Systems Operation
416D, 420D, 424D, 428D, 430D, 432D, 438D and 442D Backhoe Loaders
Hydraulic and Steering System
Media Number -RENR3583-06 Publication Date -01/10/2005 Date Updated -21/10/2005
i01699851
Piston Pump (Implement and Steering)
SMCS - 4306; 5070
S/N - BKG1-UP
S/N - BRG1-UP
S/N - BML1-UP
S/N - BFP1-UP
S/N - BNB1-UP
S/N - BLN1-UP
S/N - BGP1-UP
S/N - BLL1-UP
S/N - BPN1-UP
S/N - FDP1-UP
S/N - BKC1-919
S/N - B2D1-UP
S/N - BKR1-UP
S/N - BNS1-UP
S/N - BPE1-UP
S/N - BGJ1-1049
S/N - BRY1-UP
S/N - BMC1-1059
S/N - BLD1-UP
S/N - BNK1-UP
S/N - BMT1-UP
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Illustration 1 g00542183
Variable Displacement Piston Pump and Compensator Valve
Compensator valve that is equipped on the following machines (BNK1-2501BML1-2280BLN1-
4543FDP1-7198BFP1-UPBGJ1-UPBKC1-UPBMC1-UPBGP1-UPBKR1-UPBLL1-UPBMT1-
UPBNB1-UPBNS1-UPBLD1-1594BPE1-UPBPN1-UPBRY1-0746BRG1-0827BKG1-UP)
(1) Pump control valve, (2) Actuator piston, (3) Piston shoe, (4) Swashplate, (5) Drive shaft, (6) Shoe plate,
(7) Piston, (8) Bias piston, (9) Bias spring, (10) Cylinder barrel, (11) Port plate, (12) Pressure compensator
spool and (13) Flow compensator spool
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Illustration 2 g00876979
Compensator valve that is equipped on the following machines (BNK2502-UPBML2281-UPBLN4544-
UPFDP7199-UPBLD1595-UPBRY0747-UPBRG0828-UP)
(1) Pump control valve, (12) Pressure compensator spool, (13) Flow compensator spool and (14) Orifice
The piston pump for the hydraulic system is controlled by the load signal from the
implements. The piston pump senses both pressure and flow needs. The piston pump also
senses hydraulic power. When none of the hydraulic circuits are being used, the pump is at
low pressure standby.
If one or more circuits are being used, the resolver network compares the control valve
work port pressures. The single highest pressure felt flows to flow compensator spool (13).
The flow compensator (13) keeps the pump output at a level that is needed in order to fulfill
the flow and pressure requirements of the system.
The pump outlet pressure is maintained about 2200 kPa (320 psi) above the needed
pressure of the work port by flow compensator spool (13) .
The system pressure will be greater than the requirements for the highest work port
pressure unless the pump is at full stroke. Margin pressure is the difference between the
pressure that is needed at the work port and the supply pressure that is higher.
The pressure compensator valve limits maximum system pressure. This protects the
hydraulic system from damaging high pressures.
The control valve also controls the maximum output pressure of the pump. When the work
port pressure rises above the pressure in Table 1, pressure compensator spool (12) overrides
flow compensator spool (13). This causes the pump to destroke. This occurs at
approximately 690 kPa (100 psi) below the maximum pressure setting. If another circuit
requires flow, the flow compensator valve will allow the pump to upstroke for the circuit
while system pressure is limited.
Table 1
416D and 424D All other machines
20700 kPa (3000 psi) 22750 kPa (3300 psi)
The pump has two control pistons, bias piston (8) and actuator piston (2). The bias spring
(9) in the bias piston causes swashplate (4) to move. The movement of the swashplate will
cause the pump to upstroke or the movement will cause the pump to destroke.
Actuator piston (2) has a larger area than the bias piston. Actuator piston (2) causes the
swashplate to destroke the pump. Flow compensator spool (13) and pressure compensator
spool (12) changes pump output by regulating the discharge pressure of the pump that is
acting on actuator piston (2) .
Orifice (14) (if equipped) limits the flow of oil from the actuator piston to the tank. The
pump will have smoother response when the pump upstrokes.
Low Pressure Standby
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Illustration 3 g00759395
Pump and Compensator Operation
(1) Orifice, (2) Torque limiter, (3) Spring, (4) Line to control valve, (5) Hole, (6) Actuator piston, ( 7)
Swashplate, (8) Bias piston, (9) Bias spring, (10) Case drain, (11) Passage, (12) Passage, (13) Passage, (14)
Passage, (15) Pressure compensator spool, (16) Passage, (17) Flow compensator spool, (18) Cavity, (19)
Signal line from control valve, (20) Spring, (DD) First Signal pressure reduction, (BB) First system pressure
reduction and (FF) Return oil
Start the machine.
The pump is at low pressure standby, when the implement controls are in the HOLD
position and the steering is inactive.
There are no flow or pressure demands from the implements on the pump but there is signal
pressure in line (19) due to the bleed orifice in the priority valve.
Before the engine is started, bias spring (9) holds swashplate (7) at a maximum angle. As
the pump begins to turn, this causes oil to flow. The flow of oil builds up pressure in the
system because of the closed centers of the implement valves.
The pressure in passage (13) is felt at the bottom of the spool for flow compensator (17)
and the spool for pressure compensator (15). As this pressure increases, the pressure pushes
the spool for the flow compensator against spring (20). Spool (17) moves up. The
movement of the spool opens passage (13) to passage (16) in order to allow the pressure oil
to flow to actuator piston (6) .
The oil acts against the actuator piston. The oil pressure overcomes the force of bias spring
(9) and supply pressure in bias piston (8). This causes the piston to move to the right. The
piston moves the swashplate toward the minimum angle. The actuator piston continues to
move to the right. The actuator piston uncovers hole (5). Uncovering the hole allows oil to
drain into the case.
Hole (5) limits the maximum travel of the actuator piston (6) to the right. The pump will
produce enough flow in order to account for the system leakage. The pump will also
produce enough flow in order to account for the leakage to the pump case.
Upstroking
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Illustration 4 g00759396
Pump and Compensator Operation
(1) Orifice, (2) Torque limiter, (3) Spring, (4) Line to control valve, (5) Actuator piston, (6) Swashplate, (7)
Bias piston, (8) Bias spring, (9) Case drain, (10) Passage, (11) Passage, (12) Passage, (13) Passage, (14)
Pressure compensator spool, (15) Passage, (16) Flow compensator spool, (17) Cavity, (18) Signal line from
control valve, (19) Spring, (CC) Signal pressure oil, (BB) First system pressure reduction and (FF) Return
oil
When the pump increases the output due to the demand for the increased flow of oil, the
pump is upstroking. Because of the increased flow demand, the signal pressure combines
with the force of the spring (19) in cavity (17) .
This combination of signal pressure and spring force is greater than the pump discharge
pressure. This combination of signal pressure and spring force causes the spool (16) to
move down. As the spool moves down, the spool blocks the flow of the supply oil to
actuator piston (5). Oil in the passage for actuator piston (13) can now drain to passage
(15). This is possible due to the blockage of oil to piston (5). The oil then flows past flow
compensator spool (16). The oil then flows past pressure compensator (14). The oil then
flows through passage (11) into case drain (9) .
Supply oil flows through passage (10) to bias piston (7). The oil acts against piston (7) and
combines with the force of bias spring (8). This causes swashplate (6) to upstroke.
This increases the pump flow. As the flow requirements are satisfied the pump output
pressure increases. The pressure increases until the pressure in passage (12) moves spool
(16) up to the metering position.
Metering
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Illustration 5 g00875165
Pump operation in metering position
(1) Orifice, (2) Torque limiter, (3) Spring, (4) Line to control valve, (5) Actuator piston, (6) Swashplate, (7)
Bias piston, (8) Bias spring, (9) Case drain, (10) Passage, (11) Passage, (12) Passage, (13) Passage, (14)
Pressure compensator spool, (15) Passage, (16) Flow compensator spool, (17) Cavity, (18) Signal line from
control valve, (19) Spring, (AA) System pressure oil, (CC) Signal pressure oil, (DD) First signal pressure
reduction and (FF) Return oil
In the metering position, the signal pressure in line (18) and the force of spring (19) equals
the pump supply pressure below spool (16) .
The pump will maintain the flow that is required in order to maintain system pressure. The
pump will stay in the metering position until the flow requirements change.
Destroking
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Illustration 6 g00759399
Pump and Compensator Operation
(1) Orifice, (2) Torque limiter, (3) Spring, (4) Line to control valve, (5) Actuator piston, (6) Swashplate, (7)
Bias piston, (8) Bias spring, (9) Case drain, (10) Passage, (11) Passage, (12) Passage, (13) Passage, (14)
Pressure compensator spool, (15) Passage, (16) Flow compensator spool, (17) Cavity, (18) Signal line from
control valve, (19) Spring, (AA) System pressure oil, (DD) First Signal pressure reduction and (FF) Return
oil
When the pump decreases the output due to the decreasing demand for the flow of oil, the
pump is destroking. The decreasing demand for the flow of oil causes a combination of the
signal pressure and the force of spring (19) in cavity (17) to be less than the pump pressure
in passage (12). Spool (16) is pushed up.
Oil behind actuator piston (5) cannot flow through passage (11) to case drain (9). Pump oil
now flows through passage (12), past the spool (16), through passage (13) and into actuator
piston (5). Pump pressure behind actuator piston (5) is now greater than the combined force
of bias piston (7) and bias spring (8). The angle of swashplate (6) decreases. This decreases
pump output and system pressure decreases.
Once the lower flow requirements are met, flow compensator spool (16) moves down to the
metering position. Swashplate (6) will maintain an angle that is sufficient to provide the
lower required flow. If all implements are returned to hold, the pump goes to the low
pressure standby.
High Pressure Stall
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Illustration 7 g00759402
Pump and Compensator Operation
(1) Orifice, (2) Torque limiter, (3) Spring, (4) Line to control valve, (5) Actuator piston, (6) Swashplate, (7)
Bias piston, (8) Bias spring, (9) Case drain, (10) Passage, (11) Passage, (12) Passage, (13) Passage, (14)
Pressure compensator spool, (15) Passage, (16) Flow compensator spool, (17) Cavity, (18) Signal line from
control valve, (19) Spring, (AA) System pressure oil and (FF) Return oil
When the hydraulic system stalls under load or when the cylinders reach the end of the
stroke, the system pressure increases. The signal pressure in line (18) and cavity (17)
becomes equal to the pump output pressure. Spring (19) keeps spool (16) shifted
downward.
When the pressure in passage (12) rises above the pressure in Table 2, the upward force on
the pressure compensator spool (14) will overcome the force of spring (3). This will cause
spool (14) to move up. Supply oil flows through passage (13) to actuator piston (5).
Table 2
416D and 424D All other machines
20700 kPa (3000 psi) 22750 kPa (3300 psi)
Pressure that is felt on the actuator piston will destroke the pump. For single valve
operation, pump output decreases while the system pressure is limited to the pressure in
Table 2. For multiple valve operation, the system pressure will be close to the maximum.
The system pressure will be close to the maximum, but the pump will produce flow in order
to meet the needs of the other circuits with the lower pressure requirements.
During a high pressure stall, movement of the control lever into the HOLD position causes
the pump to return to the low pressure standby.
Torque Limiter
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Illustration 8 g00838865
Pump operation and torque limiter
(1) Orifice, (2) Torque limiter, (3) Spring, (4) Line to control valve, (5) Actuator piston, (6) Swashplate, (7)
Bias piston, (8) Bias spring, (9) Case drain, (10) Passage, (11) Passage, (12) Passage, (13) Passage, (14)
Pressure compensator spool, (15) Passage, (16) Flow compensator spool, (17) Cavity, (18) Signal line from
control valve, (19) Spring, (AA) System pressure oil, (CC) Signal pressure oil, (DD) First signal pressure
reduction and (FF) Return oil
The torque limiter is a power limiter that maintains the displacement of the pump in inverse
proportion to the discharge pressure of the pump. When the hydraulic power demand
reaches a set value, the torque limiter will destroke the pump. If the pump does not destroke
the engine will stall.
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Illustration 9 g00875856
(1) Axis for pump flow
(2) Axis for pump output pressure
(A) Control of pump by torque limiter during backhoe operation
(B) Maximum pump flow
(C) Maximum pump output pressure
(D) Control of pump by torque limiter during loader operation
When the flow of the pump and the output pressure of the pump are near the maximum, the
torque limiter opens and the torque limiter routes some of the signal oil back to the
hydraulic tank. The torque limiter controls the signal pressure to the pump. See graph 9.
The torque limiter will control the pump at a lower pressure and a lower flow when the
loader section is being used. This is due to smaller orifices in the loader section.
When the torque limiter opens, the pump will destroke. The torque limiter is set to allow
full pump flow, whenever signal pressure is below 15180 kPa (2200 psi).
The torque limiter causes a pressure drop across orifice (1) and this lowers signal pressure
in line (18). The discharge oil of the pump that is in passage (12) causes the flow
compensator spool (16) to move up slightly. This is due to the signal oil pressure that is
lower in line (18). When spool (16) moves up, the spool opens a path for the discharge oil.
This allows the flow through passage (13) to actuator piston (5).
The oil in passage (13) acts against piston (5). This causes the piston to move to the right.
The piston moves to the right in order to destroke the pump. Destroking the pump reduces
the output of the pump in order to prevent the engine from stalling.
