9working Hydraulic System - ENGLISG-G9165

Service Manual of RS8160 Road Roller
SERVICE MANUAL
9 Working Hydraulic System
Service Manual for G9165 Grader
CONTENTS
9 Working Hydraulic System ................................................................................. 9-1
91 General................................................................................................................. 9-1
92 Description, Disassembly and Assembly of Main Components ....................... 9-10
921 Working Pump ........................................................................................... 9-10
922 Hydraulic Oil Tank .................................................................................... 9-15
923 Multitandem Valve .................................................................................... 9-23
924 Rotary Control Valve ................................................................................ 9-31
925 Middle Swivel Joint ................................................................................... 9-38
926 Hydraulic Oil Cylinders ............................................................................ 9-44
927 Other Hydraulic Components .................................................................... 9-48
93 Pressure Measurement of Working Hydraulic System ..................................... 9-50
94 Service Precautions for Working Hydraulic System......................................... 9-51
95 Diagnosis of Common Faults of Working Hydraulic System........................... 9-54
9 Working Hydraulic System

91 General
G9165 adopts double-circuit double-constant-displacement-pump open-type working hydraulic
system, which consists of an enclosed tank, two high-pressure gear pumps, two multitandem valves
and hydraulic cylinders, rotary valve and the pipelines. System pressure is controlled by pressure
valve inside the multitandem valve and system set pressure is 21MPa. The hydraulic lock that
installed on front wheel tilt cylinder and front and rear frame hinge, and the balance valve installed
on shovel blade lifting cylinder can prevent the shifting due to the weight of equipment itself and
load so as to ensure the safety of moving and the operation accuracy of blade.
The working devices of G9165 grader are powered by two high-pressure gear pumps, and the two
pumps are installed on transmission box PTO port. The left main pump is used supply high-pressure
oil to the left multitandem valve and the right main pump is used to supply high-pressure oil to the
right multitandem valve. Because of the design, the operational stability and accuracy of the grader
are improved, and the machine can continue to work if one of the two pumps is faulty.
Rotation of shovel blade is realized by rotating of the whole rotary gear ring, which is driven by
rotary valve + double oil cylinders and engagement of rotary gear ring and a small gear.
Hydraulic
oil tank
Radiator
Working
pump
Multitandem
valve
Multitandem
valve
Working
device
Fig. 9-1 Oil flow route of working hydraulic system
9-1
Fig. 9-2 Working hydraulic principle diagram

9-2

Up/down of shovel blade
The two shovel blade lifting cylinders are controlled respectively by the left multitandem valve and
right multitandem valve, and supplied by two oil lines with the same oil flow, so the two shovel
blades can be lifted or lowered synchronously, working accuracy of the grader is improved. And the
balance valve installed on the lifting cylinder can prevent the shifting due to the weight of
equipment itself and load so as to ensure the safety of moving and the operation accuracy of blade.
Fig. 9-3 Up/down of shovel blade

1 Right blade lifting cylinder
2 Left blade lifting cylinder
3 Right multitandem valve (1A/1B)
4 Left multitandem valve (10A/10B)
5 Balance valve
Swing of shovel blade

Power source of the blade swing cylinder is from the fifth valve group of right multitandem valve.
Fig. 9-4 Swing of shovel blade

1 Blade swing cylinder

9-3
3 Balance valve

Tilt (change cutting angle) and sidesway of shovel blade
Power source of the blade tilt cylinder and blade sidesway cylinder are from the fourth valve group
and third valve group of left multitandem valve, respectively. The middle swivel joint can prevent
the hydraulic pipes from intertwining when the shovel blade is rotating.
Fig. 9-5 Tilt (change cutting angle) and sidesway of shovel blade
1 Left multitandem valve (7A/7B and 8A/8B) 2 Middle swivel joint
3 Blade tilt cylinder
4 Blade sidesway cylinder

Tilt of front wheels
Fig. 9-6 Tilt of front wheels

1 Hydraulic lock
2 Front wheel tilt cylinder

9-4

Power source of the front wheel tilt cylinder is from the third valve group of right multitandem
valve. The hydraulic lock acts as a stabilizing force in the front wheel tilt oil line, eliminating the
swing phenomenon between front wheels and front frame during driving.
Hinge steering
Power source of the steering cylinder is from the fourth valve group of right multitandem valve.
The balance valve acts as a stabilizing force during steering, eliminating the twist phenomenon
between front frame and rear frame caused by load deflection.
Fig. 9-7 Hinge steering

2 Balance valve
3 Hinge steering cylinder
Shovel blade rotation
Fig. 9-8 Shovel blade rotation

2 Rotary control valve
3 Blade rotary cylinder
Power source of the shovel blade rotary cylinder is from the fifth valve group of left multitandem
valve. Pressure oil is allocated to the two rotary cylinders through the rotary control valve. The
rotary cylinders drive the two hardened small gears to rotate the rotary frame, so as to realize blade
9-5

rotation.
Unlike many other grader manufactures, we adopt double-oil-cylinder rotary mechanism rather than
hydraulic motor + turbine reducer mechanism. To enable the rotary frame rotate continuously, the
drive arm of the left rotary cylinder and right rotary cylinder are arranged with 90difference. Two
hardened small gears are used to drive the rotary frame, and in the meantime a gear is used to drive
the rotary control valve element, thus, pressure oil can be supplied to the two cylinders in proper
connecting order to realize continuous rotating of shovel blade.
Up/down of front bulldozing plate (optional module)
Power source of the front bulldozing plate lifting cylinder is from the second valve group of right
multitandem valve. Front bulldozing plate is an optional attachment, and the standard model is not
equipped with this attachment. When the bulldozing plate is not installed, the corresponding oil
ports of multitandem valve are sealed with screw plug.
Fig. 9-9 Up/down of front bulldozing plate

2 Front bulldozing plate lifting cylinder
Up/down of rear scarifier

Power source of the rear scarifier lifting cylinder is from the second valve group of left multitandem
valve. Rear scarifier is an optional attachment, and the standard model is not equipped with this
attachment. When the rear scarifier is not installed, the corresponding oil ports of multitandem
valve are sealed with screw plug.
9-6
Fig. 9-10 Up/down of rear scarifier

2 Rear scarifier lifting cylinder
Up/down of middle scarifier
Fig. 9-11 Up/down of middle scarifier

2 Middle scarifier lifting cylinder
Power source of the middle scarifier lifting cylinder is from the second valve group of right
multitandem valve. Middle scarifier is an optional attachment, and the standard model is not
9-7

equipped with this attachment. When the middle scarifier is not installed, the corresponding oil
ports of multitandem valve are sealed with screw plug.
Locking cylinder
Power source of the locking cylinder is from port A of prefill valve in brake hydraulic system, a
magnetic exchange valve is designed in the circuit to control the cylinder. A rocker switch is
installed in the cab to control the magnetic exchange valve to retract or extend the cylinder.
Fig. 9-12 Locking cylinder

1 Locking cylinder
2 Magnetic exchange valve
3 Rocker switch
Shovel blade floating (replaceable module)

Compared to standard model, the common balance valve is replaced with floating balance valve.
And a duplex solenoid valve is used to control the on-off state of oil line from prefill valve port A to
floating balance valve, so as to realize floating of shovel blade. Two rocker switches installed in the
can are used to control floating of the two blade lifting cylinders.
9-8
Fig. 9-13 Blade floating

1 Right shovel blade lifting cylinder
3 Floating balance valve
2 Left shovel blade lifting cylinder
4 Oil return block
7 Right lifting cylinder floating switch
5 Duplex solenoid valve
8 Left lifting cylinder floating switch
9-9
6 Prefill valve
92 Description, Disassembly and Assembly of Main Components

921 Working Pump
Table 9-1
Items
Parameter
Nominal displacement
32ml/r
Rated/max. pressure
25/31.5MPa
Rated/max. speed
20MPa
Volumetric efficiency
0.92
Number of teeth
14
Direction of turning
Left-hand
Fig. 9-15 Working pump
Working principle
When pump shaft rotates as Fig. 9-15, the gear
demeshes on oil absorption chamber side, oil
absorption chamber close volume increases and
partial vacuum will be formed, oil in the tank will
be pressurized into absorption chamber through the
oil absorption pipe under the force of atmospheric
pressure to fill up the inter-tooth space. As the gear
rotates, oil in transition area will be brought into oil
extrusion chamber, the gear meshes on the
extrusion side and the volume decreases to force
oil into oil circuit.
Fig. 9-16 Gear pump working principle
9-10

Composition of working pump
Fig. 9-16 Composition of working pump

1 Retainer ring
2 Retainer ring
3 Antifriction bearing
4 Lip-type seal ring for rotating shaft
5 Front cover
6 Bearing
7 Rectangular seal ring
8 Gasket
10 Lug seal ring 11 Side plate
12 Driving gear shaft
13 Driven gear shaft
14 Rivet
16 Rear cover block
17 Bolt
15 Label
9 Lug retainer ring
Disassembly and assembly of working pump
ATTENTION
Before dismantling the working pump, be sure to carefully read 95 Service Precautions for
Working Hydraulic System in this chapter.
Disassembly of working pump
1.
Connect a hose to the oil draining valve on the

bottom of hydraulic tank, and put the other end
in a clean vessel. Open the drain valve of the
tank to drain the hydraulic oil out. (Open the
filling cap of the tank to accelerate the
draining speed)
ATTENTION
Cover
1
the
discharged
contamination.
Fig. 9-17
1. Oil drain valve
9-11
oil
to
prevent

2.
Remove the head board fixing bolts, and take

down the cover plate.
1
Fig. 9-18
1. Head board
3.
Remove the fixing screws of working pump oil

absorption steel pipe, take down the screws
fission flange, and the remove the steel pipe
and O-shape ring.
1
Fig. 9-19
1 Working pump oil absorption steel pipe
4.
Disconnect the oil outlet rubber hose of

working pump.
1
Fig. 9-20
1 Straight joint
9-12

5.
Remove the fixing bolts of working pump,

take down the bolts and gaskets.
6.
Hang the working pump with lift appliance,

and then use a copper bar to knock the pump
outward, take down the pump and sealing
gasket.
7.
1
Fig. 9-21
1. Bolt
Remove the fixing screws of the straight joint,

take down the screws, fission flange and
straight joint.
2 Sealing gasket
Assembly of working pump

1.
Use four screws and a fission flange to connect

the straight joint to the pump oil outlet port.
70~80Nm
1
Fig. 9-22
1. Straight joint
2.
Use four M12 bolts and gaskets, and a sealing

gasket to connect the working pump to
transmission box PTO port.
78~104Nm
1
Fig. 9-23
1. Bolt
2 Sealing gasket
9-13

3.
Connect the oil outlet rubber hose to the

straight joint.
1
Fig. 9-24
1 Working pump oil outlet rubber hose
4.
Put O-ring in the O-ring groove of working

pump oil absorption steel pipe joint. Fix the
pipe on the working pump with four screws
and a fission flange.
70~80Nm
1
Fig. 9-25
1 Working pump oil absorption steel pipe
5.
Install the head board with bolts
6.
Fill hydraulic oil to specified level.
1
Fig. 9-26
1. Head board
9-14
922 Hydraulic Oil Tank

It is used to provide oil to the whole hydraulic system. An oil return filter is designed in the tank to
ensure the cleanliness of hydraulic oil.
Fig. 9-27 Hydraulic oil tank assembly

1 Bolt
2 Gasket
6 Bolt
7 Thick gasket
12 Oil draining joint

16 O-ring
3 Oil filling filter element

8 Gasket
13 O-ring
17 Oil absorption flange
9 Nut
10 Oil draining joint
14 Oil return flange

18 Gasket
21 Oil absorption filter element assembly 22 O-ring

25 Oil return filter
4 Round oil level pointer
19 Bolt
5 Tank
11 Ball valve
15 Ring magnet
20 Sealing gasket
23 Screw plug
24 Air filter
26 Bolt
Description of hydraulic tank components:

1.
Air filter: Since the hydraulic oil in the tank expands when heated and contracts when cooled,
so the hydraulic oil tank must connect with the atmosphere. The air filter is used to balance the
air pressure inside the tank and atmospheric pressure. It also works as a filter to keep the
circulating air clean and dry, to guarantee the cleanliness of hydraulic oil.
2.
Oil level pointer: Used to check hydraulic oil level.
3.
Oil return filter: Used to filter oil contamination out. If there is too much contamination
9-15

accumulated in filter element, which will increase pressure difference between two sides of the
filter, the filter build-in bypass valve will open if the pressure difference gets to its opening
pressure, oil will be released through bypass valve to ensure the hydraulic system operation
normal.
Oil absorption filter element
Oil filling filter element
Air filter
Oil return filter
Oil level pointer
Disassembly and assembly of hydraulic oil tank
ATTENTION
Before dismantling the hydraulic oil tank, be sure to carefully read the 94 Service Precautions
for Working Hydraulic System.
9-16

Disassembly of hydraulic oil tank
1.
Operate the control handles to lower the shovel

blades to the ground and raise the front
bulldozing plate to the highest position, and
then shut down the engine. Then operate the
control handle to lower the front bulldozing
plate to the ground.
Fig. 9-28
2.
Connect a hose to the oil draining valve on the

bottom of hydraulic tank, and put the other end
in a clean vessel. Open the drain valve of the
tank to drain the hydraulic oil out. (Open the
filling cap of the tank to accelerate the
draining speed)
ATTENTION
Cover
1
the
discharged
oil
to
prevent
contamination.
Fig. 9-29
1. Oil drain valve
3.
Remove the engine hood.

Refer to 8 Cab & Covering Parts System for
disassembly of engine hood.
4.
Remove the fixing bolts of left and right guard

plates, use lifting rope to hang the plates down.
5.
1
2
Fig. 9-30
1 Engine hood
3 Head board
3
2 Guard plate
9-17
Remove the head board.

6.
Disconnect the brake pump oil outlet rubber

hose and prefill valve oil inlet rubber hose
from the high-pressure filter.
Fig. 9-31
1 Brake pump oil outlet rubber hose
2 Prefill valve oil inlet rubber hose
7.
Disconnect the oil return pipes from hydraulic

oil tank.
1 2
3
4
Fig. 9-32
1 Oil return pipe from port T of
high-pressure filter safety valve
2 Oil return pipe from port T of oil
return block
3 Oil outlet pipe from port T of
priority valve
4 Oil pipe from port O of prefill
valve
9-18
1
Fig. 9-33
1 Radiator oil return pipe
8.
Disconnect the hydraulic tank oil outlet rubber

hose from working pump oil absorption steel
pipe.
Fig. 9-34
1 Working pump oil absorption steel
pipe
2 Fixing clamp
9.
Remove the fixing bolts of hydraulic oil tank

support, lift down the tank.
1
Fig. 9-35
1 Bolt
9-19

Assembly of hydraulic oil tank
1.
Lift the hydraulic oil tank to the rear frame for

assembling, install and tighten the fixing bolts.
78~104Nm
1
Fig. 9-36
1 Bolt
2.
Install the clamps to connect the hydraulic tank

oil outlet rubber hose to working pump oil
absorption steel pipe.
Fig. 9-37
1 Working pump oil absorption steel
pipe
2 Fixing clamp
9-20

3.
Connect the oil return pipes to hydraulic oil

tank.
ATTENTION
Mark the hydraulic pipes orderly to prevent
confusion.
Part 1: Straight joint 45~65Nm
Oil pipe 45~65Nm
Part 2: Oil pipe 45~65Nm
1 2
3
4
Fig. 9-38
1 Oil return pipe from port T of
high-pressure filter safety valve
2 Oil return pipe from port T of oil
return block
3 Oil outlet pipe from port T of
priority valve
4 Oil pipe from port O of prefill
valve

Oil pipe 45~65Nm
Part 4: Oil pipe 45~65Nm
Radiator oil return pipe 120~145Nm
1
Fig. 9-39
1 Radiator oil return pipe
9-21

4.
Connect the brake pump oil outlet rubber hose

and prefill valve oil inlet rubber hose to the
high-pressure filter.
Fig. 9-40
1 Brake pump oil outlet rubber hose
2 Prefill valve oil inlet rubber hose
5.
Install the fixing bolts of head board.
6.
Install the fixing bolts of left and right guard

plates.
7.
Assemble the engine hood.

Refer to 8 Cab & Covering Parts System for
assembly of engine hood.
8.
1
2
Fig. 9-41
1 Engine hood
3 Head board
3
2 Guard plate
9-22
Fill hydraulic oil to specified level.
923 Multitandem Valve

The grader is designed with two multitandem valves, and each multiandem valve is mainly
composed of valve body, five valve groups in series, check valve and relief valve. Operate the
control handles to control the valves elements, so as to obtain the motion we desired.
Fig. 9-42 Schematic diagram of multitandem valve

Inlet check valve: Used to prevent reflux of pressure oil, to avoid cylinder dive.
Main relief valve: The valve a pilot operated cartridge valve, and set pressure of the valve is
214Bar.
Function of valve groups in multitandem valve
Right multitandem valve
Left multitandem valve
Fig. 9-43 Multitandem valve

1 Up/down of shovel blade
4 Hinge steering
2 Up/down of front bulldozing plate
5 Swing of shovel blade
8 Sidesway of shovel blade
6 Rotary cylinder
9 Scarifier
3 Tilt of front wheels

7 Tilt of shovel blade
10 Up/down of shovel blade

9-23

Composition and structure of multitandem valve
Fig. 9-44 Structure of right multitandem valve

1 Valve element end cap
2 End cap fixing nut
3 Valve element end cap fastening screw
4 Spring seat
5 Spring
6 Operating valve block assembly
7 Flat gasketSeal
8 Dust ring
9 O-ring
10 Valve element assembly
11 Valve body
12 Seal assembly
16 Check valve element

19 Oil outlet valve block assembly
22 Fastening screw
23 Nut

20 Nut
24 Relief valve assembly
27 Valve body
9-24
14 O-ring
15 Spring
18 Oil inlet valve block assembly

21 Fastening screw
25 Plug assembly
Fig. 9-45 Structure of left multitandem valve

1 Valve element end cap
3 Valve element end cap fastening screw
4 Spring seat
5 Spring
7 Flat gasketSeal
8 Dust ring
9 O-ring
11 Valve body
12 Seal assembly
16 Check valve element

19 Oil outlet valve block assembly
22 Fastening screw
23 Nut

20 Nut
24 Relief valve assembly
27 Valve body
9-25
14 O-ring
15 Spring
18 Oil inlet valve block assembly

21 Fastening screw
25 Plug assembly
Disassembly and assembly of multitandem valve
ATTENTION
Before dismantling multitandem valve, be sure to carefully read the 94 Service Precautions for
Working Hydraulic System.
Disassembly of the multitandem valve
1.
Remove the fixing bolts of the left and right

guard plates, take down the bolts and guard
plates.
1
Fig. 9-46
1 Left guard plate
2.
Remove the fixing bolts of the plate, take

down the bolts and plate.
1
Fig. 9-47
1 Plate
9-26

3.
Remove the connecting bolts of the control

pull rod and multitandem valve connecting rod.
Take down the bolts, nuts and gaskets.
1
2
3
Fig. 9-48
1 Multitandem valve connecting rod
2 Control pull rod
3 Bolt
4.
Disconnect the oil pipes from multitandem

valve.
ATTENTION
confusion.
1
Fig. 9-49
1 Oil pipe
5.
Remove the connecting nuts of multitandem

valve support and frame. Lift down the valve.
Fig. 9-50
1 Multitandem valve support
2 Nut
9-27

6.
Remove the pipe joints.
7.
Remove the cotters and connecting pins.
8.
Remove the fixing screws of multitandem
1
Fig. 9-51
1 Pipe joint
1
2
3
Fig. 9-52
2 Cotter
3 Connecting pin
valve.
1
Fig. 9-53
1 Screw
9-28

Assembly of the multitandem valve
1.
Fix multitandem valve on the support with

screws.
2.
Install the cotters and connecting pins.
3.
Install the pipe joints to the corresponding oil
1
2
3
Fig. 9-54
2 Cotter
3 Connecting pin
4 Screw
ports of multitandem valve.

Pipe joint 35~45Nm
1
Fig. 9-55
1 Pipe joint
4.
Install multitandem valve assembly to the

machine with four M10 nuts.
Nut 45~59Nm
Fig. 9-56
1 Multitandem valve support
2 Nut
9-29

5.
Connect the oil pipes to multitandem valve

orderly.
Pipe 65~85Nm
1
Fig. 9-57
1 Oil pipe
6.
Use bolts to connect the control pull rod and

multitandem valve connecting rod.
1
2
3
Fig. 9-58
2 Control pull rod
3 Bolt
7.
1
Fig. 9-59
1 Bolt
2
2 Plate
9-30
Install the fixing bolts (M620) of the plate.

8.
Use M620 bolts to fix the left and right guard

plates on cab.
Fig. 9-60
1 Left guard plate
924 Rotary Control Valve

The rotary control valve is installed on top of the connecting rack, and it is the main component of
shovel blade rotary mechanism. Its function is to supply pressure oil to the two cylinders in proper
connecting order to realize continuous rotating of shovel blade.
Fig. 9-61 Rotary control valve
9-31
Fig. 9-62 Schematic principle diagram of rotary control valve

Working principle of rotary control valve
During rotation of shovel blade, port AA of rotary
is always connected with chamber A of rotary
control valve, and port BB of rotary is always
connected with chamber B of rotary control valve.
In the initial position, the left rotary cylinder is
fully retracted and in the same line with the drive
arm, it doesnt output driving force at this point.
The right rotary cylinder is in the middle of its
stroke and cylinder rod is perpendicular to the
Fig. 9-63
drive arm, it outputs the maximum driving force at

this point. The pressure oil from port AA enters
rod-side chamber of the right rotary cylinder
through the valve, and the oil in the piston-side
chamber of the cylinder returns to port BB through
the valve. Under this circumstance, the piston rod
of right rotary cylinder retracts to drive the rotary
frame to rotate anticlockwise via the drive arm and
small gear. Meanwhile, rotary valve element will
be driven by gear to achieve synchronous rotation.
9-32

As the rotary valve element rotates, the pressure oil
from port AA enters piston-side chamber of the left
rotary cylinder and rod-side chamber of the right
rotary cylinder through the valve. Under this
circumstance, the piston rod of left rotary cylinder
extends and that of right rotary cylinder retracts to
drive the rotary frame to rotate anticlockwise
collaboratively.
Fig. 9-64
When the left rotary cylinder is perpendicular to

the left drive arm, the right rotary cylinder and
drive arm are in the same line. At this point, only
the left rotary cylinder drives rotary frame to rotate
anticlockwise.
Under
this
circumstance,
the
pressure oil from port AA enters piston-side

chamber of the left rotary cylinder, and the oil in
the rod-side chamber of the cylinder returns to port
Fig. 9-65
BB through the valve.
When the left rotary cylinder is 180 to the left

drive arm, the left rotary cylinder and drive arm are
in the same line. At this point, only the right rotary
cylinder drives rotary frame to rotate anticlockwise.
Under this circumstance, the pressure oil from port
AA enters piston-side chamber of the right rotary
cylinder, and the oil in the rod-side chamber of the
cylinder returns to port BB through the valve.
Fig. 9-66
9-33

drive arm, the pressure oil from port AA enters
rod-side chamber of the left rotary cylinder and
piston-side chamber of the right rotary cylinder
through the valve. Under this circumstance, the
piston rod of left rotary cylinder retracts and that of
right rotary cylinder extends to drive the rotary
frame to rotate anticlockwise collaboratively.
Fig. 9-67
drive arm, the right rotary cylinder and drive arm
are in the same line. At this point, only the left
rotary cylinder drives rotary frame to rotate
anticlockwise.
Under
this
circumstance,
the
pressure oil from port AA enters rod-side chamber

of the left rotary cylinder, and the oil in the
piston-side chamber of the cylinder returns to port
BB through the valve.
Fig. 9-68
Working principle for clockwise rotation of shovel
blade is similar.
9-34
Disassembly and assembly of rotary control valve
ATTENTION
Before dismantling rotary control valve, be sure to carefully read the 94 Service Precautions
for Working Hydraulic System.
Disassembly of the rotary control valve
1.
Disconnect all oil pipes from rotary control

valve.
ATTENTION
confusion.
Fig. 9-69
1 Pipe joint
2 Oil pipe
2.
Screw off the three fixing bolts of rotary

control valve, take down the bolts and gaskets.
3.
Take down the valve.
4.
Take down the transmission shaft, sleeve, and
Fig. 9-70
1 Bolt
the gaskets between rotary control valve and
frame.
Fig. 9-71
1 Gasket
2 Transmission shaft
9-35

5.
As shown in Fig. 9-72, use a clamp to fix the

rotary control valve, and then remove the pipe
joints.
Fig. 9-72
1 Pipe joint

Assembly of the rotary control valve
1.
As shown in Fig. 9-73, use a clamp to fix the

rotary control valve, and then install the pipe
joints.
Fig. 9-73
1 Pipe joint
2.
Install the same number of gaskets as that of

the removed ones. Install the transmission
shaft and sleeve.
Fig. 9-74
1 Gasket
2 Transmission shaft
9-36

3.
Fix the rotary control valve on frame with

bolts.
Fig. 9-75
4.
Tighten the valve fixing bolts.
5.
Connect the oil pipes to the corresponding oil
Fig. 9-76
1 Bolt
ports of rotary control valve.
Fig. 9-77
1 Pipe joint
2 Oil pipe
9-37
925 Middle Swivel Joint

The middle swivel joint is installed on top-middle area of swing frame. The middle swivel joint can
prevent the hydraulic pipes from intertwining when the shovel blade is rotating.
Technical parameters
Rotary torque: 30~60Nm
When
assembling
the
swivel joint, make sure it
can rotate freely and no
external force is exerted on
it.
Fig. 9-78
a, b to shovel blade tilt cylinder
c, d to shovel blade sidesway cylinder
Fig. 9-79 Schematic diagram of middle swivel joint

1 Screw plug
2 O-ring
3 Rotary shaft
4 Water seal
5 Anti-wear ring
6 Rotary seal ring
7 Rotary body
8 Water seal
9 Baffle
10 Gasket
11 Bolt
Fig. 9-80 Middle swivel joint assembly
9-38
Disassembly and assembly of middle swivel joint
ATTENTION
Before dismantling the middle swivel joint, be sure to carefully read the 94 Service
Precautions for Working Hydraulic System.
Disassembly of the middle swivel joint
1.
Disconnect the two oil pipes.
2.
Remove the four fixing nuts of cover plate,

take down the nuts and gaskets.
3.
Hold up the cover plate gently.
ATTENTION
Be gently when holding up the cover plate,
there are two oil pipes under the plate.
1
2
3
4
Fig. 9-81
1 To piston-side chamber of blade
swing cylinder oil pipe
2 To rod-side chamber of blade swing
cylinder oil pipe
3 Cover plate
4 Nut
4.
Disconnect the two oil pipes under the cover

plate, take down the cover plate.
ATTENTION
confusion.
1
2
Fig. 9-82
cylinder oil pipe
9-39

5.
Disconnect the four oil pipes from the middle

swivel joint.
ATTENTION
confusion.
1
2
3
4
Fig. 9-83
1 To port 8B of multitandem valve oil pipe
2 To port 8A of multitandem valve oil pipe
1
Fig. 9-84
1 Plate
6.
Remove the fixing nuts of the plate.
7.
Remove the fixing bolts of the four pipe
2
2 Nut
clamps.
1
Fig. 9-85
1 Pipe clamp
9-40

8.
Disconnect the four bottom oil pipes from the

middle swivel joint.
ATTENTION
confusion.
9.
Remove the four pipe joints.
10. Remove the six fixing nuts of the middle

swivel joint, take down the nuts and gaskets.
1
2 3
4
Fig. 9-86
1 To rod-side chamber of blade tilt
cylinder oil pipe
2 To rod-side chamber of blade
sidesway cylinder oil pipe
3 To piston-side chamber of blade tilt
cylinder oil pipe
Then take down the bolts and middle swivel

joint.
Assembly of the middle swivel joint

1.
Use six M12 bolts and nuts to fix the middle

swivel joint on frame.
2.
Install the four pipe joints.

45~65Nm
3.
Connect the four bottom oil pipes to the

corresponding oil ports of middle swivel joint.
65~85Nm
1
2 3
4
Fig. 9-87
1 To rod-side chamber of blade tilt
cylinder oil pipe
2 To rod-side chamber of blade
3 To piston-side chamber of blade tilt
cylinder oil pipe
9-41

4.
Use bolts, nuts and gaskets to fix the plate on

bottom of middle swivel joint.
Fig. 9-88
1 Plate
2
2 Nut
5.
Use M1020 bolts and pipe clamps to fix oil

pipes on the connecting plate.
1
Fig. 9-89
1 Pipe clamp
6.
Connect the four upper oil pipes to the middle

swivel joint.
Pipe joint 45~65Nm
Oil pipe 65~85Nm
1
2
3
4
Fig. 9-90
9-42

7.
Connect the two oil pipes under the cover

plate.
Oil pipe 65~85Nm
1
2
Fig. 9-91
cylinder oil pipe
8.
Use the bolts and nuts to fix cover plate.
9.
Connect the two top oil pipes.

Oil pipe 65~85Nm
1
2
3
4
Fig. 9-92
cylinder oil pipe
3 Cover plate
4 Nut
9-43
926 Hydraulic Oil Cylinders
Fig. 9-93 Structure of hydraulic oil cylinder

1 Piston fixing nut
2 Piston seal
3 Piston
4 Cylinder tube
5 Cover
6 Wearing ring
7 O-ring
8 Back-up ring
9 Seal ring for shaft
10 Dust ring
11 Piston rod
12 Cylinder cover nut
13 Flat gasket
Specification of hydraulic oil cylinders applied in the grader working hydraulic cylinder
Table 9-2
Unit: mm
Cylinder
diameter
Piston rod
diameter
Piston travel
115
50
303
4120004769
90
50
1379.5
Shovel blade swing cylinder
4120004768
90
50
693.5
Locking cylinder
4120004765
80
60
63.5
Shovel blade rotary cylinder
4120004766
80
35
279.5
Shovel blade sidesway cylinder
4120004767
90
50
1346
Shovel blade tilt cylinder
4120004771
100
50
260.5
Front wheel tilt cylinder
4120004762
100
50
169
Cylinder name
Product code
Hinge steering cylinder
4120004770
Shovel blade lifting cylinder
9-44

Precautions when disassembling hydraulic oil cylinder:
1
Be sure to unload the hydraulic system (pressure relief) before disassembling the cylinder.
Otherwise high-pressure oil in the circuit will spray out at high speed when disconnecting the
hydraulic oil pipes, safety accident may occur. Thus, before disassembling you should loosen
the regulating handle or pressure adjusting screw of relief valve to unload the hydraulic circuit
first, and then turn off the power source to shut down the entire hydraulic system. At this point,
you can start to disconnect the oil pipes. To prevent getting hurt by residual pressure oil, you
should loosen the pipe joint slowly and pay attention to check whether there is overflowing oil,
be careful in this process.
Hydraulic oil cylinder is the actuator of hydraulic system. So before removing the cylinder, be
sure to hang or support its driven device (working device) properly to prevent hurting people or
crushing the machine. Before disassembling, you can start the machine and operate the control
handles to let the cylinder move to suitable position for the convenience of assembling, and do
not forget to unload the hydraulic system after that.
Before disassembling the hydraulic oil cylinder, you should pay attention to check whether the
cylinder is designed with hydraulic lock. If so, remove the hydraulic lock first. Otherwise the
cylinder will contain pressure oil locked by the hydraulic lock, which will make it difficult to
disassemble the cylinder and bring potential hazard to the people and machine. When removing
the hydraulic lock, you can use clean cloth to wrap up the connecting area (pipe joint, or
something similar) first, to avoid splashing of high-pressure oil.
When disassembling the hydraulic oil cylinder, you should be aware of the main structure of
the cylinder, never do the disassembling work blindly. Since different hydraulic oil cylinder has
different size, structure and use purpose, they are intended to be disassembled in different ways.
So before the disassembling, you can refer to the cylinder engineering drawings provided by
our company. If the drawings are not available, you should check the cylinder carefully and set
a proper disassembly sequence.
In a general way, when disassembling the hydraulic oil cylinder, you should drain the hydraulic
oil in the cylinder out first, and then remove the end cover, then pull out the piston rod and
piston assembly. When disassembling the components, do not hammer fiercely. If it is
inevitable, a copper bar should be used to avoid damaging the parts. Some parts need to be
disassembled with special tools, these tools must be available. For fine thread part, you can use
a copper rod to vibrate it first, and then use special wrench to loosen it gently, do not bump it
fiercely. Some bolts were coated with thread locking sealant when assembling, which are hard
to disassemble, and the thread may get damaged if you remove the bolt forcibly. In this case,
9-45

you can heat the bolt to let the sealant fall out first.
6
Pay attention to avoid damaging the piston rod thread, oil port thread, piston rod surface and
inner wall of cylinder sleeve. Long and thin part (piston rod) should be placed on suitable
support to prevent getting deformed or distorted. Do not use sharp tools to disassemble the
seals to avoid scratching them. If the seals are difficult to disassemble, you can soak them in
water to soften them, and then remove them. Before and after disassembling the cylinder, you
should always take measures to prevent the parts and components from getting contaminated by
dust and impurities. For example, the maintenance work should be performed in clean
environment, and use plastic cloth rather than cotton cloth to cover the disassembled
components and parts.
The disassembled parts and components should be inspected carefully, damaged and aged
part/component should be replaced. In the case that the cylinder had severe internal or external
leakage problem during normal use, if the piston rod and cylinder tube are in good condition,
then the problem must be caused by worn or aged seals. If the cylinder tube was subject to
strike damage, you should use internal dial gauge to check whether the tube is deformed. Check
the cylinder tube, piston rod and other moving parts for scratch and pull damage, replace the
repair the damaged parts according to the damage condition. If the damaged part is determined
to be repaired, you should grind to flat the damaged area with fine oil stone first, and then
polish it with abrasive paper.
Precautions when assembling hydraulic oil cylinder:

1
All parts and components should be cleaned and dried before assembling, parts and
components that need to be coated with sealant when assembling should be cleaned with
cleaning agent or acetone. Curing time of the sealant is about 20min, which means you should
tighten the coated part/component to required torque in 20min.
Install the seals correctly. When installing an O-ring, do not drag/expand it to the state of
permanent deformation or roll along the shaft to assemble it, otherwise it may get twisted and
result in oil leakage. When installing a Y-ring, V-ring or stepped labyrinth seal ring, pay
attention to the installing direction, a reversely fitted Y-ring, V-ring or stepped labyrinth seal
ring will cause oil leakage. For Y-ring, its lip should face the pressure oil chamber, and pay
attention to differentiate if the Y-ring is for shaft or for hole, do not install a wrong Y-ring.
V-ring is composed of a back-up ring, a seal ring and a compression ring. The back-up ring can
deform the seal ring for sealing, when installing the seal ring, the side with open mouth should
face the pressure oil chamber. When adjusting the compression ring, it should be limited to no
oil leakage, do not compress it too tight to avoid oversized sealing resistance. For stepped
9-46

labyrinth seal ring, the stepped end should face the pressure oil chamber. If the seal is for
moving part or fits with moving part, coat it with hydraulic oil when assembling. Disassembled
seal ring and dust ring should be replaced with new ones.
3
Bolts and lock nuts for pressure-bearing part/component are disposable, do not reuse them.
Pressure-bearing
part/component
should
not
be
replaced
arbitrary,
original
spare
parts/components are preferable. Most of the fixing or connecting bolts have tightening torque
and tightening order requirements, some of them even have tightening angle requirements. So
when tightening the bolts, be sure to use a special wrench or torque wrench and follow these
requirements. Bolts of the same component should be tightened to the same torque
symmetrically. Long and thin part (piston rod) should be placed on suitable support to prevent
getting deformed or distorted when tightening the fastening bolts.
4
Some piston seals will swell after being assembled, which may get cut or scratched when
assembling the piston and piston rod assembly. In this case, you should use cone shrinking
sleeve to shrink the seal. If there is no cone shrinking sleeve, you can make one by yourself
according to the dimensions of piston and cylinder tube. Generally, the taper of the sleeve
should be about 30, and diameter of the small end of the sleeve should be equal to that of the
cylinder tube. After assembling the piston and piston rod, you should measure the coaxiality
and straightness in the overall length.
All moving parts and components should be coated with hydraulic oil for lubrication when
assembling. The fine thread of some large part should be coated with lubricating grease, if the
thread was subject to burn damage, coat it with molybdenum disulfide grease for lubrication.
After the maintenance, you must perform pressure leak tests before putting the machine into
operation again. If the cylinder is designed with hydraulic lock, the hydraulic lock mustnt be
installed during the tests. When performing the test, you should retract and extend the cylinder
for several times at low pressure to discharge the air, and pay attention to check for any
abnormal phenomenon. Then increase the pressure gradually to check for leakage.
9-47
927 Other Hydraulic Components

Hydraulic lock
The hydraulic lock is composed of two pilot operated check valves. When the reversing valve is in
neutral position and the hydraulic system is loaded, the hydraulic lock can keep the cylinder stopped
at the original position.
For working hydraulic system of G9165 grader, the front wheel tilt circuit and up/down of scarifier
circuit are designed with hydraulic lock.
Table 9-3
Item
Parameter
Rated pressure
240Bar
Rated flow
55L/min
Opening pressure
2.1Bar
Pilot ratio
4:1
Fig. 9-94
Balance valve
The balance valve can change resistance coefficient automatically according to working condition
(pressure difference) of the system. When the system pressure varies in a certain range, the balance
valve can keep the oil flow the same.
For working hydraulic system of G9165 grader, the hinge steering circuit, shovel blade swing
circuit and up/down of shovel blade circuit are designed with balance valve.
Table 9-4
Items
Parameter
Control pressure area ratio
4:1
Set pressure
240Bar
Flow
70L/min
Max. working pressure
350Bar
Fig. 9-95
Floating balance valve
Compared to common balance valve, the floating balance valve is designed with floating function.
When there is pressure oil acts on the control port D, the two check valves inside the floating
balance valve will open. At this point, both piston-side chamber and rod-side chamber of shovel
9-48

blade lifting cylinder are connected to oil return channel, and the shovel blade is in floating
condition under the weight of working device and its own weight.
Fig. 9-96
Duplex solenoid valve
The duplex solenoid valve is used to control the on-off state of oil line from prefill valve to control
port of floating balance valve, so as to realize floating of shovel blade.
Table 9-5
Fig. 9-97
Cross relief valve
Fig. 9-98
9-49
Items
Parameter
Rated pressure
207Bar
Voltage
24V
93 Pressure Measurement of Working Hydraulic System

Pressure measuring tools
Pressure gauge with measuring range of 40MPa, piezometer tube
Pressure measuring points
Oil inlet port of multitandem valve
Fig. 9-99 Right multitandem valve
Fig. 9-100 Left multitandem valve
Pressure measuring method

Raise the cylinders to build pressure.
Standard working hydraulic system pressure
214.13.5Bar.
9-50
94 Service Precautions for Working Hydraulic System

The most common fault for high-pressure and high-precision hydraulic devices is that fouling (alien
material) occurs in the hydraulic circuit. Thus, pay special attention to the cleanliness when adding
hydraulic oil or removing and refitting the hydraulic devices.
1.
Pay attention to working environment.

Avoid adding hydraulic oil, replacing filter or
repairing machine in rain or at windy and dirty
place.
2.
Removing
and
servicing
machine
on
outdoor site.
Chances are that fouling will enter the
equipment if removal and service are done on
outdoor site; moreover, it is difficult to
Fig. 9-101
appraise
equipments
performance
after
eliminating the faults. So this is only suitable

for replacing components. Removal and
service of the hydraulic devices should be
conducted in special dust-free workshop and
the performance of the hydraulic devices
should be appraised with special testing
device.
3.
Seal up the openings.

After removing the pipes or components, all
openings should be sealed with cap, adhesive
paper or plastic bag so as to prevent fouling or
dirt from entering them. If you let the openings
be exposed or clogged with rags, fouling is
liable to get into them or the leaking oil will
stain the surrounding places, which is not
allowed to happen. Instead of draining oil on
Fig. 9-102
the ground, you should collect the drained oil

and take it back to handle it on your own.
9-51

4.
Prevent any fouling or dirt from entering

the system during the oil refilling operation.
Prevent any fouling or dirt from being mixed
into the hydraulic oil when refilling hydraulic
oil and be sure to keep the oil filler and the
surrounding surface clean as well as use clean
oil pump and container. Utilizing oil cleaning
device will filter the fouling deposited during
the storage period from the oil, which is more
Fig. 9-103
effective for refilling oil.

5.
The hydraulic oil should be changed when

the oil temperature is high.
When the hydraulic oil or other oil is hot, their
fluidity is good and the deposited sludge is
easy to be flushed away by the oil. Therefore,
it is recommended to change oil when the oil is
hot. Discharge the old oil fully (not only the
oil in the hydraulic oil tank but also the oil in
the filter and plugs of the pipeline) as possible
as you can when changing oil. If there is old
oil residual, the fouling and deposited sludge
will be mixed with the new oil, shortening the
service life of the new oil.
6.
Flushing operation.
The fouling, oil sludge and old oil in the
hydraulic oil circuit should be flushed away
Rinsing
oil
with rinsing oil when changing oil after the

disassembly and assembly of the hydraulic
devices. Normally, flushing is conducted for
two times: primary flushing with rinsing oil
and
secondary
hydraulic oil.
Fig. 9-104
9-52
flushing
with
specified

7.
Cleaning operation.
Get rid of the sludge and fouling in the
hydraulic oil circuit with oil cleaning device
after repairing the hydraulic device (pump,
control valve, etc.) or when the machine is
operating. The oil cleaning device is used to
remove the ultrafine granule that cannot be
removed by the filter in the hydraulic device,
which is a very effective cleaning tool.
Fig. 9-105
8.
Torque requirements
The securing operation should be conducted in strict accordance with the torque required in this
manual during the process of removal, refitting and service of the hydraulic system. Excessive
or insufficient torque will lead to hydraulic oil leakage.
ATTENTION
For the torque that is not indicated, please refer to relevant requirements in Chapter 0
General of this manual.
9.
Deflation (air bleeding) of working hydraulic system

After replacement of hydraulic pump, hydraulic cylinder, hydraulic pipe, joint and all kinds of
valves, bleeding operation must be done.
The specific bleeding steps are as follows:
1) Open the filler cap of hydraulic tank.
2) Start the engine; run the engine at idle for 5 minutes, and then retract and extend all
cylinders from bottom for about 2~3 times, keep the stroke within 50~60 mm.
3) Keep the engine run at low speed, and then retract and extend all cylinders fully for about
3~5 times to bleed the air in hydraulic circuit.
4) After the bleeding, set the machine and working device in standard position, check
hydraulic oil level and tighten the filler cap.
5) Shut down the engine, check for leakage.
9-53
95 Diagnosis of Common Faults of Working Hydraulic System

Table 9-6
S/N
Fault phenomenon
Possible causes
System pressure is
insufficient or no
pressure
The pump is seriously worn, and

has severe internal leakage
Hydraulic oil temperature is too
high
The hydraulic circuit has leakage
problem
Relief valve is abnormal or
clogged
Spring failure
System flow is small
Hydraulic oil and

transmission oil are
mixed with each other
Hydraulic
pump
produces
abnormal
noise and vibrates
Heavy manipulation
Action
failure
hydraulic cylinder
Too
high
temperature
of
oil
Replace the pump

Refer to Fault 7
Find out the leaking point
and fix it
Repair or replace the
valve
Replace the spring
Low oil level in hydraulic tank, the

pump is not able to absorb enough
oil
The hydraulic oil viscosity is too
big because of low temperature,
the pump is not able to absorb
enough oil
Stop the machine and fill

oil to specified level
Warm up the oil
Severe internal leakage problem
Replace or repair the

faulty component
Pump shaft seal failure
Replace the pump oil seal
The hydraulic system is infiltrated

with air
Deflate the system as

required
pump
Low oil level in hydraulic tank.

Hydraulic pump failure
Elimination methods
Multitandem valve element gets

stuck by dirt
Clean the valve element
Multitandem valve spring failure
Replace the spring
There is air accumulated in the

cylinder
Deflate the cylinder as

required
Piston seal is damaged
Replace the seal
Long-time overload operation
Take a break
System pressure is too high
Adjust
Low oil level in hydraulic tank.

Environment temperature is high
Severe internal leakage problem
9-54

Stop the machine and let
it cool down
faulty component

9working Hydraulic System - ENGLISG-G9165

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Service Manual of RS8160 Road Roller

9 Working Hydraulic System

Service Manual for G9165 Grader

Service Manual for G9165 Grader

9 Working Hydraulic System

Fig. 9-1 Oil flow route of working hydraulic system

Service Manual for G9165 Grader

Fig. 9-2 Working hydraulic principle diagram

Service Manual for G9165 Grader

Fig. 9-3 Up/down of shovel blade

2 Left blade lifting cylinder

3 Right multitandem valve (1A/1B)

4 Left multitandem valve (10A/10B)

Swing of shovel blade

Fig. 9-4 Swing of shovel blade

2 Right multitandem valve (5A/5B)

Service Manual for G9165 Grader

3 Blade tilt cylinder

4 Blade sidesway cylinder

Fig. 9-6 Tilt of front wheels

2 Front wheel tilt cylinder

3 Right multitandem valve (3A/3B)

Service Manual for G9165 Grader

Fig. 9-7 Hinge steering

3 Hinge steering cylinder

Shovel blade rotation

Fig. 9-8 Shovel blade rotation

2 Rotary control valve

3 Blade rotary cylinder

Service Manual for G9165 Grader

Fig. 9-9 Up/down of front bulldozing plate

2 Front bulldozing plate lifting cylinder

Up/down of rear scarifier

Service Manual for G9165 Grader

Fig. 9-10 Up/down of rear scarifier

2 Rear scarifier lifting cylinder

Up/down of middle scarifier

Fig. 9-11 Up/down of middle scarifier

2 Middle scarifier lifting cylinder

Service Manual for G9165 Grader

Fig. 9-12 Locking cylinder

2 Magnetic exchange valve

Shovel blade floating (replaceable module)

Service Manual for G9165 Grader

Fig. 9-13 Blade floating

2 Left shovel blade lifting cylinder

4 Oil return block

7 Right lifting cylinder floating switch

5 Duplex solenoid valve

8 Left lifting cylinder floating switch

Service Manual for G9165 Grader

92 Description, Disassembly and Assembly of Main Components

Fig. 9-15 Working pump

Service Manual for G9165 Grader

Fig. 9-16 Composition of working pump

4 Lip-type seal ring for rotating shaft

7 Rectangular seal ring

10 Lug seal ring 11 Side plate

12 Driving gear shaft

13 Driven gear shaft

16 Rear cover block

9 Lug retainer ring

Disassembly and assembly of working pump