289419094-9Working-Hydraulic-System-ENGLISG-LG955N

Service Manual of RS8160 Road Roller
SERVICE MANUAL
9 Working Hydraulic System
1 Introduction
Service Manual for LG955N Wheel Loader
CONTENTS
9 Working Hydraulic System.................................................................................9-1
91 System Principle Description..............................................................................9-1
92 Description, Disassembly and Assembly of Hydraulic System Components.....9-2
921 Working Pump.............................................................................................9-2
922 Hydraulic Oil Tank......................................................................................9-8
923 Multitandem Valve....................................................................................9-15
924 Hydraulic Cylinders..................................................................................9-29
93 Service Precautions for Working Hydraulic System.........................................9-48
94 Testing and Adjusting of Working Hydraulic System Pressure........................9-51
941 Measuring and Adjusting of Main Safety Valve Pressure.........................9-51
942 Measuring and Adjusting of Overload Valve Pressure..............................9-53
95 Diagnosis and Solutions for Common Faults of Hydraulic System..................9-55
951 Unexpected Forward Tilt of Bucket..........................................................9-55
952 Boom Sinking............................................................................................9-56
953 Boom Rises Slowly...................................................................................9-58
954 Lifting Incapacity of Boom.......................................................................9-60
955 Bucket Slow Motion..................................................................................9-60
956 Working Incapacity of Bucket...................................................................9-60
1
9 Working Hydraulic System

91 System Principle Description
Fig. 9-1 Hydraulic principle diagram

Working device hydraulic system is composed of multitandem valve, flexible shaft operating
mechanism, boom cylinder, bucket cylinder, hydraulic oil tank, and pipeline accessories.
The multitandem valve is a double valve, one part for bucket, one for boom. Extending, retracting
and holding of bucket cylinder and boom cylinder can be realized by operate this valve to realize all
kinds of operation requirements. Operate the boom operating handle to move the boom part valve
element left and right to connect different oil ports, thereby lifting, lowering or floating of boom can
be realized; operate the bucket operating handle, forward tilt and backward tilt of bucket can be
realized.
92 Description, Disassembly and Assembly of Hydraulic System

9-1
Components
921 Working Pump
Technical parameters
Theoretical displacement 160ml/r
Rated rotating speed 2350r/min
Rated pressure 18MPa
Connecting type Rectangular spline
Fig. 9-2 Structure 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 9 Lug retainer ring
10 Lug seal ring 11 Side plate 12 Driving gear shaft 13 Driven gear shaft
14 Rivet 15 Label 16 Rear cover block 17 Bolt
Working pump is double gear pump. It is composed of front pump cover, rotating seal shaft, seal
ring, O-shape seal ring, side plate, pump body, bearing, rear pump cover, driving gear and driven
gear.
A P
A
Working principle
When pump shaft rotates as Fig. 9-3, the gear

demeshes on oil absorption chamber side, oil
9-2
T
absorption chamber close volume (T) increases and

A 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 A will be brought into
oil extrusion chamber P, the gear meshes on the
extrusion side and the volume decreases to force
oil into oil circuit.
Fig. 9-3 Working principle
Fault diagnosis of working pump
Table 9-2
S/N Fault phenomenon Cause Elimination method
Oil in hydraulic tank reduces, Measure the pressure and
1 while oil in transmission box Damaged oil seal. replace oil seal ring or
increases. working pump.
Oil in hydraulic tank increases, Measure the pressure and
2 while oil in transmission box Damaged oil seal. replace oil seal ring or
reduces. working pump.
Oil leakage of pump body Damaged O-ring or loose Replace the O-ring or
3
junction surface. bolt. fasten the bolt.
Check and replace the
4 Oil leakage of pump body Bump body crack.
working pump.
Excessive wear of spline Replace the spline shaft
shaft. or working pump.
Excessive wear of side Replace the side plate or
Abnormal sound produced by plate. working pump.
5
steering pump. Out of tolerance of spine Replace the spline shaft
shaft. or working pump.
Replace the bearing or
Bearing failure.
working pump.
Insufficient output flow result in Excessive wear of side Replace the relevant parts
6
slow motion. plate or gear. or working pump.
Disassembly and assembly of working p[ump

 ATTENTION
Before dismantling the working pump, be sure to carefully read 93 service precautions for
working hydraulic system.
9-3
Disassembly of working pump

1. Pressure relief.
Start the machine and drive it to the flat
spacious place. Raise the boom to the highest
position. Tilt the bucket backward, and then
shut down the engine.
Push the control handle of the pilot valve
towards right slowly. Let the bucket tilt
forward gently to drain the oil in bucket
cylinder.
Fig. 9-4
After the bucket reaches its extreme position,
push the handle forward gently. Let the boom
fall slowly to drain the oil in boom cylinder.
Keep the bucket flat on ground. Then operate
the handle left and right, back and forth for
5~6 times to drain the internal oil pressure of
the system.
2. Fix the loader tires with wood blocks stably.
3. Remove the cab floor mat.
1
Fig. 9-5
1 Mat
4. Remove the fixing bolts of maintenance cover

plate in the cab, and then take down the plate-
seat assembly down.
1 9-4
Fig. 9-6
1 Maintenance cover plate
5. Loosen the bolts that used to fix working

pump oil absorption steel pipe on pump oil
inlet port, take down the bolts, fission flange
and O-ring, and then remove the steel pipe.
1
Fig. 9-7
1 Working pump oil absorption steel pipe
6. Loosen the bolts that used to fix working

pump oil outlet steel pipe on pump oil outlet
port, take down the bolts, fission flange and O-
ring, and then remove the steel pipe.
1
Fig. 9-8
1 Working pump oil outlet steel pipe
7. Loosen the connecting nuts between working

pump and speed changer-torque converter
assembly, remove the nuts and gaskets; and
then take down the working pump and sealing
gasket.
1 2
Fig. 9-9
1 Pump sealing gasket
9-5
2 Nut
Assembly of the working pump

1. Connect the working pump to transmission
box end face with four M12 nuts and gaskets
and pump sealing gasket.
75±5 Nm
 ATTENTION
 Before the assembly, you should clean the
working pump thread holes with KESAI
1755 high-efficiency cleaner, and then apply
1 2
Fig. 9-10 KESAI 1545 anaerobic sealant on the studs
1 Pump sealing gasket for sealing.
2 Nut
 Be sure to tighten the studs first.
2. Remove the protector of each oil port, put an

O-ring in O-ring groove of working pump oil
outlet steel pipe joint, and then fix it on the
working pump oil outlet port end face with
four M10×55 bolts.
52±10Nm
1
Fig. 9-11
1 Working pump oil outlet steel pipe
O-ring in O-ring groove of working pump oil
absorption steel pipe joint, and then assemble
it to the working pump oil absorption port end
face with four M10×55 bolts.
90±20Nm
1
Fig. 9-12
1 Working pump oil absorption steel pipe 9-6
4. Install the maintenance cover plate-seat

assembly on the platform in cab with bolts.
1
Fig. 9-13
1 Maintenance cover plate
8. Reset the cab floor mat.
1
Fig. 9-14
1 Mat
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. Hydraulic oil filters should be replaced periodically
according to requirements in related manual.
9-7
To steering pump oil absorption rubber hose
To working pump oil absorption rubber hose

To breather
To steering gear oil return rubber hose

Filter fineness: 120um
To priority valve oil return hose
To multiandem valve oil return hose
Filter fineness: 10um

Opening pressure of bypass valve: 0.3MPa
Fill hydraulic oil for about 246L when oil temperature i
Fig. 9-15 Hydraulic oil tank assembly

1 Oil absorption flange assembly 2 Oil filling filter element 3 Oil return block
4 Round oil pointer 5 Hydraulc oil tank 6 Oil drain plug 7 Oil return filter element
Disassembly and assembly of hydraulic oil tank
 ATTENTION
Before dismantling the hydraulic oil tank, be sure to carefully read the 93 Service Precautions
for Working Hydraulic System in this chapter.
Disassembly of hydraulic oil tank
9-8
1. Pressure relief.
Start the machine and drive it to the flat
spacious place. Raise the boom to the highest
position. Tilt the bucket backward, and then
shut down the engine.
towards right slowly. Let the bucket tilt
forward gently to drain the oil in bucket
cylinder.
Fig. 9-16
fall slowly to drain the oil in boom cylinder.
Keep the bucket flat on ground. Then operate
the handle left and right, back and forth for
5~6 times to drain the internal oil pressure of
the system.
2. Fix the loader tires with wood blocks stably.
3. Remove the oil drain plug on bottom of

hydraulic oil tank to drain all hydraulic oil to a
clean vessel. Tighten the plug after the
draining.
1
1
Fig. 9-17
1 Oil drain plug
4. Remove the six fixing bolts of left platform.
1 1
9-9
Fig. 9-18
1 Left platform
5. Lift left platform down.
1
Fig. 9-19
1 Left platform
6. Loosen the fixing clamps of working pump oil
absorption rubber hose and steering pump oil
absorption rubber hose respectively.
7. Loosen the fixing clamps between breather
rubber hose and breather steel pipe.
8. Remove the fixing bolts of radiator oil return
steel pipe, remove the fixing bolt of the steel
pipe clamp, take down the bolts, clamp and
O-ring.
1 2 3 4 5
Fig. 9-20
1 Radiator oil return steel pipe
2 Working pump oil absorption hose
3 Steering pump oil absorption hose
4 Breather hose5 Pipe clamp
9. Remove the connecting bolts between oil

return block and hydraulic oil tank.
1 2
Fig. 9-21
1 Oil return block2 Bolt 9-10
10. Hang hydraulic oil tank with lifting rope.
Fig. 9-22
11. Remove the connecting bolts between

hydraulic oil tank and frame, and lift down the
hydraulic oil tank.
1
Fig. 9-23
1 Bolt
1
Fig. 9-24
1 Bolt Assembly of hydraulic oil tank
1. Apply suitable hydraulic oil on inner surface
of working pump and steering pump oil
9-11
absorption rubber hose end, place the hose

fixing clamps for assembling, lift hydraulic oil
tank and put it on left side of rear frame,
connect the working pump and steering pump
oil absorption rubber hoses to the tank.
2. Apply AT262 thread locking sealant on the

Fig. 9-25
M16 bolts, connect the hydraulic oil tank to
rear frame with the bolts and gaskets. Adjust
the tank assembly to suitable position, tighten
the front bolts first, and then tighten the rear
bolts.
225±30Nm
1
Fig. 9-26
1 Bolt
1
Fig. 9-27
1 Bolt 3. Adjust and tighten the fixing clamps of
working pump oil absorption rubber hose and
steering pump oil absorption rubber hose.
1 2 3 4 5
Fig. 9-28 4. Put O-ring in O-ring groove of radiator oil
1 Radiator oil return steel pipe
2 Working pump oil absorption hose return steel pipe, fix the pipe on hydraulic oil
3 Steering pump oil absorption hose
4 Breather hose5 Pipe clamp 9-12
tank with four bolts, and tighten the pipe

clamps.
78~104Nm
5. Connect breather rubber hose and breather
steel pipe, and tighten the clamps.
6. Fix the oil return block on hydraulic oil tank

with bolts.
1 2
Fig. 9-29
1 Oil return block2 Bolt
7. Lift and connect the left platform to hydraulic
oil tank, install the six M12×30 bolts
1
Fig. 9-30
1 Left platform
1 1
Fig. 9-31 9-13
1 Left platform
8. Fill hydraulic oil.

1) Fill specified hydraulic oil into the tank
through the oil filling port, tighten the oil
filler cap until the oil level pointer points
at the middle scale.
2) Start the engine, operate to lift and lower
the boom, forward tilt and backward tilt
the bucket, left steer and right steer the
Fig. 9-32
loader extremely for 2~3 times, in order to
fill up the oil cylinders and pipe with
hydraulic oil. And then run the engine idly
for about 5min to bleed the air in the
system out.
3) Shut down the engine, check hydraulic oil
level again after the level gets stable, it is
appropriate if the level is width Middle
Scale±2, add if insufficient.
923 Multitandem Valve
The multiandem valve adopts unitary double-slide-valve structure, which is mainly composed of
boom part reversing valve, bucket part reversing valve, safety valve, overload oil supplementary
valve and check valves. Oil circuits of the two reversing valves are in series.
9-14
Fig. 9-33 Multitandem valve
Oil port Component

P Connected with working pump oil 1 Check valve, reduce the settlement of
outlet port boom cylinder
T Back to oil tank after cooling in 2 Bucket part inlet check valve, prevent
radiator bucket cylinder dive
A1 Connected with piston-side chamber 3 Bucket cylinder piston-side overload oil
of bucket cylinder supplementary valve, set pressure 20MPa
B1 Connected with rod-side chamber of 4 Bucket cylinder rod-side overload oil
bucket cylinder supplementary valve, setting pressure
12MPa
A2 Connected with piston-side chamber 5 Main safety valve, setting pressure
of boom cylinder 18.5MPa
B2 Connected with rod-side chamber of
boom cylinder
9-15
Fig. 9-34 Inner structure of multiandem valve

1 Cotter pin 2 Gasket 3 Round-shoulder pin 4 Boom valve element
5 Compression plate 6 Dust ring 7 Gasket 8 O-ring 9 O-ring
10 Plug of pressure measuring port 11 Small end cover 12 O-ring 13 Check valve spring
14 Check valve 15 O-ring 16 O-ring 17 Screw plug 18 Valve body 19 Base plate
20 Spring seat 21 Spring 22 Steel ball 23 Sealing gasket 24 End cover
25 Gasket 26 Bolt 27 Rubber plug 28 Rubber plug 29 End cover
30 Bolt 31 Sealing gasket 32 Spring pressing seat 33 Return spring 34 Spring seat
35 Safety valve 36 Piston-side overload oil supplementary valve 37 Overload valve block
38 Screw plug 39 O-ring 40 Bolt 41 Gasket 42 Overload oil supplementary valve block
43 O-ring 44 Rod-side overload oil supplementary valve 45 O-ring 46 Bucket valve element
Bucket part reversing valve is a 6/3 valve, which can control the forward tilt, backward tilt and
holding of the bucket.
Boom part reversing valve is a 6/4 valve, which can control the lifting, holding, lowering and
floating of boom. Spring in the boom return sleeve can press the steel ball to the two ends and keep
the ball stuck in the V-groove of locating sleeve inwall, so the boom part slide valve element can be
fixed in any action position of the four movements.
A check valve is designed in inlet port of bucket part reversing valve and boom part reversing valve
respectively, the check valves are pressed against the valve seat by spring. Check valve can prevent
9-16
hydraulic oil reflux during reversing to overcome “dive” phenomenon. Besides, check valve can
produce backpressure for oil returning to keep the system stable.
Working principle of multiandem valve
1) Neutral position (sealed position)
The position of bucket slide valve rod and boom slide valve rod is shown in Fig. 9-35. Two both
ends of bucket cylinder and boom cylinder are sealed, the two cylinders remain at a certain position,
hydraulic oil from working pump flows from port P to port T through the middle oil gallery and
then flows back to oil tank. At this point, safety valve is closed, and the system circulates without
load.
Fig. 9-35 Cutaway view of multitandem valve

2) Bucket forward tilt
Bucket slide valve moves toward right to seal oil duct IV, VI and V; connect oil duct II and III; and
connect oil duct VIII and IX. Pressure oil flows from port P into oil duct III through bucket part
inlet check valve, then goes through oil duct II to multitandem valve port B1, finally enters into the
bucket cylinder rod-side chamber; hydraulic oil in bucket cylinder piston-side chamber flows
through multitandem valve port A1, oil duct VIII and IX through port A1, returns back to oil tank,
which makes the piston rod of bucket cylinder retract to realize bucket forward tilt.
9-17
3) Bucket backward tilt

Bucket slide valve moves toward left to seal oil duct IV, VI and V; connect oil duct I and II; and
connect oil duct VII and VIII. Pressure oil flows from port P into oil duct VII through bucket part
inlet check valve, then goes through oil duct VIII to multitandem valve port A1, finally enters into
the bucket cylinder piston-side chamber; hydraulic oil in bucket cylinder rod-side chamber flows
through multitandem valve port B1, oil duct II and oil duct I, returns back to oil tank, which makes
the piston rod of bucket cylinder extend to realize bucket backward tilt.
Fig. 9-36 Cutaway view of bucket part reversing valve

4) Boom lifting
Boom slide valve moves toward left to seal oil duct III, V and IV; pressure oil flows into oil duct V
through port P and bucket part middle oil duct, and goes through the check valve into oil duct VII,
finally enters into the boom cylinder piston-side chamber through the multitandem valve port A2.
9-18
Hydraulic oil in boom cylinder rod-side chamber flows through multitandem valve port B2, oil duct
II and oil duct I, return back to oil tank through multitandem valve port T, which makes the piston
rod of boom cylinder extend to realize lifting of boom.
5) Boom lowering
Boom slide valve moves toward right to seal oil duct III, V and IV; pressure oil flows into oil duct
III through port P and bucket part middle oil duct, finally flows from oil duct II into boom cylinder
rod-side chamber through the multitandem valve port B2. Hydraulic oil in boom cylinder piston-
side chamber flows through multitandem valve port A2, oil duct VII and oil duct VIII, returns back
to oil tank through multitandem valve port T, which makes the piston rod of boom cylinder retract
to realize lowering of boom.
6) Boom floating
The oil coming from oil pump goes through neutral unload groove into oil return duct and then
flows back to oil tank; while the cylinder piston-side is connected to oil return duct VIII via oil duct
VII, the cylinder rod-side is connected to oil return duct via middle oil duct, and zero-pressure idle
loop is formed in the system. The boom cylinder works in free floating state under the action of
working device’s weight and ground acting force.
Fig. 9-37 Cutaway view of boom part reversing valve

7) Main safety valve
Safety valve is used to control the system pressure, it is a cartridge valve installed on the
multitandem valve, and it’s a pilot operated valve that consisting of main valve part and pilot valve
part. The opening and closing of main valve are controlled by the pilot valve part. When the system
pressure is low and cannot overcome the pressing force of pilot valve spring to open the pilot valve,
the main valve stays in close state, and there is no oil flowing through the small damping hole in the
center of main valve element, thus the oil pressure on main valve element both ends is equal. Under
the action of the main valve spring, the main valve element will stay in leftmost end position to
close the by-pass oil duct between the upper pressure chamber and oil return chamber on valve
9-19
body.
When the system pressure rises and overcome the pressing force of pilot valve spring to open the
pilot valve, a small amount of pressure oil will flow through the small damping hole, and flows
from the pilot valve opening port back to the oil return duct of oil chamber. Due to the action of
small damping hole, oil pressure on the main valve element right end is less than the left end. When
the right-toward acting force, which is acted on the main valve element and produced by pressure
difference between the ends, is greater than the pressing force of main valve spring, main valve
element will be forced right to valve port, a large amount of pressure oil will overflow back to the
tank through the oil return hole, to realize the effect of overload safety protection. The set pressure
of safety valve is 18MPa.
When the system pressure is lower than the set pressure of safety valve, the pilot valve closes, the
oil to the small damping hole stops flowing, the pressure difference disappears and the main valve
element resets.
Fig. 9-38 Safety valve

1 Main valve spring 2 Main valve element 3 Pilot valve
4 Pilot valve spring 5 Pressure adjusting screw
8) Overload oil supplementary valve
Overload oil supplementary valve is a combination of pilot operated relief valve and check valve.
The pilot operated relief valve is installed on the multitandem valve with bolts, two oil ports are
connected to the oil ducts of bucket cylinder piston-side and rod-side chamber respectively, the
other two are connected to the oil return duct. The check valve is integrated in multiandem valve
body, two oil ports are connected to the oil ducts of bucket cylinder piston-side and rod-side
chamber respectively, the other two are connected to the oil return duct.
9-20
When bucket part reversing valve is in neutral, both rod-side chamber and piston-side chamber of
bucket cylinder are sealed. At this point, if severe impacts act on the bucket, the overload oil
supplementary valve can prevent dramatic rise of local pressure.
Fig. 9-39 Overload valve

1 Valve sleeve 2 Slide valve 3 Cone valve 4 Spring 5 Cone valve
6 O-ring 7 Poppet valve 8 Pressure adjusting spring 9 O-ring 10 Poppet
valve seat 11 Pressure adjusting screw 12 Lock nut
In the process of the boom lifting, overload oil supplementary valve can conduct oil discharging and
supplementing automatically. For instance, when the boom is lifted to a certain position, the piston
rod of bucket cylinder will be forced to extend outward, which will make the oil pressure in the
bucket cylinder rod-side chamber rise up sharply, the oil cylinder or hydraulic pipe can be damaged
under such circumstance. However, because overload valve is designed in the system, it can make
the oil trapped in the oil cylinder rod-side chamber return back to the hydraulic oil tank through the
overload valve. The volume of oil cylinder rod-side chamber decreases, meanwhile, the volume of
oil cylinder piston-side chamber increases and partial vacuum will be formed. At this moment the
oil supplementary valve opens to add hydraulic oil into the bucket cylinder piston-side chamber, in
order to eliminate the partial vacuum.
When the loader is unloading, it can help to make the bucket tip down quickly under the action its
own weight, and hits the stop block freely to dump all the materials inside the bucket. During this
process, after the bucket barycenter crosses the lower hinge point, the bucket will turn increasingly
under the action of gravity; but the movement velocity of bucket cylinder is limited by the oil
supply rate of the hydraulic pump. In this case, oil supplementary valve can make the bucket
cylinder piston-side chamber overflow timely and at the same time refills oil to the bucket cylinder
9-21
rod-side chamber, to make the bucket tip down quickly under the action its own weight, and hits the
stop block freely to dump all the materials inside the bucket.
Disassembly and assembly of multitandem valve

 ATTENTION
Before dismantling multitandem valve, be sure to carefully read the 93 Service Precautions for
Working Hydraulic System in this chapter.
Disassembly of the multitandem valve
1 Start the machine and drive it to the front of
bearing frame (Put the bearing frame on flat
spacious ground in advance), adjust the
location of the machine. Raise the boom to the
highest position. Tilt the bucket backward to
the extreme position, and then shut down the
engine. Push the control handle of the pilot
valve towards right gently. Let the bucket tilt
Fig 9-40 forward under the action of gravity to drain the
oil in bucket cylinder. After the bucket reaches
its extreme position, push the handle forward
gently, to let the boom falling on the bearing
frame. Then operate the handle left and right,
back and forth for 5~6 times to release the
internal oil pressure of the system.
2 Pull up parking brake and wedge the loader
tires with wood blocks stably.
3 Remove the fixing bolts of front cover plate
and take the front cover plate down.
1
Fig 9-41 4 Loosen the connecting bolts between boom
1 Front cover plate
part piston-side/rod-side steel pipes and
multiandem valve, take down the bolts and O-
1 2
Fig 9-42 rings, disconnect the steel pipes.
1 Boom part piston-side steel pipe
9-22
2 Boom part rod-side steel pipe
5 Loosen the connecting bolts between oil inlet

block of multiandem valve and P port of
multiandem valve, take down the bolts, O-ring
and oil inlet block.
1 2
Fig 9-43
1 Bolt
2 Oil inlet block
6 Loosen the connecting bolts between bucket
part piston-side/rod-side steel pipes and
multiandem valve, take down the bolts and O-
rings, disconnect the steel pipes.
7 Loosen the connecting bolts between oil return
steel pipe and multiandem valve, take down
the bolts, nuts, gaskets and O-ring, disconnect
the steel pipe.
1 2 3
Fig 9-44
1 Bucket part piston-side steel pipe
2 Bucket part rod-side steel pipe
3 Multiandem valve oil return steel pipe
8 Loosen the fixing clamps of bucket slide valve

part rod-side and piston-side steel pipes.
Loosen the U-shape fixing bolts of boom slide
valve part rod-side and piston-side steel pipes.
(Doesn’t need to be removed).
1 9-23
Fig 9-45
1 Pipe fixing clamp
1
Fig 9-46
1 Pipe fixing clamp
1
Fig 9-47
1 U-shape fixing bolt
9 Loosen the fixing bolts of the valve operating

flexible shaft shield, take down the bolts,
nuts, gaskets and shield.
1 2
Fig. 9-48
1 Shield2 Bolt
9-24
10 Remove the cotter pin in the connection

between the operating flexible shaft and
multiandem valve element, take down the
copper pin, gasket and pin shaft.
1
Fig. 9-49
1 Operating flexible shaft
1. Loosen the fixing bolts between multitandem

valve and the valve support, and lift down the
valve.
1
Fig. 9-50
1 Bolt
Assembly of the multitandem valve

1. Install the multitandem valve on the valve
support with two M12×145 bolts, gaskets and
nuts.
 ATTENTION
Do not tighten the bolts in this step, note that
big gasket is used here.
90±15Nm
1
Fig. 9-51
1 Bolt
9-25
2. Remove the protector of each oil port and put

an O-ring in O-ring groove of multiandem
valve oil return steel pipe, connect the pipe to
multiandem valve support with M12×175,
M12×145 and M10×65 bolts, nuts and gaskets,
tighten these bolts and the bolts used to fix
multitandem valve on the valve support (step
1).
M12 bolt: 90±15Nm
1
Fig 9-52
M10 bolt: 52±10Nm
3. Connect the two operating flexible shafts to

multiandem valve element with pin shaft,
gasket and copper pin.
 ATTENTION
Keep the boom slide valve element in floating
position (refer to Fig. 9-35), adjust the flexible
shafts until they are coaxial to the
corresponding valve elements. The pin shaft
1 should be parallel to ground.
Fig. 9-53
1 Operating flexible shaft
4. Fix the valve operating flexible shaft shield on

valve support with two M8×25 bolts, gaskets
and nuts.
1 2
Fig. 9-54
1 Shield2 Bolt
5. Put O-ring in O-ring groove of bucket part

piston-side/rod-side steel pipes, and then
9-26
connect the pipes to corresponding oil ports of

multiandem valve with four M10×30 bolts and
fission flange respectively.
52±10Nm
1 2 3
Fig 9-55
1 Bucket part piston-side steel pipe
2 Bucket part rod-side steel pipe
6. Put O-ring in O-ring groove of oil inlet block,
and then connect the block to P port of
multiandem valve with four M10×85 bolts.
52±10Nm
1 2
Fig 9-56
1 Bolt
2 Oil inlet block 7. Put O-ring in O-ring groove of boom part
piston-side/rod-side steel pipes, and then
connect the pipes to corresponding oil ports of
multiandem valve with four M10×30 bolts
respectively.
52±10Nm
1 2
Fig 9-57
1 Boom part piston-side steel pipe
2 Boom part rod-side steel pipe
8. Tighten the fixing clamps of bucket slide valve

part rod-side and piston-side steel pipes.
Tighten the U-shape fixing bolts of boom slide
valve part rod-side and piston-side steel pipes.
1 9-27
Fig 9-58
1 Pipe fixing clamp
1 1
Fig 9-59 Fig 9-60
1 Pipe fixing clamp 1 U-shape fixing bolt
9. Fix the maintenance cover plate on front frame

with bolts.
1
Fig 9-61
1 Front cover plate
924 Hydraulic Cylinders
9-28
Fig. 9-62 Boom cylinder

1 Seat 2 Piston rod 3 Dust ring 4 Y-shape seal ring 5 Bearing ring
6 Combination seal for shaft 7 Bearing ring 8 Cylinder cover 9 O-ring
10 Cylinder block 11 Piston 12 O-ring 13 Bearing ring
14 Combination seal for hole 15 Boom cylinder sleeve 16 Bolt 17 Gasket
18 Skeleton dust ring
Fig. 9-63 Bucket cylinder

1 Piston rod 2 Dust ring 3 U-shape seal ring 4 Guide ring 5 Combination seal for shaft
9-29
6 Guide ring 7 O-ring 8 O-ring 9 Retainer ring 10 Cylinder cover

11 Cylinder block 12 O-ring 13 Guide ring 14 Combination seal
15 Steel ball 16 Screw 17 Contamination ring 18 Piston 19 Skeleton dust ring
20 Sleeve 21 Gasket 22 Screw 23 Grease cup 24 Sleeve
Notes for installing hydraulic cylinder seal
1 Before installing the seal, grease it properly.
2 Before installing a dust ring, crimp the ring in the way as shown in ①, install it in the way ②
will very difficult and more likely to fall off after assembly.
3 When installing piston seals, the opening position of two neighboring seal should be more than
90o different.
Fig. 9-64
Inspection and clean of disassembled hydraulic cylinder
1 Check after disassembling
Clean the parts first, and then check whether it is worn, crack or has other problems by visual.
2 Maintenance method
Comply to the following procedures to correct the piston rod problem: Planish the axial scratch
with oilstone. If the scratch is too depth that can embed a nail, replace the rod immediately. If
there is smooth dent, planish the protrudent around with oilstone to adjust; if the dent is too
big, replace or re-plate the rod immediately.
Important! Repolish the rod after re-plating, the re-plating thickness should be at least
0.25mm.
Attention! If the base metal is hurt during planishing, then the rod must be re-plated.
3 Maintenance guides
1 Clearance between piston rod and rod bush

If the clearance exceeds 0.25mm, you must replace the bush.
2 Bended piston rod

Maximum allowable bending for piston rod is 1mm/m.
For measurement, use V-shape blocks support two parallel ends of the rod and put a dial
9-30
indicator in the middle, rotate the piston rod and record the highest and the lowest value in the
meantime.
Disassembly and assembly of boom cylinder

 ATTENTION
Before dismantling the boom cylinder, be sure to carefully read the 93 Service Precautions for
Working Hydraulic System in this chapter.
Disassembly of the boom cylinder
1. Start the machine and drive it to the front of
bearing frame (Put the bearing frame on flat
spacious ground in advance), adjust the
location of the machine. Raise the boom to the
highest position. Tilt the bucket backward to
the extreme position, and then shut down the
engine. Push the control handle of the pilot
valve towards right gently. Let the bucket tilt
Fig. 9-65
forward under the action of gravity to drain the
oil in bucket cylinder. After the bucket reaches
its extreme position, push the handle forward
gently, to let the boom falling on the bearing
frame. Then operate the handle left and right,
9-31
2. Disconnect the connection between the steel

pipes and rubber hoses of boom cylinder rod-
side and piston-side respectively.
1 2
Fig. 9-66
1 Boom cylinder rod-side rubber hose
2 Boom cylinder piston-side rubber hose
3. Bind the cylinder body with lifting rope and

lift it up a bit. Then loosen boom cylinder front
pin fixing bolt, remove the bolt and gasket.
Fig. 9-67
4. Then loosen boom cylinder front pin fixing

bolt, remove the bolt and gaskets.
1 2
Fig 9-68
1 Pin2 Bolt
5. Disassemble boom cylinder front pin, remove

the adjusting gasket, and avoid scratching the
pin during the operation.
1
9-32
Fig 9-69
1 Pin
6. Remove the fixing bolts of front mud fender,

rotate the mud fender clockwise for a certain
angle to make the disassembling and
assembling of boom cylinder rear pin
convenient.
1
Fig 9-70
1 Pin
7. Loosen the fixing bolt of boom cylinder rear
pin, take down the bolt and gasket.
1
Fig 9-71
1 Pin
8. Remove boom cylinder rear pin, lift the
cylinder away.
1 9-33
Fig 9-72
1 Pin
9. Remove the fixing bolts of boom cylinder rod-

side steel pipe.
side pipe clamp, take down the bolts, steel pipe
and O-ring.
1 2 3
Fig 9-73
1 Pipe clamp
2 Boom cylinder rod-side steel pipe
3 Bolt

side steel pipe, take down the bolts, steel pipe
and O-ring.
1 2 3
Fig 9-74
1 Bolt
2 Boom cylinder piston-side steel pipe
3 Bolt
9-34
Assembly of the boom cylinder

1. Remove the relevant protectors, put an O-ring
in O-ring groove of boom cylinder rod-side
steel pipe, and then fix the pipe on rod-side oil
port of boom cylinder with four M10×30 bolts.
52±10Nm
2. Fix the rod-side steel pipe on boom cylinder
block with pipe clamp and two M8×20 bolts.
1 2 3
Fig 9-75
1 Pipe clamp
2 Boom cylinder rod-side steel pipe
3 Bolt
3. Put an O-ring in O-ring groove of boom

cylinder piston-side steel pipe, and then fix the
pipe on piston-side oil port of boom cylinder
with two M10×50 and two M10×55 bolts.
52±10Nm
4. Fix the piston-side steel pipe on boom cylinder
block with a M10×20 bolt.
1 2 3
Fig 9-76
1 Bolt
2 Boom cylinder piston-side steel pipe
3 Bolt

lift it to assembling position.
Fig. 9-77 9-35

6. Apply some grease on boom cylinder rear pin,

and then use it to connect boom cylinder to the
front frame.
 ATTENTION
1) Note that piston-side pipes should be on
the outside, do not make mistakes.
2) Do not damage the grease cup when
knocking the pin.
1
Fig 9-78
1 Pin
7. Install the fixing bolt of boom cylinder rear

pin.
225±52Nm
1
Fig 9-79
1 Pin
8. Apply some grease on boom cylinder front
pin, add a gasket, and then start the engine.
Operate pilot handle to adjust stroke of boom
cylinder piston rod, keep its connecting hole
aligned with the pin joint hole on boom, and
connect them with pin.
 ATTENTION
Be careful when assembling the boom
1 cylinder, the screw seat on piston rod head
Fig 9-80
1 Pin should be on outside; use proper numbers of
gaskets to ensure the clearance between piston
rod head end face and boom is within
0.5~1.5mm.
9-36
9. Fix boom cylinder front pin on piston with

bolt.
1
Fig 9-81
1 Pin
10. Remove the protectors, put an O-ring in O-ring

groove of boom cylinder rubber hoses, fix the
hoses on boom cylinder rod-side and piston-
side steel pipes with fission flange and four
M10×30 bolts respectively.
 ATTENTION
The two hoses should be parallel and free of
1 2
Fig. 9-82 distortion.
1 Boom cylinder rod-side rubber hose 52±10Nm
2 Boom cylinder piston-side rubber hose
11. Reset the front mud fender and install the

fixing bolts.
1
Fig 9-83
1 Pin
12. Add grease to boom cylinder front pin grease

cups until there is grease squeezed out of the
fitting surface.
9-37
Fig 9-84
13. Add grease to boom cylinder rear pin grease

cups until there is grease squeezed out of the
fitting surface.
Fig 9-85
Disassembly and assembly of bucket cylinder

 ATTENTION
Before dismantling the bucket cylinder, be sure to carefully read the 93 Service Precautions
for Working Hydraulic System in this chapter.
Disassembly of the bucket cylinder
1 Pressure relief.
9-38
Fig 9-86
Start the machine and drive it to flat spacious

place. Raise the boom to the highest position.
Tilt the bucket backward to the extreme
position, and then shut down the engine.
towards right gently. Let the bucket tilt
forward under the action of gravity to drain the
oil in bucket cylinder.
falling under the action of gravity to drain the
oil in boom cylinder. Keep the bucket flat on
ground. Then operate the handle left and right,
2 Wedge the tires with wood blocks stably.
1. Loosen the fixing bolts of flat fender, take

down the bolts, gaskets and flat fender.
1
Fig 9-87
1 Flat fender
2. Loosen the connecting bolts between the
bucket cylinder piston-side rubber hose and
piston-side steel pipe, and then remove the
bolts, fission flange and rubber hose, protect
the oil ports in time.
During disassembling the hydraulic
connections, do not loosen the connection bolt
rashly and completely to avoid oil bursting out
1
Fig 9-88 9-39
1 Bucket cylinder piston-side rubber hose
due to incomplete pressure relief.
3. Loosen the connecting bolts between the

bucket cylinder rod-side rubber hose and rod-
side oil port, and then remove the bolts, fission
flange and rubber hose, protect the oil port in
time.
1
Fig 9-89
1 Bucket cylinder rod-side rubber hose

keep the rope with a certain pretension force.
1
Fig. 9-90
1 Bucket cylinder
5. Loosen the fixing bolt of bucket cylinder front

1 9-40
Fig. 9-91
1 Pin
6. Remove bucket cylinder front pin.

 ATTENTION
Avoid scratching the pin during the operation
1
Fig. 9-92
1 Pin
7. Loosen the fixing bolt of bucket cylinder rear

1
Fig. 9-93
1 Pin
8. Remove bucket cylinder front pin and

adjusting gaskets, lift bucket cylinder down
and put it on suitable support.
1 2
Fig. 9-94
1 Pin2 Grease pipe
9-41
9. Remove the front-end fixing bolts of bucket

cylinder piston-side steel pipe.
10. Remove the rear-end fixing bolts of bucket
cylinder piston-side steel pipe, take down the
bolts, steel pipe and O-ring. Take measures to
protect the disconnected oil ports in time.
1
Fig 9-95
1 Steel pipe
Assembly of the bucket cylinder

O-ring in O-ring groove of bucket cylinder
piston-side steel pipe, and fix the pipe on
piston-side oil port with two M10×50 and two
M10×55 bolts and gaskets separately.
52±10Nm
2. Fix the piston-side steel pipe on bucket
1 cylinder block with a M10×20 bolt.
Fig 9-96
1 Steel pipe

lift it to assembling position.
Fig 9-97
4. Apply some grease on pin. Lift the cylinder up

to proper position with lifting rope, use the pin
to connect the cylinder to front frame.
9-42
Fig 9-98
 ATTENTION
Put gaskets on connecting end faces, ensure the
fitting clearance between two end faces is within
0.5~1.5mm by using different type and number
of gaskets.
5. Fix the rear pin on front frame with gasket and

a M16×30 bolt.
225±52Nm
1
Fig. 9-99
1 Pin
6. Install the graease pipe.
1 2
Fig. 9-100
1 Pin2 Grease pipe
7. Start the engine and operate pilot handle to
adjust stroke of bucket cylinder piston rod,
keep its connecting hole aligned with the pin
joint hole on rocker arm, and connect them
with pin.
9-43
Fig 9-101
8. Fix the front pin on rocker arm with gasket and

a M16×30 bolt.
225±52Nm
1
Fig. 9-102
1 Pin
9. Put an O-ring in O-ring groove of bucket

cylinder piston-side rubber hose, fix the hoses
on bucket cylinder piston-side steel pipe with
fission flange and four M10×30 bolts.
 ATTENTION
Do not distort the hose.
52±10Nm
1
Fig. 9-103
1 Bucket cylinder piston-side rubber hose
10. Put an O-ring in O-ring groove of bucket

cylinder rod-side rubber hose, fix the hoses on
bucket cylinder rod-side oil port with fission
flange and four M10×30 bolts.
 ATTENTION
Do not distort the hose.
52±10Nm
1 9-44
Fig. 9-104
1 Bucket cylinder rod-side rubber hose
11. Fix the flat fender on bucket cylinder piston

rod head with two M10×20 bolts and gaskets.
1
Fig 9-105
1 Flat fender
12. Add grease to grease cup until there is grease

squeezed out of the fitting surfaces.
1
Fig 9-106
1 Grease nozzle
1
Fig 9-107
1 Grease nozzle
9-45
93 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. 9-108
appraise equipment’s 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
Fig. 9-109 9-46

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
the ground, you should collect the drained oil
and take it back to handle it on your own.
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. 9-110 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
Rinsing oil
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
Fig. 9-111
9-47
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 flushing with specified
hydraulic oil.
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.8 9-112
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.
1. 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.
9-48
5) Shut down the engine, check for leakage.
94 Testing and Adjusting of Working Hydraulic System Pressure

941 Measuring and Adjusting of Main Safety Valve Pressure
Pressure measuring
Required oil temperature for measurement: 45~55oC.
Pressure measurement tools
Pressure gauge with the measuring range of 40MPa, quick-change pressure measuring joint,
piezometer tube
Pressure measuring point
Measuring port on multiandem valve oil inlet block
Pressure measuring standard
18MPa
Pressure measuring method (take boom in
1
lowering position for example) Fig 9-113
1 Pressure measuring port
Put the working device flat on ground, pull up
the parking brake, and then wedge the tires with
wood blocks tightly, shut down the engine. Operate the operating handle for10 times and turn
steering wheel left and right for about 5 times to release residual pressure in hydraulic circuit;
prepare the measurement tools.
1 Connect measuring tools
 Remove the plug of pressure measuring port;
 Connect the quick-change pressure measuring joint to pressure measuring port;
 Connect piezometer tube to the quick-change pressure measuring joint;
 Connect the pressure gauge with measuring range Fig. 9-114
of 40MPa to the tube.

2 Start the engine, and operate the pilot operating handle to retract the bucket. After the bucket
gets to its extreme position, increase the accelerator to the maximum size (2200r/min)
gradually. Observe the pressure gauge and record the steady pressure value, and that is the
current working pressure for working hydraulic system.
9-49
3 To get more accurate result, put the boom in other positions and repeat the measurement.
ATTENTION
After the measurement, disassemble the measurement tools and wipe them clean.
Adjusting method
Multiandem valve of LG953N wheel loader is installed on front frame and the main safety valve is
on the side of oil inlet port, covered with lead seal. Remove the lead seal and loose the lock nut,
rotate the adjusting screw to change main safety valve set pressure.
Fig. 9-115 Pressure adjusting of main safety valve

1 Lock nut 2 Lead seal 3Adjusting screw
 Rotate the adjusting screw clockwise to increase the set pressure.
 Rotate the adjusting screw anticlockwise to decrease the set pressure.
 The pressure will change 4MPa if turning the adjusting screw for one circle. So each time you
adjust the pressure, it’s better to turn the adjusting screw for 1/4~1/5 circle, measure the
pressure according to the method exposed in this manual and tighten the lock nut after the
adjustment.
 Lock nut: 35±5Nm
9-50
942 Measuring and Adjusting of Overload Valve Pressure

Pressure measuring
Required oil temperature for measurement: 45~55oC.
Pressure measurement tools
Pressure gauge with the measuring range of 40MPa, quick-change pressure measuring joint,
piezometer tube
Pressure measuring point
Measuring port on bucket cylinder piston-side steel pipe
Pressure measuring standard
20MPa
Pressure measuring method (take boom in 1
Fig 9-116
lowering position for example) 1 Pressure measuring port
Put the working device flat on ground, pull up the
parking brake, and then wedge the tires with wood
blocks tightly, shut down the engine. Operate the operating handle for10 times and turn steering
wheel left and right for about 5 times to release residual pressure in hydraulic circuit; prepare the
measurement tools.
4 Connect measuring tools
 Remove the plug of pressure measuring port;
 Connect the quick-change pressure measuring joint to pressure measuring port;
 Connect piezometer tube to the quick-change pressure measuring joint;
 Connect the pressure gauge with measuring range Fig. 9-117
of 40MPa to the tube.

5 Start the engine, and operate the pilot operating handle to retract the bucket. After the bucket
gets to its extreme position, increase the accelerator to the maximum size (2200r/min)
gradually. Observe the pressure gauge and record the steady pressure value, and that is the
current working pressure for working hydraulic system.
6 To get more accurate result, put the boom in other positions and repeat the measurement.
ATTENTION
After the measurement, disassemble the measurement tools and clean them up.
Adjusting method
Multiandem valve of LG953N wheel loader is installed on front frame. Bucket piston-side and rod-
9-51
side overload valves are on the bottom of multiandem valve, the piston-side one is on bucket side,
while the rod-side one is on cab side. Bothe the overload valves are covered with lead seal.
Fig. 9-118 Pressure adjusting of overload valve

1 Lock nut 2 Lead seal 3Adjusting screw
 Rotate the adjusting screw clockwise to increase the set pressure.
 Rotate the adjusting screw anticlockwise to decrease the set pressure.
 The pressure will change 2MPa if turning the adjusting screw for one circle.
 Lock nut: 35±5Nm
ATTENTION
 Because set pressure of bucket cylinder piston-side overload valve is higher than that of
main safety valve, so its pressure must be adjusted on specialized test-bed other than on
the machine directly.
 Pressure of rod-side overload valve cannot be adjusted for now.
95 Diagnosis and Solutions for Common Faults of Hydraulic System

951 Unexpected Forward Tilt of
9-52
Bucket
Fault phenomena: When operating handle of pilot valve is in neutral position, the bucket tilt
forward unexpectedly.
Fault analysis: Because link mechanisms are used in working device, when the bucket is under
retract state and operating handle of pilot valve is in neutral position, the bucket cylinder piston-side
chamber will suffer extra force caused by self-weight. At this point, if there is leakage in piston-side
chamber, it will result in unexpected forward tilt of bucket.
Six situations can cause the leakage in piston-side chamber of bucket cylinder:
1 Obvious external leakage exists in pipelines, joints and fitting surfaces from the piston-side
chamber to multitandem valve.
2 Multitandem valve bucket slide vale part fails to go back to neutral position (because valve
element gets stuck, valve element of pilot valve cannot reset or there are faults exist in the
valve body, such as sand holes and grooves that connect to piston-side chamber).
3 While inner leakage exists in bucket cylinder, leakage also exists from rod-side chamber to oil
outlet port.
4 Low overload pressure for bucket cylinder piston-side overload valve (may caused by damaged
pressure adjusting spring, valve element stuck in open position, dirt exists in the conical fitting
surface between valve element and valve body, or there are defects exist in the valve body, such
as sand holes and grooves that connect to piston-side chamber).
5 Leakage exists in bucket cylinder piston-side oil compensation valve (may caused by damaged
reset spring, valve element stuck in open position, dirt exists in the conical fitting surface
between valve element and valve body, or there are defects exist in the valve body, such as sand
holes and grooves that connect to piston-side chamber)
6 Excessive wear of selector valve body or element, which result in fit clearance between valve
body and valve element is far more than design value.
Diagnosis and solutions:
1 Six situations that cause leakage are listed above and the simplest and easiest to diagnose is the
first one: Start the machine and lift the boom to a certain height, retract the bucket to its
extreme position, and then observe the pipelines, joints and fitting surfaces from the piston-side
chamber to multitandem valve to find out whether there are obvious external leakage
phenomena exist.
2 If the first situation is being excluded, consider the second situation: Start the machine and
operate pilot valve handle to lift the boom to highest position, and retract the bucket to its
extreme position, and then shut down the engine, disassemble the two pilot pipes that
connected to two ends of multitandem valve bucket slide vale part. At this point, if the
9-53
unexpected forward tilt phenomenon disappeared, then we can come to a conclusion that the
fault is caused by pilot valve, which causes multitandem valve bucket slide vale part fails to go
back to neutral position. Disassemble and clean the pilot valve or replace it. Otherwise, check
the third situation.
3 For the third situation, we can do some simple check: Start the machine and operate pilot valve
handle to lower the boom to lowest position, and retract the bucket to its extreme position, and
then shut down the engine, disconnect bucket cylinder piston-side rubber hose and diver it to
hydraulic oil tank. Start the machine again, operate the pilot valve handle to backward tilt the
bucket, observe whether there is oil comes out from piston-side oil port continually. If there is,
which means server inner leakage exists in bucket cylinder, the cylinder needs to be repaired or
replaced. Otherwise, check the fourth and fifth situations.
4 For the fourth and fifth situations, method of pressure detection can be used: Connect a 0-
250Bar pressure gauge to gauge port of bucket cylinder piston-side chamber. Start the machine
and operate pilot valve handle to extend the bucket to its extreme position; step on the gas and
operate pilot valve handle to lift the boom, at the same time, check whether the reading on the
gauge reach the design value when the boom is lifting. If not, either situation mentioned in the
first place is possible, the overload valve or oil compensation valve for bucket cylinder piston-
side chamber need to be checked and cleaned.
5 If situation 1 to situation 5 have been excluded and the fault still exists, then stop the machine,
low boom and bucker to lowest positions and disassemble multitandem valve bucket slide
valve part, look through the valve element, valve opening and their fitting situation.
952 Boom Sinking
Fault phenomena: When operating handle of pilot valve is in neutral position, the boom sinks
automatically and exceeds allowed range.
Fault analysis: When the boom is lifted and stays in a certain height, the boom cylinder piston-side
chamber will suffer extra force caused by self-weight. At this point, if there is leakage in piston-side
chamber, the boom will fall automatically.
Four situations can cause the leakage in piston-side chamber of boom cylinder:
1 Obvious external leakage exists in pipelines, joints and fitting surfaces from the piston-side
chamber to multitandem valve.
2 Multitandem valve boom slide vale part fails to go back to neutral position (because valve
element gets stuck, valve element of pilot valve cannot reset or there are defects exist in the
9-54
valve body, such as sand holes and grooves), which cause boom cylinder rod-side chamber
connect to pump, or piston-side chamber connect to oil return port.
3 While inner leakage exists in boom cylinder, leakage also exists from rod-side chamber to oil
outlet port.
1 Four situations that cause leakage are listed above and the simplest and easiest to diagnose is
the first one: Start the machine and lift the boom to highest height, and then observe the
pipelines, joints and fitting surfaces from the piston-side chamber to multitandem valve to find
out whether there are obvious external leakage phenomena exist.
2 If the first situation is being excluded, consider the second situation: Start the machine and
operate pilot valve handle to lift the boom to highest position, and retract the bucket to its
extreme position, and then shut down the engine, disassemble the two pilot pipes that
connected to two ends of multitandem valve bucket slide vale part. At this point, if the boom
sinking phenomenon disappeared, then we can come to a conclusion that the fault is caused by
pilot valve, which causes multitandem valve boom slide vale part fails to go back to neutral
position. Disassemble and clean the pilot valve or replace it. Otherwise, check the third
situation.
3 For the third situation, we can do some simple check: Start the machine and operate pilot valve
handle to lift the boom to highest position, and retract the bucket to its extreme position, and
then shut down the engine, disconnect boom cylinder piston-side rubber hose and divert it to
hydraulic oil tank. Start the machine again, operate the pilot valve handle to lower the boom,
observe whether there is oil comes out from piston-side oil port continually. If there is, which
means server inner leakage exists in boom cylinder, the cylinder needs to be repaired or
replaced. Otherwise, check the fourth situation.
4 If situation 1 to situation 3 have been excluded and the fault still exists, then stop the machine,
low boom and bucker to lowest positions and disassemble multitandem valve boom slide valve
part, look through the valve element, valve opening and their fitting situation.
953 Boom Rises Slowly
Fault phenomena: When the diesel engine is running under rated speed, operate pilot valve handle
to lift the boom from lowest to highest position, the time it needed exceeds full load lifting time.
Fault analysis: Consider the characteristics of Hydraulic power units, the reason for boom lifting
slowly: insufficient flow from hydraulic pump to cylinder.
Nine situations are listed below that may cause insufficient flow from hydraulic pump to
9-55
cylinder:
1 Severe external leakage exists in joints, pipelines, valves and fitting surfaces from pump to
boom cylinder piston-side chamber.
2 The hydraulic oil contain a lot of bubble or turns black, or goes bad, and its viscosity has been
changed.
3 Blocked oil absorption filter or oil absorption pipe, which make the working pump hard to suck
oil.
4 Severe inner leakage exists in working pump.
5 Severe inner leakage exists in boom cylinder (caused by cylinder scoring or damaged sealing
element).
6 Low adjusting pressure of multitandem valve main safety valve (may caused by damaged
pressure adjusting spring, valve element stuck in open position, or there are defects exist in the
valve body, such as sand holes and grooves that connect to oil return chamber).
7 Severe inner leakage exists between oil inlet channel an oil return channel of multitandem
valve body (caused by sand hole or breakage of valve body).
8 Excessive wear of selector valve element or valve opening of multitandem valve boom slide
valve part, which result in fit clearance between valve body and valve element is far more than
design value.
9 Insufficient opening of multitandem valve (because selector valve element gets stuck, valve
element of boom cylinder piston-side pilot valve cannot reset or there are sand holes and
grooves exist in the valve body, or low setting pressure of combination valve that result in
insufficient pilot pressure).
1 For all situations mentioned above, firstly, we should start the machine and lift the boom, check
out whether there is obvious external leakage exists in pipelines, joints and fitting surfaces from
working pump to boom cylinder piston-side chamber.
2 If there is no severe external leakage, then basic inspection should be done: Whether the
hydraulic oil level is above “LOW” level, whether there is too much bubble in hydraulic oil or
the oil turns black. Add hydraulic oil if necessary; if the oil turns bad, clean the tank and the
whole hydraulic system, and then replace the oil.
3 If the hydraulic oil is good, then start the machine and operate pilot handle to retract the bucket,
at the same time, listen carefully and check whether there is screaming in working pump. If
there is, which means the pump have severe oil absorption problem, check and clean oil
absorption filter and rubber hoses.
9-56
4 If there is no screaming phenomenon, check the forth situation: Start the machine, operate the
pilot valve to load the pump for 1-2 minutes, then shut down the engine; carefully touch the
shell of working pump, if it feels too hot, then we can come to a conclusion that severe inner
leakage exist in working pump, which causes the oil shortage problem.
5 For the fifth to ninth situations, we need to do some simple tests first: Connect a 0-40MPa
pressure gauge to gauge port of multitandem valve P port. Start the machine and operate pilot
valve handle to pressurize the hydraulic system, at the same time, check whether the reading on
the gauge reach the design value. If not, check situation 5 to 8 one by one.
6 For the fifth situation, start the machine and operate pilot valve handle to lower the boom to
lowest position, and retract the bucket to its extreme position, and then shut down the engine,
disconnect boom cylinder piston-side rubber hose and divert it to hydraulic oil tank. Start the
machine again, operate the pilot valve handle to lower the boom, observe whether there is oil
comes out from piston-side oil port continually. If there is, which means server inner leakage
exists in boom cylinder, the cylinder needs to be repaired or replaced.
7 For situation 6: Check and clean main safety valve, if there is irreparable damage for valve
element or valve body, please replace the safety valve.
8 If situation 6 and 7 are being excluded and the system pressure still fails to reach design value,
then focus on situation 7 and 8. Disassemble multitandem valve boom slide valve part, look
through the valve element, valve opening and their fitting situation.
9 If the hydraulic system pressure reaches design value but the boom still lifting slow, check the
ninth situation: Operate pilot valve handle to lower the boom and bucket to their lowest
positions, and then open the spring-free end cover (the one with short axial dimension) of
multitandem valve boom slide valve part, force the valve element to do axial movement, check
whether the rod can get to the right positions, whether it can return to neutral position smoothly.
954 Lifting Incapacity of Boom

Fault phenomena: When the diesel engine is running under rated speed, operate pilot valve handle
to lift the boom under full load, the boom fails to be lifted.
Fault analysis: The most direct reason for lifting incapacity of boom is low pressure of boom
cylinder piston chamber.
Primary reasons for low pressure in boom cylinder piston chamber:
1 Low overload pressure for main safety valve of multitandem valve (may be caused by damaged
pressure adjusting spring, valve element stuck in open position, or there are defects exist in the
valve body, such as sand holes and grooves that connect to oil return chamber).
9-57
2 Severe inner leakage of working pump, because that the system cannot build up pressure or the
system pressure cannot reach design value.
3 Severe inner leakage exists in boom cylinder (caused by cylinder scoring or damaged sealing
element ).
4 Severe inner leakage exists between oil inlet channel an oil return channel of multitandem
valve body (caused by sand hole or breakage of valve body), because that the system cannot
build up pressure or the system pressure cannot reach design value.
Focus on the four reasons mentioned above and refer to Boom raises slowly for troubleshooting.
955 Bucket Slow Motion
Refer to Boom raises slowly for troubleshooting.
956 Working Incapacity of Bucket
Refer to Lifting incapacity of boom for troubleshooting.
9-58

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Service Manual of RS8160 Road Roller

9 Working Hydraulic System

9 Working Hydraulic System

Fig. 9-1 Hydraulic principle diagram

92 Description, Disassembly and Assembly of Hydraulic System

Fig. 9-2 Structure of working pump

When pump shaft rotates as Fig. 9-3, the gear

absorption chamber close volume (T) increases and

Disassembly and assembly of working p[ump

Disassembly of working pump

3. Remove the cab floor mat.

4. Remove the fixing bolts of maintenance cover

5. Loosen the bolts that used to fix working

6. Loosen the bolts that used to fix working

7. Loosen the connecting nuts between working

Assembly of the working pump

2. Remove the protector of each oil port, put an

4. Install the maintenance cover plate-seat

8. Reset the cab floor mat.

922 Hydraulic Oil Tank

To steering pump oil absorption rubber hose

To working pump oil absorption rubber hose

To steering gear oil return rubber hose

To priority valve oil return hose

To multiandem valve oil return hose

Filter fineness: 10um

Fill hydraulic oil for about 246L when oil temperature i

Fig. 9-15 Hydraulic oil tank assembly

3. Remove the oil drain plug on bottom of

4. Remove the six fixing bolts of left platform.

5. Lift left platform down.

9. Remove the connecting bolts between oil

10. Hang hydraulic oil tank with lifting rope.

11. Remove the connecting bolts between

absorption rubber hose end, place the hose

2. Apply AT262 thread locking sealant on the

tank with four bolts, and tighten the pipe

6. Fix the oil return block on hydraulic oil tank

8. Fill hydraulic oil.

Fig. 9-33 Multitandem valve

Oil port Component

Fig. 9-34 Inner structure of multiandem valve

Fig. 9-35 Cutaway view of multitandem valve

3) Bucket backward tilt

Fig. 9-36 Cutaway view of bucket part reversing valve

Fig. 9-37 Cutaway view of boom part reversing valve

Fig. 9-38 Safety valve

Fig. 9-39 Overload valve

Disassembly and assembly of multitandem valve

5 Loosen the connecting bolts between oil inlet

8 Loosen the fixing clamps of bucket slide valve

9 Loosen the fixing bolts of the valve operating

10 Remove the cotter pin in the connection

1. Loosen the fixing bolts between multitandem

Assembly of the multitandem valve

2. Remove the protector of each oil port and put

3. Connect the two operating flexible shafts to

4. Fix the valve operating flexible shaft shield on

5. Put O-ring in O-ring groove of bucket part

connect the pipes to corresponding oil ports of

8. Tighten the fixing clamps of bucket slide valve

9. Fix the maintenance cover plate on front frame

924 Hydraulic Cylinders

Fig. 9-62 Boom cylinder