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Low Pressure Hydraulic System

SD22 to SD32
 Hydraulic System Principles

Hydraulic Components:

Input: Pumps
Output: Cylinders, Motors
Controls: Valves
Equipment: Oil tank, Piping, Filters, Oil Cooler
 Transmission & Steering Hydraulics
Low Pressure Hydraulic System:

1. Transmission and steering systems are known as the low

pressure hydraulic system.
2. Transmission and steering control systems are separated to
each other.
3. Transmission and steering control systems draw oil from
different pumps.
4. Transmission and steering control systems using the same oil
from the steering clutch case.
Structures and functions of main components of low pressure system

1. Gear Pumps
None variable pumps used for bulldozers are all the 30kg - class
gear pumps, which have relatively a simple structure.
Transmission and steering pumps cannot handle too high pressures and
is applicable for relatively low pressure only.
Structures and functions of main components of low pressure system

2. Transmission Hydraulic Control Valve Group

Dozers share the same transmission hydraulic control valve
system which is composed of six kinds of valves, namely, modulating
relief valve, quick return valve, reducing valve, speed valve, directional
valve and safety valve.
The modulating relief valve, reducing valve and the quick return
valves are used for modulating and regulating the transmission
pressures, please note that reducing valve are used in first speed only.
The speed selector valve is to change different speeds.
The directional selector valve is to change forward and reverse
direction.
The safety valve is their to prevent machine movement if the
machine is being started when the transmission control lever is not in
neutral position.
 Pressure Measurement to Diagnose hydraulic problems

3. Important Measurements
a. Oil brand, quality and grade are correct, steering case oil level
correct.
b. Warm-up engine, ensure coolant and oil temperature are in 70-
90oC.

4. Measurement Method
Measure the oil pressure at engine low idle and high idle speed,
Except the torque converter pressures at high idle only.

5. Measure Points
Standard Pressure. (Theoretical data in manual)
Low Pressure Hydraulic System
To Servo Valves To Servo Valves
To Servo Valves
 Pressure check points

（Check Points）
1.（T/M）
2.（OUT）
3.（IN）
4.（LB）
5.（RB）
RC LC RB LB IN OUT T/M
6.（LC）
7.（RC）
Pressure check points
 Testing of Pressure Chart – Example only.

items Setting Setting Temperature(℃)

Pressure Pressure（Mpa)
（Mpa)
Low Idle High Idle Speed
Speed
Engine oil ≧0.1 0.41±0.07 70-80
Torque Converter In --- 0.7-0.9 Cold (First)
Torque Converter Out --- 0.3-0.5 70-110
Transmission Pump 1.6-2 2-2.5 50-55
Reducing Valve 1.2 1-1.25 50-55
Lubricating --- 0.15 50-55
Steering Clutch 0.9-1.3 1.2-1.7 50-55
Brake & Steering Relief 2.1-2.5 2.2-2.9 50-55
Main Hydraulic Relief 13.3-14 13.8-14.7 45-55
Valve
 Diagnose problems
Torque Converter

1. Torque converter inlet pressure too high

a) Remove and clean inlet relief valve
b) Replace torque converter inlet relief valve
c) Clean or replace the outlet relief valve

2. Torque converter outlet pressure too high

a) Remove and clean outlet relief valve
b) Adjust relief valve pressure to correct specification
c) Replace outlet relief valve

3. Torque converter outlet pressure too low

a) Check steering relief valve pressure at low and high idle
b) Remove, inspect and clean outlet relief valve
c) Remove, inspect and clean inlet relief valve
d) Carry out torque converter oil leakage test
e) Check torque converter filter screen
f) Check torque converter scavenge pump
g) Recondition torque converter
 Diagnose problems

Torque Converter
3. Torque converter overheating
a) Check steering case oil level if correct
b) Check transmission clutches for slippages
c) Check brakes if not binding
d) Check steering clutches if not slipping
e) Check gauge and sender unit for accuracy
• Check transmission magnetic screen for metal particles
• Check transmission and steering filters for metal particles
a) Check torque converter outlet pressure
b) Check steering relief valve pressure at low and high idle
c) Remove, inspect and clean outlet relief valve
d) Remove, inspect and clean inlet relief valve
e) Carry out torque converter oil leakage test
f) Check torque converter filter screen
g) Check torque converter scavenge pump
h) If oil leakage is correct, clean transmission oil cooler
i) Check scavenge pump
j) If scavenge pump is correct remove and repair torque converter
 Diagnose problems

Transmission

1. Transmission pressures take too long to show when starting engine and pressures not
correct
a) Check transmission oil level
b) Pump suction poor – Check suction hose and clamps
c) Transmission magnetic screen seals not sealing
d) Transmission pump seals worn
e) Transmission pump worn.
f) Steering pump suction line not air tight (Sucking air)
g) Steering pump seals worn

2. Transmission pressures low at low idle but correct at high idle

a) Transmission pump sucking air
b) Transmission pump worn

3. Transmission pressure staying at 0 MPa at low and high idle

a) Check transmission oil level
a) Transmission pump worn and sucking air
b) Transmission control valve faulty
 Diagnose problems
Transmission

4. Machine not moving in any speed or direction but transmission pump pressure correct
a) Check parking brake if not engaged
b) Check transmission linkages
c) Transmission control valve faulty

5. Machine moving in all forward speeds but no reverse speeds

a) Check transmission control linkages adjustment
b) Reverse clutch faulty – Pressure test

6. Machine not moving in first speed

a) Reducing valve faulty – pressure test
b) First speed clutch faulty - pressure test
 Diagnose problems
Steering and brakes

1. Steering pressures take too long to show when starting engine and pressures not
correct
a) Check transmission oil level
b) Pump suction poor – Check suction hose and clamps
c) Transmission magnetic screen seals not sealing
d) Steering pump seals worn
e) Steering pump worn.
f) Transmission pump suction line not air tight (Sucking air)
g) Transmission pump seals worn

2. Steering pressures low at low idle but correct at high idle

a) Steering pump sucking air
b) Steering pump worn

3. Steering pump pressure staying at 0 MPa at low and high idle

a) Check transmission oil level
a) Steering pump worn and sucking air
b) Steering relief valve faulty
 Diagnose problems
Steering and brakes

1. Steering relief valve pressure are low or to high at high idle

a) Adjust steering relief valve pressure to correct specifications – pressure test

2. Steering filter housing cracked

a) Steering relief valve orifice blocked and valve stuck

3. Machine only turn to one side when pulling steering clutch lever
a) Check and adjust brakes
b) Check control lever linkages or cables
c) Check steering clutch pressures – pressure test

4. Brakes not stopping machine correctly and turning sluggish

a) Check and adjust brakes
b) Check brakes pressures
 Diagnose problems
Steering and brakes

5. Brake adjustment needs no be carried out to often

a) Check parking brake linkages for correct operation
b) Check brake control linkages adjustments
c) Check lock on brake adjuster
d) Check operator for correct operation