816D Propel System / Operating Hydraulic

System Operation Principle

 Table of Contents
1 Hydrostatic Drive System ..................................................................................................3
1.1 Hydraulic Drive System Introduction .......................................................................................................4
1.2 Drive Pump Introduction: .........................................................................................................................5
1.3 Parts of Drive Pump.................................................................................................................................5
1.4 Introduction to Drive Pump Operation Principle ......................................................................................7
1.5 Drive motor ..............................................................................................................................................9
1.6 Introduction to Refilling Lines ................................................................................................................11
1.7 Cooling Hydraulic System .....................................................................................................................12
2 Introduction to Hydrostatic System Operation..............................................................13
2.1 Hydrostatic Bulldozer Power Transmission Path Diagram....................................................................13
2.2 Hydrostatic Function Realization and Principles ...................................................................................14
2.3 Introduction to Operating Mode .............................................................................................................15
2.3.1. Start-Acceleration Process.........................................................................................................15
2.3.2. Brake Pedal Deceleration Function............................................................................................15
2.3.3. Steering Function .......................................................................................................................16
3 Test Adjustment ...............................................................................................................17
3.1 Adjustment Preparation .........................................................................................................................17
3.2 Precharge Propel Pump with Hydraulic Oil (Air Removal) ....................................................................17
3.3 Drive Pump Zero Adjustment ................................................................................................................18
3.4 Hydrostatic System Pressure Test Points .............................................................................................18
Measuring point 1: Hydraulic oil pressure measurement in high pressure circuit.....................................19
Measuring point 2:Refilling pressure measurement..................................................................................20
Measuring point 3:Housing overflowing pressure measurement ..............................................................20
Measuring point 4: Brake pressure measurement ....................................................................................21
Measuring point 5: Pilot control pressure test points ................................................................................21
4 Pilot Hydraulic System.....................................................................................................22
4.1 System Construction..............................................................................................................................22
4.2 Key Component Introduction .................................................................................................................23
4.2.1. Multi-way Shuttle Valve ..............................................................................................................23
4.2.2. HYDRAULIC CYLINDERS.........................................................................................................23
4.2.3. Precautions in Hydraulic Cylinder Removal: ..............................................................................25
4.3 816DOperation Hydraulic Schematic Introduction ................................................................................26
4.4 Adjustment and Test..............................................................................................................................27
Measuring point 1: Normal hydraulic system operating pressure .............................................................27
Measuring point 2: Pilot hydraulic system normal operating pressure measurement ..............................27
5 System Fluid Cleanliness Control ..................................................................................28

2
1 Hydrostatic Drive System
As a kind of modern traction construction machinery, in order to adapt to the forward and reverse travel and braking
requirements of the machine, adapt to the load characteristics of the random load of its drive system, and make
each part of the bulldozer function fully, this bulldozer adopts the closed hydrostatic drive system, which is
consisted of the variable pump and variable motor, and also the left and right independent drive circuits consisting
of dual-pump and dual motor. The circuits on both sides perform the unified control, which can realize the forward
and backward movement of the vehicle and the corresponding speed change, and can also operate separately to
realize the different radius turning or spot turning.
The hydrostatics drive replaces the mechanical devices in traditional mechanical or hydro mechanical drives, such
as torque converter, gearbox, central drive and steering, meanwhile, the hydraulics drives and controls make it
easy to realize the automation, full or sectional stepless variable speed, and can fully utilize the mechanical
efficiency.

Pilot Hydraulic System

Drive System
Cooling

3
1.1 Hydraulic Drive System Introduction

1. Drive Pump 2. Filter 3. Travel Motor

The machine power is provided by the diesel engine. The engine drives the drive pump to rotate, and the pump and
the motor make up the closed circuit. The charge pump suctions oil from the hydraulic tank and then pumps the
filtered hydraulic oil into the drive pump. The hydraulic oil is flowing forward or backward in the pump-motor circuit
through the high-pressure oil pipe to realize the forward, reserve and turning of the bulldozer. The ECM sends a
signal to control the displacement of the pump and the motor by controlling the pump or motor swashplate position,
controlling the traveling speed.

4
1.2 Drive Pump Introduction:
The main pump of the propel system is a two-way swashplate variable pump. The pump housing is a one-piece
type. It integrates with many valve blocks, including the control function modules required by closed system, such
as high voltage relief valve, check valve, swashplate angle control circuit and refilling pressure control circuit. It is
connected to the back side of the engine with the coupling, and operates through the drive pump driven by the
engine.

1.3 Parts of Drive Pump

S1/S2: Proportional solenoid valve (front pump): Control the angle and direction of the swashplate by controlling the front drive pump control oil
circuit, in order to control the displacement and direction of the drive pump;
S3/S4: Proportional solenoid valve (rear pump): Control the angle and direction of the swashplate by controlling the rear drive pump control oil
circuit, in order to control the displacement and direction of the drive pump;
S5: Turn on or off the servo cylinder control oil circuit of the drive pump;
S6: Turn on or off the brake control oil circuit to release or apply the brake;
PS1: Brake port: connected to the final drive brake;
PS2: Brake pressure tap, a pressure interface used to measure the brake pressure;
PS: Servo cylinder pressure tap, a pressure interface used to measure the servo cylinder;
X1/X2: Servo cylinder pressure tap;
R: Venting hole / housing relief pressure tap, used to measure the housing pressure;

5
T1: Case drain interface, connected to the hydraulic tank;
G2: Motor flush interface;
G3: Pilot accumulator connection interface;
G4: High pressure relief valve, the highest pressure of the control system is 50 MPa
G5: Refilling relief valve: used for the refilling system pressure of 3.2 Mpa;
MA/MB: Propel pressure taps, the pressure interfaces used to measure the pressure of the front and rear pumps during traveling;
Z1/Z2: Servo cylinder zero adjustment bolt;

A/B : Connection ports of left and right motor;

T2: Case drain port.

6
1.4 Introduction to Drive Pump Operation Principle

① Proportional Solenoid ② Proportional Solenoid

③ Hydraulic Lock ④ Brake Solenoid

Valve Valve ⑤ Servo Cylinder

⑥ High Pressure Relief ⑦ Refilling Relief Valve(3.2 Mpa) ⑧ High Pressure Relief
Valve Differential Valve Differential Pressure45
Pressure45 Mpa) Mpa)

1. Drive shaft 5. High-pressure side 9. Barrel

2. Retaining plate 6. Through-drive flange 10. Piston
3. Controller 7. Controller plate 11. Slipper pad
4. Stroke piston 8. Low-pressure side 12. Swashplate

7
The pumps for the hydrostatic drive system are Axial piston variable double pumps. The double pumps are
mounted to the rear of the engine by coupling. The input shaft of the front pump engages a coupling that is
mounted to the flywheel of the engine in order to drive the double pumps.
Torque and rotational speed are applied to the drive shaft (1) by an engine. The drive shaft is connected by splines
to the barrel (9) to set this in motion. With every revolution, the pistons (10) in the cylinder bores execute one
stroke whose magnitude depends on the setting of swashplate (12). The pistons hold the slipper pads (11) onto the
glide surface of the swashplate with the retaining plate (2) and guide them along. The swashplate setting during a
rotation causes each piston to move over the bottom and top dead centers and back to its initial position. Here,
hydraulic fluid is fed in and drained out through the two control slots in the control plate (7) according to the stroke
displacement. On the high-pressure side (5) the hydraulic fluid is pushed out of the cylinder chamber and into the
hydraulic system by the pistons. At the same time, hydraulic fluid into the growing piston chamber on the
low-pressure side (8). In a closed circuit, supported by the return and charge pressure.
The pressure spikes which occur during very rapid swiveling operations as well as the maximum pressure are
safeguarded by the superordinate high-pressure relief valves. These valves open if the set value is exceeded.
Thereby depressurizing the low-pressure side. The fluid quantity remains constant in the closed circuit. The
leakage a the pump and motor must be replaced by the charge pump.
The charge pump continuously supplies a sufficient volume of fluid (charge volume) from a reservoir to the
low-pressure side of the closed circuit via check valve to replenish in the internal leakage of the variable pump and
consumer.
The swivel angle of the swashplate (12) is steplessly varied. Controlling the swivel angle of the swashplate
changes the piston stroke and therefore the displacement. Adjusting the swashplate through the neutral
position will change the direction of flow (make reversing operation possible). The swivel angle is controlled
hydraulically by means of stroke piston. The swashplate is mounted in swivel bearing for easy motion and the
neutral position is spring-centered. Increasing the swivel angle increases the displacement; Reducing the angle
results in a corresponding reduction in displacement.
If the swivel angle of the swashplate (12) is zero, pistons (10) do not move in and out of barrel (9) and there is no oil
flow. Pilot oil from charge pump in order to perform the following tasks:

• Keep barrel (9) full of oil.

• Lubricate and clean the pump components.
• Provide make UP oil for internal loss of oil that is due to leakage.
• Provide pilot oil to servo valve (3) in order to shift actuator piston (10) and change the swivel angle of swashplate
(12).
• Provide oil in order to release the parking brakes.
The position of swashplate (12) is determined by actuator piston (1). The transmission control lever that is lo Cat ed
on the left console sends signals to the electronic control module ( ECM ). The ECM interprets the signals and the
ECM sends pulse The signal oil is filtered through passage to the corresponding end of the direction, the signal oil
gets filtered through the pilot oil screens. Piston (4) .
As actuator piston (4) begins to move, the swivel angle of swashplate (12) begins to increase. As piston (10)
follows swashplate (12), pistons (10) begin to move in and out of barrel (9). As Piston (10) moves out of barrel (9),
oil is drawn from the passage of port (8) of the drive loop through port plate. As piston (10) follows swashplate (12)
and the piston moves into barrel (9) , the oil is pushed through port plate into the passage to port (5) of the drive
loop.
As the swivel angle of swashplate (12) increases, the output flow of the pump also increases.

8
1.5 Drive motor

(1) Drive shaft (6) Piston (11) Ring gear

(2) Motor case (7) Minimum displacement screw (12) Spring
(3) Port (8) Head (13) Barrel
(4) Retainer (9) Solenoid (14) Maximum displacement screw
(5) Speed sensor (10) Pivot pin (15) Control lens

The piston motors convert hydrostatic energy into mechanical energy. The piston motors are mounted to the
brakes that are located on the final drive. The piston motors are infinitely variable and the speeds of the piston
motors are controlled by the motor displacement servo valve in head (8).
The following components rotate within the piston motor:

• Drive shaft (1)

• Retainer (4)
• Pistons (6)
• Barrel (13)
The following components do not rotate with the piston motor:

• Motor case (2)

• Head (8)
• Control lens (15)
Spring (12) pushes barrel (13) against control lens (15) in order to ensure a high pressure seal between barrel (13)
and control lens (15) and between control lens (15) and head (8) .
Control lens (15) has two oil control slots. One control slot is for the high-pressure loop. The other control slot is for
the low-pressure loop.
When the high-pressure oil is at the high pressure loop port, oil from the port flows to the control slot in control lens
(15). oil in the control slot flows into the cylinders of barrel (13) that are over the control slot .

9
The spherical piston heads are held in the sockets in the drive shaft (1) by retainer (4). Pistons (6) are held by
barrel (13). Barrel (13) rotates around pivot pin (10) which is at an angle To the axis of drive shaft (1). As a result of
the bent axis relationship between the barrel and the shaft, the pistons move in and out of the cylinders as pressure
oil enters the cylinders and pressure oil leaves the cylinders. CE s the pistons, the barrel and the drive shaft to
rotate.
While the pistons, the barrel and the drive shaft continue to rotate, piston (6) reaches the fully retracted position. At
the same time, the cylinder begins to overlap the control slot in control lens (15) on the low-pressure side of At the
point, the piston starts to move back into the barrel (13). As piston (6) moves back into barrel (13), piston (6)
pushes oil out of the cylinder through the control slot to the lo- Pressure side of the loop.
The motor bearings receive oil for lubrication and for cooling from the fan pump. The oil flows from the fan pump to
an orifice in the hydraulic block through port (3) to the motor bearings. The remainder of the internal components
are lubricated by this oil and by normal leakage from pistons (6) and from barrel (13) .
Speed sensor (5) sends two signals back to the ECM as the teeth of ring gear (11) rotate past speed sensor (5).
The signals that are produced by speed sensor (5) determine the speed of the motor and the direction of the motor.

10
1.6 Introduction to Refilling Lines

②
①
⑤

① Working Pump, supply the oil to the blade lift cylinder;

② Charge Pump, supply the oil to the pilot hydraulic system and refill the hydrostatic system;
③ Pilot Valve, control the pilot oil to control the working valve;
④ Pilot Hydraulics Lock, located at the bottom of the cab, control the ON/OFF of the pilot oil in the pilot hydraulics system to prevent incorrect
operation;
⑤ Refilling Filter, filter the hydraulic oil from the charge pump;

Function of Charge Pump

The charge pump refills the low pressure pipe in the system with oil, the oil is filtered by the refilling filter, then the
clean hydraulic oil is provided to the low pressure section of the drive pump-motor high pressure circuit and other
control circuits. Its main functions are as follows:
1. Refill the low pressure pipe in the system with oil through the refilling check valve, to compensate the system
leakage, and establish a certain low pressure in the low pressure pipeline to improve the suction performance
of the pump and prevent the cavitation and air from entering the system;
2. The heat generated in the system is taken away through the circulation of the oil in the refilling circuit, and the
system temperature is dropped after cooling;
3. The control pressure oil circuit of the variable control mechanism is provided to ensure the normal operation of
the control system.
4. To provide the control oil to the brake system.
5. To provide the control oil to the pilot system.

11
1.7 Cooling Hydraulic System
④
①

② ○
5

① Hydraulic Oil Tank

② Drive pump
③ To cooler pipeline
④ Radiator
⑤ To hydraulic tank pipeline

12
2 Introduction to Hydrostatic System Operation
2.1 Hydrostatic Bulldozer Power Transmission Path Diagram

Undercarriage

Sprocket Segment

Left Final Drive

Left Drive Motor

Engine Coupling Drive Pump

Right Drive Motor

Right Final Drive

Sprocket Segment

Undercarriage

Power Transmission Path Diagram

The bulldozer used with hydrostatic drive has a simple mechanism, easy manufacturing and maintenance,
equipped with infinitely variable speed, high transmission efficiency and excellent operating comfort.

13
2.2 Hydrostatic Function Realization and Principles
4
○ 5
○ 6
○ 7
○

○
1

○
19

2
○
○
10

○
15 ○
16 ○
15

○
14
○
20

○
24
○
18
○
13 ○
12
○
11 ○
23
9
○
8
○
○
17

○
21

3
○
○
22

7
○ 5
4
○ ○ 6
○

Caution: See the 816D Hydraulics schematic for details.

(1) Speed Sensor (9) Hydraulic Oil Return Tank (17) Cooling Water Tank
(2) Left Motor (10) Left Motor Case Drain (18) Front Drive Pump
(3) Right Motor (11) Rear Drive Pump (19) Check Valve
(4) Piston Cylinder (12) Working Pump (20) Servo Cylinder
(5) Spring (13) Pilot Pump (21) Pump Case Drain
(6) Brake Assembly (14) Pilot Filter (22) Hydrostatic Tank
(7) Motor Solenoid Valve (15) Pump Proportional Solenoid Valve (23) Pump Control Oil Shutoff Valve
(8) Purge Valve (16) Pilot Oil and Hydrostatic System Refilling (24) Brake Solenoid Valve

14
As shown in the figure, SEM816D hydrostatic bulldozer propel drive hydraulics system consists of two identical
closed circuits, each closed circuit contains the drive variable pump, its adjusting mechanism travel motor,
adjusting mechanism and relief valve; The drive variable pump is driven by the coupling connected with the engine,
and the travel motor drives the travel mechanism through the final drive to advance, reverse or steer the bulldozer.
The two closed circuits share a refilling circuit, which consists of a pump, an oil filter, a refilling relief valve, and a
refilling check valve.
In this system, the drive variable pump functions as both the Hydraulics energy unit and the main control assembly.
By changing the pump displacement to change the amount and direction of pump flow, you can change the output
speed and direction of the hydraulics motor. When the system has a obvious change in the external load by
changing the motor displacement, the pressure of the Hydraulics changes within a small range.

2.3 Introduction to Operating Mode

2.3.1. Start-Acceleration Process
When the whole machine is in the stop state, the displacement of the drive pumps (11) (18) are zero, and that of
the drive motors (2) (3) are maximum.
When the engine is started, the hydrostatic lever will be turned to the forward or reverse gear depending on the
driver operation. Take the forward gear for example, the sensor under the joystick guard will give and send the
signal to ECM, then ECM analyzes this signal and sends the control signal to the front and rear drive pump
proportional solenoid valves (15) and the motor solenoid valves (7) on both sides, the whole machine will run
forward. As the driver's throttle increases or the speed adjusted by the governor roller increases, the pump
displacement gradually increases and the motor displacement does not change. When the pump reaches the
maximum displacement, if the desired speed has not been achieved yet, the motor displacement on both sides
begin to gradually decrease until the minimum set displacement is achieved while the pump maintains the
maximum displacement, and the whole machine reaches the maximum speed.

2.3.2. Brake Pedal Deceleration Function

When the driver begins to depress the brake pedal, its operating travel changes, the position sensor generates a
signal and transmits it to the ECM, the ECM analyzes this signal and sends the signal current to the (15) pump
proportional solenoid valve and (7) the motor solenoid valve, to control the machine deceleration. As the signal
strength to the motor solenoid valve is weakened, the motor control variable cylinder operates in upper stroke, and
the motor displacement is gradually increased until the maximum displacement is achieved;
When the motor reaches the maximum displacement, if the brake pedal is continuously pressed at this time, the
ECM sends a signal to control the (15) pump proportional solenoid valve, and the pump displacement begins to
gradually decrease until it reaches the minimum (0) displacement, the machine speed continues dropping;
When the brake pedal is pressed all the way to the floor, the pedal will trigger the kickout switch installed at the
bottom of the pedal, the kickout switch sends the signal current to ECM, then ECM analyzes this signal and sends
the control signal to (15) pump proportional solenoid valve and (7) motor solenoid valve, so that the motor returns
to the maximum displacement, and the pump achieves the minimum displacement. At the same time, the ECM
sends a 0 volt electrical signal to the (24) brake solenoid valve. Since the signal sent to the brake solenoid valve
(24) is 0 volt, the solenoid valve is reversed under the action of the spring. The pilot hydraulic oil from the front
pump is blocked at the (24) brake solenoid valve, and the hydraulic oil in the left and right motor piston cylinders
flow to the brake solenoid valve through the pipeline, then return to the hyrdostatic tank through the hydraulic lines.
When the hydraulic oil flows out of the left and right motor piston cylinders, the spring (5) pushes the piston against
the brake assembly to activate the brake function.

15
2.3.3. Steering Function
When the machine is traveling, if the driver turns the hydrostatic lever to left (or right) steering position,the sensor
under the joystick guard will give and send the signal to ECM, then ECM analyzes this signal and sends the control
signal to the front and rear drive pump proportional solenoid valves (15) and the motor solenoid valves (7) on both
sides, ECM controls the front and rear drive pumps and the right and left drive motors independently, in order to
control the machine straight traveling better and achieve the steering accuracy. With the increasing of steering
strength, the steering can be divided into three phases:
a. Slight steering: V1 > 0, V2 > 0, V1 > V2;
b. Steering transition phase:V1 > 0，V2 =0，V1 > V2;
c. Large steering：V1 >0 ，V2 < 0，V1 > V2;

Figure A Figure B Figure C

16
3 Test Adjustment
After operating for a certain time, the hydraulic system must be properly adjusted, and these tasks must be carried
out under the guidance of a professional.

3.1 Adjustment Preparation

1. The bulldozer track must be suspended and the whole machine is reliably set to prevent from accidents during
commissioning;
2. Check each hydraulic oi line carefully for proper connection, and all line connections must be tightened as
required;
3. Check the hydrostatic tank level and add it to above 2/3 of the oil level dipstick, the machine runs for
5~8minutes, the hydrostatic oil level in 2~3 lines is most suitable. When refueling, always ensure the
cleanliness of the oil. Use the hydraulic oil recommended by the manufacturer.

3.2 Precharge Propel Pump with Hydraulic Oil (Air Removal)

Open the air bleed plug R. Caution: This plug needs to be reinstalled after commissioning.
Add the hydraulic oil (with the same grade as that in the tank) to oil pump housing through the vent R until the
housing is fully filled. Caution: The air in the pump may not be discharged smoothly during the filling process,
causing the oil overflowing before air discharged fully. The pressure joints are recommended to install on the bleed
plug holeR, and connect the pressure gauge of 1 Mpa range to prevent oil from spilling out. It is necessary to wait
for a while to make sure that the oil level does not drop before the plug can be screwed on.

17
3.3 Drive Pump Zero Adjustment

1. Mechanical Zero Adjustment

• Connect the X1 and X2 ports with a 6mm diameter hydraulic hose;
• The electric control level is in the neutral and braking state;
• Attach the pressure gauge with a range of 6 Mpa to MAand MB pressure test points;
• Unscrew the locknut and use the Allen wrench to adjust the screw bar at the top of the Z1/Z2 servo cylinder,
to make both pressure gauges display the same pressure, about 2.9?0.15 Mpa.
• Retighten the locknuts.
2. Hydraulics Zero Adjustment
• Attach the pressure gauge with a range of 1 Mpa to the X1and X2 ports of the oil pump;
• The electric control level is in the neutral and braking state;
• Loosen the locknuts on the proportional solenoid valve;
• Adjust the hydraulics zero adjustment screw, to make both pressure gauges display the same reading (with
an error of no more than 0.03 Mpa). When adjusting the hydraulics zero adjustment screw, take note that the
rotation angle in each direction should not exceed 45 degrees.
• Tighten the locking screw on the proportional solenoid valve.

3.4 Hydrostatic System Pressure Test Points

Under the normal machine operating conditions, the ECM controls the movement of the machine. When the ECM
is faulty, a simple inspection can be performed according to the following mechanical test points. (Only the basic
understanding is given here. In the case of ECM normal operation, the various mechanical measurements are not
recommended.）

Pressure gauge range selection: In order to prevent from the gauge damage, the maximum pressure measured by
the pressure gauge generally does not exceed 2/3 of its upper limit; to ensure the accuracy of the measurement,
the measured pressure must not be lower than 1/3 of the upper limit. When the measured pressure fluctuates
greatly, the pressure variation range should be 1/3 to 1/2 of the upper limit of the scale. The pressure gauge
measurement accuracy is divided into six levels: 0.5, 1.0, 1.5, 2.0, 2.5 and 4. Generally, the pressure gauge of 1.5
accuracy level can be used. The pressure gauge used to correct the pressure gauge accuracy should be 0.5 level.

18
Measuring point 1: Hydraulic oil pressure measurement in high pressure circuit

• MA: Hydraulic oil pressure in left (front pump) high pressure circuit, when the machine is moving forward
• MB: Hydraulic oil pressure in right (rear pump) high pressure circuit, when the machine is moving backward
 Technical parameter: Rated pressure for normal hydrostatic system operation: 41500 Kpa, maximum49650
KPa.
Adjusting procedure-Crossover relief valve
1. Remove the access panel in the floor of the cab.
2. Enter the machine.
3. Remove the cap from crossover relief valve G4*4 that is not within the specification.
4. The crossover relief valve for REVERSE is on the top side of the pump. The crossover relief valve for
FORWARD is on the bottom side of the pump.
5. Loosen locknut (4).
6. Turn adjustment screw (5) in order to adjust the relief pressure. Turn the adjustment screw clockwise in
order to increase the pressure or turn the adjustment screw counterclockwise in order to decrease the
pressure. One full turn of the adjustment screw is approximately 19000 kPa (2756 psi).
Note: When you adjust the crossover relief valve in order to decrease the pressure, turn the adjustment
screw for an additional one quarter turn past the estimated adjustment setting. Then, turn the adjustment
screw clockwise for one quarter turn.
7. Maintain the position of adjustment screw (5) as you tighten locknut (4).
8. Recalibrate the electronic pressure override valve.
Repeat step 3 through step 7 until the all crossover relief valves have been adjusted.
Repeat "Testing Procedure - Crossover Relief Valve" until all pressures are within specifications.

19
Measuring point 2:Refilling pressure measurement

Refilling Pressure
Measuring Points

(1) Use 6 Mpa pressure gage to test charge pressure on charge filter.
(2) The engine speed should be 1900±50 rpm.
(3) The charge pressure at pressure tap should be 3200±150 Kpa. Relief valve (G5) is not adjustable and must be replaced if the charge relief
pressure is out of specification.

Measuring point 3:Housing overflowing pressure measurement

• R:Housing overflowing pressure
 Technical parameter: Rated pressure for hydrostatic system drive pump housing under normal operation:
0~345 Kpa,Cold environment (-18C -40C) less than 500 Kpa at steady state

20
Measuring point 4: Brake pressure measurement
• PS2: Hydrostatic system brake pressure test points
 Technical parameter: Hydrostatic system brake pressure under normal operation: 2700Kpa-3650KPa

Measuring point 5: Pilot control pressure test points

• PS: Hydrostatic system pilot control pressure test points
 Technical parameter: Rated pressure for hydrostatic system pilot control under normal
operation:2700KPa-3650KPa

21
4 Pilot Hydraulic System
The operating hydraulic system on the bulldozer is used to control the push arm and the dozer in the bulldozer
operating unit and other attachments' movement. The operating device's hydraulic system is used to control the
action of the dozer (optional rear scarifier) by the pilot hydraulic system to achieve various operation requirements:
blade lifting, lowering, fixing, floating, changing the tilt angle, and the scarifier (if equipped) blade lifting, lowering
and fixing. This system is available in two structures: two-way pilot and triple pilot operated.

4.1 System Construction

The hydraulic system oil circuit is mainly divided into two parts: the pilot control oil circuit and the main operating oil
circuit. The action of the main operating oil circuit is controlled by the pilot control oil circuit to realize the small flow,
large flow under low pressure control and high pressure. The main components of the operating hydraulic system
are: hydraulic tank, double pump, multi-way shuttle valve, pilot operated valve, blade lift cylinder, tilt cylinder,
scarifier cylinder and other automatic reset devices.
In the operating hydraulic system, the double pump is connected to the rear side of the drive pump directly, is
powered by the engine and provides the operating hydraulic system with pressurized oil.

1. Lifting cylinder 5. Rear ripper control valve 9. Working Pump

2. Oil diverter valve 6. Solenoid valve 10. Scarifier cylinder
3. Operating valve 7. Rear ripper cylinder
4. Operating pilot valve 8. Pilot pump

22
4.2 Key Component Introduction
4.2.1. Multi-way Shuttle Valve
This machine uses an integral multi-way shuttle valve, which is available in two configurations. One is the double
valve, which can control the blade lift cylinder and tilt cylinder. The other is the triple valve, which can control the
blade lift cylinder, tilt cylinder and scarifier cylinder, and also control the hydraulic winch.
The main relief valve controls the operating hydraulic system pressure. If the relief valve is damaged, it will affect
the performance of the entire operating system. During the operation, there will be a phenomenon of weak lift, slow
lift or no lift. The rated set pressure for the main relief valve in this multi-way valve is 19000?500 Kpa.

4.2.2. HYDRAULIC CYLINDERS

a) Blade Lift Cylinders

1. Cylinder block 4. (5, 7, 8, 10, 11, 12, 13) Ring seal package 14. Stop block
2. Hinge shaft sleeve 6. Piston 15. Joint bearings
3. Nut 9. Cylinder head 16. Piston rod

23
b) Tilt Cylinder

1. Cylinder block 11. Washer 15. Stop block

2. (3, 5, 6, 8, 9, 10) Ring seal package 12. Bolt 16. Joint bearings
4. Piston 13. Bushing
7. Cylinder head 14. Piston rod

c) Scarifier cylinder

1. Cylinder block 6. Piston 16. Piston rod

2. Hinge shaft sleeve 9. Cylinder head 17. Bushing
3. Hinge shaft protector 14. Washer
4. (5, 7, 8, 10, 11, 12, 13) Ring seal package 15. Bolt

24
The three hydraulic cylinders on the machine use the single bar double acting piston type hydraulic cylinders. This
cylinder has two oil ports. As there is only one piston rod, the piston has different stressed area in both ends. When
the same amount of pressurized oil is input from different ports, the reciprocating speed of the piston is not equal;
When the oil supply pressure is constant, the force applied on both sides of the piston is not equal.

4.2.3. Precautions in Hydraulic Cylinder Removal:

1. Before removing the hydraulic cylinder, the hydraulic circuit should be relieved. Otherwise, the pressurized oil
in the circuit will be quickly ejected once the oil pipe connected with the cylinder is loosened. When the
hydraulic circuit is relieved, loosen the hand wheel or the pressure adjusting screw at the relief valve, etc. to
unload the pressurized oil, then cut off the power or cut off the power source to stop the hydraulics unit.
2. Prevent the piston rod top thread, port thread and piston rod surface, cylinder liner inner wall, etc. from damage
during removal. In order to prevent the slender parts such as piston rods from bending or deforming, they
should be placed and supported with chock for balance.
3. The removal should be done in order, and the removal order is slightly different due to the different structure
and size of the hydraulic cylinders. Usually, discharge the fluid in the two chambers of the cylinder, then remove
the cylinder head, and finally remove the piston and piston rod. When removing the cylinder head of the
hydraulic cylinder, the special tools are used for the HSGK key or snap ring. The flat shovel is prohibited. For
the flanged end cover, it must be screwed out and no hammering or hard prying is allowed. When the piston
and piston rods are difficult to remove, do not force them out. You should first find out the cause and then
remove them.
4. Before and after removal, try to create the conditions to prevent the parts of the hydraulic cylinder from being
contaminated by the dust and impurities around it. For example, it should be removed under the clean
environment as much as possible; all parts should be covered with a plastic cloth after removal, and should not
be covered with pillows or other work cloth.
5. The cylinders should be carefully checked after removal to determine which parts can continue to be
used, which parts can be repaired and reused, and which parts must be replaced.
6. All parts must be carefully cleaned before installation.
7. To install the sealing units properly at each area.
8. A special wrench should be used to tighten the thread coupling. The torque should meet the standard
requirements.
9. When the installation is completed, the piston assembly should be moved without obstruction and uneven
resistance.
10. When the hydraulic cylinder is mounted to the main engine, the inlet and outlet connectors must be ring sealed
and secured to prevent from oil leakage.
11. When installed according to the requirement, the reciprocating motion should be performed several times
under low pressure to eliminate the gas in the cylinder.

25
4.3 816DOperation Hydraulic Schematic Introduction

⑨
⑧

⑤
⑦
③

○
10

1. Double pump 5. Accumulator 9. Proportional pilot valve

2. Lift cylinder 6. Return oil filter element 10. Hydraulic tank
3. Solenoid valve 7. Tilt cylinder
4. Relief valve 8. Multi-way shuttle valve

The blade lift control lever of the proportional pilot valve (9) has four control positions: "lift", "neutral", "float" and
"lower", used to control the dozer action; the tilt valve stem has "left tilt", "neutral" and "right tilt" control position,
used to control the dozer action.
The engine operates through the drive pump and the double pump (operating / refilling) driven by the coupling.
When the control levers of the pilot valve (9) are in neutral position and the blade lift valve stem and the tilt valve
stem of the multi-way valve (8) and the scarifier control valve stem are also in the neutral position, the oil from the
double pump (1) overflows back to the tank through the multi-way valve (8) and the pilot solenoid valve (3). When
the engine is running, if the lift control valve stem of the pilot control valve (9) is pushed to the "lift" position, the pilot
oil enters the rear control chamber of the multi-valve (8) second (lifting) via the pilot valve (9). Push the valve stem
forward, the pressurized oil in the main oil passage enters the small chamber of the blade lift cylinder through the
multi-valve second, the cylinder piston moves up to realize the lifting of the dozer; and when the lift control valve
stem of the pilot control valve (9) is pushed to the "lower" position, the pilot oil enters the front control chamber of
the multi-way valve (8) second (lifting) via the pilot valve (9), push the valve stem back, and the pressurized oil in
the main oil passage goes into the blade lift cylinder large chamber via the multi-way valve second and the cylinder
piston moves down to realize the lowering of the dozer; the other tilt cylinders and the scarifier cylinders operate in
turn.
This machine adopts the integral multi-way shuttle valve, and the double pump simultaneously supplies oil to each
shuttle valve of the multi-way valve. The return chamber of each valve is also directly connected to the main return
port of the multi-way valve. Each shuttle valve can only be operated independently and cannot operate at the same
time.

26
4.4 Adjustment and Test
Measuring point 1: Normal hydraulic system operating pressure
• P7: Normal hydraulic system operating pressure
 Technical parameter: Rated pressure for normal hydraulic system operation19000?500 Kpa
 Pressure Joint Specification:PT-30

P7

Measuring point 2: Pilot hydraulic system normal operating pressure measurement

• P8: Pilot hydraulic system normal operating pressure
 Technical parameter: Rated pressure for normal pilot hydraulic system operation: 2700Kpa-3650Kpa
 Pressure Joint Specification:PT-29

P8

27
5 System Fluid Cleanliness Control
Importance of Ensuring System Fluid Cleanliness

Oil Contamination

Worn Element Plugged Element

Sucking

Damaged Element

System
Performance Degradation
/ Malfunction

Two Natural Enemies to Hydraulic System:

A. Oil Contamination
B. System Sucking
Source of Hydraulic System Pollution:
1. External pollution
2. Pollution during installation
3. Pollution caused by starting system
4. Internal pollution
5. Wear
6. New oil
7. Pollution caused by maintenance
Advice on Ensuring Fluid Cleanliness

• Clean all oil pipes before installation;

• Do not apply paint to the fuel tank. Remove the welding slag carefully by using flour before installation;
• The fuel tank and the pipelines should be thoroughly cleaned when changing the fuel. When refueling, the
fuel filter with filtration accuracy of 10 um is used to fill;
• The oil suction tube, oil drain tube, oil return tube should be properly installed;
• Ensure that the temperature rise in the fuel tank does not exceed the hydraulic fluid requirements, generally
not exceeding 70 degrees. (once exceeding 80 degrees, for every 10 degrees increment, the speed of
component damage increases exponentially);
Replace the bad seals in time (to prevent the air from entering the system), replace the water coolers in time (to
prevent the water from entering the system);

28