HYDRAULIC SYSTEM

CUSTOMER SUPPORT T O U G H W O R L D . T O U G H E Q U I P M E N T.
DEPARTMENT
C O N T E NT S
 1. Hydraulic system of excavator
 2. The introduction of hydraulic pipe line
 3. Pressure test and adjust
 4. Troubleshooting
1. Hydraulic system of excavator
1.1 Hydraulic system parameters
1.2 Drive diagram of hydraulic system
1.3 Hydraulic system schematic
1.3.1 Negative flow control system
1.3.2 Boom raise
1.3.3 Boom lower
1.3.4 Arm out
1.3.5 Arm In (with regeneration)
1.3.6 Arm In (without regeneration)
1.3.7 Bucket in
1.3.8 Bucket out
1.3.9 Swing left
1.3.10 Swing right
1.3.11 Forward travel (high speed)
1.3.12 Backward travel (low speed)
1.3.13 Straight travel
1 . 1 H Y D R A U L I C S Y S T E M PA R A M E T E R S
　 Item Unit 920D/922D 923D/925D 936D
Double Double Double
1 Main pump type 　 Variable Axial Variable Axial Variable Axial
Piston Pump Piston Pump Piston Pump
2 Main pump displacement cc 108 115 140
3 Main pump total flow L/min 2×215 2×230 2×280
4 Relief pressure, main MPa 32.2 32.2 32.2
5 Relief pressure, boost MPa 34.6 34.6 34.6
6 Swing Circuit pressure MPa 25.5 25.5 26.2
7 Travel circuit Pressure MPa 32.2 32.2 32.2
Boom Head/Rod Relief
8 MPa 36.3/36.3 36.6/36.6 36.3
Pressure
Arm Head/Rod Relief
9 MPa 37.2/37.2 36.6/37.2 36.3
Pressure
Bucket Head/Rod Relief
10 MPa 35.3/36.3 36.6/37.2 36.3
Pressure
11 Option Relief Pressure Mpa 19.6 19.6 36.3
1.1 Hydraulic system parameters
　 Item Unit 920D/922D 923D/925D 936D
12 Pilot pump type 　 Gear pump Gear pump Gear pump
13 Pilot pumpdisplacement cc 　 10 10 15
L/
14 Pilot pump flow min 20 20 30
　
15 Pilot pressure MPa 3.9 3.9 3.9
Boom cylinder
mm 120×85×1187- φ125×φ90×1350× 150×105×150
16 (Bore×rod×Stroke -Min.
　 1794 1950 5
Installation Dimension )
Arm cylinder
mm 135×95×1450- φ140×φ105×1610 165×115×179
17 (Bore×rod×Stroke -Min.
　 2063 ×2235 5
Installation Dimension )
Bucket cylinder
mm 120×85×1058- φ130×φ90×1075×
18 (Bore×rod×Stroke -Min. 145×95×1220
　 1593 1665
Installation Dimension )
Hydraulic oil
19 L 230/330 230/330 240/450
(tank/system)
20 Swing motor gear oil L 3.4 4.4 10.5
21 Drive motor gear oil L 5.5*2 5.5*2 9.5*2
1.1 Hydraulic system parameters
　 Item Unit 920D/922D 923D/925D 936D

12 Pilot pump type 　 Gear pump Gear pump Gear pump

13 Pilot pump displacement cc 　 10 10 15
L/
14 Pilot pump flow min 20 20 30
　
15 Pilot pressure MPa 3.9 3.9 3.9
Boom cylinder
mm 120×85×1187- φ125×φ90×1350× 150×105×150
16 (Bore×rod×Stroke -Min.
　 1794 1950 5
Installation Dimension )
Arm cylinder
mm 135×95×1450- φ140×φ105×1610 165×115×179
17 (Bore×rod×Stroke -Min.
　 2063 ×2235 5
Installation Dimension )
Bucket cylinder
mm 120×85×1058- φ130×φ90×1075×
18 (Bore×rod×Stroke -Min. 145×95×1220
　 1593 1665
Installation Dimension )
Hydraulic oil
19 L 230/330 230/330 240/450
(tank/system)
20 Swing motor gear oil L 3.4 4.4 10.5
21 Drive motor gear oil L 5.5*2 5.5*2 9.5*2
 1.2 DRIVE DIAGRAM OF HYDRAULIC
SYSTEM

Drive Control oil Control

Engine Pilot pump Pilot valve Driver

Control oil
Drive Work oil Work oil
Work pump Main valve Motor

Work oil Carry out

Carry out
Implement work Cylinder Swing 、 Travel
1.3 Hydraulic system schematic
3
1.3.1 Negative flow control system
1.3.2 Boom raise
BOOM RAISE
1.3.3 Boom lower
BOOM LOWER
1.3.4 Arm out
ARM OUT
1.3.5 Arm in (with regeneration)
ARM IN
WITH REGENERATION
1.3.6 Arm in (without regeneration)
ARM IN
WITHOUT REGENERATION
1.3.7 Bucket in
BUCKET IN
1.3.8 Bucket out
BUCKET OUT

M
1.3.9 Swing left
SWING LEFT
1.3.10 Swing right
SWING RIGHT
1.3.11 Forward travel (high speed)
FORWARD TRAVLE(HIGH SPEED)
1.3.12 Backward travel (low speed)
BACKWARD TRAVLE(LOW SPEED)
1.3.13 Straight travel
STRAIGHT TRAVLE
Table of contents

 1. Hydraulic system of excavator

 2. The introduction of hydraulic pipe line
 3. Pressure test and adjust
 4. Troubleshooting
 2.1 MAIN PUMP PIPING

Case Drain
hose Pressure
Working hose sensor

Solenoid Proportional
 Reducing Valve

Oil inlet tube

Sensor for hydraulic

oil temperature
 2.2 SWING MOTOR PIPING

Working
hose
Make up
oil inlet Swing pressure
test point

Port for
lubricating Case drain
oil hose

Swing relief valve Oil dipstick

Models ：
920D 、 922D
 2.3 SWING MOTOR PIPING

Make up oil
Case drain inlet
hose

Port for
Swing relief
lubricating
valve
oil

Oil dipstick

Swing pressure
test point
Working hose

Models ：
923D 、 925D
 2.4 PILOT HYDRAULIC PIPE LINE (PILOT
VA LV E B L O C K )

Accumulator

Pilot relief
valve

Pressure sensor
Pilot pressure
test point

Pilot filter

Models ：
920D(Ⅲ) 、 922D(Ⅲ)
Table of contents

 1. Hydraulic system of excavator

 2. The introduction of hydraulic pipe line
 3. Pressure test and adjust
 4. Troubleshooting
3.1 SYSTEM PRESSURE TEST

P2 P1 a2 a1
Port P1 、 P2 pressure test:(pressure test
ports a1 、 a2 dimension:G1/4)

1.Remove the plug a1/a2 in the illustration with a

spanner and connects with a pressure testing joint
and a pressure gauge(with a range of 0~70MPa);

2.Start engine, Slowly operate the excavator to

raise the hydraulic oil temperature to 50±5℃;then
read the data from the gauge;

3.Remove pressure gauge and pressure testing

joint. Tighten the plugs to a torque of 16Nm.

Models ：
920D(Ⅱ) 、 922D(Ⅱ) 、 922
D(Ⅲ) 、 923D(Ⅱ) 、 925D(Ⅱ)
、 925D(Ⅲ)
3.2 SYSTEM PRESSURE ADJUST
HỆ THỐNG ĐIỀU CHỈNH ÁP LỰC

1. Start the engine, increase it‘s rotating speed slowly to full speed ；
Khởi động động cơ, tăng lên nó quay tốc độ chậm tới tốc độ đầy đủ
2.Set the excavator monitor to the function of checking the left and right pump
Thiết lập màn hình máy xúc đến chức năng kiểm tra áp suất bơm trái và bên p
3.Turn on the pilot cutoff lever, operate the work implements to let the hydrauli
temperature raises to 50±5℃, then operate the boom up or arm to extreme po
make the main relief valve open. At the moment the pressure value should be
31.8~32.8MPa, then press the burst button located on the right joystick, the pr
value should be 33.3~34.3MPa ；
Turn về việc thí điểm cắt đòn bẩy, vận hành công trình thực hiện để cho nhiệt
lực làm tăng đến 50 ± 5 ℃, sau đó hoạt động sự bùng nổ lên hoặc cánh tay v
để làm cho các van xả chính mở. Tại thời điểm này giá trị áp lực nên được 31
32.8MPa, sau đó nhấn nút chụp nằm trên phím điều khiển bên phải, giá trị áp
được 33,3 ~ 34.3MPa
4. If the pressure values are not in the arrange above, we need to adjust them
procedure:
Nếu các giá trị áp lực không nằm trong sắp xếp ở trên, chúng ta cần phải điều
chúng như thủ tục sau đây:
(1) Loose locknut number 3 with open-end wrench(30mm);
3.2 System pressure adjust
(2) Press the burst button located on the right joystick ， turn number 4
slightly inwards or outwards slowly with inner hexagon spanner(6mm) and
check the pressure value in the monitor.Stop turning number 4 when the
pressure value reaches to 33.3-34.3MPa, then tighten number 3 ， loose
the burst button located on the right joystick ;

(3) Loose locknut number 5 with open-end wrench(22mm) in anticlockwise

direction.Turn number 4 inwards or outwards slowly with hexagon
spanner(6mm) and check the pressure value in the monitor. Stop turning
number 4 and tighten number 5 when the pressure value reaches to
31.8~32.8MPa.

Main relief valve

Models ：
920D(Ⅱ) 、 922D(Ⅱ) 、 922
D(Ⅲ) 、 923D(Ⅱ) 、 925D(Ⅱ)
、 925D(Ⅲ)
3.3 PILOT PRESSURE TEST

Pilot pressure test and adjust:(pressure

test port a3 dimension:G1/4)

1. Remove the plug a3 （ number466 ） in

the illustration with a pressure testing joint
and a spanner and connects with a pressure
gauge(with a range of 0~6MPa);

2.Start engine, Slowly operate the excavator

to raise the hydraulic oil temperature to
50±5℃;

3.Set the engine speed to full speed , check

The port of pilot the pressure gauge,the value should be
pressure test a3 between 3.9~4.1MPa.
Models ：
920D(Ⅱ) 、 922D(Ⅱ) 、 9
23D(Ⅱ) 、 925D(Ⅱ) 、 92
5D(Ⅲ)
3.4 Pilot pressure test
1. Remove the plug number 2 or 4 in the illustration
by hand and connects with a pressure gauge(with
a range of 0~6MPa);

2.Start engine, Slowly operate the excavator to

raise the hydraulic oil temperature to 50±5℃;

3.Set the engine speed to full speed, check the

pressure gauge,the value should be between
3.9~4.1MPa.

Models ：
920D(Ⅱ) 、 922D(Ⅱ) 、 92
2D(Ⅲ) 、 923D(Ⅱ) 、 925
D(Ⅱ) 、 925D(Ⅲ)
3.5 PILOT PRESSURE ADJUST
If the Pilot pressure value is incorrect,
adjust it as following procedure:
(1)Loose locknut 312 with open-end
wrench(22mm)as shown in the illustration.
Tighten screw 311 by inner hexagon
spanner(6mm). The pressure will increase
when rotate in clockwise direction and
decrease when rotate in anticlockwise
direction. Tighten locknut 312 when the
pressure value reaches to 3.9~4.1MPa.
After that, pressure adjustment is finished.

(2)Remove pressure gauge and pressure

testing joint. Tighten the plug to a torque of
Pilot pressure 16Nm.
adjust bolt
Models ：
920D(Ⅱ) 、 922D(Ⅱ) 、 9
23D(Ⅱ) 、 925D(Ⅱ) 、 92
5D(Ⅲ)
3.6 PILOT PRESSURE ADJUST
If the Pilot pressure value is incorrect, adjust
it as following procedure:
Pilot relief
valve (1)Loose locknut that installed on the pilot relief
valve as shown in the illustration. The pressure
will increase when rotate in clockwise direction
and decrease when rotate in anticlockwise
direction. Tighten locknut 312 when the pressure
value reaches to 3.9~4.1MPa. After that, pressure
adjustment is finished.

(2)Remove pressure gauge and pressure testing

joint. Tighten the plug to a torque of 16Nm.

Models ：
922D(Ⅲ)
Table of contents

 1. Hydraulic system of excavator

 2. The introduction of hydraulic pipe line
 3. Pressure test and adjust
 4. Troubleshooting
4.1 Hydraulic components works slowly

　 Cause Solutions
1 Low oil level Add oil to oil tank to the full mark
Run the engine to preheat
2 Cold oil
hydraulic system
3 Wrong hydraulic oil Use the correct oil
Solve the problem of low engine
4 Slow engine speed
speed
5 Pilot oil loops Check the pilot circuit
6 Worn pump Replace or repair worn parts
Restricted pump
7 Check pump suction pipe
suction pipe
4.2 Hydraulic oil over hot
　 Cause
1 Wrong hydraulic oil
2 Low oil level
3 Worn pump
Clogged radiator or oil
4
cooler
5 Oil cooler bypasses
6 Relief valve
7 Unclean oil
Improper adjustment for
8
the hydraulic components
Solutions
Use the correct oil
Add oil to oil tank to the full
mark
Replace or repair worn parts
Clean or rearrange the
radiator fins
Check one-way valve of the
oil return
Check and adjust the relief
valve
Add oil after draining oil
Proper adjustment for the
hydraulic components
4.3 Low pressure or no oil pres-sure

　 Cause Solutions

1 Wrong oil Use the correct oil

Proper adjustment for

Improper adjustment for the
2 the hydraulic
hydraulic components
components

3 No oil in the hydraulic system Add the correct oil

Replace or repair worn
4 Worn cylinder
parts
Check and adjust the
5 Relief valve
relief valve
4.4 Cylinder can work but can not lift load

　 Cause Solutions
Replace or repair worn
1 Worn pump
parts
Low pressure of main relief Check and adjust the
2
valve main relief valve pressure
3 Low oil level Add oil
Clean the filter and the
4 Clogged the filter
system
5 Pump suction pipeline leaks Check suction pipeline
4.5 One control lever does not work

　 Cause Solutions
Low pressure of the oil port Check and adjust the oil
1
relief valve port relief valve pressure
2 Tube or hose damaged Repair or replace
Hydraulic components
3 Tighten
loosen
O-ring is damaged when
4 Replace a new O-ring
assembled
Repair or replace worn
5 Pilot valve
parts of pilot valve
6 Pilot lines Repair or replace
4.6 One cylinder does not work

　 Cause Solutions

Replace and repair worn

Spool of control valve
1 parts of control valve or
damaged or polluted by dust
cleaning it
2 Tube or hose damaged Repair or replace

3 Hydraulic components loosen Tighten

O-ring of hydraulic
4 Replace a new O-ring
components damaged
Replace and repair worn
5 Pilot valve parts of hand pilot valve or
clean it
6 Pilot pipeline failure Repair or replace
4.7 One travel motor does not work

　 Cause Solutions

Replace and repair worn

1 Travel motor trouble
2 Center swivel joint trouble
Do not set free brake
3 Replace and repair brake
pedal
4 Travel pilot valve
parts of travel motor or clean
it
Check for internal leakage
of center swivel joint
Repair or replace worn parts
of travel pilot valve or clean
it

5 Pilot circuit Repair or replace

4.8 Can not swing

　 Cause Solutions

Swing brake release Replace and repair swing

1
valve brake release valve

Replace and repair worn

2 Swing motor
parts of swing motor

Replace and repair worn

3 Pilot valve parts of hand pilot valve or
clean it
 THANK YOU
T O U G H W O R L D . T O U G H E Q U I P M E N T.