Hydraulic system of

SG18 grader

Shantui Construction Machinery Co.,

Ltd Institute
Jinke
 Hydraulic
y system
y
Hydraulic system of SG18 grader is
mainly composed of:
¾ Working oil tank
¾ Working hydraulic system
¾ Steering hydraulic system
¾ Service braking hydraulic system
¾ Variable speed and moment pipeline
system
 Workingg oil tank （1）
• The purpose of hydraulic oil tank is oil storage and heat emission. At
the same time,, it can separate
p air and sundries from oil.
• Hydraulic oil tank of grader is open oil tank. When hydraulic system is
operating, the level of oil tank is up or down at times. When the level is up,
air is exhausted from inside to outside. When the level is down, air is
sucked from outside to inside. To purify the oil in tank, air filter is installed
vertically on the cover of oil tank to filter the sucked air. At the same time,
air filter is also oil filler. Newly filled working oil can enter into oil tank
only after it must be filtered so that dirt particle in oil can be eliminated. In
addition, when hydraulic system is operating, air filter can maintain the
balance between pressure in oil tank and air pressure to avoid cavitations
that is possible in pump.
 Workingg oil tank （2）
• Oil suction filter and oil return filter are in hydraulic oil tank.
• Oil suction
i filter
fil can protect oil il pump from
f sucking
ki larger
l machinery
hi
impurities. When vacuum pressure is -0.02MPa because filter element is
blocked by contaminant, bypass valve installed on the upper end of filter
element can be opened automatically to keep normal operation of oil pump. pump
• Oil return filter can filter metal particles in hydraulic system due to
abrasion of components and rubber impurities of sealing elements to keep
cleanliness of oil returning oil tank.
tank When oil pressure is 0.35MPa
0 35MPa because
filter element is blocked by contaminant or oil temperature in system is too
low, bypass valve installed at the lower of filter element can be opened
automatically to keep normal operation of oil filter and hydraulic system.
system
 Oil suction filter flow
rate: 630L/min
Oil return filter Precision: 180 micron
Fl rate
Flow t : 630L/min
630L/ i Air filter
precision：20μ Oil filler
 Workingg oil tank （3）
• Duringg cleaningg or replacing
p g filter element,, if onlyy screws
on the mounting flange are screwed off, pull up mounting
flange to clean or replace filter element.
• Oil level gauge is installed outside of oil tank.
tank It can show
clearly oil level that should be kept basically at the mid
position of oil level gauge.
• Wh hhydraulic
When d li oil il requires
i being
b i changed,
h d oilil drain
d i valve
l
at the bottom of oil tank is opened to discharge waste oil and
clean oil tank.
• This filter element is with self-closed valve: During
overhauling the system, oil in oil tank cannot flow out. During
replacing filter element, contaminant in filter element can be
taken out of oil tank.
 Workingg hydraulic
y system（1）
y

• 1. Instructions
• This system is quantitative double-pump double-
loop system (e.g. figure 15 schematic diagram of
operating hydraulic system). It is composed of one
enclosed type oil tank, one double gear pump, two
multi-way change valves and hydraulic cylinder,
cylinder
hydraulic motor and pipe of hydraulic device etc.
Double pump is installed at the output of gear box.
Therefore, double pump is always turned together
with the engine. If only engine is turning, hydraulic
control system can be operated
operated.
 Workingg hydraulic
y system
y （2）

• Independent hydraulic system is composed of

multi-way change valve and double pump etc.
Working pressure of system is 16MPa. Flow rate is
Q=72.5L/min (when RPM of engine is 2300r/m).
• Left and right lifting cylinders are supplied oil by
two loops with equal flow rate. Therefore, two lifting
cylinders are basically synchronous and at the same
speedd to
t improve
i operating
ti performance
f off grader.
d
 Workingg hydraulic
y system
y （3）
2.System principle 1、Hydraulic oil tank
2、Double pump
3、Multi-way change valve
4 Two way hydraulic lock
4、Two-way
5、Lifting cylinder of shovel
blade
6、Tilt cylinder of shovel blade
7 Balance valve
7、Balance
8、Oil filter
9、Rotary joint
10、Side out cylinder of shovel
blade
11、Hydraulic lock
12、Angle modulation cylinder
13、Tilt cylinder of front wheel
14 Rotary motor
14、Rotary
 Workingg hydraulic
y system
y （4）
• a).Setting up system pressure
• System
y ppressure is controlled by
y internal pressure
p valve of multi-way y
valve (see above figure pilot overflow valve pressure value is 16MPa).
• b).Working principle：
• Hydraulic loop：oil from P1 outlet of double pump（2）enters into
multi-way valve and returns oil tank(1) through oil return pipeline and oil
return filter (8).
• Two-way
Two way hydraulic lock (4) on the tilt cylinder of shovel blade,
hydraulic lock (11) on the tilt cylinder of front wheel and balance valve (7)
on the lifting cylinder of shovel blade can prevent from displacement due to
self-weight
g of equipment
q p and load so as to ensure travelingg safety
y and
operating accuracy of shovel nose tool.
Overflow valve at this position（below oil inlet and
outlet）can be used to adjust the pressure of multi-
way valve (Set value is 16MPa）

HUSCO multi-way change valve

Rated flow rate：75L/min
Set pressure：16MPa
All
Allowable
bl backpressure：1.5MPa
b k 1
Two-way hydraulic lock

Double pump
Steering pump：displacement 20ml/r
Brake pump： displacement 16ml/r
Double pump
for working system
displacement 32ml/r
 Balance valve
Eliminate noise, impact and
vibration of cylinder during using
hydraulic lock in the past
Function：lock cylinder to lower
the cylinder stably without noise

Two-wayy hydraulic
y lock
Two-way hydraulic
lock can
prevent from
slight
tilt of cylinder
during leveling.
 Workingg hydraulic
y system
y （5）
• Rotary device of shovel blade is composed of worm gear drive and
hydraulic motor. JZK cycloid hydraulic motor (14) uses end plane flow
distribution to compensate automatically abrasion of flow distribution plane
and keep motor run always under the lasting and efficient operating
condition and save a lot of energy source.
• High pressure oil enters into motor through oil inlet. Then through flow
distribution pressure plate, flow distribution couple axle and flow
distribution support plate, it is used to drive rotation of rotor and generate
mechanical torque that is transferred to worm screw of worm gear case and
worm gear drive through output shaft to drive pinion and girth gear and
achieve rotation of shovel blade.
• The maximum allowable working pressure of double gear pump is
21MPa. The highest RPM is 2500r/m.
 Working hydraulic system （6）
Point of
measurin
g
pressure
Rotary motor
Displacement：195ml/min
Working pressure：16MPa
The maximum RPM：385r/min
 Steering
g hydraulic
y system（1）
y
• 1.Instructions
• Front wheel steering system uses full hydraulic steering
device. This system is full hydraulic steering gear, FKC valve
block and cylinder etc.
• 2.System
2 System schematic diagram（see next page）
• 3. Operating principle
• Operating
p g principle:
p p When engine g is running, g, oil is sucked
from oil tank (1) by steering pump (9). Oil output from pump
enters into valve block of steering gear. Left and right
diversion of steeringg cylinder
y on front wheel is controlled byy
steering wheel.
• Hydraulic lock (11) installed in the steering oil circuit of
frame has stable function to eliminate swing phenomenon of
frame during machine is traveling.
Steering
g hydraulic
y system
y （2）
1.Working oil tank
2.Multi-way change
valve
3.Double pump
4.Oil filter
5 St i componentt
5.Steering
6.Steering cylinder of
front wheel
7 Steering cylinder of
7.Steering
frame
8.Hydraulic lock
9.Double pump
p p
10.Oil filter
 Combination valve block
Pressure of safety valve：12.5MPa
P
Pressure off overload
l d valve：20MPa
l 20MP

Steering gear
Eton BZZ-320
Displacement：320ml/r
Steering torque：2.8-4.0Nm

Two-way hydraulic lock

 Steering
g hydraulic
y system
y （3）
• Steering gear
 Service braking hydraulic system（1）
• 1. System schematic diagram 1、Working brake
pressure switch
（The minimum brake
pressure 100bar monitor）
2. Brake valve
3、Brake light switch
4、Hydraulic accumulator
5、Micro measurement
connector
6、Pre-fill
fill valve
l
7、Brake wheel cylinder
8、Double pump
9、Rough filter
10、Hydraulic oil tank
11、Bleed screw plug
12、Rim brake
 Service braking hydraulic system （2）
• 2.Operating principle
• Service braking hydraulic system is single loop hydraulic system that
acts on four rear wheels of g grader. When engine
g is running,g oil is sucked
from oil tank (10) by brake pump (8). Oil output from the pump enters into
two accumulators (4) through pre-fill valve (6) to pressurize two
accumulators below 123bar and shut off oil when pressure of two
accumulators reach 150bar.
• That oil is filled into accumulator (4) only requires short time. Later, oil
returns working oil tank by pre-fill valve.
• That oil is filled into accumulator (4) is preferred. Therefore, pressure
oil required by system is available as soon as engine runs brake system.
system
• Press down the brake valve (2) then pressure oil in accumulator loop
flows to brake wheel cylinder (7) that actuates brake shoe of rim brake
(12).
• At the same time, brake light is switched on by brake light switch (3).
• Pressure of brake system is measured through micro measurement
connector (5) by using special pressure gage.
To brake Brake valve
Nominal brake pressure：10MPa

To oil tank

Oil from the accumulator

Bypass to oil tank
Oil return pin extractor cylinder
To accumulator

Oil return

Pre-fill valve
Pre-fill flow rate：17L/min
At 15MPa, cut off，at 12.3
Mpa, begin inflation
 Oil from pre-fill valve

Accumulator
N i l volume：1L
Nominal l e 1L
Nominal pressure：20MPa
Inflation pressure：8MPa-9MPa

To brake

Oil feed pin extractor cylinder

 Brake pressure
Measurement point
Nominal pressure：
10MPa
Left and right symmetry
Variable speed and moment pipeline
system
Oil outlet of gearbox
To oil cooler
Pressure：3.5bar or so
Oil inlet of torque converter
From oil cooler
Pressure：
5bar or so
 Fault analysis and troubleshooting of hydraulic system（1）

• 1.Working and steering hydraulic system

Fault
Reason Elimination
Flow rate 1.Oil pump is worn or damaged. 1.Clean up or replace
is too low 2.Filter is blocked. 2. Clean up or replace
Or pressure 3.Oil level is too low. 3.Fill oil
is 4. Flow valve is adjusted wrongly. 4.Adjust as required
abnorma
b 5 Oil circuit of hydraulic system is blocked
5.Oil blocked. 5 Clean
5.Clean
l.

Oil leakage 1.Joint is loosening. 1.Tighten joint

2. Seal ring is damaged. 2.Repair or replace new parts
Rotation of
shovel 1.Oil is leaking from joint of hydraulic motor. 1.Replace sealing element
blade is 2.Parts in hydraulic motor is worn. 2.Replace hydraulic motor
ineffecti
ve.
Working
hydrauli
c oil is
mixed Oil seal of working oil pump is invalid. Replace oil seal
with oil
of gear
box.
Abnormal
noise 1.Air enters and oil level is too low. 1.Fill oil and exhaust air
and 2.Oil is too cold and viscosity is too high or 2.Heat
vibratio air is sucked by pump. 3.Repair and replace
n are in 3.Pump is in failure.
pump.
Fault analysis and troubleshooting of hydraulic system （2）

Control
1.Control valve is blocked by dirt. 1.Clean
handle is
2.Spring is invalid. 2.Replace
heavy.

Action of
1.Air is accumulated in cylinder. 1.Check and exhaust
cylinder is
2.Seal of piston is damaged. 2.Replace seal ring
not reliable

1.Continuous
.Co t uous opeoperation
at o w
with
t load
oad for
o a long
o g
1.Pause
1 P operation
ti
time
Oil 2.Adjust to authorized pressure
2.System pressure is too high.
temperature 3.Fill oil
3.Oil in oil tank is not sufficient.
is too high. 4.Shut down and cool down
4.Ambient temperature is too high.
5.Overhaul relevant components
5.Inside leakage
g is much.

1.Oil level is too low.

1.Fill oil to specified oil level
2.Oil suction pipe is blocked.
2.Clean or replace to remove clog
Vacuum 3. Air enters into oil suction pipe of working
3.Check and exhaust
occurs in oil oil pump.
pump
4.Change oil
suction. 4. Viscosity of hydraulic oil is large.
5.Repair or replace
5.Leakage of gear pump is serious.
6.Observe after operation
6.Oil is thick in cold weather.
Fault analysis and troubleshooting of hydraulic system （2）

• 2.Brake system

Fault Reason
Elimination
1.Oil is leaking in brake oil circuit.
1.Eliminate oil leak
2.Air enters into brake oil.
2. Exhaust from air faucet of wheel
Unable to 3.Oil circuit is blocked.
cylinder
brake or 4.Clearance between shoe pplate and brake
3 Clean and dredge oil circuit
3.Clean
failure drum is too much.
4.Adjust
5.There is oil dirt on the liner of brake
5.Clear up oil dirt
shoe.
6.Check pressure（nitrogen）
6.Pressure of accumulator is low.

Brake 1.Oil circuit is blocked and oil return is 1.Clean and dredge
cannot difficult. 2.Overhaul or replace brake valve
be 2. Brake valve lever is seized or release
disenga
g spring is invalid or broken. 3.Adjust
ged. 3 Clearance
3. Cl off brake
b k band
b d is
i too small.
ll

Parking 1.There is oil dirt on the braking surface

brake is on parking brake. 1.Clear up oil dirt.
in 2 Idle stroke of parking brake is too
2. 2 Adjust
2.Adjust
failure. much.