HYDRAULIC CIRCUIT

"FLOW SHARING"
DISMANTLING OF COMPONENTS

MAFLOSH.01
 INDEX

INTRODUCTION ......................................................................................................................... 1
HYDRAULIC SYSTEM DIAGRAM............................................................................................... 2
SYSTEM COMPONENTS AND CONNECTIONS........................................................................ 3
DISMANTLING AND SERVICE OF THE COMPONENTS .......................................................... 4
 1 - INTRODUCTION

This manual provides the information necessary for a correct and safe way to carry out maintenance
works not included in the INSTRUCTION HANDBOOK FOR OPERATING AND MAINTENANCE; it is
addressed to qualified fitters, who know enough about mechanical components and the functioning of
hydraulic and electrical systems for the machine on which it is operating.
The action necessary to implement and enforce the policies related to the Environment and Health and
Safety procedures are left to the responsability of the workshop manager.

This is the symbol used to identify the size of the spanner used for operations described in this
handbook. The spanner type will be advised only if it is different from the standard.

HYDROSTATIC OIL

ESSO HVI 46
Viscosity (ISO 3448) = 46.
Classification to DIN 51524,2 = HLP 46.

If a different brand of oil is used, ensure that is has the caracteristics equal to the specified ESSO products.
Should you wish to change the product brand, the system must be flushed clean of the original oil.
The use of oils with characteristics different to the above ESSO product will bring to the automatic withdrawal of
the warranty on all components of the hydrostatic system.

Check oil level daily.

Replace oil and cartridge filter (86) at the intervals shown in the INSTRUCTION HANDBOOK.

CHECK INSTRUMENTS
It is advisable to use the following pressure gauges (glycerine immersed) and instruments:

- 2 pressure gauges, scale end 600 bar (one of them is already assembled in the vehicle cab)
- 1 pressure gauge, scale end 40 bar.
- 1 R.P.M. counter, scale end 5000 RPM.
- 1 thermometer, scale end 100° C.
- 1 tester : current I = 1,5 A (scale end) / voltage V = 30 V (scale end).

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2 - HYDRAULIC SYSTEM DIAGRAM

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 2 - HYDRAULIC SYSTEM DIAGRAM

1 Suction line filter

2 Return line filter
3 Pump
4 Diesel engine
12 Volume recovery valve
17 Power steering
18 Steering directional control valve
19 Steering rams
22 Pressure gauge
23 Main directional control valve
24 Telescoping ram lock valve
25 Lifting ram
27 Telescoping ram
30 Compensation valve
31 Compensation ram
32 Carriage ram lock valve
33 Carriage ram
36 Front snap couplings Ø 1/2"
42 Snap coupling Ø 1/2"
66 Movements locking solenoid valve
68 Lifting ram lock valve
90 Pressure check plug
94 Accumulator
140) Blocco logico

127 - P3 (T2) = Reference to part. n° 127 connection P3 (T2) hydrostatic transmission circuit.

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 3 - SYSTEM COMPONENTS AND CONNECTIONS

INDEX

MAIN COMPONENTS OF A "Flow Sharing" SYSTEM ..........................................................................................2

GENERAL POINTS FOR A "Flow Sharing" HYDRAULIC SYSTEM DIAGRAM.......................................................3

LS PUMP (Load Sensing) and "DFR" (3) ................................................................................................................4

THE LOGIC BLOCK (140) ......................................................................................................................................6

THE DISTRIBUTOR (23)........................................................................................................................................7

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 3 - SYSTEM COMPONENTS AND CONNECTIONS

MAIN COMPONENTS OF A "Flow Sharing" SYSTEM

WARNING!!! This is only an example of a hydraulic system. It is intended purely as an illustration

and for didactic purposes. When carrying out a maintenance operation, ALWAYS refer to the hydraulic
system diagram present in the machine's "Operator's Manual".

(3) THE LS PUMP (Load Sensing) and the "DFR

(23) THE DISTRIBUTOR

(140) THE LOGIC BLOCK

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 3 - SYSTEM COMPONENTS AND CONNECTIONS

GENERAL POINTS FOR A "Flow Sharing" HYDRAULIC SYSTEM DIAGRAM

WARNING!!! This is just an extract from a generic hydraulic system diagram. It is intended purely as
an illustration and for didactic purposes. When carrying out maintenance operations ALWAYS refer to the
hydraulic system diagram present in the machine's "Operator's manual".

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 3 - SYSTEM COMPONENTS AND CONNECTIONS

LS PUMP (Load Sensing) and "DFR" (3)

Pump diagram

S) Suction from tank L1) Pump stopper

L) Casing drainage to tank DFR) DFR apparatus
X) Piloting signal of circuit VLS) Stand-by pressure register
B) Supply to circuit VP) Pump maximum pressure register
L) Tank drainage 90) Pressure testing point

Functioning of the pump

The LS pump is a variable piston pump, so, has variable delivery.

Variable delivery is obtained using a system of axle pistons which, turning in a drum, slide on a plate (flat) that can
be inclined at various angles.
Modifying the angle of the plate changes the course of the pistons, producing a different delivery.
The main characteristic of this pump is that it has a variable delivery that depends on the demands of the system,
always following the formula:

P = pxQ

where:

P = Power
p = Pressure
Q = Flow

In other words, the pump works at constant power, reducing the delivery when the circuit demands a higher
pressure.
When there is no demand for oil, the pump positions itself at its minimum delivery and, the circuit pressure,
remains on stand-by with a value that, in this application, is about 22-24 bar (stand-by pressure).
When the operator acts on the machine's hydraulic controls, a pressure signal reaches the pump from the
distributors via the piloting line and the pump increases its delivery.
The piloting line gives a signal of retro-action to the pump and, the pump regulates its delivery depending on the
pressure demands at that moment.
The regulating apparatus of the pump is the DFR.

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 3 - SYSTEM COMPONENTS AND CONNECTIONS

On the DFR apparatus there are two regulators:

Stand-by pressure regulator (VLS)

The stand-by pressure is the pressure that permanently pressurises the circuit, when hydraulic manoeuvres are
not being carried out. The stand-by pressure retroactively returns to the pump non appena as soon as the
operator decides to carry out a hydraulic manoeuvre.

Pump maximum pressure regulator (VP)

When the circuit pressure reaches the input value, this mechanism causes the pump plate to turn towards its
minimum angle, progressively reducing the capacity.

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 3 - SYSTEM COMPONENTS AND CONNECTIONS

THE LOGIC BLOCK (140)

Main components

a) Electro-valve for manoeuvres release

b) Maximum pressure valve
c) Servo controls pressure reducer valve
d) Logic element
e) LS line unidirectional valve
f) Servo controls line filter
g) LS residual pressure drainage valve
h) Steering line unidirectional valve

Logic block functioning

NB!!! To understand clearly, reference to the

complete diagram of the machine is recommended
(See Chapter 2).

Release of manoeuvres system

The manoeuvres release electro-valve (a) controls the system.
When it isn't supplied, open the passage of oil arriving from the pump (P1) towards the opposite side of the
logic element (d) which, due to the spring and the difference in surfaces, closes blocking the passage (P5) and
the servo control (Ps).
When (a) is supplied, the valve closes the passage (P1) towards the opposite side of the logic element (d) and,
the residual pressure of this side, discharges across the opening (g) towards the LS line.
On (P1) there is the stand-by pressure (25 bar) which is sufficient to overcome the force of the opposite spring
(18 bar).
The logic element (d) moves, opening the passage of oil towards the main distributor sections (P5) and the
servo controls (Ps). Note that the steering is connected to (P4), before the manoeuvres release valve (a) and
so is always supplied.

Servo controls pressure reducer valve

In the same block, there is the reducer valve (c); this ensures that the servo controls receive a pressure of 20
bar. Before the valve (c), there is a filter (f).

LS unidirectional valve
A unidirectional valve (e) prevents the LS signal coming from the distributor sections (LS3) from discharging
across the steering LS line (LS4). With this configuration, the LS signal arriving from the steering orbit (LS4)
also acts on the logic element (d), thereby ensuring priority to the steering.

Steering unidirectional valve

A unidirectional valve separates the steering mandates (P4 and Pa) from the rest of the circuit, to ensure that
the oil inside the accumulator can supply the steering if the engine breaks down.

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 3 - SYSTEM COMPONENTS AND CONNECTIONS

THE DISTRIBUTOR (23)

Main components

i) Entrance section
j) Servo controls sections
k) Stopper
l) LS residual pressure drainage
m) LS maximum pressure valve
n) Rods with servo control
o) Compensators
p) Unidirectional valves

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

INDEX

LOAD SENSING PUMP SERVICE .........................................................................................................................2

"DFR" REGULATOR SERVICE ..............................................................................................................................2

SERVICE OF THE LOGIC BLOCK.........................................................................................................................5

SERVICE OF THE DISTRIBUTOR.......................................................................................................................12

PRESSURES CHECK ..........................................................................................................................................24

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

LOAD SENSING PUMP SERVICE

NB!!! Service of the pump is considerably difficult and must be carried out by competent
technicians. Therefore it will not be dealt with in this manual.

"DFR" REGULATOR SERVICE

WARNING!!! When carrying out the following operations on the machine, a certain amount of
hydraulic oil could leak from the system. Prepare a suitable collection system to avoid polluting the earth
and unnecessary waste.

NB!!! These operations can be carried out without removing the DFR from the pump and without
altering the settings.

Service of regulation system for stand-by pressure

(1) Slider (4) Washer

(2) Spring guiding pin (5) Regulation group
(3) Spring

- Unscrew the stand-by pressure regulation group

(5).

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

- Remove the stand-by pressure regulation group (5); with the aid of a magnet extract in order, the spring guide
(2) and the internal slider (1).

Service of the pump maximum pressure regulation system

(1) Slider (4) Spring

(2) Spring guide (5) Washer
(3) Spring (6) Regulation group

- Unscrew the regulation group (6).

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

- Remove the regulation group (6); with the aid of a magnet extract in order, the spring guide (2) and the
internal slider (1).

Removal of the DFR from the pump

- Disconnect the pilot hose (A) from the DFR, and

the four securing screws (B) of the pump.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

SERVICE OF THE LOGIC BLOCK

Key words

(CS) Chassis side

(US) Upper side
(BS) Boom side
(LS) Lower side
(RS) Rear side
(FS) Front side

Identification of main components

(a) Electro-valve for manoeuvres release

(b) Maximum pressure valve
(c) Pressure reducer valve for servo controls
(d) Logic element

NB!!! There are other components inside

the block.

Dismantling of manoeuvres release electro-valve (a) - (BS)

- Unscrew the plastic nut and extract the solenoid.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

- Unscrew and remove the electro-valve (a).

Dismantling and service of the maximum valve (b) - (US)

- Remove the stopper (7) and, holding firm the body of the electro-valve, unscrew the regulation screw (5).

- Remove the regulation screw (5); unscrew the body of the electro-valve (1).

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

- Remove the electro-valve (b) from the logic

block and extract from its interior: the spring (4),
the central washer (3) and the rod (2).

(1) Electr-valve body (5) Regulation screw

(2) Rod (6) O.Ring
(3) Spring centring washer (7) Stopper
(4) Spring

Dismantling and service of servo control pressure reducer valve (c) - (US)

- Holding firm the body of the valve (1), unscrew and remove the blocking nut (5) of the regulation screw.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

- Unscrew and remove the reulation screw (4).

- Unscrew and remove the valve from the logic block (cextract from its interior: the spring with the centring
washer (3) and the rod (2).

(1) Electro-valve body (4) Regulation screw

(2) Rod (5) Blocking nut
(3) Spring with centring washer

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

Removal and service of logic element (d) - (US)

- Unscrew and remove the stopper (3) and the spring (2).

- With the aid of a magnet (X), extract the rod

from the hole (1).

(1) Rod (3) Stopper

(2) Spring

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

Removal of the residual pressure LS drainage valve (g) - (BS)

- Unscrew and remove the stopper (1)

- Unscrew and remove the screw (2); check that the opening (O) of the screw, is free from impurities.

Removal and service of the LS line unidirectional valve (e) - (LS)

- Remove the stopper (5) and the internal components.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

(1) O-ring (4) Spring

(2) Valve casing (5) Stopper
(3) Sphere

Access to the filter (f) and to the unidirectional steering valve (h) - (FS)

- The unidirectional valve for the steering (h), can be inspected directly by removing the connector. To access
the filter (f), the stopper (T) needs to be removed.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

SERVICE OF THE DISTRIBUTOR

The distributor is composed of three parts:

(1) The entrance part

(2) The distributor parts
(3) The servo controls

THE ENTRANCE PART (1)

In the entrance part, there are three

connections and three devices.

The three connections are:

(A) = return to the tank "T".
(B) = to the servers "P".
(C) = Load Sensing signal "LS".

the three devices are:

(k) = stopper.
(l) = pressure drainage valve LS.
(m) = maximum pressure valve LS.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

Removal of the stopper (k)

- Unscrew and remove the stopper (k).

- With the aid of a magnet, extract the internal rod.

Removal and service of the maximum pressure valve LS (m)

- Unscrew and remove the stopper, also extract the spring and washer.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

- Unscrew and remove the valve body, extract from it the internal components: the rod and the gaskets.

(1) Gaskets (4) Washer

(2) Valve body (5) Spring
(3) Rod (6) Stopper with regulation

Removal and service of the pressure drainage valve LS (l)

- Unscrew and remove the stopper (k).

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

- Unscrew and remove the valve body, extract from it the internal components.

- Check cleaning of the filter (X)

(1) Valve body (4) Washers

(2) Rod (5) Stopper
(3) Spring

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

PARTS OF THE DISTRIBUTOR (2)

Removal of the stopper (A)

- Unscrew the three nuts indicated and, extend the relevant rods.

- Remove the stopper (A); the parts and the entrance part, are now separate.

Removal and service of the unidirectional valves (p)

- Unscrew the stopper and extract the valve and the spring.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

(1) Valve
(2) Spring
(3) Stopper

Removal and service of the compensator (o)

- Unscrew and remove the stopper; with the aid of a magnet, extract the compensator.

(1) Compensator
(2) Stopper

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

Removal of stoppers from lines A and B

- Unscrew and remove the stoppers from both

sides of each section.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

Separation of the electro-hydraulic servo controls

- Separate the sections one from the other (this will facilitate dismantling of the servo controls). Remove the
two fixing screws (for each servo control which is to be dismantled) from the corresponding section.

- Extend the servo control from the rod.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

Removal of the rod (n)

- Remove the components from the end of the rod.

- On the other side of the section, remove the four fixing screws of the mechanical control, then extend it.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

- From the side of the centring spring, completely

extract the rod.

(1) Rod with centring spring (5) Rod shaft

(2) Upper gasket (6) Servo control piston
(3) Closure flange (7) Lock nut
(4) Lower washer with gasket

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

THE ELECTRO-HYDRAULIC SERVO CONTROL (3)

Dismantling of entrance filter

- Unscrew and remove the connector(1).

- With a screwdriver, unscrew and extract the filter (2); check that it isn't dirty.

LED check

- Remove the lower stopper from the electrics section; check that the LED is illuminated.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

Removal and check of electrics

- Remove the four securing screws from the electrics compartment.

- Extract the cylinder containing the rod.

- Extract the rod (2) from its base (1) and check that the interior isn't dirty.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

PRESSURES CHECK

Stand-by pressure check

WARNING!!! If the machine on which the pressures are to regulated is equipped with active
suspensions at the front (E.A.S.), before starting make sure that these are in "MANUAL" mode.

- Acting on the "DFR", remove the stopper (1) and the holding washer, then loosen the lock nut(2) on the stand-
by pressure regulator.

- Start the heat engine.

WARNING!!! From this moment, until the

end of the calibration, do not carry out any
hydraulic manoeuvres.

- Work the register screw (R), until the manometer

registers about 24 bar.

- Tighten the lock nut, put the washer and stopper

back, disconnect the manometer and turn off the
engine.

Maximum pressure check

The maximum pressure is regulated by the maximum pressure valve that releases the pilot pressure when it
reaches the set measurement.
Whenever this system has problems, the maximum pressure regulator of the pump DFR will bring the level back
to the minimum angle, so cutting the flow.
To avoid any problem of high pressure that could damage the system, a maximum pressure valve is situated on
the manoeuvres block logic group.
Due to the complexity of the system there is an exact procedure for regulating the LS maximum pressure valve to
210 bar and the DFR regulator and the distributor maximum pressure valve to 230 and 250 bar, respectively.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

- Loosen the lock nut (1) and completely tighten

the LS maximum pressure valve (2) at the head
of the distributor.

- Remove the stopper (T), loosen the lock nut (D) and completely tighten the pump maximum pressure
regulator on the DFR.

- On the manoeuvres block logic block remove the stopper (T1) and loosen by a few turns the maximum
pressure valve register (R1). This is necessary to avoid excessive pressure which can damage the system.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

- On the "DFR", connect a manometer with a

maximum of 600 bar.

- Switch on the heat engine; bring it to 1500

revs/min and, carry out a hydraulic manoeuvre
up to its limit; lower the register of the logic block
maximum pressure, until the manometer reads
250 bar.

- Bring the heat engine to 1500 revs/min; carry out

a hydraulic manoeuvre up to its limit; lower the
register of the "DFR" maximum pressure valve,
until the manometer reads 230 bar.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

- Keeping the heat engine at 1500 revs/min., carry

out a hydraulic manoeuvre up to its limit; lower
the register of the LS maximum pressure valve
at the head of the distributor until the manometer
reads 210 bar.

- The calibration is finished; turn off the engine, disconnect the manometer; tighten the lock nut and replace the
stopper.

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