Claas Targo K50, Targo K60, Targo K70 Repair Manual

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HYDRAULICS

ELECTRICS

TECHNICAL DATA

CLCL

AS TAS T

AS T

AS TAS T

ARGO K50 K60 K70ARGO K50 K60 K70

ARGO K50 K60 K70

ARGO K50 K60 K70ARGO K50 K60 K70

The machines in this handbook are designed essentially for agricultural and associated applications. This is their intended use.

Any modifications made to the machine without prior written approval from CLAAS or if the machine is used in any way contrary to the intended use or if the machine is not properly driven or maintained then the Company will not accept any liability whatsoever for any damage or injury (whether direct or consequential).

The method of operation and maintenance specified in this handbook should be strictly adhered to. For your parts requirements, it is essential that only genuine CLAAS parts are fitted. Any resultant damage

from non-genuine parts will invalidate your machine warranty. CLAAS operates a policy of continuous improvement to its products and reserve the right to change specifi-

cations and equipment without notice. Therefore some information within this handbook may differ from your machine.

This manual is designed to service machines:

from Serial No. 51200011 up to Serial No. 51200727.

from Serial No. K5D00100 from Serial No. K6D00100 from Serial No. K7D00100

INTRODUCTION

General Machine identification Health and Safety

SAFETY WARNINGS

SECTION 1

HYDRAULICS

Description and Operation 1.1

Description 1.1

General 1.1 Dumping (dissipation) of hydraulic pressure 1.1 To dump brake system pressure 1.1 To dump a system pressure 1.1 Hydraulic Circuit - Single Circuit Braking (up to Machines S/No.51200317) 1.2 Hydraulic Circuit - Single Circuit Braking (from Machines S/No.51200318 to 51200471) 1.4 Hydraulic Circuit - Single Circuit Braking (from Machines S/No.51200472 to 51200551) 1.6 Hydraulic Circuit - Single Circuit Braking (from Machines S/No.51200552 to 51200727) 1.8 Hydraulic Circuit - Dual Circuit Braking (up to Machines S/No.51200317) 1.10 Hydraulic Circuit - Dual Circuit Braking (from Machines S/No.51200318 to 51200471) 1.12 Hydraulic Circuit - Dual Circuit Braking (from Machines S/No.51200472 to 51200551) 1.14 Hydraulic Circuit - Dual Circuit Braking (from Machines S/No.51200552 to 51200727) 1.16

Components

General 1.18 Hydraulic tank 1.18 Suction line connections to hydraulic tank 1.18 Return hose connections to hydraulic tank (up to Machines S/No.51200471) 1.18 Return hose connections to hydraulic tank (from Machines S/No.51200472) 1.18 Hydraulic pump (load sensing) 1.19 Pump compensator (load sensing) 1.19 Tank filter 1.19 Filler/Breather 1.19 Auxiliary hydraulic pump 1.19 Fan motor (up to Machines S/No.51200471) 1.20 Fan reverse motor (from Machines S/No.51200472) 1.20 Pressure reducing valve (PRV) for the parking brake (up to Machines S/No.51200551) 1.21 Pressure filter 1.21 Single circuit brake pressure servo valve (MICO) (up to Machines S/No.51200471) 1.22 Duel circuit brake pressure servo valve (MICO) (up to Machines S/No.51200471) 1.22 Single circuit brake pressure servo valve (SAFIM) (from Machines S/No.51200472) 1.23 Duel circuit brake pressure servo valve (SAFIN) (from Machines S/No.51200472) 1.23 Accumulator(s) 1.24 Pressure switch 1.24 Pressure switch (transmission dump) 1.24 Front axle 1.25 Steering cylinder (front) 1.25 Pressure switch (brake light) 1.25 Pressure switch (parking brake) 1.26 Rear axle 1.26 Steering cylinder (rear) 1.26 Non-return valve 1.26 Steering valve 1.27

Steering in Neutral position 1.27

Steering in Operation 1.28 Pressure relief valve 1.28 Steering selector valve 1.29

CONTENTS

Components (continued)

Control valve 1.30

Outlet section (PVP) 1.31

Function 1.31

Extension section 1.32

Function 1.32

Crowd section 1.33

Function 1.33

Lift section 1.34

Function 1.34

1st service/2nd service section 1.35

Function 1.35

Inlet section (PVSP) section 1.36

Function 1.36 Accumulator 1.38 Tap 1.38 Trailer brake valve 1.38 Trailer brake coupling 1.38 Extension cylinder 1.39 Load control valve 1.39 Crowd cylinder 1.40 Load control valve 1.40 Compensator cylinder 1.41 Lift cylinder 1.41 Load control valve 1.42 Diverter valve 1.43 Manifold 1.43 Autohitch cylinder 1.44 1st service couplings 1.44 2nd service couplings 1.44 Trailer tipping connection 1.44 St art-up valve 1.44 Non-return valve (up to Machine S/No.51200317 only) 1.45 Pressure relief valve (up to Machine S/No.51200471 only) 1.45 Breather 1.45 Parking brake valve (from Machine S/No.51200552 only) 1.46 Fan reverse valve (from Machine S/No.51200472 only) 1.47 Oil cooler (from Machine S/No.51200472 only) 1.48

Operation 1.49

General 1.49 Relief valves 1.49 System pressure checks 1.50 LS pump 1.52

LS pump compensator operation 1.52 Standby position (engine switched off) 1.53 Standby position (engine started) 1.54 Pump goes into delivery 1.56 Constant volumetric flow 1.58 Downstroking of the pump 1.59 Maximum pressure limiting (pressure relief valve function) 1.45 Adjusting the pump 1.63

CONTENTS

Maintenance 1.64

Torque tightening 1.64 Hydraulic level 1.66

Check 1.66

Hydraulic tank 1.67

Removal 1.67 Installation 1.67

Hydraulic pump (LS) 1.68

Removal 1.68 Installation 1.68

Auxiliary hydraulic pump 1.69

Removal 1.69 Installation 1.69

Fan motor (up to Machines S/No.51200471 only) 1.70

Removal 1.70 Installation 1.70

Fan motor bearings (up to Machines S/No.51200471 only) 1.71

Removal 1.71 Installation 1.71

Fan motor (from Machines S/No.51200472 only) 1.72

Removal 1.72 Installation 1.72

Fan drive bearings (from Machines S/No.51200472 only) 1.73

Removal 1.73 Installation 1.73

Fan reverse valve (from Machines S/No.51200472 only) 1.74

Removal 1.74 Installation 1.74

Parking brake valve (from Machines S/No.51200472 only) 1.75

Removal 1.75 Installation 1.75

Hydraulic filter 1.76

Removal 1.76 Installation 1.76

Brake valve (MICO) (up to Machines S/No.51200471 only) 1.77

Operation 1.77

Brake valve (SAFIM) (from Machines S/No.51200472 only) 1.77

Operation 1.77

Single brake valve (MICO) (up to Machines S/No.51200471 only) 1.78

Removal 1.78 Installation 1.78 Servicing 1.79

Dismantling 1.79 Assembly 1.80

Single brake valve (SAFIM) (from Machines S/No.51200472 only) 1.81

Removal 1.81 Installation 1.81 Servicing 1.82

Dismantling (General) 1.82 Assembly (General) 1.82 Dismantling (Brake master module) 1.83 Assembly (Brake master module) 1.83 Dismantling (Brake valve module) 1.84 Assembly (Brake valve module) 1.84

CONTENTS

Dual brake valve (MICO) (up to Machines S/No.51200471 only) 1.85

Removal 1.85 Installation 1.85 Servicing 1.86

Dismantling 1.86 Assembly 1.88

Dual brake valve (SAFIM) (from Machines S/No.51200472 only) 1.89

Removal 1.89 Installation 1.89 Servicing 1.90

Removal and installation (General) 1.90 Dismantling (Brake master module) 1.90 Assembly (Brake master module) 1.90 Dismantling (Brake valve module) 1.91 Assembly (Brake valve module) 1.91

Trailer brake valve 1.92

Removal 1.92 Installation 1.92 Servicing 1.93

Dismantling 1.93 Assembly 1.94

Brake system bleeding 1.95

General 1.95

Diverter valve 1.96

Removal 1.96 Installation 1.96

Manifold 1.97

Removal 1.97 Installation 1.97

Control valve 1.98

Removal 1.98 Installation 1.98 Servicing 1.99 Dismantling 1.99 Assembly 1.99 Spool sections 1.101

General 1.101 Dismantling 1.101 Assembly 1.101

Inlet section (PVSP) 1.103

General 1.103 Dismantling 1.103 Assembly 1.103

Outlet section (PVP) 1.104

General 1.104 Dismantling 1.104 Assembly 1.104

Steering 1.105

Description 1.105 Operation 1.105 Checking the steering system 1.107

Steering cylinder 1.107 Steering unit (OSPF) 1.107 Servicing 1.107

Steering valve assembly 1.108

Removal 1.108 Installation 1.108 Servicing 1.109 Dismantling 1.109 Assembly 1.109

CONTENTS

Hydraulic cylinders 1.110

Extension cylinder 1.110

Removal 1.110 Installation 1.111

Crowd cylinder 1.112

Removal 1.112 Installation 1.112

Compensator cylinder 1.113

Removal 1.113 Installation 1.113

Lift cylinder 1.114

Removal 1.114 Installation 1.114

Extension, crowd, compensator and lift cylinder 1.115

Servicing 1.115 Dismantling 1.115 Assembly 1.115

Autohitch cylinder 1.117

Removal 1.117 Installation 1.117 Dismantling 1.117 Assembly 1.118

Carriage locking cylinder 1.119

Removal 1.119 Installation 1.119 Dismantling 1.119 Assembly 1.120

Steering cylinder 1.121

Removal 1.121 Installation 1.121 Dismantling 1.122 Assembly 1.122

SECTION 2

ELECTRICS

Circuit diagrams

Circuit diagram key - Wiring terminations 2.1 Circuit diagram key - Components 2.2 Circuit diagram key - General Information 2.4 Power generation, S tarting, Non APC (Sheet 1) 2.4 Power generation, Starting, With APC (Sheet 1A) 2.5 Hydraulic controls, Steering control, Safe load indicator , Large lock out relay (Sheet 2) 2.6 Hydraulic controls, Steering control, Safe load indicator , Mini lock out relay (Sheet 2A) 2.7 Wipers, Washers, Horn, Worklights (Sheet 3) 2. 8 Wipers, Washers, Horn, Worklights combined boom/side worklights, Switching (Sheet 3A) 2.9 Head/side lights, Fog lights, Number plate lights, Head Flasher (Sheet 4) 2.10 Head/side lights, Fog lights, Number plate lights, Head Flasher (Sheet 4A) 2.11 Turn indicators, Reverse lamps, S teer sensors, S top lights, Radio (Sheet 5) 2.12 Inst display , Sensor switches, Fan motor , Aircon, Interior light, Beacon, Fuel Sender , Fan reverse, Hydraulic temp. (Sheet 6) 2.13 APC 50 with Ign controlled APC bat feed, Screened sensor cable, P/brake link (Sheet 7) 2.14

Non APC,Correct P/brake and trans dump, No P/brake controller , Circuit link (Sheet 7A) 2.15 Chassis loom (Illustration) 2.16 Engine loom (Illustration) 2.17 Cab loom (Illustration) 2.18

CONTENTS

Longitudinal stability indicator 2.19

Description 2.19 Sensor 2.20

Specification 2.20

Display Module 2.20

Specification 2.20

Testing and adjustment 2.23

Troubleshooting 2.23 Visual inspection 2.23 System check 2.24 Error indications from the display module 2.25

Sensor - test 2.25

General 2.25 Procedure to test the operation of the sensor 2.26 Procedure to install a sensor 2.27 Procedure to replace the display module 2.28

Calibration 2.29

Calibration procedure 2.29 Resetting the zero point 2.31

Testing load sensor function 2.32

Functional test of load sensor indicator 2.32 Procedure 2.33

Main instrument panel 2.34

Description 2.34 Removal 2.34 Installation 2.34 Functional description 2.35

Solo control joystick 2.36

Removal 2.36 Installation 2.36

Starter 2.37

Removal 2.37 Installation 2.37

Fusebox and relays 2.38

Description 2.38 Removal 2.38 Installation 2.38

Alternator 2.40

Alternator drive belt check 2.40 Removal 2.41 Installation 2.41

Automatic powershift 2.42

Automatic powershift controller 2.42 Removal 2.42 Installation 2.42

Forward / Neutral / Reverse (FNR) switch assembly 2.43

Removal 2.43 Installation 2.43

CONTENTS

SECTION 3

TECHNICAL DATA

Dimensions 3.1 Performance 3.2 Machine speed (km/hr) for 106 hp 3.2 Carriage 3.3 Cycle time 3.3 Engine 3.4 Cooling 3.4 Transmission 3.4 Tyres 3.4 Hydraulics 3.5 Electrics 3.5 Capacities 3.5

INTRODUCTION

General

The contents of this Repair Manual, although correct at the time of publication, may be subject to alteration by the manufacturer without notice.

This manual assumes that maintenance personnel have a sound knowledge of workshop practices and safety procedures associated with the repairs of this type of machine. This manual is designed to assist with the more specialised information required for removal and strip-down of major components.

It is recommended that the relevant part of this Repair Manual is studied carefully before proceeding with any maintenance.

Machine identification

To make sure that the correct parts are obtained, always quote the machine Serial Number when ordering parts.

Health and Safety

To prevent injury to personnel and damage to equipment and machinery, care must be taken to operate in a safe manner. Read the Safety Warnings that follow and always work in a safe manner and obey the relevant Warnings.

Throughout this manual and on the machine there are safety notes. Each note starts with a single word. The meaning of these single words is as follows:

Identifies a hazard exists. If proper precautions are not taken, it is highly probable that the operator (or others) could be killed or seriously injured.

Identifies a reminder of safety practices. Failure to observe these safety practices could result in injury to the operator (or others) or damage to the machine.

In general these notes are used to indicate that the procedures being described in the manual must be followed to avoid serious injury or death to yourself or others. The notes are also used to protect the machine from unsafe maintenance practices.

NOTE: An identification number in bold type, after an item, refers to the number of that item in the main hydraulic schematic illustration.

SAFETY WARNINGS

Always wear correct fitting protective clothing. Loose or baggy clothing can be extremely dangerous when operating or maintaining a machine.

Where possible, only work on or close to engines or machinery when they are stopped. If this is not practical, remember to keep tools, test equipment and all parts of your body well away from moving parts.

Avoid contact with exhaust pipes and exhaust manifolds when the engine is running; these can be very hot.

Many liquids used on this machine are harmful if taken internally or splashed into the eyes. In the event of accidentally swallowing oil, diesel fuel, anti-freeze, battery acid etc., DO NOT induce vomiting, but OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY.

Always obtain advice before mixing oils; some are incompatible.

Never run an engine in an enclosed space unless an exhaust extraction system is used.

Always Disconnect battery cables before using an external charger to prevent damage to electrical system components.

Always Disconnect battery cables before working on the electrical system to prevent injury caused by electric shock.

When it is necessary to work on the electrical system with power on, for fault diagnosis, always have a safety man in attendance

Any dust found on the machine or produced during work on the machine should be removed by extraction, not by blowing. Dust waste should be dampened, placed in a sealed container and marked for safe disposal.

Always dump pressure from the hydraulic system before carrying out any maintenance or adjustment (refer to page 1.1).

Never leave the machine unattended with pressure in the system.

Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put your face close to suspected leaks. If hydraulic fluid penetrates your skin OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY. Never allow unqualified personnel to attempt to remove or replace any part of the machine.

Always use the correct lifting equipment to remove large or heavy components.

Never attempt to lift or hold up the machine using the lash-down points.

SECTION 1

HYDRAULICS

HYDRAULICS 1.1

DESCRIPTION AND OPERATION

DESCRIPTION General

The hydraulic system supplies the power for boom manipulation, attachments, brakes and steering.

A hydraulic oil reservoir has a filter breather cap and supplies the main and auxiliary hydraulic pumps.

The reservoir is also fitted with a sight gauge. With the boom in the lower position, retracted and with the carriage tilted forward, the oil level will be visible in the gauge above the red line.

The main hydraulic pump is driven from the engine gearbox and is of the variable displacement type. Pressurized oil from the hydraulic pump is directed to the hydraulic control valve assembly (PVG). The control valve is modular in construction and combines individual sections (slices), each with a different use. At one end of the control valve is the priority module (PVSP), which controls the supply of hydraulic oil to the steering and brake systems. The remaining oil is supplied to those sections of the control valve that control each boom service.

Dumping (dissipation) of hydraulic pressure

Always dump all hydraulic pressure from the system before servicing any hydraulic component.

Ensure there is sufficient space and headroom around machine before operating any hydraulic control.

To dump brake system pressure

1. Stop the engine.

2. Make sure the machine is parked on firm and level ground and chock the wheels.

3. Turn the ignition switch to position (1).

4. Set the parking brake switch, if necessary, to the parking brake applied position.

The brakes, steering and boom services each supply a load-sensing signal, hydraulically, to the main hydraulic pump. This maintains the optimum supply of oil to those services.

The auxiliary hydraulic pump is driven by the engine timing case gears and supplies pressurized oil to the motor of the engine cooling fan. It also supplies oil to the front axle parking brake units, to keep the parking brake off. When this hydraulic pressure is released, spring pressure applies the parking brake.

The hydraulic tank is divided into clean and dirty sides by a mesh filter. A low-pressure filter is installed in the oil supply to the cooling fan system. This filter constantly filters the hydraulic fluid and a blockage indicator, installed in the filter, operates a warning light in the cab when servicing is required.

Modifications, such as the introduction of a reverse cooling fan or different brake servo valves, will change the basic layout of the system. To obtain the correct component layout you must refer to the applicable schematic illustration, which can be located using the batch Serial Number (S/No.) for the particular machine.

5. Press the brake pedal repeatedly until the brake charge warning lamp illuminates.

6. Press the brake pedal a further twenty times to ensure that residual pressure in the brake system is fully dissipated.

7. Turn the ignition switch to off.

To dump a system pressure

NOTE: This procedure applies to all machine hydraulic

systems, except brakes.

1. Stop the engine.

2. Make sure the machine is parked on firm and level ground and chock the wheels.

3. Turn the ignition switch to position ‘I’.

3. Operate the applicable system until all hydraulic pressure has been dissipated.

4. Turn the ignition switch to off.

HYDRAULICS 1.2

HYDRAULIC CIRCUIT - SINGLE CIRCUIT BRAKING (up to Machine S/No.51200317)

HYDRAULICS 1.3

Key to hydraulic circuit - single circuit braking

1. Hydraulic tank (reservoir)

2. Hydraulic pump, load sensing (LS)

3. LS pump compensator

4. Gauze filter (Not Serviceable)

5. Filler/breather

6. Auxiliary hydraulic pump

7. Fan motor

8. Pressure reducing valve (parking brake control)

9. Pressure filter

10. Brake servo valve

11. Accumulator

12. Pressure switch (116 bar)

13. Pressure switch (15 bar)

14. Front axle (park brake actuators)

15. Steering cylinder (front)

16. Pressure switch (5 bar)

17. Pressure switch (16 bar)

18. Rear axle

19. Steering cylinder (rear)

20. Non-return valve

21. Steering control valve (Danfoss OSPF)

22. Steering selector valve (attached to OSPF valve)

23. Pressure relief valve (175 bar)

24. Shock valve (225 - 245 bar)

25. Hydraulics control valve (PVG 32)

26. Outlet section (PVP)

27. Extension section

28. Crowd/compensator section

29. Lift section

30. 1st auxiliary section (carriage/autohitch)

31. 2nd auxiliary section

32. Pressure relief valve (290 bar)

33. Pressure raising spool

34. Pilot valve

35. Shock valve (175 bar)

36. Inlet section (PVSP)

37. LS shuttle valve

38. Proportional controller

39. Shock valve (265 bar)

40. Controller (not proportional)

41. Priority valve (brakes and steering)

42. Priority valve (steering)

43. Filter

44. Brake accumulator charge valve (BAC)

45. Accumulator

(up to Machine S/No.51200317)

46. Tap

47. Trailer brake valve

48. Trailer brake coupling

49. Extension cylinder

50. Load control valve

51. Crowd cylinder

52. Load control valve

53. Compensator cylinder

54. Lift cylinder

55. Load control valve

56. Diverter valve

57. Manifold

58. Cylinder, autohitch

59. 1st service couplings

60. 2nd service couplings

61. Trailer tipping coupling

62. Start-up valve

63. Non-return valve

64. Pressure relief valve (160 bar)

65. Test point 1 (main system pressure LS)

66. Test point 2 (parking brake release pressure)

67. Test point 3 (steering system pressure)

68. Test point 4 (brake circuit)

69. Test point 5 (main circuit pressure P)

70. Auxiliary breather

HYDRAULICS 1.4

HYDRAULIC CIRCUIT - SINGLE CIRCUIT BRAKING (from Machine S/No.51200318 to 51200471)

HYDRAULICS 1.5

Key to hydraulic circuit - single circuit braking

1. Hydraulic tank

2. Hydraulic pump, load sensing (LS)

3. LS pump compensator

4. Gauze filter (Not Serviceable)

5. Filler/breather

6. Auxiliary hydraulic pump

7. Fan motor

8. Pressure reducing valve (parking brake control)

9. Pressure filter

10. Brake valve

11. Accumulator

12. Pressure switch (116 bar)

13. Pressure switch (15 bar)

14. Front axle (park brake actuators)

15. Steering cylinder (front)

16. Pressure switch (5 bar)

17. Pressure switch (16 bar)

18. Rear axle

19. Steering cylinder (rear)

20. Non-return valve

21. Steering control valve (Danfoss OSPF)

22. Steering selector valve (attached to OSPF valve)

23. Pressure relief valve (175 bar)

24. Shock valve (225 - 245 bar)

25. Hydraulic control valve (PVG 32)

26. Outlet section (PVP)

27. Extension section

28. Crowd/compensator section

29. Lift section

30. 1st auxiliary section (carriage/autohitch)

31. 2nd auxiliary section

32. Pressure relief valve (290 bar)

33. Pressure raising spool

34. Pilot valve

35. Shock valve (175 bar)

36. Inlet section (PVSP)

37. LS shuttle valve

38. Proportional controller

39. Shock valve (265 bar)

40. Controller (not proportional)

41. Priority valve (brakes and steering)

42. Priority valve (steering)

43. Filter

44. Brake accumulator charge valve (BAC)

45. Accumulator

(from Machine S/No.51200318 to 51200471)

46. Tap

47. Trailer brake valve

48. Trailer brake coupling

49. Extension cylinder

50. Load control valve

51. Crowd cylinder

52. Load control valve

53. Compensator cylinder

54. Lift cylinder

55. Load control valve

56. Diverter valve

57. Manifold

58. Cylinder (autohitch)

59. 1st service couplings

60. 2nd service couplings

61. Trailer tipping coupling

62. Start-up valve

63. NOT FITTED

64. Pressure relief valve (160 bar)

65. Test point 1 (main system pressure LS)

66. Test point 2 (parking brake release pressure)

67. Test point 3 (steering system pressure)

68. Test point 4 (brake circuit)

69. Test point 5 (main circuit pressure P)

70. Auxiliary breather

HYDRAULICS 1.6

HYDRAULIC CIRCUIT - SINGLE CIRCUIT BRAKING (from Machine S/No. 51200472 to 51200551)

HYDRAULICS 1.7

Key to hydraulic circuit - single circuit braking

1. Hydraulic tank

2. Hydraulic pump, load sensing (LS)

3. LS pump compensator

4. Gauze filter (Not Serviceable)

5. Filler/breather

6. Auxiliary hydraulic pump

7. Fan motor

8. Pressure reducing valve (parking brake control)

9. Pressure filter

10. Brake valve (Safim type)

11. Accumulator

12. Pressure switch (116 bar)

13. Pressure switch (15 bar)

14. Front axle (park brake actuators)

15. Steering cylinder (front)

16. Pressure switch (5 bar)

17. Pressure switch (16 bar)

18. Rear axle

19. Steering cylinder (rear)

20. NOT FITTED

21. Steering control valve (Danfoss OSPF)

22. Steering selector valve (attached to OSPF valve)

23. Pressure relief valve (175 bar)

24. Shock valve (225 - 245 bar)

25. Hydraulic control valve (PVG 32)

26. Outlet section (PVP)

27. Extension section

28. Crowd/compensator section

29. Lift section

30. 1st auxiliary section (carriage/autohitch)

31. 2nd auxiliary section

32. Pressure relief valve (290 bar)

33. Pressure raising spool

34. Pilot valve

35. Shock valve (175 bar)

36. Inlet section (PVSP)

37. LS shuttle valve

38. Proportional controller

39. Shock valve (265 bar)

40. Controller (not proportional)

41. Priority valve (brakes and steering)

42. Priority valve (steering)

43. Filter

44. Brake accumulator charge valve (BAC)

45. Accumulator

(from Machine S/No.51200472 to 51200551)

46. Tap

47. Trailer brake valve

48. Trailer brake coupling

49. Extension cylinder

50. Load control valve

51. Crowd cylinder

52. Load control valve

53. Compensator cylinder

54. Lift cylinder

55. Load control valve

56. Diverter valve

57. Manifold

58. Cylinder, autohitch

59. 1st service couplings

60. 2nd service couplings

61. Trailer tipping coupling

62. Start-up valve

63. NOT FITTED

64. Pressure regulator, 120 bar

65. Test point 1 (main system pressure LS)

66. Test point 2 (parking brake release pressure)

67. Test point 3 (steering system pressure)

68. Test point 4 (brake circuit)

69. Test point 5 (main circuit pressure P)

70. Auxiliary breather

71. NOT FITTED

72. Fan reverse valve

73. Oil cooler

HYDRAULICS 1.8

HYDRAULIC CIRCUIT - SINGLE CIRCUIT BRAKING (from Machine S/No. 51200552 to 51200727)

HYDRAULICS 1.9

Key to hydraulic circuit - single circuit braking

1. Hydraulic tank

2. Hydraulic pump, load sensing (LS)

3. LS pump compensator

4. Gauze filter (Not Serviceable)

5. Filler/breather

6. Auxiliary hydraulic pump

7. Fan motor

8. NOT FITTED

9. Pressure filter

10. Brake valve (Safim type)

11. Accumulator

12. Pressure switch (116 bar)

13. Pressure switch (15 bar)

14. Front axle (park brake actuators)

15. Steering cylinder (front)

16. Pressure switch (5 bar)

17. Pressure switch (16 bar)

18. Rear axle

19. Steering cylinder (rear)

20. NOT FITTED

21. Steering control valve (Danfoss OSPF)

22. Steering selector valve (attached to OSPF valve)

23. Pressure relief valve (175 bar)

24. Shock valve (225 - 245 bar)

25. Hydraulic control valve (PVG 32)

26. Outlet section (PVP)

27. Extension section

28. Crowd/compensator section

29. Lift section

30. 1st auxiliary section (carriage/autohitch)

31. 2nd auxiliary section

32. Pressure relief valve (290 bar)

33. Pressure raising spool

34. Pilot valve

35. Shock valve (175 bar)

36. Inlet section (PVSP)

37. LS shuttle valve

38. Proportional controller

39. Shock valve (265 bar)

40. Controller (not proportional)

41. Priority valve (brakes and steering)

42. Priority valve (steering)

43. Filter

44. Brake accumulator charge valve (BAC)

45. Accumulator

(from Machine S/No.51200552 to 51200727)

46. Tap

47. Trailer brake valve

48. Trailer brake coupling

49. Extension cylinder

50. Load control valve

51. Crowd cylinder

52. Load control valve

53. Compensator cylinder

54. Lift cylinder

55. Load control valve

56. Diverter valve

57. Manifold

58. Cylinder, autohitch

59. 1st service couplings

60. 2nd service couplings

61. Trailer tipping coupling

62. Start-up valve

63. NOT FITTED

64. Pressure regulator, 120 bar

65. Test point 1 (main system pressure LS)

66. Test point 2 (parking brake release pressure)

67. Test point 3 (steering system pressure)

68. Test point 4 (brake circuit)

69. Test point 5 (main circuit pressure P)

70. Auxiliary breather

71. Parking brake valve

72. Fan reverse valve

73. Oil cooler

HYDRAULICS 1.10

HYDRAULIC CIRCUIT - DUAL CIRCUIT BRAKING (up to Machine S/No.51200317)

HYDRAULICS 1.11

Key to hydraulic circuit - dual circuit braking

1. Hydraulic tank

2. Hydraulic pump, load sensing (LS)

3. LS pump compensator

4. Gauze filter (Not Serviceable)

5. Filler/breather

6. Auxiliary hydraulic pump

7. Fan motor

8. Pressure reducing valve (parking brake control)

9. Pressure filter

10. Brake valve

11. Accumulator

12. Pressure switch (116 bar)

13. Pressure switch (15 bar)

14. Front axle (park brake actuators)

15. Steering cylinder (front)

16. Pressure switch (5 bar)

17. Pressure switch (16 bar)

18. Rear axle

19. Steering cylinder (rear)

20. Non-return valve

21. Steering control valve (Danfoss OSPF)

22. Steering selector valve (attached to OSPF valve)

23. Pressure relief valve (175 bar)

24. Shock valve (225 - 245 bar)

25. Hydraulic control valve (PVG 32)

26. Outlet section (PVP)

27. Extension section

28. Crowd/compensator section

29. Lift section

30. 1st auxiliary section (carriage/autohitch)

31. 2nd auxiliary section

32. Pressure relief valve (290 bar)

33. Pressure raising spool

34. Pilot valve

35. Shock valve (175 bar)

36. Inlet section (PVSP)

37. LS shuttle valve

38. Proportional controller

39. Shock valve (265 bar)

40. Controller, (not proportional)

41. Priority valve (brakes and steering)

42. Priority valve (steering)

43. Filter

44. Brake accumulator charge valve (BAC)

45. Accumulator

(up to Machine S/No.51200317)

46. Tap

47. Trailer brake valve

48. Trailer brake coupling

49. Extension cylinder

50. Load control valve

51. Crowd cylinder

52. Load control valve

53. Compensator cylinder

54. Lift cylinder

55. Load control valve

56. Diverter valve

57. Manifold

58. Cylinder, autohitch

59. 1st service couplings

60. 2nd service couplings

61. Trailer tipping coupling

62. Start-up valve

63. Non-return valve

64. Pressure relief valve (160 bar)

65. Test point 1 (main system pressure LS)

66. Test point 2 (parking brake release pressure)

67. Test point 3 (steering system pressure)

68. Test point 4 (brake circuit)

69. Test point 5 (main circuit pressure P)

70. Auxiliary breather

HYDRAULICS 1.12

HYDRAULIC CIRCUIT - DUAL CIRCUIT BRAKING (from Machine S/No.51200318 to 51200471)

HYDRAULICS 1.13

Key to hydraulic circuit - dual circuit braking

1. Hydraulic tank

2. Hydraulic pump, load sensing (LS)

3. LS pump compensator

4. Gauze filter (Not Serviceable)

5. Filler/breather

6. Auxiliary hydraulic pump

7. Fan motor

8. Pressure reducing valve (parking brake control)

9. Pressure filter

10. Brake valve

11. Accumulator

12. Pressure switch (116 bar)

13. Pressure switch (15 bar)

14. Front axle (park brake actuators)

15. Steering cylinder (front)

16. Pressure switch (5 bar)

17. Pressure switch (16 bar)

18. Rear axle

19. Steering cylinder (rear)

20. Non-return valve

21. Steering control valve (Danfoss OSPF)

22. Steering selector valve (attached to OSPF valve)

23. Pressure relief valve (175 bar)

24. Shock valve (225 - 245 bar)

25. Hydraulic control valve (PVG 32)

26. Outlet section (PVP)

27. Extension section

28. Crowd/compensator section

29. Lift section

30. 1st auxiliary section (carriage/autohitch)

31. 2nd auxiliary section

32. Pressure relief valve, 290 bar

33. Pressure raising spool

34. Pilot valve

35. Shock valve (175 bar)

36. Inlet section (PVSP)

37. LS shuttle valve

38. Proportional controller

39. Shock valve (265 bar)

40. Controller (not proportional)

41. Priority valve (brakes and steering)

42. Priority valve, steering

43. Filter

44. Brake accumulator charge valve (BAC)

45. Accumulator

(from Machine S/No.51200318 TO 512471)

46. Tap

47. Trailer brake valve

48. Trailer brake coupling

49. Extension cylinder

50. Load control valve

51. Crowd cylinder

52. Load control valve

53. Compensator cylinder

54. Lift cylinder

55. Load control valve

56. Diverter valve

57. Manifold

58. Cylinder, autohitch

59. 1st service couplings

60. 2nd service couplings

61. Trailer tipping coupling

62. Start-up valve

63. NOT FITTED

64. Pressure relief valve (160 bar)

65. Test point 1 (main system pressure LS)

66. Test point 2 (Park brake release pressure)

67. Test point 3 (steering system pressure)

68. Test point 4 (brake circuit)

69. Test point 5 (main circuit pressure P) 70 Auxiliary breather

HYDRAULICS 1.14

HYDRAULIC CIRCUIT - DUAL CIRCUIT BRAKING (from Machine S/No.51200472 to 51200551)

HYDRAULICS 1.15

Key to hydraulic circuit - dual circuit braking

1. Hydraulic tank

2. Hydraulic pump, load sensing (LS)

3. LS pump compensator

4. Gauze filter (Not Serviceable)

5. Filler/breather

6. Auxiliary hydraulic pump

7. Fan motor

8. Pressure reducing valve (parking brake control)

9. Pressure filter

10. Brake valve

11. Accumulator

12. Pressure switch (116 bar)

13. Pressure switch (15 bar)

14. Front axle (park brake actuators)

15. Steering cylinder (front)

16. Pressure switch (5 bar)

17. Pressure switch (16 bar)

18. Rear axle

19. Steering cylinder (rear)

20. Non-return valve

21. Steering control valve (Danfoss OSPF)

22. Steering selector valve (attached to OSPF valve)

23. Pressure relief valve (175 bar)

24. Shock valve (225 - 245 bar)

25. Hydraulic control valve (PVG 32)

26. Outlet section (PVP)

27. Extension section

28. Crowd/compensator section

29. Lift section

30. 1st auxiliary section (carriage/autohitch)

31. 2nd auxiliary section

32. Pressure relief valve, 290 bar

33. Pressure raising spool

34. Pilot valve

35. Shock valve (175 bar)

36. Inlet section (PVSP)

37. LS shuttle valve

38. Proportional controller

39. Shock valve (265 bar)

40. Controller (not proportional)

41. Priority valve (brakes and steering)

42. Priority valve, steering

43. Filter

44. Brake accumulator charge valve (BAC)

45. Accumulator

(from Machine S/No.51200472 TO 512551)

46. Tap

47. Trailer brake valve

48. Trailer brake coupling

49. Extension cylinder

50. Load control valve

51. Crowd cylinder

52. Load control valve

53. Compensator cylinder

54. Lift cylinder

55. Load control valve

56. Diverter valve

57. Manifold

58. Cylinder, autohitch

59. 1st service couplings

60. 2nd service couplings

61. Trailer tipping coupling

62. Start-up valve

63. NOT FITTED

64. Pressure regulator, 120 bar

65. Test point 1 (main system pressure LS)

66. Test point 2 (Park brake release pressure)

67. Test point 3 (steering system pressure)

68. Test point 4 (brake circuit)

69. Test point 5 (main circuit pressure P) 70 Auxiliary breather

71. NOT FITTED

72. Fan reverse valve

73. Oil cooler

HYDRAULICS 1.16

HYDRAULIC CIRCUIT - DUAL CIRCUIT BRAKING (from Machine S/No.51200552 to 51200727)

HYDRAULICS 1.17

Key to hydraulic circuit - dual circuit braking

1. Hydraulic tank

2. Hydraulic pump, load sensing (LS)

3. LS pump compensator

4. Gauze filter (Not Serviceable)

5. Filler/breather

6. Auxiliary hydraulic pump

7. Fan motor

8. NOT FITTED

9. Pressure filter

10. Brake valve (Safim type)

11. Accumulator

12. Pressure switch (116 bar)

13. Pressure switch (15 bar)

14. Front axle (park brake actuators)

15. Steering cylinder (front)

16. Pressure switch (5 bar)

17. Pressure switch (16 bar)

18. Rear axle

19. Steering cylinder (rear)

20. Non-return valve

21. Steering control valve (Danfoss OSPF)

22. Steering selector valve (attached to OSPF valve)

23. Pressure relief valve (175 bar)

24. Shock valve (225 - 245 bar)

25. Hydraulic control valve (PVG 32)

26. Outlet section (PVP)

27. Extension section

28. Crowd/compensator section

29. Lift section

30. 1st auxiliary section (carriage/autohitch)

31. 2nd auxiliary section

32. Pressure relief valve, 290 bar

33. Pressure raising spool

34. Pilot valve

35. Shock valve (175 bar)

36. Inlet section (PVSP)

37. LS shuttle valve

38. Proportional controller

39. Shock valve (265 bar)

40. Controller (not proportional)

41. Priority valve (brakes and steering)

42. Priority valve, steering

43. Filter

44. Brake accumulator charge valve (BAC)

45. Accumulator

(from Machine S/No.51200552 TO 512727)

46. Tap

47. Trailer brake valve

48. Trailer brake coupling

49. Extension cylinder

50. Load control valve

51. Crowd cylinder

52. Load control valve

53. Compensator cylinder

54. Lift cylinder

55. Load control valve

56. Diverter valve

57. Manifold

58. Cylinder, autohitch

59. 1st service couplings

60. 2nd service couplings

61. Trailer tipping coupling

62. Start-up valve

63. NOT FITTED

64. Pressure regulator, 120 bar

65. Test point 1 (main system pressure LS)

66. Test point 2 (Park brake release pressure)

67. Test point 3 (steering system pressure)

68. Test point 4 (brake circuit)

69. Test point 5 (main circuit pressure P) 70 Auxiliary breather

71. Parking brake valve

72. Fan reverse valve

73. Oil cooler

1.18 HYDRAULICS

COMPONENTS

General

NOTE: An identification number in bold type, after an

item, refers to the number of that item in the main hydraulic schematic illustration.

Hydraulic tank (1)

A single hydraulic reservoir feeds the main and auxiliary systems of the machine. A sight glass is fitted to check system contents. An internal 40 µm mesh filter (pre-filtration) separates the clean and dirty sides of the tank. Both system suction lines are taken from the clean side of the mesh filter. All return lines go to a manifold and return fluid to dirty side of tank for pre filtration.

Specifications: Nominal tank capacity 67 litres

Total system capacity (oil) 128 litres

Suction line connections to hydraulic tank

1. Sight glass

2. Suction - Main Pump

3. Drain plug

4. Suction - Auxiliary Pump

5. Filler

Return hose connections to hydraulic tank

(up to Machine S/No.51200471)

5. Return from PVG (Main Control Valve)

6. Return from LS Pump and Filter

7. From LS Pump Case Drain

8. Breather (connected to Filler)

9. Return from Brake and Steering circuits

10. From Trailer Brake (optional)

11. Return from Parking Brake PRV

Return hose connections to hydraulic tank

(from Machine S/No.51200472)

5. Return from PVG (Main Control Valve)

6. Return from LS Pump and Filter

7. (Blank fitted)

8. Breather (connected to Filler)

9. Return from Brake circuit

10. From Trailer Brake (optional)

11. Return from Brake and Parking Brake circuit

HYDRAULICS 1.19

Hydraulic Pump (load sensing) (2)

The load sensing hydraulic pump supplies pressure to operate all services, except the fan motor and parking brake circuits.

Specifications Pressure (P) 250 bar (3625 psi) Pressure (load sensing) 14 bar (200 psi) Pressure (stand-by) 20 bar (290 psi)

Capacity (flow) (up to Machine S/No.51200471) 122 l/min @ 2300 rpm (from Machine S/No.51200472) 122 l/min @ 2200 rpm

Pump compensator (load sensing) (3)

The LS pump compensator controls the stand-by pressure of the pump when services are not demanding oil, then causes the pump to swash and deliver full pressure when a service is operated. The valve also contains a pressure relief valve.

Tank filter (4)

The filter (not illustrated) is in the hydraulic tank and separates the return side from the clean side of the tank and is rated at 40 mm.

Filler/breather (5)

The hydraulic tank is replenished through the filler/ breather (5) which contains a filter rated at 7µm. The filler breather maintains a positive pressure of 0.3 bar (4 psi) in the hydraulic tank.

Auxiliary hydraulic pump (6)

The auxiliary pump supplies pressure to operate the engine cooling fan motor and keep the parking brake off while the engine is running.

Specifications Pressure 160 bar (2320 psi) (Max allowable in circuit) Capacity (flow) 50 l/min @ 2300 rpm

NOTE: On Machines up to S/No.51200317, a non-return valve (63), between the auxiliary pump (6) and the PRV (8) maintains line pressure security from any fluctuation in the auxiliary circuit. This prevents any immediate application of the parking brake in the event of engine or hydraulic failure.

1.20 HYDRAULICS

Fan motor (7)

NOTE: Fitted to machines up to S/No.51200471only.

This type of fan motor is hydraulically operated from the auxiliary circuit and is fitted as part of the engine cooling system. The fan is secured to the drive shaft with a woodruff key, nut and tab washer. A cartridge pressure relief valve (64) is attached to the fan motor.

Specifications: Pressure relief valve 160 bar (2320 psi)

1. To pressure filter (9)

2. Fan motor (7)

3. Pressure - auxiliary pump (6)

4. Return to tank (1)

Fan reverse motor (7)

NOTE: Fitted to machines from S/No.51200472 only.

5. Pressure relief valve (64)

This type of fan motor is hydraulically operated from the auxiliary circuit and is fitted as part of the Reverse Fan engine cooling system. The fan is secured to the drive shaft with a woodruff key, nut and tab washer.

1. Fan reverse valve (72)

2. Fan motor (7)

3. Fan reverse valve (72)

4. Return to tank (1)

HYDRAULICS 1.21

Pressure Reducing Valve (PRV) - for the parking brake (8)

NOTE: (Fitted to Machines up to S/No.51200551

only

The Pressure Reducing Valve (PRV) (8) for the parking brake is electrically controlled from a switch in the cab (refer to electrical section). The PRV is located in the engine pod for Machines up to S/ No.51200317 and adjacent to the front axle for Machine S/No's.51200318 to 51200551. The switch operates a solenoid on the valve to give proportional operation. The pressure can be tested using test point 2 (66 - Refer to Page 1.30), which is in the output from connection A.

NOTE: The voltage to the solenoid is supplied through a voltage transformer, to achieve the proportionality required.

Under no circumstances should battery voltage be applied to this solenoid.

Specifications: Operating pressure 16 bar (230 psi)

Maximum pressure 20 bar (290 psi) Solenoid 3mm/12vdc/100% prop

Pressure filter (9)

NOTE: (Fitted to Machines up to S/No.51200471 only)

The oil pressure filter (9) is installed in the return line, between the fan motor (7) and the hydraulic tank (1).

NOTE: (Fitted to Machines from S/No.51200472 only)

The oil pressure filter (9) is installed in the return line, between the reverse fan valve (72) and the hydraulic tank (1).

If the filter becomes blocked, a filter blockage warning light in the cab illuminates and a bypass will open at 3.5 bar (50 psi).

T. Return to hydraulic tank (1) P. Supply from Auxiliary pump (6) A. Supply to Parking Brake actuators (14)

When the warning light is illuminated NO filtration is taking place. Always change the filter IMMEDIATELY.

Specifications Filtration 10µm

1. Pressure switch

2. Bypass valve

3. Filter bowl

4. Filter media

1.22 HYDRAULICS

Single circuit brake pressure servo valve (MICO) (10)

NOTE: Fitted to Machines up to S/No.51200471 only.

The brake pressure servo valve can be either single or dual depending on the model of the machine.

The operation of the servo valve is proportional to brake pedal movement. When the brake pedal is pressed, the valve (10) allows pressure in the accumulator (11) to apply the brakes. When the brake pedal is released, the valve (10) closes the pressure line from the accumulator (11) and diverts brake pressure from the brake units to the hydraulic tank (1), releasing the brakes.

Specification

Brake pressure at A 44 bar (640 psi)

Dual circuit brake pressure servo valve (MICO) (10)

NOTE: Fitted to Machines up to S/No.51200471 only.

With a dual brake servo valve (10), the front and rear brakes are operated independently of each other by separate feed and return lines from the servo valve.

Specification

Brake pressure at A (not shown) 44 bar (640 psi)

Servo Valve - Single circuit brake pedal

P Pressure supply from Accumulator (11) T Return to Hydraulic Tank (1) A Supply to Brakes on Front (14) and Rear (18)

Axles

Servo Valve - Dual circuit brake pedal

P Pressure supplies from Accumulators (11) T Return from Hydraulic Tank (1) A (not shown) - Supply to Brakes on Front (14)

and Rear (18) Axles

HYDRAULICS 1.23

Single circuit brake pressure servo valve (SAFIM) (10)

NOTE: Fitted from Machines Serial No.51200472

only

The brake pressure servo valve can be either single or dual depending on the model of the machine. The valve is constructed from 3 separate modules, the master cylinder, valve body and end plate. Brake pedal travel and braking pressure are set using an adjusting screw, located on the base on the brake valve.

The operation of the servo valve (1) is proportional to brake pedal movement. When the brake pedal is pressed, a pivoted lever moves a master cylinder, which positions an associated sprung loaded plunger. The plunger is in contact with the main shuttle valve in the valve body Refer to Page 1.84). The shuttle valve controls the flow of the pressure oil supply from the brake accumulator. The accumulator is supplied from the inlet (PVSP) section of the main hydraulic control valve. When the shuttle valve is moved, the oil supply from the accumulator is allowed to flow to the outlet connection in the end plate, which supplies the front and rear brakes units.

Servo Valve - Single circuit brake pedal

P Pressure supply from Accumulator (11) T Return to Hydraulic Tank (1) A Supply to Brakes on Front (14) and Rear (18)

Axles

When the brake pedal is released, spring pressure in the master valve releases pressure on the shuttle valve and repositions the brake pedal. The shuttle valve moves under spring pressure to close the oil supply from the accumulator and divert residual oil pressure from the brake system to the hydraulic tank, releasing the brakes.

Specification: Brake pressure at A 44 bar (640 psi)

Dual circuit Brake pressure servo valve (SAFIM) (10)

NOTE: Fitted from Machines Serial No.51200472

only

The construction and operation of the dual brake servo valve is similar to the single servo valve. The primary difference is that the front and rear brakes are operated independently of each other by separate feed and return lines from the servo valve.

Specification: Brake pressure at A 44 bar (640 psi)

Servo Valve - Dual circuit brake pedal

P Pressure supply from Accumulators (11) T Return to Hydraulic Tank (1) A Supply to Brakes on Front (14) and Rear (18)

Axles

1.24 HYDRAULICS

Accumulator(s) (11)

The nitrogen charged accumulator(s) provide hydraulic pressure for efficient operation of the brakes under all pump load conditions. One accumulator is fitted for the single brake system and two are fitted for the dual brake system. The accumulator(s) are located in the chassis behind the cab assembly.

Specifications

Pre-charge pressure 41 bar (595 psi) Oil capacity 0.75 litre

Pressure switch (12)

The pressure switch illuminates a warning light in the cab when brake pressure drops to a critical level. The pressure switch is located adjacent to the accumulator(s) (11) behind of the cab structure, forward of the rear axle.

Specification Operating pressure 116 bar (1682 psi) falling

Pressure switch (transmission dump) (13)

When the transmission dump selector switch in the cab is operated the pressure switch will disconnect transmission when the brakes are applied. The pressure switch is located adjacent to the transmission drop box, above the drive shaft.

Specification Operating pressure 15 bar (217 psi) rising

HYDRAULICS 1.25

Front axle (14)

The front axle contains double reduction bevel and planetary hub reduction gears and a limited slip differential. Braking is by inboard multi-disc units, the axle also contains a parking brake.

The outboard wheel hubs are steerable, operated by a steering cylinder (15) attached to the axle.

Steering cylinder (front) (15)

The front steering cylinder is a double acting hydraulic cylinder, supplied with pressure operating oil from the Steering Control Valve (21). The two cylinder rams have a ball joint end fitting, which connect to the swivel hubs for the front wheels. The front steering cylinder is attached to the rear of the front axle, above the drive shaft housing.

Specification

Stroke (lock to lock) 200 mm Bore 85 mm

Pressure switch (brake light) (16)

When the brake pedal is depressed the pressure switch operates and illuminates the brake stoplights at the rear light clusters. The switch is located in the brake pipes on the right side of the front axle.

Specification

Operating pressure 5 bar (72 psi) rising

1.26 HYDRAULICS

Pressure switch (parking brake) (17)

When the parking brake pressure (17) falls below 16 bar (232 psi) the pressure switch illuminates a warning light in the cab. The switch is located in the brake pipes on the right side of the front axle.

If light is on, parking brake has been applied.

If light comes on when parking brake is not applied, stop vehicle and investigate fault.

Specification Operating pressure 16 bar (232 psi) rising

Rear axle (18)

The rear axle (18) contains double reduction bevel and planetary hub reduction gears and a limited slip differential. Braking is by inboard multi-disc units (when taken as an option).

The outboard wheel hubs are steerable, operated by a steering cylinder (19) attached to the axle.

Steering cylinder (rear) (19)

The rear steering cylinder (19) is a double acting hydraulic cylinder, supplied with pressure operating oil from the Steering Control Valve. The two cylinder rams have a ball joint end fitting, which connect to the swivel hubs for the front wheels. The rear steering cylinder is attached to the front of the rear axle, above the drive shaft housing.

Specification

Stroke (lock to lock) 200 mm Bore 85 mm

Non-return valve (20)

The non-return valve (NRV) allows pressure supply oil to be supplied from the main hydraulic control valve to the Brake Servo valve. The NRV (20) prevents oil from the brake servo valve returning into the main control valve. This valve is fitted to Machines for certain markets only.

HYDRAULICS 1.27

Steering valve (21)

The steering system is dynamic and fully load sensing and is supplied with pressure operating oil from the load sensing (LS) output of the inlet section (PVSP) (36) on the main hydraulic control valve (25). The valve contains a PRV (23) and two shock valves (24).

Steering in Neutral position

When the steering valve is in the neutral position, the spring in the priority valve (42) moves the valve to allow the oil to pass freely, from the load sensing line, through the priority valve (42) and the steering control valve (21) to the hydraulic tank (1). The oil supply from the hydraulic pump (2) is locked.

As back pressure increases at the spool of the priority valve (42), the valve spring is compressed and the spool moves to allow oil to flow to the working hydraulics.

STEERING - NEUTRAL POSITION

1.28 HYDRAULICS

Steering in Operation

As the steering wheel is turned, the rotary valve proportionally directs the oil flow from the LS line of the inlet section (PVSP) (36) to the steering selector valve (21) (not shown). The LS line is not fully closed until the rotary valve is fully open. When the steering input is stopped, the rotor passages close, steering input stops and the system returns to the loadsensing mode.

Specification

Type OSPF250LS PRV 170-175 bar (2465-2537 psi) Shock valve 225-245 bar (3262-3552 psi)

STEERING - RIGHT TURN OPERATION

Pressure relief valve (23)

If an overpressure condition exists, a pressure relief valve (PRV) will bypass pressure oil from the spring side of the priority valve (42) to the hydraulic tank (1). The upstream oil pressure is greater and moves the spool valve, against the spring, allowing oil to be supplied to the working hydaulics.

Specification: Operating pressure 175 bar (254 psi)

HYDRAULICS 1.29

Steering selector valve (22)

The steering selector valve is solenoid operated and diverts oil to the respective ports of the steering cylinders. Three modes of steering are available by selecting the steering mode switch in the cab to give either two-wheel steering (front wheels), four-wheel steering or ‘crab’ steering.

The machine must always be stationary before changing steering modes.

C 1 To rear steering cylinder (19) C 2 To rear steering cylinder (19) C 4 To front steering cylinder (15) T Return to hydraulic tank (1) P From inlet section (36) CF - Line

C 3 T o front steering cylinder (15) O OSPF250 valve A Adapter E Selector valve

LS From inlet section (36) LS – Line

1.30 HYDRAULICS

Control valve (25)

The control valve consists of up to five individual spool valves, with common pressure and return lines, linked together by an inlet and outlet cover. The inlet (PVSP) (36) contains a priority valve (43) (steering) module and brake accumulator charge valve (44). The spools, outlet cover and PSVP are secured together with tie bolts. The individual components of the valve described are (26) to (44).

Key to control valve

NOTE: Numbers in bold type refer to identification numbers on main hydraulic schematic.

1 Outlet section (PVP) (26) 2 Test Point 1 (65) 3 Boom extend/retract section (27) 4 Crowd/compensator section (28) 5 Boom lift/lower section (29) 6 1st auxiliary section (30) 7 2nd auxiliary section (31) 8 Manual operation module 9 Brake and Accumulator Charge valve (BAC) (44) 10 Steering Priority Valve (42) 11 Inlet Section (PVSP) (36) 12 Brakes/Steering Priority Valve (12)

Key to control valve (continued)

13 Tie bolt 14 Washer 15 Nut 16 LS Shuttle Valve (37) 17 Pressure supply (36) 18 Brake and Accumulator Charge valve (BAC) (44) 19 Steering Valve (22) 20 Electric module (38, 40) 21 Test Point 4 (68) 22 2nd Service Couplings (60) 23 2nd Service Couplings (60) 24 Diverter Valve (56) 25 Diverter Valve (56) 26 Load Control Valve (55) 27 Lift Cylinder (54) 28 Relief valve, crowd back (39) 29 Load Control Valve (52) 30 Crowd Cylinder (51) 31 Relief valve, crowd forward (36) 32 Test {Point 5 (69) 33 Extension Cylinder (49) 34 Load Control Valve (50) 35 Relief valve, main system (32) 36 Pilot pressure regulator (34) 37 Hydraulic Tank (1)

HYDRAULICS 1.31

Outlet section (PVP) (26)

Ac Accumulator PP Pilot pressure LS Load sensing T Return to tank P Pressure

32 Main pressure relief valve (RV1-290 bar) 34 Pilot pressure regulator (14 bar) 33 Compensator (pressure raising spool) (10 bar) 69 Test point

Function

The closed centre provides for ultimate system protection and the provision of pilot pressure for the operation of the spools.

1.32 HYDRAULICS

Extension section (27)

A Port A - connection to service B Port B - connection to service PP Pilot pressure LS Load sensing T Return to tank P Pressure

(37) LS shuttle valve (38) Controller, proportional

Function

Extension service is fully proportional and operated electrically to provide oil flow to the extension circuit.

When the spool is moved from the neutral position, oil at P (standby pressure 20 bar (290 psi)) is delivered to the consumer (service). The oil at the consumer meets a resistance (i.e. to move the piston) and the pressure at P rises to overcome this force. The P line is connected permanently to the LS line; therefore the pump receives a signal to swash to the required position to provide the pressure required to overcome the resistance. The pressure at P will therefore be the LS pressure plus the standby pressure of 20 bar (290 psi).

The pump will always react to the highest pressure requested when more than one service is operated by virtue of the LS shuttle valve in each section.

When the valve returns to neutral the pressure at P drops and therefore the pressure in the LS line also drops.

The spool is operated by pilot oil pressure delivered by the electrical actuator under the command of the ‘Solo’ joystick and is fully proportional.

In neutral the spool is ‘half-motored’, connecting port B to the T line.

HYDRAULICS 1.33

Crowd section (28)

A Port A - connection to service B Port B - connection to service PP Pilot pressure LS Load sensing T Return to tank P Pressure

(35) Shock and anti-cavitation valve - Port A

(RV2-175 bar)

(37) LS shuttle valve (38) Controller, proportional (39) Shock and anti-cavitation valve - Port B

(RV3-265 bar)

Function

Crowd service is fully proportional and operated electrically to provide oil flow to the crowd circuit.

The pump will always react to the highest pressure requested when more than one service is operated by virtue of the LS shuttle valve in each section.

When the valve returns to neutral the pressure at P drops and therefore the pressure in the LS line also drops.

The spool is operated by pilot oil pressure delivered by the electrical actuator under the command of the ‘Solo’ joystick and is fully proportional.

In neutral the spool is closed’, neither of the consumer ports A or B are connected to the T line. This enables self-levelling operation from the compensator cylinder.

To protect the circuit, shock valves are provided in both A and B ports.

1.34 HYDRAULICS

Lift section (29)

A Port A - connection to service B Port B - connection to service PP Pilot pressure LS Load sensing T Return to tank P Pressure

(37) LS shuttle valve (40) Controller, proportional

Function

Lift service is fully proportional and operated electrically to provide oil flow to the lift circuit.

The pump will always react to the highest pressure requested when more than one service is operated by virtue of the LS shuttle valve in each section.

When the valve returns to neutral the pressure at P drops and therefore the pressure in the LS line also drops.

The spool is operated by pilot oil pressure delivered by the electrical actuator under the command of the ‘Solo’ joystick and is fully proportional.

In neutral the spool is ‘half-motored’, connecting port B to the T line.

HYDRAULICS 1.35

1st service (30)/2nd service (31) section

A Port A - connection to service B Port B - connection to service PP Pilot pressure LS Load sensing T Return to tank P Pressure

(37) LS shuttle valve (40) Controller, non-proportional

Function

1st service/2nd service is non-proportional and operated electrically to provide oil flow to the 1st service/2nd service circuit.

When the spool is moved from the neutral position, oil at P [standby pressure 20 bar (290 psi)] is delivered to the consumer (service). The oil at the consumer meets a resistance (i.e. to move the piston) and the pressure at P rises to overcome this force. The P line is connected permanently to the LS line; therefore the pump receives a signal to swash to the required position to provide the pressure required to overcome the resistance. The pressure at P will therefore be the LS pressure plus the standby pressure of 20 bar (290 psi).

The pump will always react to the highest pressure requested when more than one service is operated by virtue of the LS shuttle valve in each section.

When the valve returns to neutral the pressure at P drops and therefore the pressure in the LS line also drops.

The spool is operated by pilot oil pressure delivered by the electrical actuator under the command of the ‘Solo’ joystick.

These sections, although electrically controlled, are non-proportional. Operation of the buttons on the ‘Solo’ joystick operate these sections as an on-off switch.

In neutral the spool is closed, neither of the consumer ports A and B are connected to the T line.

1.36 HYDRAULICS

Inlet section (PVSP) (36)

LS (1) Load sensing (to steering valve) CF Steering valve B1 Main brake B2 Trailer brake (optional) B3 Pressure test point (67) LS Load sensing T Return to tank P Pressure A BAC valve spring

(37) LS shuttle valve (41) Priority valve (42) Steering priority valve (compensator) (43) Filter (44) Brake accumulator charge (BAC) (68) Test point

Function

The inlet section (PVSP) provides oil to: (a) The brake circuit through the BAC valve (44), this

gives a charge of between 138-159 bar (2000-2300 psi) and operates in preference to all other services. Brake charge pressure can be tested at test point B3 (68).

(b) The steering circuit with oil on demand by the steering priority valve (42).

The oil arriving at P is delivered to the BAC valve and onto the accumulators, the resistance to charging the accumulator causes the pressure to rise at P which, as it is connected to the LS line via the BAC valve, signals to the pump. The pump responds by delivering oil at the required pressure.

The system charges at 138 bar and stops charging at 159 bar. At the upper limit 159 bar, the oil pressure at P overcomes the force of the BAC valve spring (A) and closes the connection between P and LS; the pump therefore goes to standby. When the pressure in P falls below 138 bar, the spring force opens the valve and the system recharges.

At the same time, pump pressure is supplied to the steering unit via the CF port. If the steering is not being used, the pump at standby pressure overcomes the spring force in the priority valve (41) and supplies oil to the other consumers.

When the steering wheel is moved, the resistance to oil from the steering cylinders builds in the CF line. This is also sensed by the LS line, which, as it is linked to the steering priority valve (42). makes sure steering is given priority as well as signalling the pressure requirement to the pump.

HYDRAULICS 1.37

1.38 HYDRAULICS

Accumulator (45)

The nitrogen charged accumulators (1) provide hydraulic pressure for operation of spools when engine is switched off. The accumulators are attached to brackets, located adjacent to the main hydraulic control valve (25).

Specifications Pre-charge pressure 7 bar (100 psi) Oil capacity 0.75 litre

Tap (46)

The tap valve (3) (46) is located on the rear service plate (1) and connects the return line from the autohitch manifold (2) to the hydraulic tank. When operated, the tap valve (3) allows return oil from the autohitch manifold(2) to flow to the hydraulic tank. The return line downstream from the tap valve (3) connects to the return line from the trailer brake valve (4). The tap valve (3) is used to convert the dual acting service for the autohitch to single acting service for trailer tipping.

Trailer brake valve (47)

The trailer brake valve, if fitted, is located on the rear service plate and is connected to the inlet section (36) of the main hydraulic control valve (25), the hydraulic tank (1) and the trailer coupling (48). When a trailer brake is connected to the trailer brake coupling and the brakes are applied, the porting of the valve applies proportional pressure to the trailer brake. When the brakes are released, the valve diverts the hydraulic oil to the hydraulic tank (1).

1 Accumulators

1 Service plate 3 Tap valve (46) 2 Manifold 4 Trailer valve

The valve is pilot operated by a signal taken from the operation of the service brakes.

Key to Trailer Brake Valve

1 Outlet to Trailer Brake Coupling (48) 2 Inlet from Tap (46) 3 Pressure supply (B2)

Trailer brake coupling (48)

The trailer brake coupling (1) is a self-sealing, quick release coupling, located on the rear service plate (2). The coupling is used to connect a trailer braking system to the trailer brake valve (47), if fitted.

Key to Trailer Brake Coupling

1 Trailer brake coupling 2 Rear service plate

HYDRAULICS 1.39

Extension cylinder (49)

The boom extension cylinder is fitted inside the boom of the machine and is supplied with operating pressure oil from a load control valve (50).

Specification:

Type K 50 Stroke 1971 mm

Bore 80 mm

Type K 60 Stroke 2111 mm

Bore 80 mm

Type K 70 Stroke 2917 mm

Bore 80 mm

Load control valve (50)

The load control valve for the extension cylinder is fitted in the pressure oil supply lines, between the extension section (27) and the boom extension cylinder (49). The valve prevents any load movement in the event of hose bursts or leakage. If the valve is defective, a complete new cartridge must be fitted.

The load control valve is factory set and should never be dismantled or adjusted except for resealing.

Key to Load Control Valve

1. From the extension section (27)

2. Extension cylinder (rod side)

3. Extension cylinder (full bore side)

4. From the extension section (27)

5. Pilot pressure

6. Supply pressure

7. Pressure relief

1.40 HYDRAULICS

Crowd cylinder (51)

The crowd cylinder is fitted inside the head of the boom and controls the operation of the head attachments. The crowd cylinder is supplied with operating pressure oil from the crowd/compensator section (28) and a load control valve (52).

Specification:

Stroke 350 mm Bore 125 mm

Load control valve (52)

The load control valve for the crowd cylinder is fitted between the crowd cylinder (51) and the crowd/compensator section (28). The valve prevents any load movement in the event of hose bursts or leakage. If the valve is defective, a complete new cartridge must be fitted.

The load control valve is factory set and should never be dismantled or adjusted except for resealing.

Key to Load Control Valve

1. From the crowd/compensator section (28)

2. Crowd/compensator cylinder (rod side)

3. Crowd/compensator cylinder (full bore

side)

4. From the crowd/compensator section (28)

5. Pilot pressure

6. Supply pressure

7. Pressure relief

HYDRAULICS 1.41

Compensator cylinder (53)

The compensator extension cylinder is fitted below and to the rear of the extension boom and is connected to the load control valve (52) and the crowd/compensator section (28).

Specification

Stroke 750 mm Bore 63 mm

ILLUSTRATION REQUIRED (IPC 723)

Lift cylinder (54)

The lift cylinder is fitted below and forward of the extension boom. The lift cylinder is supplied with operating pressure oil from the lift section (29) and a load control valve (55).

Specification

Type K50 Stroke 1325 mm

Bore 125 mm

Type K60 Stroke 1325 mm

Bore 125 mm

Type K70 Stroke 1400 mm

Bore 125 mm

1.42 HYDRAULICS

Load control valve (55)

The load control valve for the lift cylinder is fitted in the pressure oil supply lines, between the lift section (29) and the lift extension cylinder (54). The valve prevents any load movement in the event of hose bursts or leakage. If the valve is defective, a complete new cartridge must be fitted.

The load control valve is factory set

and should never be dismantled or adjusted except for resealing.

Key to Load Control Valve

1. From the lift section (29)

2. Lift cylinder (rod side)

3. Lift cylinder (full bore side)

4. From the lift section (29)

5. Pilot pressure

6. Supply pressure

7. Pressure relief

HYDRAULICS 1.43

Diverter valve (56)

The diverter valve, if fitted, is attached to a bracket, which is fitted to the rear service plate, to the left side of the chassis member. The valve is connected between the 1st auxiliary section (30) and the 1st service couplings (59) and autohitch manifold (57).

The valve is solenoid operated and selected by a rocker switch in the cab. When selected, the valve diverts oil from the 1st auxiliary service to the rear of the machine where it can be utilized to operate trailer tipping or autohitch.

Specification:

Solenoid Operating voltage 12V DC

Key to Diverter Valve

1 To the 1st service coupling (59) 2 To the 1st service coupling (59) 3 Autohitch manifold (57)

4. Autohitch manifold (57) 5-10. Not used

11. To the 1st auxiliary section (30)

12. To the 1st auxiliary section (30)

Manifold (57)

The manifold is attached to the rear service plate and is located between the autohitch cylinder (58) and the diverter valve (56). The manifold is used to deliver oil to the autohitch or trailer tipping services.

1.44 HYDRAULICS

Autohitch cylinder (58)

The autohitch cylinder, if fitted, is located on the rear of the machine and is used to automatically connect and lift a trailer onto the machine. The pressure oil supplies to the autohitch cylinder are from the autohitch manifold (57).

Specification

Stroke 325 mm Bore 60 mm

1st service couplings (59).

The 1st service couplings (not illustrated) are of the quick-release type and are used to attach hydraulic services to the front of the machine.

2nd service couplings (60)

The 2nd service couplings are of the quick-release type and, if fitted, are used to attach a second hydraulic attachment to the front of the machine.

Trailer tipping connection (61)

The trailer tipping connection (not illustrated) is of the quick-release coupling type and, if fitted, connects hydraulic supplies to the trailer tipping service.

Start-up valve (62)

The start-up valve is fitted in the hydraulic supply line between the LS hydraulic pump (2) and the control valve PVSP inlet section (36). An internal spring valve opens the start-up valve to divert fluid to the hydraulic tank (1) when the engine is being started, offloading the build-up of pressure. When the LS hydraulic pump builds up sufficient pressure, the fluid pressure overcomes the spring valve, which closes and prevents fluid from flowing back to the hydraulic tank (1).

HYDRAULICS 1.45

Non-return valve (63)

(Up to Machine S/No.51200317 only) This is a simple non-return valve, which maintains

system pressure for the parking brake circuit, in the event of hydraulic or engine failure.

Pressure relief valve (64)

(Up to Machine S/No.51200471 only)

The cartridge pressure relief valve is attached to the cooling fan motor (7) and relieves excess pressure in the hydraulic fluid supply to the motor. The valve relieves pressure by diverting hydraulic fluid flow to the hydraulic tank (1).

Specifications

Pressure relief valve 160 bar (2320 psi)

Breather (70)

The breather is fitted to the overflow line from the filler neck to tank return and ensures that the hydraulic tank is vented. This prevents any build up of positive or negative air pressure inside the tank, which would cause damage to the tank or restrict fluid flow.

1.46 HYDRAULICS

Parking brake valve (71)

(From Machine S/No.51200552 only)

The parking brake valve is fitted between the hydraulic tank (1), the cooling fan motor (7) and the fan reverse valve circuit (72). The valve is solenoid operated from a switch in the operators cab and applies the parking brake.

The valve is supplied with hydraulic fluid from the fan reverse valve (72) and has a solenoid operated valve and a pressure relief valve. When selected by the operator, the solenoid valve operates to supply hydraulic fluid to the parking brake actuators on the front axle. When de-selected, the valve releases the hydraulic fluid pressure to the parking brake and returns the fluid flow to the hydraulic tank (1).

Specifications

Pressure relief valve 18 bar (261 psi) max Solenoid voltage 12V DC

Key to Parking Brake Valve

1. Solenoid operated valve

2. Pressure relief valve A Supply to Parking Brake actuators (14) P Supply from Fan Reverse Valve (72) T Return to hydraulic tank (1)

HYDRAULICS 1.47

Fan reverse valve (72)

(From Machine S/No.51200472 only)

The fan reverse valve is fitted between the hydraulic tank (1), the cooling fan motor (7) and the parking brake valve (71). The valve is manually operated from a switch in the operators cab and reverses the direction of rotation of the engine cooling fan. This enables debris that is blocking the radiator to be blown clear to restore correct cooling.

The valve is supplied with hydraulic fluid from the auxiliary hydraulic pump (6) and has a solenoid operated valve, servo valve, pressure relief valve and a temperature operated switch. In normal operating conditions, the hydraulic fluid supply from the auxiliary pump (6) is directed by the solenoid valve to the fan motor (7). The return fluid is directed by the solenoid valve, through the oil cooler (73) to the hydraulic tank (1).

If the radiator becomes blocked, the temperature of the hydraulic fluid increases. When the fluid temperature reaches 100 °C, the temperature switch is operated. This illuminates a warning light in the operators cab. When the operator holds down the cab selector switch, the solenoid valve operates to reverse the flow of hydraulic fluid to the fan motor, reversing the direction of fan rotation.

A connection from the fan reverse valve supplies operating fluid to the parking brake valve (71).

Specifications

Pressure relief valve 140 bar (2030 psi) max Temperature switch 100 °C Solenoid voltage 12V DC

Key to Fan Reverse Valve

1. Solenoid operated valve

2. Non-return valves

3. Servo valve

4. Pressure relief valve

5. Temperature switch A Return from fan motor (7) B Supply to fan motor (7) M Temperature switch T Return to hydraulic tank (1) P1 Oil supply from auxiliary pump (6) P2 Supply to Parking brake valve (71)

1.48 HYDRAULICS

Oil cooler (73)

(From Machine S/No.51200472 only)

An oil cooler is fitted in the return line to the hydraulic tank (1), between the fan reverse valve (72) and the oil pressure filter (9). The oil cooler is attached by brackets to the machine structure with two bolts and washers.

The oil cooler has three tubular cooling elements, through which the hydraulic fluid flows on the return to the hydraulic tank. The hydraulic fluid is cooled by engine coolant flowing over the three cooling elements.

HYDRAULICS 1.49

OPERATION

General

NOTE: An identification number in bold type, after

an item, refers to the number of that item in the main hydraulic schematic illustration.

Hydraulic fluid reaches the control valve inlet section (PVSP) (36) from the load-sensing pump. Spools are closed centre, dead headed into a pressure adjustment spool. When a spool is actuated pressure is fed through the shuttle valve circuit to the spring chamber behind the pressure adjustment spool. This action restricts fluid return to tank and increases pump pressure to operate the selected circuit through the spool valve slice. Hydraulic pressure is now directed to the service with return flow diverted to tank.

If the control/spool is not released when the spool reaches the end of its travel, the fluid builds up pressure. This pressure is also sensed in the LS circuit, when this pressure reaches maximum of 250 bar (3625 psi) the pump de-swashes.

Do not adjust the factory set relief valves in the crowd spool.

The crowd spool contains two relief valves, one for the crowd forward or dump (RV2) (35) set at 175 bar (2538 psi) and one for the crowd back (RV3) (39) set at 265 bar (3843 psi).

Relief valves RV2 and RV3 are factory set and cannot be adjusted. The pressure setting is stamped on the valve, the spring colours do not relate to the pressure rating of the valve.

It is important that the relief valves are not allowed to remain open for more than a few seconds, otherwise extreme fluid temperatures will result and cause damage to the hydraulic seals and reduce the life of the hydraulic fluid.

The speed of operation of the services is related to the amount of spool movement and therefore fluid flow.

If external pressure is generated by accidental contact with buildings or road surfaces, etc, the System is protected by installation of relief valves.

Relief valves

Relief valves are fitted to the control valve to control system pressure and the carriage/crowd service pressure.

The boom extend/retract, lift/lower and all auxiliary pressures are protected by the main system relief valve (RV1) (32) in the outlet section (PVP) (25) of the control valve (25). The relief valve is set at 290 bar (4205 psi). It is unlikely that this is opened, as in normal circumstances the pump de-swashes when 250 bar (3625 psi) is sensed in the LS line.

1.50 HYDRAULICS

System pressure checks

NOTE: Only check hydraulic pressure when oil is at

normal working temperature (60 ± 4°C) and with engine at fast idle (1800 rpm).

Five test points are available as follows:

Test point 1 (65) (main system) - load sensing side

Located on the LS line from compensator valve of the main pump.

1. Connect pressure gauge to test point 1 (65).

2. Start engine. This gauge will indicate the load sensing signal required by any of the services being operated.

3. Operate any service. When a service is operated to its limit, the maximum pressure of 250 bar (3625 psi) will be maintained and the pump will ‘deswash’.

4. Read pressure gauge.

5. Check pressure does not exceed 250 bar (3625 psi).

3 LS pump compensator valve 65 Test point

Test point 2 (66) (Park Brake Circuit)

On machines up to S/No 51200317 and from S/No 51200728, the test point is located in the engine compartment, on the bulkhead above the LS pump.

1. Connect pressure gauge to test point 2 (66).

2. Start engine.

4. Read pressure gauge.

5. Check pressure is between 16 to 20 bar (232 to 290 psi).

On machines from S/No 51200318 to 51200727 the test point 2 (66) is located to the rear of the front axle.

8 Pressure reducing valve 66 Test point

66 Test point

HYDRAULICS 1.50A

Test point 3 (67) (priority steering)

Located adjacent to the bulkhead plate for steering and brake hose connections at the front right of the cab.

1. Connect pressure gauge to test point 3 (67).

2. Start engine.

3. Whilst steering the wheels, the gauge will show the pressure of the oil supplied to the steering unit.

4. Read pressure gauge.

5. Check pressure - at full steering this will be 175 +/

- 10 bar (2538 +/- 145 psi).

67 Test point

1.50B HYDRAULICS

HYDRAULICS 1.51

Test point 4 (68). (Brake circuit)

This test point is located on the inlet section (PVSP) (36) of the main valve (25), on port B3.

1. Connect pressure gauge to test point 4 (68).

2. Start engine.

3. Read pressure gauge.

4. Check pressure - when operating the gauge will read the stored pressure in the accumulator. Recharge will occur at 138 +/- 5 bar (2001 +/- 72.5 psi) and stop charging sat 160 +/- 5 bar (2321 +/-

72.5 psi).

NOTE: The test port will allow measurement of oil pressure in the brake charge circuit.

NOTE: When other services are used, the pressure seen at this Test Point will be up to a maximum of 250 bar (3625 psi).

NOTE: For dual circuit brake machines, this reading is only accurate whilst the brakes are being charged.

Test point 5 (69). (Main system – pressure P)

This test point is located on the outlet section (PVP) (26) of the main valve (25).

1. Connect pressure gauge to test point 5 (69).

2. Start engine.

3. The gauge will read the pressure raised by the pump when demanded by the boom services and will be higher than the LS pressure by 20 bar (290 psi) (stand-by).

4. Read pressure gauge.

5. Check pressure is up to 270 +/- 10 bar (3916 +/- 72.5 psi).

36 PVSP inlet section 68 Test point

26 PVP outlet section 69 Test point

1.52 HYDRAULICS

LS pump (2)

The load sensing hydraulic pump supplies pressure to operate all services, except the fan motor and hydraulic filter. The pump operation phases are as follows:

LS pump compensator (3) operation

The pressure spring of the volumetric flow controller (3) is designed so that the pump pressure acting on the face is always 20 bar (290 psi) higher than the load pressure acting via port (2).

The pressure of 20 bar (290 psi) is the stand-by pressure.

The pressure regulator (4) limits the pressure in the service hydraulic circuit to 250 ±5 bar (3625 ±70 psi) (PRV function).

1. LS compensator (3)

2. Inlet port

3. Volumetric flow controller

4. Pressure regulator

5. Connection to pump

6. Connection to control plunger of pump

7. Connection to tank

8. Orifice

AA Supply oil BB Oil at reduced pressure D D Control oil LL Tank

HYDRAULICS 1.53

Stand-by position (engine switched off)

With the machine switched off there is no pressure in the hydraulic system. Pressure spring (17) has pushed the volumetric flow controller (3) up to the stop. In this position, the upper side of control plunger (10) is connected to the tank via the volumetric flow controller (3).

The control spring (11) has moved the swash plate (13) to maximum deflection.

9. LS pump (2)

1. LS compensator (3)

3. Volumetric flow controller

10. Control plunger

11. Control spring

12. Pump drive

13. Swash plate

14. Plunger

15. Pump inlet port

16. Pump outlet port

17. Pressure spring (stand-by pressure)

18. Control edge

19. Adjustment screw (stand-by pressure)

20. Adjustment screw (max; pump pressure)

21. Pressure spring

22. Control edge

AA Supply oil BB Oil at reduced pressure D D Control oil LL Tank

1.54 HYDRAULICS

Stand-by position (engine started)

All control valves are in the neutral position. The swash plate (13) is at maximum deflection.

With the machine started, the pump delivers maximum volumetric flow via pump outlet (16) to the control spool of all the control valves.

As the control spools are completely shutting off the oil flow, the pressure increases and acts on the right hand side of the volumetric flow controller (3) which is moved to the left against the pressure spring (stand-by pressure) (17). Control edge (18) is opened so that pressure acts on the upper side of control plunger (10). Swash plate (13) is now moved back against control spring (11) into the minimum delivery position. This process is completed within 10 milliseconds.

In this pump position

• Only the volumetric flow required to

compensate leakage losses is generated.

• The pressure required for the initial actuation of

a consumer is maintained.

Since every control valve is actuated when in the neutral position, the inlet port (2) for the load pressure is pressure free.

In order to move the volumetric flow controller (3); the pump pressure only has to overcome the force of the pressure spring (stand-by pressure) (17). The pressure require to do this is 22 bar (320 psi) and is referred to as the ‘low pressure stand-by pressure’.

The ‘low pressure stand-by pressure’ is slightly higher than the stand-by pressure of 20 bar (290 psi).

Depending on the setting of the volumetric flow controller (3) and the pump leakage, the ‘low pressure stand-by pressure’ and the stand-by pressure may be equal. However, the stand-by pressure can never be higher than the ‘low pressure stand-by pressure’.

The ‘low pressure stand-by pressure’ cannot be preset and may vary between machines. It changes with increasing leakage in the pump or system.

The pump remains in the ‘low pressure stand-by’ position until one of the valves is actuated. In this position, the pump requires very little drive energy.

HYDRAULICS 1.55

9. LS pump (2)

1. LS compensator (3)

2. Inlet port

3. Volumetric flow controller

10. Control plunger

11. Control spring

13. Swash plate

16. Pump outlet port

17. Pressure spring (stand-by pressure)

18. Control edge

AA Supply oil BB Oil at reduced pressure EE Oil from charge pump LL Tank

1.56 HYDRAULICS

Pump goes into delivery

When a control valve is actuated and thus increased delivery volume is demanded from the pump, the pump pressure drops slightly.

The following conditions are created at the volumetric flow controller (3):

• The pump pressure acts on the right hand

face.

• The load pressure and the spring force of the

pressure spring (stand-by pressure) (17) acts in the spring chamber.

As the load pressure and the spring force of the pressure spring (stand-by pressure) (17) is larger than the pump pressure acting on the right face volumetric flow controller (3) is moved to the right up to the stop.

As a result:

• The passage of the pump pressure to control

plunger (10) is barred.

• Control plunger (10) is linked to the tank (no

pressure on the upper side of the plunger).

• Swash plate (13) is deflected by control

spring (11).

Increased volumetric flow demand. Example:

A selective control valve is actuated. The load pressure is 140 bar (1508 psi); the pump moves to a pressure of 160 bar (1537 psi) 140 bar load pressure + 20 bar stand-by pressure).

If an additional second selective service is now actuated with a load pressure of 100 bar (1450 psi), the pump pressure drops slightly.

The pressure on the upper side of control plunger (10) is also reduced as a result and the angle of swash plate (13) is increased so that the delivery volume is increased until the additional volumetric flow demand of the second service is satisfied.

The pump now delivers a higher volumetric flow through the pump outlet (16). This process is referred to as ‘upstroking’. The volumetric flow of the pump is determined by the throttling effect of the open control spool cross-section or by the setting of the flow divider of a selective control valve.

Lower volumetric flow demand

If the control valve cross-section is reduced (the volumetric flow is to be reduced), the load pressure at inlet port (2) drops.

The force conditions at volumetric flow controller (3) change as a result, so that it is pushed to the left up against the pressure spring in relation to the drop in pressure.

Control plunger (10) is pressurized and the angle of the swash plate (13) is reduced; the delivery of the pump is reduced until the volumetric flow demand is satisfied.

HYDRAULICS 1.57

9 LS pump (2)

1. LS compensator (3)

2. Inlet port

3. Volumetric flow controller

10. Control plunger

11. Control spring

13. Swash plate

16. Pump outlet port

17. Pressure spring (stand-by pressure)

AA Supply oil D D Control oil EE Oil from charge pump LL Tank

1.58 HYDRAULICS

Constant volumetric flow

During operation of a consumer with a constant load (e.g. hydraulic motor), the volumetric flow controller (3) is actuated into a stable position.

The following pressure conditions then exist at the volumetric flow controller (3):

• Load pressure (signal pressure) plus the spring

force of stand-by pressure spring (17) act on the left-hand face.

• The pump pressure acts on the right hand side.

The difference in pressure is the stand-by pressure, which corresponds to the force of pressure spring (17). The stand-by pressure should be 20 bar

(290 psi); it can be set with adjustment screw (19).

9. LS pump (2)

1. LS compensator (3)

3. Volumetric flow controller

17. Pressure spring (stand-by pressure)

19. Adjustment screw

AA Supply oil BB Oil at reduced pressure D D Control oil EE Oil from charge oil LL Tank

HYDRAULICS 1.59

Downstroking of the pump

The pump is downstroked under the following conditions:

• A control valve is moved to the neutral position;

no volumetric flow is required.

• During operation, one control valve is moved to

the neutral position or to the precision control range. A smaller volumetric flow is required.

The pump must always be downstroked when a smaller volumetric flow is required.

The downstroking process is started when the pressure and the spring force of the pressure acting on the right face of the volumetric flow controller (3) is higher than that acting on the left hand face (in the spring chamber).

In this case the volumetric flow controller (3) is moved to the left against the pressure spring (17) and control edge (18) opens. This leads to an increased pressure on the upper side of the control plunger (10), which reduces the angle of the swash plate (13) against the control spring (11) and the volumetric flow is reduced.

The volumetric load controller (3) and swash plate (13) are in a constant position.

The pump delivers the volumetric flow required for the two consumers.

If the second selective control valve, 100 bar (1450 psi) load pressure, is now moved to the neutral position, the volumetric flow has to be reduced as now only the first selective service has to be supplied.

This is achieved by switching off one of the selected circuits. This causes the pump pressure to rise briefly, as the volumetric flow is now only delivered to the first selective control valve.

The volumetric flow controller (3) is moved to the left, the control edge (18) opens and the pressure on the upper side of control plunger (10) is reduced.

The angle of the swash plate (13) is decreased so that the delivery volume is reduced.

If a selective control valve is moved to the precision control range (a very small volumetric flow is to be delivered to the consumer), the load pressure at inlet port (2) drops.

The force conditions at the volumetric flow controller (3) change as a result so that it is pushed to the left, up against the pressure spring (17) in relation to the drop in pressure.

The control edge (18) is opened so that control plunger (10) is pressurized. The angle of swash plate (13) is reduced; the delivery of the pump is reduced until the volumetric flow demand is satisfied.

Example

During parallel operation of two selective services, the load pressures are 140 bar (1508 psi) and 100 bar (1450 psi).

The pump moves to a pressure of 160 bar (1537 psi) (140 bar load pressure + 20 bar stand-by pressure).

1.60 HYDRAULICS

9 LS pump (2)

1. LS compensator (3)

2. Inlet port

3. Volumetric flow controller

10. Control plunger

11. Control spring

13. Swash plate

17. Pressure spring (stand-by pressure)

18. Control edge

AA Supply oil BB Oil at reduced pressure D D Control oil EE Oil from charge pump LL Tank

HYDRAULICS

Maximum pressure limiting (pressure relief valve function)

The pressure in the hydraulic system is limited to 250 ±5 bar (3625 ± 70 psi) in order to prevent damage to the components. This function is performed by the pressure regulator (4).

During normal operations (working pressure < max: pressure) pressure regulator (4) is pushed to the right, up against the stop by pressure spring (21).

If for example, a selective control valve is actuated and the cylinder reaches its end position, the load pressure at inlet port (2) rises until it is equal to the pressure at pump outlet port (16).

Under these pressure conditions:

Volumetric flow controller (3) is pushed to the right against the stop by pressure spring (17).

1.61

Pressure regulator (4) is pushed to the left, up to the stop against the force of pressure spring (21).

This movement takes place at a pressure of to 250 ± 5 bar (3625 ± 70 psi). Control edge (18) is opened so that the pump pressure acts on the upper side of control plunger (10).

The swash plate (13) is now moved to its ‘minimum delivery’ position against the force of control spring (11). This process takes 8-10 milliseconds.

The pump now delivers the minimum volumetric flow against the maximum pressure of to 250 ± 5 bar (3625 ± 70 psi).

The hydraulic system remains at the maximum pressure level until the selective control valve is moved to the neutral position.

1.62

HYDRAULICS

9 LS pump (2)

1. LS compensator (3)

2. Inlet port

3. Volumetric flow controller

4. Pressure regulator

10. Control plunger

11. Control spring

13. Swash plate

16. Pump outlet

17. Pressure spring (standby pressure)

18. Control edge

21. Pressure spring

AA Supply oil BB Oil at reduced pressure DD Control oil EE Oil from charge pump LL Tank

HYDRAULICS

Adjusting the pump

1.63

The main system pressure and the standby pressure can be adjusted using the adjusters (19 and 20) on the LS compensator valve (1). The procedure for adjusting the hydraulic pressure is as follows:

NOTE: Only check hydraulic pressure when oil is at normal working temperature (60 ± 4°C) and with engine at fast idle (1800 rpm).

Main system pressure Connect pressure gauge to test point 1 (65). Start engine. This gauge will indicate the load

sensing signal required by any of the services being operated. Operate any service and read the pressure requirement, when a service is operated to its limit the maximum pressure of 250 bar (3625 psi) will be maintained and the pump will ‘deswash’.

Read pressure gauge. Adjust pressure spring (21) using adjuster screw

(20) to set the pressure to 250 ± 5 bar (3625 ± 70 psi)

Standby pressure

Connect pressure gauge to test point 5 (69). Start engine. Make sure all services are in neutral

then read the pressure gauge. The pressure should be 20 bar (290 psi). Adjust pressure spring (17) using adjuster screw (19) to set the standby pressure to 20 bar (290 psi).

1. LS compensator (3)

3. Volumetric flow controller

17. Pressure spring (standby pressure)

19. Adjuster screw (standby pressure)

20. Adjuster screw (main pressure)

21. Pressure spring (main pressure)

AA Supply oil BB Oil at reduced pressure DD Control oil LL Tank

1.64

MAINTENANCE

Torque tightening

Where torque tightening figures are not given in the procedures, use the torque tightening settings in the following tables related to that fitting. The figures relate to thread sizes and are applicable to steel only and have a tolerance of 10%.

Male Union Adaptors

HYDRAULICS

Tub e O/D

Series

6L G1/8A 16 6S G1/4A 55 8L G1/4A 35 8S G1/4A 55

10L G1/4A 35

10S G3/8A 80

12L G3/8A 70

12S G3/8A 80

15L G1/2A 90

16S G1/2A 115

18L G1/2A 90 20S G3/4A 180 22L G3/4A 180 25S G1A 310 28L G1A 310 30S G1 1/4A 450 35L G1 1/4A 450 38S G1 1/2A 5 40 42L G1 1/2A 5 40

6L M 10x1 18 6S M 12x1.5 35 8L M 12x1.5 25 8S M 14x1.5 55

10L M 14x1.5 45 10S M 16x1.5 70

12L M 16x1.5 55 12S M 18x1.5 90

15L M 18x1.5 70 16S M 22x1.5 135

18L M 22x1.5 125 20S M 27x2 180 22L M 26x1.5 180 25S M 33x2 310 28L M 33x2 310 30S M 42x2 450 35L M 42x2 450 38S M 48x2 540 42L M 4 8x2 5 40

Thread Torque Nm

HYDRAULICS

DKO Fittings

1.65

Walform Fittings

:miDebuT

)5.1x01(L01M9154 )5.1x21(L21M2215 )5.1x51(L51M7247 )0.2x81(L81M2307

)5.2ro0.2x22(L22M63531 )5.2ro0.2x22(L82M14661

:miDebuT

)5.1x01(L01M9105 )5.1x21(L21M2207 )5.1x51(L51M72001 )0.2x81(L81M23081

)5.2ro0.2x22(L22M63032 )5.2ro0.2x22(L82M14033

hcnerW

eziS

hcnerW

eziS

euqroT

Controlled Final Assembly Fittings

:miDebuT

)5.1x01(L01M9105 )5.1x21(L21M2207 )5.1x51(L51M72001 )0.2x81(L81M23511

)5.2ro0.2x22(L22M63032 )5.2ro0.2x22(L82M14033

hcnerW

eziS

Flexible Hoses

:miDebuT

)5.1x01(L01M9154 )5.1x21(L21M2215 )5.1x51(L51M7247 )0.2x81(L81M2307

)5.2ro0.2x22(L22M63531 )5.2ro0.2x22(L82M14661

hcnerW

eziS

euqroT

1.66

HYDRAULIC LEVEL

Check

1. Position the machine on level ground.

2. Make sure all hydraulic cylinders are fully closed.

3. Stop the engine, apply the parking brake.

HYDRAULICS

4. Open the engine pod cover.

5. Check hydraulic tank sightglass (2), make sure fluid level shows in sightglass and is above the red line.

NOTE: Wait for two minutes, after engine is stopped, before checking fluid level.

6 .Replenish fluid if necessary as follows:

The cap maintains an air pressure of

0.3 bar in the hydraulic tank.

7. Clean filler cap (1) and remove.

8. Top up hydraulic tank with fluid to correct level and refit filler cap.

9. Close engine pod cover.

1. Filler cap

2. Sightglass

HYDRAULICS

HYDRAULIC TANK (1)

Removal

NOTE: Removal and installation of the hydraulic

tank is possible with the machine on the ground.However, increasing the ground clearance or positioning the machine over a pit will make the operation easier and quicker.

1.67

Installation

1. Installation is the reverse of removal.

2. Use new hose clips and gaskets

3. Refer to Page 1.66 and replenish the hydraulic tank before engine is started.

1. Position the machine over a pit, if available, or lift on axle stands.

2. Stop the engine and chock the machine, apply the parking brake.

3. Refer to page 1.1 and dump hydraulic pressure then disconnect the battery.

NOTE: The hydraulic tank contains 67 litres (15 gal) of fluid.

4. Remove the drain plug (2) and drain the hydraulic fluid into a suitable container. Do not reuse the hydraulic fluid unless it can be specially filtered and tested.

5. Remove the hose clips (9) from the suction hoses (4 & 5) of the main and auxiliary pumps and the filler hose (3). Remove the hoses from the hydraulic tank (1).

4. Purge the hydraulic system by starting the engine and operating all services to fully extend and retract cylinders several times.

5. Refer to Page 1.66, check the hydraulic level and replenish if necessary.

6. Remove the two sightglass attachment bolts and remove the sightglass (6).

7. Remove the screws securing the return manifold (7) to the tank and lift the manifold to release the gasket (8).

8. Support the hydraulic tank; remove the two nuts from the studs and the two bolts securing the tank to the engine and transmission sub-assembly. Lower the tank and remove from beneath the machine.

9. Fit blanks to all openings on the tank and hoses on the machine to prevent the ingress of dirt.

1. Hydraulic tank

2. Drain plug

3. Filler hose

4. Suction hose – auxiliary pump

5. Suction hose – main pump

6. Sightglass

7. Return manifold

8. Gasket

9. Hose clips

1.68

HYDRAULIC PUMP (LS) (2)

HYDRAULICS

Removal

NOTE: The hydraulic pump (LS) is located in the

engine compartment, attached to the gearbox. Remove components as necessary to get access to the pump.

1. Stop the engine and chock the machine, apply the parking brake.

2. Refer to page 1.1 and dump hydraulic pressure then disconnect the battery.

3. Make sure the pump is free from dirt to avoid contamination of the hydraulic system.

4. Remove the LS hose (3) from the LS compensator (2).

5. Remove the case drain hose (4) from the main body of the pump (1).

6. Remove the four cap screws (6) and washers from the pump inlet hose (5) and remove hose from pump.

4. Refer to Page 1.66 and replenish the hydraulic tank before the engine is started.

5. Purge the hydraulic system by starting the engine and operating all services to fully extend and retract cylinders several times. Refer to page 1.66, check the hydraulic level and replenish if necessary.

7. Remove the four cap screws (8) and washers from the two half-clamps (9) on the pump outlet hose (7) and remove the half-clamps and hose from pump.

8. Remove the two attachment bolts (10) and washers securing pump to gearbox (11) and remove pump.

9. Fit blanks to all openings on the pump and hoses to prevent the ingress of dirt.

Installation

1. Installation is the reverse of removal.

When fitting a new LS hydraulic pump, it is vital that the case of the pump is filled with oil before the pump is fitted.

2. Fill the pump with 0.25 litre (0.44 pt) of oil, through the case drain connection on the pump.

1. LS hydraulic pump

2. LS compensator

3. LS hose

4. Case drain hose

5. Inlet hose

6. Cap screw

7. Outlet hose

8. Cap screw

9. Half-clamp

10. Bolt

11. Gearbox

3. Use new O-rings when assembling the inlet and outlet hoses, lightly lubricated with clean hydraulic oil. Use new washers on the cap screws when assembling the inlet and outlet hoses.

HYDRAULICS

AUXILIARY HYDRAULIC PUMP (6)

Removal

NOTE: The auxiliary hydraulic pump is located in

the engine compartment, attached to the timing case. Remove components as necessary to get access to the pump.

1. Stop the engine and chock the machine, apply the parking brake.

2. Refer to page 1.1 and dump hydraulic pressure then disconnect the battery.

3. Make sure the pump is free from dirt to avoid contamination of the hydraulic system.

1.69

4. Remove the inlet hose (2) from the pump (1).

5. Remove the outlet hose (3) from the pump (1).

6. Remove the five cap screws and washers securing the pump to the timing case (4) and remove the pump.

7. Fit blanks to all openings on the pump and hoses to prevent the ingress of dirt.

8. When a new pump is to be installed, remove the nut (6) and washer (7) securing the drive gear (8) to the pump shaft. Remove the drive gear and woodruff key from the shaft.

Installation

1. Installation is the reverse of removal.

2. Use new washers (9) on the cap screws (10) when assembling the inlet and outlet hoses.

1. Auxiliary pump

2. Inlet hose

3. Outlet hose

4. Timing case

3. Use a new gasket (5) between the pump and timing case when installing the pump.

4. Refer to page 1.66, check the hydraulic level and replenish if necessary before the engine is started.

5. Purge the hydraulic system by starting the engine and operating all services to fully extend and retract cylinders several times.

6. Check the hydraulic level and refer to Page 1.66 and replenish if necessary.

5. Gasket

6. Nut

7. Washer

8. Gear

9. Washer

10. Cap screw

1.70

FAN MOTOR (7)

NOTE: Up to Machines S/No.51200471 only.

Removal

1. Stop the engine and chock the machine, apply the parking brake.

2. Refer to page 1.1 and dump hydraulic pressure then disconnect the battery.

3. Open engine cover to gain access to fan motor.

4. Remove fan guard by unscrewing fasteners (1) and lifting guard clear.

5. Disconnect the three hydraulic hoses from the fan motor (5); blank the fan motor connections and open hoses.

HYDRAULICS

6. Loosen the V-belt pivot fastener (2) and link arm fasteners (3 & 4). Remove V-belt (6) from pulley (7).

7. Remove the nut and washer (8 & 9) securing pulley (7) to fan motor and remove pulley.

8. Remove the four bolts, washers and nuts (10, 11 & 12) securing fan motor to mounting bracket (13) and remove fan motor.

Installation

1. Installation is the reverse of the above procedure.

2. Make sure the woodruff key is fitted to the fan motor drive shaft before fitting the pulley.

3. Tension the V-belt and check tension using a 'Fenner' or similar tension indicator. A force of 30 N at the mid-point on the belt should give a deflection of 8 mm.

4. Refer to Page 1.66, check the hydraulic level and replenish if necessary.

HYDRAULICS

FAN DRIVE BEARINGS

NOTE: Up to Machines S/No.51200471 only.

Removal

1. Stop the engine and chock the machine, apply the parking brake.

2. Refer to page 1.1 and dump hydraulic pressure then disconnect the battery.

3. Open engine cover to gain access to fan motor.

4. Remove the fuel sediment bowl from its bracket.

5. Remove fan guard by unscrewing bolts (1) and lifting guard clear.

6. Loosen the V-belt pivot bolts (2) and link arm bolts (3). Remove V-belt (4) from pulley (5).

1.71

7. Loosen the mounting bolts (6) for the radiator and the bolts (7) beneath the fan motor and pull the radiator forwards slightly.

8. Remove the securing bolts from the fan carrier (8) and remove fan (9) complete with carrier.

9. Remove the setscrew (10) and washers (11 & 12) securing pulley (5) to the hub (13). Using a suitable puller, remove the pulley from the hub.

10. Remove the woodruff key (14) from the hub shaft and remove the hub from hub carrier.

11. Remove circlip (15) then push out bearing (16). Note position of spacer (17) then, using a small punch, remove bearing (18) from carrier.

Installation

1. Installation is the reverse of the above procedure.

2. Make sure the woodruff key is fitted to the hub shaft before fitting the pulley.

3. Make sure the spacer is fitted tbetween the bearings before fitting the bearings.

4. Tension the V-belt and check tension using a 'Fenner' or similar tension indicator. A force of 30 N at the mid-point on the belt should give a deflection of 8 mm.

1. Bolt 10 Setscrew

2. Bolt 11 Washer

3. Bolt 12 Washer

4. V-belt 13 Hub

5. Pulley 14 Woodruff key

6. Bolt 15 Circlip

7. Bolt 16 Bearing

8. Carrier 17 Spacer

9. Fan 18 Bearing

1.72

FAN MOTOR (7)

NOTE: From Machines S/No.51200472 only.

Removal

1. Stop the engine and chock the machine, apply the parking brake.

2. Refer to page 1.1 and dump hydraulic pressure then disconnect the battery.

3. Open engine cover to gain access to fan motor (4).

4. Remove fan guard (3) by unscrewing nuts (1) and washers (2) and lifting clear the guard (3 ).

5. Disconnect the three hydraulic hoses from the fan motor (4) and blank the fan motor connections and open hoses.

HYDRAULICS

6. Loosen the four bolts (9), washers (10) and nuts, that attach the fan motor (4) to the fan casing (8). Remove V-belt (11) from the pulley (5).

7. Remove the nut (6) and washer (7) securing the pulley (5) to the fan motor (4). Remove the pulley (5).

8. Remove the four bolts (9), washers (10) and nuts, that attach the fan motor (4) to the fan casing (8). Remove the fan motor (4) from the machine.

Installation

1. Installation is the reverse of the above procedure.

2. Make sure the woodruff key is fitted to the fan motor drive shaft before fitting the pulley (5).

3. Tension the V-belt (11) and check tension using a 'Fenner' or similar tension indicator. A force of 30 N at the mid-point on the belt should give a deflection of 8 mm.

1. Nut 7 Washer

2. Washer 8 Fan casing

3. Guard 9 Bolt

4. Fan motor 10 Washer

5. Pulley 11 V-belt 6 Nut

4. Refer to Page 1.66, check the hydraulic level and replenish if necessary.

HYDRAULICS

FAN DRIVE BEARINGS

NOTE: From Machines S/No.51200472 only.

Removal

1. Stop the engine and chock the machine, apply the parking brake.

2. Refer to page 1.1 and dump hydraulic pressure then disconnect the battery.

3. Open engine cover to gain access to fan motor.

4. Remove the fuel sediment bowl from its bracket.

5. Refer to Page 1.72 and do steps 4 and 6, to remove the fan guard and loosen and remove the V-belt (7).

6. Remove the eight nuts and washers that secure the fan carrier (8) to the radiator. Remove the fan carrier (8), with the fan (14) and pulley (6) attached.assembly attached.

1.73

7. Remove the four securing bolts (16) and washers (15) that secure the fan (14) to the hub (13). Remove the fan (14).

8. Remove the setscrew (4) and washer (5) securing the pulley (6) to the hub (13). Using a suitable puller, remove the pulley (6) from the hub (13).

9. Remove the woodruff key (12) from the hub shaft and remove the hub (13) from hub carrier.

11. Remove circlip (9) then push out bearing (10). Note position of spacer (11) then, using a small punch, remove bearing (10) from carrier.

Installation

1. Installation is the reverse of the above procedure.

2. Make sure the woodruff key (12) is fitted to the hub shaft before fitting the pulley (6).

3. Make sure the spacer (11) is fitted between the bearings (10) before fitting the bearings.

4. Tension the V-belt (7) and check tension using a 'Fenner' or similar tension indicator. A force of 30 N at the mid-point on the belt should give a deflection of 8 mm.

1. Nut 9. Circlip

2. Washer 10. Brearing

3. Guard 11. Spacer

4. Bolt 12. Woodruff key

5. Washer 13. Hub

6. Pulley 14. Fan

7. V-belt 15. Washer

8. Fan carrier 16. Bolt

1.74

FAN REVERSE VALVE (72)

NOTE: From Machines S/No.51200472 only.

Removal

1. Stop the engine and chock the machine, apply the parking brake.

2. Refer to page 1.1 and dump hydraulic pressure then disconnect the battery.

3. Open engine cover to gain access to fan reverse valve (2) on the air cleaner bracket.

4. Disconnect the electrical connectors to the fan reverse valve solenoid (3) and the temperture switch.

HYDRAULICS

5. Disconnect the five hydraulic hoses (1) from the fan reverse valve (2) and blank the valve connections and open hoses.

6. Remove the bolts (5) and washers (4) that attach the fan reverse valve (2) to the air cleaner bracket. Remove the fan reverse valve (2) from the machine.

Installation

1. Installation is the reverse of the above procedure.

2. Refer to page 1.66, check the hydraulic level and replenish if necessary before the engine is started.

3. Purge the hydraulic system by starting the engine and operating the fan reverse system and all services. Fully extend and retract cylinders several times.

4. Refer to Page 1.66. Check the hydraulic level and replenish if necessary.

1. Hoses

2. Fan reverse valve

3. Solenoid valve

4. Washer

5. Bolt

HYDRAULICS

PARKING BRAKE VALVE (71)

NOTE: From Machines S/No.51200472 only.

Removal

1. Stop the engine and chock the machine, apply the parking brake.

2. Refer to page 1.1 and dump hydraulic pressure then disconnect the battery.

3. Gain access to parking brake valve (1), located on the machine structure, adjacent to the front axle.

4. Disconnect the electrical connector to the parking brake valve solenoid (4).

5. Disconnect the three hydraulic hoses (5) from the parking brake valve (1) and blank the valve connections and open hoses.

1.75

6. Remove the bolt (6), washer (3) and nut (2) that attach the parking brake valve (1) to the structure. Remove the parking brake valve (1) from the machine.

Installation

1. Installation is the reverse of the above procedure.

2. Refer to page 1.66, check the hydraulic level and replenish if necessary before the engine is started.

3. Purge the hydraulic system by starting the engine and operating the fan reverse system and all services. Fully extend and retract cylinders several times.

4. Refer to Page 1.66. Check the hydraulic level and replenish if necessary.

1. Parking brake valve

2. Nut

3. Washer

4. Solenoid valve

5. Hoses

6. Bolt

1.76

HYDRAULIC FILTER (9)

Removal

NOTE: The hydraulic filter is fitted in the engine

compartment. Remove components as necessary to get access to the filter.

1. Stop the engine and chock the machine, apply the parking brake.

2. Refer to page 1.1 and dump hydraulic pressure then disconnect the battery.

3. Make sure filter is free from dirt to avoid contamination of the hydraulic system.

4. Remove the indicator lead (2) from the indicator switch on the hydraulic filter (1).

HYDRAULICS

5. Remove the inlet hose (3) and outlet hose (4) from the filter (1) and fit blanks to the hoses and filter.

6. Remove the four attachment bolts (6) securing the filter to the mounting bracket (5) and remove the filter.

7. Fit blanks to all openings on the filter and hoses to prevent the ingress of dirt.

Installation

1. Installation is the reverse of removal.

2. Refer to the service manual and fit a new filter element.

3. Refer to page 1.66, check the hydraulic level and replenish if necessary before the engine is started.

1. Hydraulic filter (9)

2. Indicator lead

3. Inlet hose

4. Outlet hose

5. Mounting bracket

6. Bolt (Qty 4)

4. Purge the hydraulic system by starting the engine and operating all services to fully extend and retract cylinders several times.

5. Refer to page 1.66, check the hydraulic level and replenish if necessary.

HYDRAULICS

1.77

BRAKE VALVE (MICO) (10)

NOTE: Up to Machines S/No.51200471 only.

Operation

A single or tandem brake valve (MICO type) is fitted to the machine, depending on model. The method of operation is as follows:

NOTE: The single and tandem brake valve operation is similar, the tandem design has two spools and two sets of ports to allow for independent operation of each system regardless of condition of the other half.

With no force applied to the brake pedal, the valve is in the neutral position and hydraulic system pressure at the pressure port is blocked by the spool, the brake pressure port is open to tank through the tank port.

Initial application of the brake pedal moves the spool into a position where all the ports are closed and brake pressure has not been applied. Further movement of the pedal moves the spool beyond the closed position and allows pressurised fluid to flow to the brake port. When pedal movement is stopped, the pressure at each end of the spool balances and fluid flow stops. If further pressure is applied to the brake pedal the spool will allow more fluid to pass to the brakes until the spool balances again. Maximum brake pressure is achieved when the brake pedal is fully depressed and the piston is bottomed in the housing.

When the brake pedal is released, the spool moves to close the pressure port and gradually open the tank port to allow brake pressure to return to tank.

BRAKE VALVE (SAFIM) (10)

NOTE: From Machines S/No.51200472 only.

Operation

A single or tandem brake valve (SAFIM type) is fitted to the machine, depending on model. The method of operation is as follows:

NOTE: The single and tandem brake valve operation is similar. The primary difference is that the front and rear brakes are operated independently of each other by separate feed and return lines from the servo valve.

The brake pressure servo valve can be either single or dual depending on the model of the machine. The valve is constructed from 3 seperate modules, the master cylinder, valve body and end plate. Brake pedal travel and braking pressure are set using an adjusting screw, located on the base on the brake valve.

The operation of the servo valve is proportional to brake pedal movement. When the brake pedal is pressed, a pivoted lever moves a master cylinder, which positions an associated sprung loaded plunger. The plunger is in contact with the main shuttle valve in the valve body. The shuttle valve controls the flow of the pressure oil supply from the brake accumulator. The accumulator is supplied from the inlet (PVSP) section of the main hydraulic control valve. When the shuttle valve is moved, the oil supply from the accumulator is allowed to flow to the outlet connection in the end plate, which supplies the front and rear brakes units.

When the brake pedal is released, spring pressure in the master valve releases pressure on the shuttle valve and re-positions the brake pedal. The shuttle valve moves under spring pressure to close the oil supply from the accumulator and divert residual oil pressure from the brake system to the hydraulic tank, releasing the brakes.

1.78

SINGLE BRAKE VALVE (MICO) (10)

HYDRAULICS

NOTE: Up to Machines S/No.51200471 only.

Removal

NOTE: The brake valve is fitted forward of the cab.

Remove the front cover and any components as necessary to get access to the brake valve.

1. Stop the engine and chock the machine, apply the parking brake.

2. Refer to page 1.1 and dump hydraulic pressure then disconnect the battery.

3. Make sure brake valve is free from dirt to avoid contamination of the hydraulic system.

4. Position a suitable container under the valve to collect any oil spillage during removal.

5. Make sure the hoses are identified before removal to help installation.

3. Refer to Page 1.66 and replenish the hydraulic tank before the engine is started.

4. Bleed the brake system (refer to Page 1.95) and test the brakes.

5. Purge the hydraulic system by starting the engine and operating all services to fully extend and retract cylinders several times.

6. Refer to Page 1.66, check the hydraulic level and replenish if necessary.

6. Remove the system pressure hose (2) from brake valve connector ‘P’.

7. Remove the return hose (3) from brake valve connector ‘T’.

8. Remove the service hose (4) from brake valve connector ‘A’. Take care not to lose the orifice located in the fitting.

9. Remove the two attachment bolts (5) securing the brake valve (1) to the mounting bracket (6) and remove the brake valve.

10. Fit blanks to all openings on the brake valve and hoses to prevent the ingress of dirt.

Installation

1. Installation is the reverse of removal.

2. Make sure that the spool of the brake valve is fully out. If necessary, adjust the brake pedal adjustment cap-screw inside the cab until the spool of the brake valve is fully out. Then torque tighten the cap-screw lock nut to 25-27 Nm (18-20 lbf/ft.).

1. Brake valve (10)

2. Pressure hose ‘P’

3. Return hose ‘T’

4. Service hose ‘A’

5. Bolt

6. Bracket

Torque tighten the components as follows:

Bolt (5) – 25-27 Nm (18-20 lbf/ft.)

HYDRAULICS

1.79

SINGLE BRAKE VALVE (MICO) (10) Servicing

NOTE: Up to Machines S/No.51200471 only.

Servicing is normally restricted to the replacement of seals. When the bore of the cylinder or the piston is scored, the brake valve must be replaced.

Dismantling

1. Make sure all the blanks are secure in the ports then clean any dirt off the assembly before dismantling.

2. Remove boot (20*) from piston (19).

3. Remove piston (19), springs (15**), (16), (17) and shims (14) from housing bore.

NOTE: Some models also use a 6.35 mm (0.25 in.) spacer with shims. Note the number of shims removed from housing.

9. Remove O-ring (8*) and cup (10*) (note orientation) from spacer (11). Remove O-ring (8*) and O-rings (6*) from sleeve (7).

4. Examine bearing (18) for wear or damage, only remove if necessary.

NOTE: Excessive wear on bearing (18) and piston (19) require replacement.

5. Remove retainer assembly (13) from housing bore (a ball bearing is pressed into the retainer).

6. Loosen nut (1) and remove end plug (4) from housing. Remove spring (5), nut (1), washer (2) and O-ring (3*) from end plug (4).

7. Use a wooden dowel to remove spacer (11), sleeve (7) and spool (9) assembly from housing bore.

NOTE: Take care not to scratch or mark sleeve (7) or housing bore.Sleeve (7) and spool (9) are a matched pair and must not be mixed with other parts. Excessive wear on sleeve or spool will require replacement.

8. Separate spacer (11) and spool (9) from sleeve (7).

1. Nut 11. Spacer

2. Washer 12. Housing 3*. O-ring 13. Retainer assembly

4. End plug 14. Shim(s)

5. Spring 15.** Spring 6*. O-ring 16. Spring

7. Sleeve 17. Spring 8*. O-ring 18. Bearing

9. Spool 19. Piston

10.* Cup 20*. Boot

* Included in repair kit ** Not used in all models

NOTE: Take care not to damage cup or O-ring grooves or bore.

1.80

SINGLE BRAKE VALVE (MICO) (10) Assembly

Use a repair kit when assembling the valve, the repair kit contains a new cup, boot and O-rings.

Before assembly, lightly lubricate the parts from the repair kit and the spool and sleeve with clean hydraulic oil.

Make sure all parts are clean before assembly.

1. Install a new cup (10*) in spacer (11) and one new O-ring (8*) on spacer (11). Note direction of cup.

2. Install two new O-rings (6*) on large diameter end of sleeve (7) and new O-ring (8*) on small end of sleeve (7).

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3. Carefully install spool (9) into sleeve (7). Note direction of spool.

4. Install sleeve (7) and spool (9) assembly into housing bore using a wooden dowel. Note direction of assembly. Install spring (5) into housing bore.

5. Install end plug (4) and torque load to 10.9-20.3 Nm (96-180 lbf/in.) to seat sleeves. Then loosen end plug ¼ turn and torque load to 1.1-6.0 Nm (1060 lbf/in.). Install new O-ring (3), washer (2) and nut (1). Hold the end plug (4) with a wrench and torque load nut to 68.1-81.4 Nm (50-60 lbf/ft.).

6. Install retainer assembly (13) in housing.

NOTE: Depress retainer (13) until it bottoms on spacer (11). Spool (9) and retainer (13) should return when released. If the spool and retainer do not return when released, the bore of sleeve (7) may be damaged.

7. Install shim(s) (14), springs (15**), (16) and (17) and piston (19) in housing bore.

1. Nut 11. Spacer

2. Washer 12. Housing 3*. O-ring 13. Retainer assembly

4. End plug 14. Shim(s)

5. Spring 15**. Spring 6*. O-ring 16. Spring

7. Sleeve 17. Spring 8*. O-ring 18. Bearing

9. Spool 19. Piston 10*. Cup 20*. Boot

* Included in repair kit ** Not used in all models

NOTE: Not all models use spring (15**). Some models also use a 6.35 mm (0.25 in.) spacer with shims. Make sure the same number of shims and the spacer, that were removed during dismantling, are installed.

8. Install new boot (20*) on housing.

9. Test the brake pressure at service hose A on brake valve. Pressure can be adjusted by adding or removing shims (14) to retainer assembly (13).

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1.81

SINGLE BRAKE VALVE (SAFIM) (10)

NOTE: From Machines S/No.51200472 only.

Removal

NOTE: The brake valve is fitted forward of the cab.

Remove the front cover and any components as necessary to get access to the brake valve.

1. Stop the engine and chock the machine, apply the parking brake.

2. Refer to page 1.1 and dump hydraulic pressure then disconnect the battery.

3. Make sure brake valve is free from dirt to avoid contamination of the hydraulic system.

4. Position a suitable container under the valve to collect any oil spillage during removal.

3. Bleed the brake system (refer to Page 1.95) and test the brakes. If necessary, adjust the brake pressure by connecting a pressure gauge to test point 68 and apply the brakes. Adjust the brake pressure by altering the position of brake pedal travel with the adjuster screw (2).

4. Refer to Page 1.66 and replenish the hydraulic tank, before the engine is started.

5. Purge the hydraulic system by starting the engine and operating all services to fully extend and retract cylinders several times.

6. Refer to Page 1.66, check the hydraulic level and replenish if necessary.

5. Make sure the hoses are identified to help installation. Disconnect the three hoses (1) from the valve (10).

7. Remove the two protective caps (3) from the brake pedal attachment bolt (4). Remove the nut (8) and bolt (4) and remove the brake pedal (5).

8. Fit blanks to all openings on the brake valve and hoses to prevent the ingress of dirt.

9. Remove the four cap screws (7) from the base plate (6).

12. Remove the brake valve assembly (10) from the machine.

Installation

1. Installation is the reverse of removal.

2. If necessary, adjust the brake pedal angle by adjusting the threaded peg (9) under the brake pedal (10). Once adjusted, tighten the peg lock nut.

1.82

SINGLE BRAKE VALVE (SAFIM) -Servicing

NOTE: From Machines S/No.51200472 only.

Servicing is normally restricted to the replacement of seals in the brake master and brake valve modules of the valve assembly. When any cylinder bore or sliding contact surface is scored, the brake valve must be replaced.

Dimantling (General)

NOTE: During intial dismantling, make sure all items

are noted and kept with the correct part of the brake valve.

1. Make sure all the blanks are secure in the ports then clean any dirt off the assembly before dismantling.

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2. Loosen the two screws (1) sufficient to remove the end plate (2) and brake valve module (3) from the brake master module (4).

3. Carefully, as an assembly, remove the end plate (2) and brake valve module (3), with the two screws (1), from the brake master module (4).

4. Carefully remove the two screws (1) and seperate the end plate (2) from the brake valve module (3).

Assembly (General)

1. Installation is the reverse of removal.

2. If necessary, adjust the brake pedal angle/brake pressure (refer to brake valve installation procedure at Page 1.81).

1. Screws

2. End plate

3. Brake valve module

4. Brake master module

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SINGLE BRAKE VALVE (SAFIM)-Servicing

1.83

NOTE: From Machines S/No.51200472 only.

Dismantling (Brake Master Module)

1. Remove the grub screw (2) that secures the pedal pivot pin (5) in position. Carefully drift out the pedal pivot pin (5) from the pedal base and extract the pedal lever (1) and cover (3).

2. Remove the end plug (4) from the brake master module (19).

3. Extract the valve cylinder (17) from the brake master module (19).

3. Before assembly, lightly lubricate the parts from the repair kit and the spool and sleeve with clean hydraulic oil.

4. Make sure all parts are clean before assembly.

4. Remove the circlip (15) from the brake master module (19).

5. Carefully extract the O-seal (13), valve assembly and gland seal (18) from the brake master module (19).

6. Remove the plug (7) and washer (6) from the brake master module (19).

7. Remove the adjuster (8) and nut (9) from the brake master module (19).

8. Remove the screw (10) and pin (12) from the valve assembly. Seperate the the two end plates (14) and (16) and three springs (11) of the valve assembly.

9. Clean and examine the valve assemby parts and bore, pedal pivot pin (5) and pivot points of the brake master module (19).

Assembly (Brake master module)

1. Installation is the reverse of the removal.

2. Make sure a new gland seal (18) and O-ring seal (13) are fitted.

1. Pedal lever

2. Grub screw

3. Cover

4. End plug

5. Pivot pin

6. Plug

7. Washer

8. Adjuster

9. Nut

10. Screw

11. Springs

12. Pin

13. O-ring seal

14. End plate

15. Circlip

16. End plate

17. Valve cylinder

18. Gland seal

19. Brake master module

1.84

SINGLE BRAKE VALVE (SAFIM) -Servicing

NOTE: From Machines S/No.51200472 only.

Dismantling (Brake Valve Module)

1. Remove the spring (8) and shuttle valve (7) and O-seal (6) from the brake valve module (9).

2. Remove the four O-seals (10) from the brake valve module (9).

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3. Remove the grub screw (5) from the brake valve module (9).

3. Remove the circlip (1) and extract the plug (11), sealing ring (2) and seal (3), valve (10) and spring (4) from the brake valve module (9).

4. Clean and examine the valve module (9), valve (4), shuttle vale (7) and plug (11).

Assembly (Brake valve module)

1. Installation is the reverse of removal.

2. Make sure a new sealing ring (2) and O-ring seals (10), (2) and (6) are fitted.

3. Before assembly, lightly lubricate the parts from the repair kit and the spool and sleeve with clean hydraulic oil.

4. Make sure all parts are clean before assembly.

1. Circlip

2. Sealing ring

3. Seal

4. Spring

5. Grub screw

6. O-ring seal

7. Shuttle valve

8. Spring

9. Brake valve module

10. O-ring seal

11. Plug

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DUAL BRAKE VALVE (MICO) (10)

1.85