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"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 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).
1-1
2 - HYDRAULIC SYSTEM DIAGRAM
2-1
2 - HYDRAULIC SYSTEM DIAGRAM
127 - P3 (T2) = Reference to part. n° 127 connection P3 (T2) hydrostatic transmission circuit.
2-2
3 - SYSTEM COMPONENTS AND CONNECTIONS
INDEX
3-1
3 - SYSTEM COMPONENTS AND CONNECTIONS
3-2
3 - SYSTEM COMPONENTS AND CONNECTIONS
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".
3-3
3 - SYSTEM COMPONENTS AND CONNECTIONS
Pump diagram
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.
3-4
3 - SYSTEM COMPONENTS AND CONNECTIONS
3-5
3 - SYSTEM COMPONENTS AND CONNECTIONS
Main components
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.
3-6
3 - SYSTEM COMPONENTS AND CONNECTIONS
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
3-7
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
INDEX
4-1
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
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.
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.
4-2
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).
4-3
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).
4-4
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
Key words
4-5
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
- 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).
4-6
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
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.
4-7
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
- Unscrew and remove the valve from the logic block (cextract from its interior: the spring with the centring
washer (3) and the rod (2).
4-8
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
- Unscrew and remove the stopper (3) and the spring (2).
4-9
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
- Unscrew and remove the screw (2); check that the opening (O) of the screw, is free from impurities.
4 - 10
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
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.
4 - 11
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
4 - 12
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
- Unscrew and remove the stopper, also extract the spring and washer.
4 - 13
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
- Unscrew and remove the valve body, extract from it the internal components: the rod and the gaskets.
4 - 14
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
- Unscrew and remove the valve body, extract from it the internal components.
4 - 15
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
- Unscrew the three nuts indicated and, extend the relevant rods.
- Remove the stopper (A); the parts and the entrance part, are now separate.
- Unscrew the stopper and extract the valve and the spring.
4 - 16
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
(1) Valve
(2) Spring
(3) Stopper
- Unscrew and remove the stopper; with the aid of a magnet, extract the compensator.
(1) Compensator
(2) Stopper
4 - 17
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
4 - 18
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
- 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.
4 - 19
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
- On the other side of the section, remove the four fixing screws of the mechanical control, then extend it.
4 - 20
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
4 - 21
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
- 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.
4 - 22
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
- Extract the rod (2) from its base (1) and check that the interior isn't dirty.
4 - 23
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
PRESSURES 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.
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.
4 - 24
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
- 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.
4 - 25
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
4 - 26
4 - DISMANTLING AND SERVICE OF THE COMPONENTS
- The calibration is finished; turn off the engine, disconnect the manometer; tighten the lock nut and replace the
stopper.
4 - 27