (8ft level)         B'    6060 mm (19'11")          6580 mm (21' 7")
Max vertical wall digging depth       C     4370 mm (14' 4")          5420 mm (17' 9")
Max digging height                    D    10390 mm (34' 1")         10660 mm (35' 0")
Max dumping height                    E     7040 mm (23' 1")          7210 mm (23' 8")
Min swing radius                      F     4870 mm (16' 0")          4540 mm (14'11")
                                            241.2 [263.2] kN          241.2 [263.2] kN
                                  SAE      24600 [26840] kgf         24600 [26840] kgf
                                           54230 [59170] lbf         54230 [59170] lbf
Bucket digging force
                                            280.5 [306.0] kN          280.5 [306.0] kN
                                  ISO      28600 [31200] kgf         28600 [31200] kgf
                                           63050 [68780] lbf         63050 [68780] lbf
                                            278.5 [303.8] kN          225.6 [246.1] kN
                                  SAE      28400 [30980] kgf         23000 [25090] kgf
                                           62610 [68300] lbf         50710 [55310] lbf
Arm crowd force
                                            291.3 [317.7] kN          235.4 [256.7] kN
                                  ISO      29700 [32400] kgf         24000 [26180] kgf
                                           65480 [71430] lbf         52910 [57720] lbf

[ ] : Power boost


                                                  1-29

--- Page 7 ---
(4) 7.06 m (23' 2") boom, 2.90 m (9' 6") arm equipped with 2.20 m3 (SAE heaped) bucket and 600 mm
       (24") triple grouser shoe and 10,200 kg (22,490 lb) counterweight.

         余           : Rating over-front               余          : Rating over-side or 360 degree

                                                  Load radius                                         At max. reach
Load point 3.0 m (9.8 ft)        4.5 m (14.7 ft) 6.0 m (19.6 ft) 7.5 m (24.5 ft) 9.0 m (29.4 ft)     Capacity       Reach
  height
                                                                                                                    m (ft)
    7.5 m kg                                                      *11360 *11360                     *9210    7190    10.11
 (24.5 ft) lb                                                     *25050 *25050                    *20310   15860    33.03
    6.0 m kg                                                      *12120 11520                      *9220    6250    10.76
 (19.6 ft) lb                                                     *26730 25400                     *20340   13770    35.15
    4.5 m kg                    *19010 *19010     *15110 *15110   *13300 11010 *12330       8060     9050    5720    11.13
 (14.7 ft) lb                   *41900 *41900     *33310 *33310   *29320 24270 *27180      17770    19940   12600    36.37
    3.0 m kg                    *23620 23090      *17420 14840    *14570 10470 12350        7770     8730    5470    11.26
   (9.8 ft) lb                  *52060 50900      *38400 32710    *32120 23090 27230       17130    19250   12050    36.80
    1.5 m kg                    *21570 *21570     *19080 14100    *15610 10020 12070        7510     8770    5460    11.16
   (4.9 ft) lb                  *47560 *47560     *42070 31080    *34410 22090 26600       16560    19320   12040    36.45
 Ground kg                      *25090 21760      *19800 13690     15860   9730 11880       7340     9180    5720    10.81
     Line lb                    *55310 47970      *43660 30190     34960 21440 26180       16170    20230   12610    35.32
   -1.5 m kg     *20350 *20350 *24810 21780       *19640 13570     15730   9610                     10110    6330    10.19
  (-4.9 ft) lb   *44860 *44860 *54690 48020       *43300 29910     34670 21180                      22280   13950    33.30
   -3.0 m kg      *28610 *28610 *23130 22020      *18630 13670    *15310   9690                    *11360    7540     9.23
  (-9.8 ft) lb    *63060 *63060 *50990 48550      *41080 30140    *33750 21360                     *25040   16620    30.17
  -4.5 m kg                      *20370 *20370    *16510 14020                                     *10730   10170     7.79
(-14.7 ft) lb                    *44910 *44910    *36390 30910                                     *23650   22430    25.43


   (5) 7.06 m (23' 2") boom, 3.38 m (11' 1") arm equipped with 2.20 m3 (SAE heaped) bucket and 600
       mm (24") triple grouser shoe and 10,200 kg (22,490 lb) counterweight.

         余           : Rating over-front               余          : Rating over-side or 360 degree

                                                  Load radius                                         At max. reach
Load point 3.0 m (9.8 ft)        4.5 m (14.7 ft) 6.0 m (19.6 ft) 7.5 m (24.5 ft) 9.0 m (29.4 ft)     Capacity       Reach
  height
                                                                                                                    m (ft)
    6.0 m kg                                                      *11640 *11640 *11410      8380 *7750       5820    11.18
 (19.6 ft) lb                                                     *25650 *25650 *25160     18480 *17080     12840    36.53
    4.5 m kg                     *17410 *17410    *14350 *14350   *12860 11130 *12030       8110 *7860       5340    11.54
 (14.7 ft) lb                    *38390 *38390    *31640 *31640   *28360 24540 *26530      17890 *17330     11780    37.70
    3.0 m kg                      *22210 *22210   *16770 15090    *14210 10580 12390        7800 *8060       5120    11.67
   (9.8 ft) lb                    *48960 *48960   *36960 33280    *31330 23320 27320       17200 *17760     11280    38.11
    1.5 m kg                      *25070 22400    *18660 14280    *15370 10100 12080        7520   8240      5100    11.57
   (4.9 ft) lb                    *55270 49380    *41150 31490    *33880 22260 26630       16570 18160      11250    37.78
 Ground kg                        *25800 21880    *19670 13790     15900   9760 11850       7310   8590      5320    11.23
     Line lb                      *56880 48230    *43370 30400     35040 21510 26120       16110 18930      11730    36.69
   -1.5 m kg     *19680   *19680 *25300 21780     *19800 13580     15700   9580 11750       7210   9370      5830    10.64
  (-4.9 ft) lb   *43390   *43390 *55780 48010     *43640 29940     34620 21130 25890       15900 20660      12860    34.77
   -3.0 m kg     *25950   *25950 *23920 21930     *19080 13600     15710   9590                  *10510      6840     9.74
  (-9.8 ft) lb   *57200   *57200 *52740 48350     *42069 29990     34630 21140                   *23180     15080    31.82
  -4.5 m kg      *27870   *27870 *21540 *21540    *17390 13850                                   *10990      8910     8.39
(-14.7 ft) lb    *61430   *61430 *47480 *47480    *38330 30530                                   *24230     19640    27.41


                                                           1-39

--- Page 8 ---
8. SPECIFICATIONS FOR MAJOR COMPONENTS
  1) ENGINE

                         Item                                   Specification
Model                                   Scania DC13
Type                                    4-cycle turbocharged charger air cooled diesel engine
Cooling method                          Water cooling
Number of cylinders and arrangement     6 cylinders, in-line
Firing order                            1-5-3-6-2-4
Combustion chamber type                 Direct injection type
Cylinder bore佴stroke                    130佴160 mm (5.12"佴6.3")
Piston displacement                     12700 cc (775 cu in)
Compression ratio                       17.5 : 1
Rated net horse power (SAE J1349)       424 Hp at 1900 rpm (316 kW at 1900 rpm)
Rated gross horse power (SAE J1995)     444 Hp at 1900 rpm (331 kW at 1900 rpm)
Maximum torque                          232 kgf余m (1678 lbf余ft) at 1300 rpm
Engine oil quantity                     38再(10 U.S. gal)
Dry weight                              1075 kg (2370 lb)
Low idling speed                        800佳50 rpm
High idling speed                       1900.50 rpm
Rated fuel consumption                  152.8 g/Hp余hr at 1900 rpm
Starting motor                          24V-5.5kW
Alternator                              24V-100A
Battery                                 2佴12V佴200Ah


  2) MAIN PUMP

                         Item                                   Specification
Type                                    Variable displacement tandem axis piston pumps
Capacity                                2佴200 cc/rev
Maximum pressure                        330 kgf/cm2 (4690 psi) [360 kgf/cm2 (5120 psi)]
Rated oil flow                          2佴380再/min (100.4 U.S. gpm / 83.6 U.K. gpm)
Rated speed                             1750 rpm
[ ] : Power boost


                                      1-49

--- Page 9 ---
3) REAR REGULATOR (1/2)


                             728 438


            Pi


730   643   708     644 645 646 801 924


            SECTION B-B


                                                Port         Port name            Port size
                                                 Pi    Pilot port                PF 1/4 - 15
                                                Psv Servo assist port            PF 1/4 - 15
                                                P2     Companion delivery port        -
                                                Pf     Powershift port                -


                                    480F2RG03


                                    2-5

--- Page 10 ---
(2) Total horsepower control
  The regulator decreases the pump tilting
  angle (delivery flow) automatically to limit
  the input torque within a certain value with


                                                          Delivery flow, Q
  a rise in the delivery pressure P1 of the
  self pump and the delivery pressure P2 of
  the companion pump.
  (The input horsepower is constant when
  the speed is constant.)
  Since the regulator is of the simultaneous
                                                                             Delivery pressure, (P1+P2)
  total horsepower type that operates by the
  sum of load pressures of the two pumps
  in the tandem double-pump system, the
  prime mover is automatically prevented
  from being overloaded, irrespective of the
  load condition of the two pumps, when
  horsepower control is under way.
  Since this regulator is of the simultaneous
  total horsepower type, it controls the tilting
  angles (displacement volumes) of the two
  pumps to the same value as represented
  by the following equation :
  Tin = P1×q / 2 π + P2×q / 2 π
      = (P1+P2)×q / 2 π
  The horsepower control function is the
  same as the flow control function and is
  summarized in the following. (For detailed
  behaviors of respective parts, refer to the
  section of flow control).


                                                   2-15

--- Page 11 ---
2. HYDRAULIC CIRCUIT


                              ps1             T3 T1        T2   T4   ps2


                                                                                            pa10
pa11
DR1'
       DR1
 pc1

  B5
                                                                                            B9
  A5
                                                                                            A9
 pb5
                  ARM1

 pa5                                                                                               pb9
                                                                            ARM2
        B4                                                                                         pa9
                                                                                                   B8
        A4                                                                                         A8
       pb4
                                                                                                   pb8
                OPTION                                                      BUCKET
                                                                                                   pa8
       pa4                                                                                 DR2'
                                                                                            DR2
       A3                                                                                          pc2
        B3                                                                                         A7
                                                                                                   B7
       pb3

 pa3
                BOOM2
                                                                                                   pb7
  B2                                                                        BOOM1
  A2
                                                                                                   pa7
 pb2                                                                                               B6
       DR3      SWING                                                                              A6
                                                                                                   pb6
 pa2                                                                        TRAVEL-LH
 pc6                                                                                               pa6
  B1
  A1
 pb1
 pa1         TRAVEL-RH
                                                                            STRAIGHT
                                                                            TRAVEL
       pr1

                                                                                            P3

                         P1         PS PT   PP PA   PH                     P2


                                                                                        480F2MC05


                                                    2-25

--- Page 12 ---
(2) Arm in (flow summation)
    When the arm 1 spool is pushed to the left by the pilot pressure of port Pa5, the oil discharged
    from pump P1 flow into the port A5 via neutral passage (L1), the load check valve (S5-1) and
    passage (S5-2).
    When the arm 2 spool is pushed to the left by the pilot pressure of port Pa9, the oil discharged
    from pump P2 flows together into the port A5 via neutral passage (R1), the load check valve
    (S9-1) and passage (S9-2).
    At the same time, as the port pc1 is pressurizing and the spool (AD3) of anti-drift valve is pushed
    down, the pressure of spring chamber (AD5) is released and the poppet (AD1) is opened and
    then the oil returned from port B5 flows into the tank passage (Ta) through the passage (S5-4)
    inside arm 1 spool to open and is connected to the passage (S5-2) and flows together into the
    port A5, the cylinder speed is raised and also is prevents the cavitation of bottom side.


                                                                                               45071MC11


                                               2-35

--- Page 13 ---
(4) The oil flow from the high pressure passage (HP) to the poppet (D) behind is only around poppet
    and orifice (F); then the high pressure passage (HP) is higher than the poppet (D)behind
    pressure.
    Thus the poppet (D) is pushed open and the oil directly flows into low pressure passage (LP).


                                                                                          45071MC18-3


(5) Make up operation
    This relief valve is built-in the cylinder port (HP) and the low pressure passage (LP), and the
    pressure oil fills up camber (G) inside via hole of piston (C).
    Thus the sleeve (K) and the main poppet (D) are securely seated by difference area of A and B.


                                                                                          45071MC18-4


                                             2-45

--- Page 14 ---
4) BRAKE SYSTEM
(1) Control valve swing brake system
    This is the brake system to stop the swing motion of the excavator during operation.
    In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance
    created by this throttling works as a brake force to slow down the swing motion.


          Work                             Deceleration                                     Stop


      A          B                           A          B                               A          B


                     MCV                                    MCV                                         MCV


 MCV A, B opened                        MCV A, B throttled                         MCV A, B closed
                                                                                                          2-48(1)


(2) Mechanical swing parking brake system
    This is function as a parking brake only when all of the RCV lever (except travel pedal) are not
    operated.


 ① Brake assembly
   Circumferential rotation of separate plate
   (16) is constrained by the groove located
   at housing (1). When housing is
                                                                 20
   pressed down by brake spring (20)
   through friction plate (15), separate plate                   10
   (16) and brake piston (17), friction force                    17
   occurs there.                                                 16
   Cylinder block (10) is constrained by this                    15
   friction force and brake acts, while brake                     1
                                                                                            Groove
   releases when hydraulic force exceeds
   spring force.

                                                                                                       21092SM15


                                                             1    Housing          16   Separate plate
                                                            10    Cylinder block   17   Brake piston
                                                            15    Friction plate   20   Spring


                                                 2-55

--- Page 15 ---
(2) Operation
    Two pieces of overload valves are located at cross-over position in the counterbalance circuit of
    brake valve and have the following functions:
  ① When hydraulic motor starts, keep the driving pressure below predetermined value and while
    accelerating, bypasses surplus oil to return line.
  ② When stopping the motor, keep the brake pressure, that develops on the outlet side of motor,
    under the predetermined value to stop the inertial force.
  ③ To accelerate sharply while starting, and to mitigate the braking shock while stopping. For these
    purposes, the developed pressure is kept comparatively low for a short period, then keep the line
    pressure as normal value. While the pressure is low, meshing of reduction gears, crawler and
    sprocket etc. can be smoothly done and the shock are absorbed.
    When starting, "A" port pressure of overload valve increases, this pressure is applied to the
    effective diameter of poppet (45-9) which seats on the poppet seat (45-10) and, at the same time,
    is delivered, via small hole, to the spring seat (45-5) located inside the sleeve (45-6) and the seat
    bore pressure increases up to "A" port pressure. The poppet (45-9) opposes to spring (45-4) by
    the force of the pressure exerted on the area difference between poppet seat's effective diameter
    and spring seat bore and keep the predetermined pressure.
    When hydraulically braking, the piston (45-7) is at the left position by the driving pressure, and
    when "A" port pressure increases, the pressure is applied also to the piston (45-7) through the
    small hole in the poppet (45-9) and piston (45-7) moves rightward until it touches the stopper in
    rear cover. In this while, the poppet (45-9) maintains "A" port pressure at comparatively low
    against the spring (45-4) force and exhaust oil to "B" port side. After the piston reached to the
    plug, the valve acts the same as at starting.


Poppet seat(45-10)             Piston(45-7)      Spring seat(45-5)             Spring(45-4)

                     Port B


Port A


            Small hole          Poppet(45-9)      Sleeve(45-6)


                                                                                                 480F2TM08


                                                2-65

--- Page 16 ---
2. FUNCTIONS
 1) FUNDAMENTAL FUNCTIONS
    The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This
    function is carried out by providing the spring at one end of the main control valve spool and apply-
    ing the output pressure (secondary pressure) of the pilot valve to the other end.
    For this function to be carried out satisfactorily, the pilot valve is composed of the following ele-
    ments.
  (1) Inlet port (P) where oil is supplied from hydraulic pump.
  (2) Output ports (1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
  (3) Tank port (T) necessary to control the above output pressure.
  (4) Spool to connect output port to inlet port or tank port.
  (5) Mechanical means to control output pressure, including springs that work on the above spools.
 2) FUNCTIONS OF MAJOR SECTIONS
    Item numbers are based on the type L1.
    The functions of the spool (3) are to receive the supply oil pressure from the hydraulic pump at its
    port P, and to change over oil paths to determine whether the pressure oil of port P is led to output
    ports 1, 2, 3 & 4 or the output port pressure oil to tank port T.
    The spring (5) works on this spool to determine the output pressure.
    The change the deflection of this spring, the push rod (9) is inserted and can slide in the plug (8).
    For the purpose of changing the displacement of the push rod through the swash plate (16) and
    adjusting nut (17) are provided the handle assy (20) that can be tilted in any direction around the
    fulcrum of the universal joint (15) center.
    The spring (7) works on the case (1) and spring seat (6) and tries to return the push rod (9) to the

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