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Workshop Manual Hydraulic System Manitou MLT845 Mercedes Benz Engine OM904LA
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HYDRAULICS
- HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS
- HYDRAULIC SCHEMATIC DIAGRAMS
- HYDRAULIC COMPONENTS LOCATION
- HYDRAULIC CONTROL AND ADJUSTEMENT
- HYDRAULIC COMPONENTS REMOVAL
- HYDRAULIC COMPONENTS REFIT
- HYDRAULIC SPECIFIC TOOLING
70
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HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS
HYDRAULIC COMPONENT SHEETS
STEERING PUMP / STEERING UNIT OSPC 200 LS
COUNTERBALANCE VALVE
BOOM SUSPENSION ELECTROVALVE (OPTION)
ACCUMULATOR UNIT
POWER ASSISTED BRAKE MASTER CYLINDER
DISTRIBUTOR SX 14 S (INLET ELEMENT)
DISTRIBUTOR SX 14 S (TILTING ELEMENT)
DISTRIBUTOR SX 14 S (TELESCOPING ELEMENTS - ATTACHMENT)
DISTRIBUTOR SX 14 S (LIFTING ELEMENT)
DISTRIBUTOR SX 14 S (CLOSING ELEMENT)
TILTING CUT-OFF VALVE (VCI)
STEERING SELECTOR
PUMP CASAPPA MVP60
HYDRAULIC PUMP A10VO EK1
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HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS
Values indicative only
(03/09/2008) F70-3-0003EN
70
1
Values for information purposes only.
HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS
Notes: _______________________________________________________________________________________________________________________________________________________________________________
L
T
P
R
LS
STEERING PUMP/DIRECTIONAL BLOCK OSPC 200 LS
LR
PT
LS
200 cm/tr
140b
200b
1
3
2
Role:
- Direct and dose the fl ow in order to supply the steering circuit.
- It is a rotating valve.
- P : Pressure.- T : Return to tank.- R : Exit towards the right side.- L : Exit towards the left side.- LS : Pilot line.
1 - Secondary relief valve.2 - Pump valve.3 - Main pressure relief valve.
(03/09/2008)F70-3-0003EN
702
Values for information purposes only.
HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS
LR
PT
LS
When the driver turns the steering wheel towards the right, he passes the fl owrate from P to R and sends pilot pressure towards the divisor to get priority.
LR
PT
LS
LR
PT
LS
When there is an impact on a wheel, the pressure increases in the line. This pressure opens the valve which enables the resulting pressure to be evacuated and therefore protects the hydraulic and mechanical steering components.
What use do the two valves that are located opposite each other on the top part of the diagram have?
What is the maximum pressure permitted in the steering circuit?
What is the LS line, without actions, connected to on the steering wheel?
When the wheels are locked to a maximum, the steering circuit increases in pressure, the LS line activates the relief valve and enables fl ow to the tank.
(03/09/2008) F70-3-0008EN
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1
Values for information purposes only.
HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS
d1COUNTER BALANCE VALVE
Notes: __________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
V1
V2
C2C1
V2V1
1 3
4
2
Role :
- Insulates the cylinder in case of hose breakage.
- Cylinder movement requires the starting of the I.C. engine.
- Limits max. pressure due to impacts.
1 - Temporization screws.2 - By-pass valve.3 - Slide with max. adjustment screw.4 - Non-return valve.
(03/09/2008)F70-3-0008EN
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Values for information purposes only.
HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS
Return control during cylinder descent.
C2C1
V2V1
C2C1
V2V1
When a position is secured, no component is able to exert suffi cient pressure to open the valve.
Only a pressure peak due to an impact can open it.
C2C1
V2V1
When the cylinder is pushed, the supply (no-return valve to pass) and return are free.
Notes: __________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
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70
3
Values for information purposes only.
HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS
What is the valve opening pressure on the diagram?
What happens when the non-return valve starts to leak?
If the temporization screw is either screwed or unscrewed, what eff ect does it have on movement?
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HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS
(08/10/2012) F70-3-0017EN
70
1HYDRAULIC CHARACTERISTICS
AND SPECIFICATIONS
Values for information purposes only.
BOOM SUSPENSION ELECTROVALVE (OPTION)
Nota :
PXV1
V2
Maximum pressure (bar)
Maximum fl owrate (L/min) 150
PX
T
C2 C1
V1V2
PX2
EV(S2)
EV(S1)AC
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HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS
(08/10/2012) F70-3-0023EN
70
1HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
Values for information purposes only.
ACCUMULATOR BLOCK
Notes : __________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
1 - Role:
Provides a reserve of pressurized oil fi r:
- Power assisted braking.- Control valve control (depending on machine).
P1/P2 : Pressure portWV : Circuit selectorDM : Pressure reducerT : Tank returnDB : Pressure relief valve (45 bar)RV : Non-return valveSBO : Membrane accumulatorU : Service port
2 - Description:
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HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS
Values for information purposes only.
Unit is supplied via P1.
Pressure reduced to 35 bar by pressure reducer, then pressure stored in accumulator.
If the pressure reducer jams the pressure relief valve opens (45 bar) to protect all components on exit U.
3 - Operation:
4 - Fill in the table below:
P1
10 b
10 b
50 b
P2
270 b
20 b
0 b
U
45 b
35 b
Commentary
Accumulator empty
Notes : __________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
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1HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
Values for information purposes only.
MASTER CYLINDER WITH ASSISTANCE
1 - Part :
- To send the pressure fl uid in order to push the brake pistion that will stop the wheels.
- To add the mechanical force (pedal) and the hydraulic force in order to help the driver.
2 - Description :
P - Assistance pressureL - Pilot pressure (LS line)N - Return to the tank line B - Brake pressureR - LHM tank
Notes : ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
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HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS
Values for information purposes only.
3 - Working :
When the driver pushes completely the brake pedal, the piston moves and the ball does not stop the oil. In this case, the pressure is sent to help the driver.
In the same time, the master cylinder sends a pilot pressure toward the fl ow divider to have the priority on braking.
When the driver begins to push on the brake pedal, all components are in contact. In this case, the LS line is cut (L).
The master cylinder is ready to send the pressure toward the brake with the assistance.
Phase 3 (during the action)
Phase 2 (the driver starts the action)
Phase 1 (no action)
The pressure from the accumulator block arrives on P. The ball stops the oil.
Due to the fact that we do not use the brake, L is connected to N. Thus, the LS line is connected to the return tank.
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3HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
Values for information purposes only.4 - Exercises :
- What is the maximum assistance pressure ?_______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
- What is the maximum pilot pressure?_______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
- What is the maximum pilot pressure?_______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
- For each connector of the master cylinder, indicate the component name with which it is connected.
P _________________________________________________________________________________
L _________________________________________________________________________________
N___________________________________________________________________________________
B___________________________________________________________________________________
R___________________________________________________________________________________
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HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS
(08/10/2012) F70-3-0037EN
70
1HYDRAULIC SPECIFICATIONS AND
CHARACTERISTICS
Values for information purposes only.
SX 14 S DISTRIBUTOR (INLET)
a
b A5B5
a
3 421
Tdd
LSM
DLS
P
D
T
Tpr
B3 A3
Pr
B1 A1
a
b A2B2 B4 A4 b
EA(O)
VS
LS
T
b
aa
EE EAEI
TAT B
ET
b
B T
EFEL
T B
b
MA
D
VCI
VRP2
1
5
3 4
Function:
- Divide the hydraulic fl ow, giving priority to steering.
- Limit maximum pressure.
- Reduce the LS pressure to zero when the control stick is returned to the neutral position.
- Cut off hydraulic movements.
1 - Priority Valve.2 - Movement cut-off valve.3 - Flow controller and fi lter.4 - Pressure limiter.5 - Non-Return Valve.
Notes: __________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
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HYDRAULIC SPECIFICATIONS AND CHARACTERISTICS
Values for information purposes only.
Tdd
LSM
DLS
P
D
T
VS
LS
TEE
Hydraulic pressure arrives at P.
- The fl ow divider valve enables priority to be given to the steering system when there is stand-by pressure equal to the spring. When the orbitrol is not called for the pressure moves the slide and applies the stand-by pressure from the pump to the valveblock modules.
- The LS limiter enables the maximum circuit pressure to be limited by limiting the pump pilot pressure. It pre-empts the action of the pump DR slide and reduces rippling.
- The regulator allows the LS pressure to fall to 0 when the control stick returns to neutral.
- The VS enables all hydraulic movements to be cut off , directing the divider pilot fl ow to the tank.
What is the function of the non-return valve?
How is the main pressure limited?
What is the exact calibration of the maximum pressure relief valve?
Tdd
LSM
DLS
P
D
T
VS
LS
TEE
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1HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
Values for information purposes only.
a
b A5B5
a
3 421
Tdd
LSM
DLS
P
D
T
Tpr
B3 A3
Pr
B1 A1
a
b A2B2 B4 A4 b
EA(O)
VS
LS
T
b
aa
EE EAEI
TAT B
ET
b
B T
EFEL
T B
b
MA
D
VCI
VRP
21
3 4
Notes : __________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
SX 14 S DISTRIBUTOR (TILT)
Function:
- Direct the hydraulic fl ow to the receiver.
- Limit impact pressure.
- Enables all movement to be stopped.
1 - Valve slide.2 - Pressure balance.3 - Pressure spike relief valve.4 - Pressure spike relief valve.
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HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS
Values for information purposes only.
B1 A1b
a
EITAT B
- The hydraulic pressure arrives at the entry module with pump stand-by pressure.
- The Pressure balance ensures communication between the main pressure line through the valveblock to the receiver feed.
- It takes the receiver pressure and communicates it to the pump.
- There is a priority between the receiver feed and pressure information transmission to avoid any rapid pressure increase as a result of a delay in slide opening relative to pump control.
Hydraulic control(Setting a)
B1 A1b
a
EITAT B
B1 A1b
a
EITAT B
Hydraulic control(Setting b)
Hydraulic control(At rest)
(09/10/2012) F70-3-0039EN
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1HYDRAULIC SPECIFICATIONS AND
CHARACTERISTICS
Values for information purposes only.
SX 14 S DISTRIBUTOR (TELESCOPING - ACCESSORY)
a
b A5B5
a
3 421
Tdd
LSM
DLS
P
D
T
Tpr
B3 A3
Pr
B1 A1
a
b A2B2 B4 A4 b
EA(O)
VS
LS
T
b
aa
EE EAEI
TAT B
ET
b
B T
EFEL
T B
b
MA
D
VCI
VRP
2 2
1 1
3
ETEA
Function:
- Direct the hydraulic fl ow to the receiver.
- Limit impact pressure.
- Enables all movement to be stopped.
1 - Valve slide.2 - Pressure balance.3 - Pressure spike relief valve.
ET
EA
Notes : __________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
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HYDRAULIC SPECIFICATIONS AND CHARACTERISTICS
Values for information purposes only.
B3 A3 B4 A4
b
aa
EAET
b
B T
- The hydraulic pressure arrives at the entry module with pump stand-by pressure.
- The Pressure balance ensures communication between the main pressure line through the valveblock to the receiver feed.
- It takes the receiver pressure and communicates it to the pump.
- There is a priority between the receiver feed and pressure information transmission to avoid any rapid pressure increase as a result of a delay in slide opening relative to pump control.
B3 A3 B4 A4
b
aa
EAET
b
B T
B3 A3 B4 A4
b
aa
EAET
b
B T
Operating principles of the electro-hydraulic controller:
Pr
TPr
Pressure reducedby SPU
Valve slide
Electro-hydraulic controller (Setting a) Electro-hydraulic controller (Setting b)
Electro-hydraulic controller (Rest state)
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1HYDRAULIC SPECIFICATIONS AND
CHARACTERISTICS
Values for information purposes only.
SX 14 S DISTRIBUTOR (ELEVATION)
a
b A5B5
a
3 421
Tdd
LSM
DLS
P
D
T
Tpr
B3 A3
Pr
B1 A1
a
b A2B2 B4 A4 b
EA(O)
VS
LS
T
b
aa
EE EAEI
TAT B
ET
b
B T
EFEL
T B
b
MA
D
VCI
VRP
3
1
2
Function:
Direct the hydraulic fl ow to the receiver.
Limit impact pressure.
Enables all movement to be stopped.
Regulates pilot pressure as per machine overload.
1. Distribution slide (includes the pilot regulation valve VRP).2. Pressure spike relief valve.3. Pressure balance.
Notes : __________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
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HYDRAULIC SPECIFICATIONS AND CHARACTERISTICS
Values for information purposes only.
Operating principles of the electro-hydraulic controller and VRP:
Pr
TPr Pressure reduced by SPU
Control Valve
Valve slide
Jet at control valve inlet for descent control
Hydraulic controller
The descent control is mixed, i.e. the hydraulic controller directly controls the slide in normal operation. The pressure relief valve, on the other hand, can reduce the slide pilot pressure if the operator wishes to reduce the fl ow sent to descent and thus the rate of descent.
Current/pressure reduction curve, VRP:
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3HYDRAULIC SPECIFICATIONS AND
CHARACTERISTICS
A5B5
a
b
EL
T B
bVRP
A5B5
a
b
EL
T B
bVRP
The hydraulic pressure arrives at the entry module with pump stand-by pressure.
The Pressure balance ensures communication between the main pressure line through the valveblock to the receiver feed.
It takes the receiver pressure and communicates it to the pump.
There is a priority between the receiver feed and pressure information transmission to avoid any rapid pressure increase as a result of a delay in slide opening relative to pump control.
Electro-hydraulic controller(Setting b)
Electro-hydraulic controller(Rest state)
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704
HYDRAULIC SPECIFICATIONS AND CHARACTERISTICS
(09/10/2012) F70-3-0041EN
70
1HYDRAULIC SPECIFICATIONS AND
CHARACTERISTICS
Values for information purposes only.
SX 14 S DISTRIBUTOR (CLOSING)
a
b A5B5
a
3 421
Tdd
LSM
DLS
P
D
T
Tpr
B3 A3
Pr
B1 A1
a
b A2B2 B4 A4 b
EA(O)
VS
LS
T
b
aa
EE EAEI
TAT B
ET
b
B T
EFEL
T B
b
MA
D
VCI
VRP
1
Function:
It contains a fl ushing valve whose function is to prevent pressure spikes arising from the premature closing of the main slide of one of the valveblock components before the pump has returned to low.
1 - Flushing Valve.
T3
Pr
Tpr
Notes : _____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
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HYDRAULIC SPECIFICATIONS AND CHARACTERISTICS
Values for information purposes only.
TprPrEF
D
The hydraulic pressure arrives at the entry module with pump stand-by pressure.
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1HYDRAULIC SPECIFICATIONS AND
CHARACTERISTICS
Values for information purposes only.
TILT CUT-OFF VALVE (VCI)
a
b A5B5
a
3 421
Tdd
LSM
DLS
P
D
T
Tpr
B3 A3
Pr
B1 A1
a
b A2B2 B4 A4 b
EA(O)
VS
LS
T
b
aa
EE EAEI
TAT B
ET
b
B T
EFEL
T B
b
MA
D
VCI
VRP
1
Function:
To authorize or not crowding, taking into account machine overload and machine software.
When powered, 35 bar pressure is applied to each side of the slide, giving rise to no crowding movement.
When unpowered, pressure can be applied to one side or the other thus enabling movement.
1 - Crowding Cut-Off Valve (VCI)
Maximum pressure (bar) 35
Maximum fl owrate (L/min) 19
Notes : __________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
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HYDRAULIC SPECIFICATIONS AND CHARACTERISTICS
(29/01/2012) F70-3-0042EN
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1HYDRAULIC SPECIFICATIONS AND
CHARACTERISTICS
Values for information purposes only.
STEERING SELECTOR
Function:
Allows the selection of 3 steering modes, depending o n t h e s t e e r i n g a l i g n m e n t s w i t c h p o s i t i o n (See instructions).
Notes : _______________________________________________________________________________________________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ _________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
A
T
P
B
3 1
3 2 1P
3 2 1
SD
TA B
ARAV
2
Position of steering selector switch:
1 - Front and rear wheels face opposite directions (circle).2 - Front wheels steer (road mode).3 - Front and rear drive wheels in the same direction (crab steering).
Nominal pressure (bar) 250
Nominal fl owrate (liters/minute) 45
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HYDRAULIC SPECIFICATIONS AND CHARACTERISTICS
(09/10/2012) F70-3-0047EN
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1HYDRAULIC SPECIFICATIONS AND
CHARACTERISTICS
CASAPPA MVP 60 PUMP
1. PEC (Pressure Electronic Control).2. Hydraulic fl ow regulator.3. Maximum displacement regulator.4. Minimum displacement regulator.5. High Pressure (B).6. Suction pressure (S).7. LS (X) line coupling. Includes fi lter and fl ow
limiter.8. Oil tank return.
B
S
X
60 cm3/trM
P
1
7
2
8
1
7
6
2
4
5
3
32
1
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702
HYDRAULIC SPECIFICATIONS AND CHARACTERISTICS
Values for information purposes only.
SECTION VIEW
DESCRIPTION
LS spring : 17 b
Pressure limiter : 315 b
Key :
1. PEC (Pressure Electronic Control).2. Hydraulic fl ow regulator.
B
S
X
315b
17b
M
P
1
2
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
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3HYDRAULIC SPECIFICATIONS AND
CHARACTERISTICS
Values for information purposes only.
FLOW ADJUSTMENT
Keeping stand-by pressure of 17 bar.
Delta P = p(B) - p(X)
Delta P generated by weak fl ow passing through the control block pressure compensator (Ref 1).
If the Delta P increases, the pumps displacement decreases.
B
S
X
Delta P
Delta P17 bar5l/min
119b
100b
119b
17b100b
M
P
D
Tdd
LSM
DLS
P
D
T
B1 A1
a
b
VS
LS
TEE EITAT B
Example: Hydraulic control (Setting b)
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
1
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HYDRAULIC SPECIFICATIONS AND CHARACTERISTICS
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1HYDRAULIC CHARACTERISTICS
ANDSPECIFICATIONS
Values indicative only
HYDRAULIC PUMP A10VO EK1
Notes: __________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Regulator DFR
Proportional electrovalve EK 1
Pump A10VO
CROSS-SECTION OF PROPORTIONAL ELECTROVALVE EK 1 AND PUMP A10VO
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HYDRAULIC CHARACTERISTICS ANDSPECIFICATIONS
Values indicative only
Description
Notes: ___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Arrival of distributor signal
Flow regulator FR
Flow regulator DR
Proportional electrovalve
Control cylinder
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3HYDRAULIC CHARACTERISTICS
ANDSPECIFICATIONS
Values indicative only
Flow of fl uids
Position of machine in stop mode or:
Governing faultGoverning deactivated
Notes: ___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
(23/05/2012)F70-3-0059EN
704
HYDRAULIC CHARACTERISTICS ANDSPECIFICATIONS
Values indicative only
Flow of fl uids
Small displacement position 60%
Notes: ___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
(23/05/2012) F70-3-0059EN
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5HYDRAULIC CHARACTERISTICS
ANDSPECIFICATIONS
Values indicative only
Flow of fl uids
Large displacement position 100%
Notes: ___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
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HYDRAULIC CHARACTERISTICS ANDSPECIFICATIONS
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HYDRAULIC SCHEMATIC DIAGRAMS
pages
MLT 845-120 H SERIES 4-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MLT 845-120 SERIES 5-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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3HYDRAULIC SCHEMATIC DIAGRAMS
HYDRAULIC DIAGRAM KEY
Item Designation Position on diagram Characteristics (Options)
A ACCUMULATOR K20
BT TRANSFER GEAR BOX Q12
CA SUCTION STRAINER I21
CAR NON-RETURN VALVE Q18/M16
CSP SAFETY VALVE COUNTERBALANCE C20/C29/C37/C41
D 6 COMPONENT DISTRIBUTOR I36
EE INLET COMPONENT K26
EI TILTING COMPONENT K29
ET TELESCOPING COMPONENT K31
EA ATTACHMENT COMPONENT K32
EL LIFTING COMPONENT K34
EF CLOSING COMPONENT K36
D3 3 POSITION STEERING DISTRIBUTOR C12
Position 1: short steering
Position 2: front wheel steering
Position 3: crab steering
EVPV GEAR CHANGE ELECTROVALVE S14
EVSE(O) 5 COMPONENT ELECTROVALVE (OPTION)
EVTF(O) BOOM HEAD ELECTROVALVE (O)(OPTION) C35
FDAV FRONT DISC BRAKE Q3
FEMS EMS HEAD FILTER M22
FR RETURN FILTER G17
M ENGINE 1104D-E44 TA O21
Idle speed 930 rpm (+20/0)
Nominal speed laden 2,200 rpm
Full speed unladen 2,400 rpm
MA MANIPULATOR M26/Q28
MER REVERSIBLE MOTOR FAN (FAN DRIVE) A6
MC MASTER CYLINDER G5
MH HYDROSTATIC MOTOR M6
N LEVEL I16
P HYDRAULIC PUMP I20
PAAV FRONT ATTACHMENT PLUG A31
PAAV(O) FRONT ATTACHMENT PLUG (OPTION) A36
PCR PUMPCOOLER CIRCUIT (FAN) G17
PD STEERING PUMP C10
PH HYDROSTATIC PUMP O20
PP PRESSURE PORT I26
PRES PRESSURE SWITCH M32/M36
PRF(O) LEAKAGE RETURN PLUG (OPTION) A17
R HYDRAULIC TANKS I22
MLT 845-120 H Series 4-E3
KEY
(08/10/2012)70-02-M209EN
704 HYDRAULIC SCHEMATIC DIAGRAMS
HYDRAULIC DIAGRAM KEY
Item Designation Position on diagram Characteristics (Options)
RAD RADIATOR K22/K23
RLF BRAKE FLUID TANK G4
RFV(O) FAN COOLER (OPTION) E17
R3V(O) 3 - WAY VALVE (OPTION) A32
TH7 MANIPULATOR TH7 I7
VAFM HAND BRAKE VALVE K3
VC COMPENSATION CYLINDER A26/C26 90x45 c320
VCI TILTING CONTROL CUT-OFF VALVE M36
VDAR REAR STEERING CYLINDER Q22
VDAV FRONT STEERING CYLINDER Q4
VI TILTING CYLINDER A20 150x75 c385
VIP-VC COMPENSATION CYLINDER BASE INSULATION VALVE E22
VIT-VC COMPENSATION CYLINDER HEAD INSULATION VALVE C23
VL LIFTING CYLINDER A38/A40 110x70 c845
VPV GEAR CHANGE CYLINDER Q13
VS SAFETY VALVE K26
VT TELESCOPE CYLINDER A28 80x60 c3150
VVT(O) CARRIAGE LOCKING CYLINDER (OPTION) A31 60x45 c183
NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine speed. 2- The calibration pressures of the secondary relief valves are at an engine speed of 1 000 rpm. 3- The pressure relief valves should be adjusted at an oil temperature of 50C.
MLT 845-120 H Series 4-E3
70
(08/10/2012) 70-02-M209EN
5HYDRAULIC SCHEMATIC DIAGRAMSHYDRAULIC DIAGRAM
14.5cm3/tr
1
125L / mn
2b
4b3
12
AA2 13
4b
300 L/mn
4bVA
V1V3
V27,6b2b
BA
BA
T
a
b
X1 X3T G A
M1 B U
190b
335b
315b110b
B L N
PA
B
T
C1 C2200b
V1 V2
350b 350b
V2V1
200bC2C1
32
1
P2P1
C4
C3
C2C1
19 cm3/trX
B
63 cm3/tr
L2L1L
TP
1 32 4
LSV2V1
C2C1
M
V2V1
C1 C2
b a
GX1 X2 MH
MBFeFa1FaPSRT1
T2
MAFsS
A
B
Y
A
T P
100 L/mn
200 cm3/tr
140b
200b
BA T
123
P
LR
PT
200b
ARAV123
123
TP
A B
2 b.
13 b.0,7 L.2
3 1
0.5b
1
2VCI
VLVL
CSPCSP
A4B4
VS
a
14V
Tdd
LSM
DLS
P
D
LS
TT
Tpr
b
a
EEEA
270bar
Pr
EI
B1 A1
280190
a
b
TA
barbar
T B
ET
A2B2
200
a
b
BT
bar
D
EFEL
B3 A3
280
23
b
bar
T B
barb
Gicleur 0.8 mmAjout Gicleur
RFV(O)
M
C
VVT(O)
R3V(O)
PRF(O)
PAAV(O)
EVTF(O)
PCR
P
FEMS
PRESPRESMA
FR
VT
CSPVC
VIVC
VIP-VC
VIT-VC
CSP
MH
BT
VPV
RADRAD
PHM
TH7
N CA
R
M
D3
PD
VDAVFDAV VDAR
CAR
EVPV
RLF
MC
X
PP
AVAFM
CAR
PAAV
10 m abs
125 m
10 m
Levage
DescenteDversement
Cavage
Accessoire
Tlescopage
MA
ES.A
V
ES.A
R
MER
190b
S
Q
O
M
K
I
G
E
C
A
21 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
A
C
E
G
K
M
O
Q
S
I
42
70
(08/10/2012)70-02-M209EN
6 HYDRAULIC SCHEMATIC DIAGRAMS
HYDRAULIC DIAGRAM KEY
Item Designation Position on diagram Characteristics (Options)
AC ACCUMULATOR G37
BA FEED BLOCK + ACCUMULATOR C19
BH HYDRAULIC UNIT S14
CA SUCTION STRAINER Q10
CSP COUNTERBALANCE VALVE E20/K24/K29/K33/K37
D 6 COMPONENT DISTRIBUTOR O31
EE INLET COMPONENT Q21
EI TILTING COMPONENT Q24
ET TELESCOPING COMPONENT Q26
EA ATTACHMENT COMPONENT Q28
EL LIFTING COMPONENT Q30
EF CLOSING COMPONENT Q31
D3 3 POSITION STEERING DISTRIBUTOR C12
POSITION 1: SHORT STEERING
POSITION 2: FRONT WHEEL STEERING
POSITION 3: STEERINGCRAB
EVTF(O) BOOM HEAD ELECTROVALVE (OPTION) C28
FDAR REAR DISC BRAKE K13
FDAV FRONT DISC BRAKE K6
FEMS EMS HEAD FILTER C21
FR RETURN FILTER Q12/Q13
M ENGINE 1104D-E44 TA Q6
IDLE SPEED 930 rpm (+20/0)
NOMINAL SPEED LADEN 2,200 rpm
FULL SPEED UNLADEN 2,360 rpm
MA MANIPULATOR I20/O37
MER ENGINE FANREVERSIBLE (FAN DRIVE) M4
MC MASTER CYLINDER C7
N LEVEL S5
P HYDRAULIC PUMP Q9
PAAR(O) REAR ATTACHMENT PLUG (OPTION) C25
PAAV FRONT ATTACHMENT PLUG A30
PAAV(O) FRONT ATTACHMENT PLUG (OPTION) A28
PD STEERING PUMP C14
PFR(O) TRAILER BRAKE COUPLING (OPTION) I21/M11
PP PRESSURE PORT O20
PCR COOLING CIRCUIT PUMP FAN
PR(O) COOLING PUMP (OPTION) Q5
PRES PRESSURE SWITCH G35/S30/M28
RF COOLER Q3/Q4
RFV(O) FAN COOLER (OPTION)) O6
MLT 845-120 Series 5-E3
KEY
HYDRAULIC DIAGRAM KEY
Item Designation Position on diagram Characteristics (Options)
RLF BRAKE FLUID TANK A6
R3VD (O) DOUBLE 3 - WAY VALVE E27
SC CIRCUIT SELECTOR E11
SCFR(O) CIRCUIT SELECTOR (TRAILER BRAKE OPTION) G7
VAFM HAND BRAKE VALVE I9
VAFR(O) TRAILER BRAKE VALVE (OPTION) G10
VAI(O) INSULATION VALVE (OPTION) C32
VASF BOOM SUSPENSION VALVE I36/I41
EV (S1) ELECTROVALVE (SOLENOID 1) G36/G41
EV (S2) ELECTROVALVE (SOLENOID 2) G33/G38
VC COMPENSATION CYLINDER E26/G26 90x45 c320
VCI TILTING CONTROL CUT-OFF VALVE O23
VCHAR(O) REAR HYDRAULIC TOW-HITCH CYLINDER (OPTION) A26 50x30 c350
VDAR REAR STEERING CYLINDER K14
VDAV FRONT STEERING CYLINDER K7
VI TILTING CYLINDER E21 150x75 c385
VIP-VC COMPENSATION CYLINDER BASE INSULATION VALVE G22
VIT-VC COMPENSATION CYLINDER HEAD INSULATION VALVE G23
VL LIFTING CYLINDER I29/I31/E36/E40 110x70 c845
VS SAFETY VALVE Q22
VT TELESCOPE CYLINDER I26 80x60 c3150
VVT(O) CARRIAGE LOCKING CYLINDER (OPTION) A32 60x45 c183
NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine speed. 2- The calibration pressures of the secondary relief valves are at an engine speed of 1 000 rpm. 3- The pressure relief valves should be adjusted at an oil temperature of 50C.
70
(08/10/2012) 70-02-M209EN
7HYDRAULIC SCHEMATIC DIAGRAMSHYDRAULIC DIAGRAM
315b110b
RLFB L
N
P
335b
190b
1
2
C1 C2200b
V1 V2
350b350b
V2V1
200bC2C1
E E1
B
A
A1
B1
2 3
1
1
2
OPTION FREINAGE REMORQUE
V2V1
C1 C2
C1 C2
V1 V2
13
2
Levage
DescenteDversement
Cavage
Accessoire
Tlescopage
C1
C2
C3
C4
P1 P2
125L/mn
19cm3/tr
2b
C
V1
V2
V2 V1
C
34
9
1Gicleur
100 L/mn
321
4b A
T
4 3 12
P
200b
3 2 1
3 2 1
2b
LS
T P
R L
P
3 2 1
TA B
200b
140b
200 cm3/tr
P2 T455B
35b
P1
U
13 bar0,7 L.
ARAV
2b
BA
BA
4b3
1 2
A
Y
T P
NB
P
Ajout Gicleur
M
C
CA
A4B4
VS
a
14V
Tdd
LSM
DLS
P
D
LS
TT
Tpr
b
a
EE
270bar
Pr
B1 A1
280 bar
190 bar
a
b
TAT B
A2B2
200
a
b
BT
bar
B3 A3
280
23
b
bar
T B
barb
Gicleur 0.8 mm
VLVT VL
CSP CSP
PRES
CSP
VCHAR(O)
R3VD(O)
PAAR(O)
VAI(O)
VVT(O)
FEMS
VC
VI
BA
PAAV
VC
VIP-VC
VIT-VC
CSP
PAAV(O)
EVTF(O)
MA
PFR(O)
SC
PD
D3MC
FD-AV VD-AV
VAFR(O)
SCFR(O)
VAFM
PRF(O)FD-ARVD-AR
RFV(O)
PR
RFRF
M
N
BH
FR FR
PP
PRES
EAEI ET
D
EFEL
VCI
ES.A
V
ES.A
R
10m 10m
125 mabsolu
MA
10m
MER
190b
BOITE MECANIQUE
14.5cm3/tr
60 cm3/trM
B
S
XP
C2
T
C2C1
V1 V2
3
21 C1 C2
1.5 L30b
PX
EV(S2)
EV(S1)
OPTION SUSPENSION DE FLCHE
VASF
VL
AC
PRES
VL
CSP
320b+15/0
30b+6/0
PX
EV(S2)
EV(S1)
VASF
320b+15/0
30b+6/0
ACAC
C1
V2
V1
70b
M
V2V1T
CLAPET PARACHUTE CLAPET PARACHUTE
VEMVEM
S
Q
O
M
K
I
G
E
C
A
21 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
A
C
E
G
K
M
O
Q
S
I
42
70
(08/10/2012)70-02-M209EN
8 HYDRAULIC SCHEMATIC DIAGRAMS
(26/09/2012) 70-03-M209EN
70
HYDRAULIC COMPONENTS LOCATION
pages
KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1 MAIN HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 HYDRAULIC LIFTING CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 HYDRAULIC BOOM CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 BOOM COMPENSATION HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 STEERING HYDRAULIC CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
(26/09/2012)70-03-M209EN
702
HYDRAULIC COMPONENTS LOCATION
KEY
1 - Main2 - Lifting3 - Boom
4 - Boom supply compensation5 - Steering
Item DesignationRepresentation on circuit Electric code
equivalence1 2 3 4 5
A ACCUMULATOR
BA FEED BLOCK + ACCUMULATOR
CA SUCTION STRAINER
CSP COUNTERBALANCE VALVE (VI)
CSP COUNTERBALANCE VALVE (VL)
CSP COUNTERBALANCE VALVE (VT)
D 7 COMPONENT DISTRIBUTOR
D3 3 POSITION STEERING DISTRIBUTOR
FEMS EMS HEAD FILTER
FR RETURN FILTER
MA MANIPULATOR
N LEVEL
P HYDRAULIC PUMP
PAAV FRONT ATTACHMENT PLUG
PD STEERING PUMP
PP PRESSURE PORT
R HYDRAULIC TANK
SC CIRCUIT SELECTOR
VCI TILTING CONTROL CUT-OFF VALVE
VC COMPENSATION CYLINDER
VI TILTING CYLINDER
VIP-VC COMPENSATION CYLINDER BASE INSULATION VALVE
VIT-VC COMPENSATION CYLINDER HEAD INSULATION VALVE
VL LIFTING CYLINDER
VT TELESCOPE CYLINDER
(26/09/2012) 70-03-M209EN
70
3HYDRAULIC COMPONENTS
LOCATION
DM
DLS
Tdd
4TP
3
12
TprPr
U
T
P1
BA
FEMS
MA
D
VCI
PP
D
P
N
R
CA
FR
HYDRAULIC CIRCUITS
1 MAIN HYDRAULIC CIRCUIT
MLT 845-120 Series 5-E3
(26/09/2012)70-03-M209EN
704
HYDRAULIC COMPONENTS LOCATION
D
MDLSS
TddTdd
4
TP3
12
TprPr
T
P
LS
FEMS
A
MA
VCI
PD
D
P
N
R
CA
FR
MLT 845-120 H Series 4-E3
(26/09/2012) 70-03-M209EN
70
5HYDRAULIC COMPONENTS
LOCATION
2 HYDRAULIC LIFTING CIRCUIT
MLT 845-120 Series 5-E3MLT 845-120 H Series 4-E3
D
VL
CSP
CSP
VL
(26/09/2012)70-03-M209EN
706
HYDRAULIC COMPONENTS LOCATION
3 HYDRAULIC BOOM CIRCUIT
MLT 845-120 Series 5-E3MLT 845-120 H Series 4-E3
VI
VT
CSP
CSP
PAAV
(26/09/2012) 70-03-M209EN
70
7HYDRAULIC COMPONENTS
LOCATION
4 BOOM COMPENSATION HYDRAULIC CIRCUIT
MLT 845-120 Series 5-E3MLT 845-120 H Series 4-E3
D
VC
VC
VIP-VC
VIT-VC
(26/09/2012)70-03-M209EN
708
HYDRAULIC COMPONENTS LOCATION
M
DLS
Tdd
D
D
PD
SC
D3
M
DLS
Tdd
D
D
PD
D3
5 STEERING HYDRAULIC CIRCUIT
MLT 845-120 Series 5-E3
MLT 845-120 H Series 4-E3
(26/09/2012) 70-04-M209EN
70
HYDRAULIC CONTROL AND ADJUSTMENT
pages
PRESSURE TAKE-OFF POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
VALUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
LOCALIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SX14 S CONTROL BLOCK CONTROL LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
DANGEROUS MOVEMENTS CUT-OFF OPERATING PRINCIPLES. . . . . . . . . . . . . . . . . . . . . . .5
REMOVAL OF SX 14 S DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1 - SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 - ESSENTIAL RULES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 - REMOVAL AND RE-FITTING OF THE SX 14 S UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 - SX 14 S UNIT REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 - SPECIFIC TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
(26/09/2012)70-04-M209EN
702 HYDRAULIC CONTROL AND ADJUSTMENT
Machine N of pressure portsValues (bars)
Typical
MLT 845-120 H Series 4-E3MLT 845-120 Series 5-E3 PP-1 270
PRESSURE TAKE-OFF POINTS
VALUES
PP-1
MLT 845-120 H Series 4-E3MLT 845-120 Series 5-E3
LOCALIZATION
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70
3HYDRAULIC CONTROL AND ADJUSTMENT
SX14 S CONTROL BLOCK CONTROL LOGIC
MLT 845-120 H Series 4-E3MLT 845-120 Series 5-E3
The JSM sends information about the direction and proportional amount for rollers 1 and 2 to the SPU computer. The computer turns the information into PWM control of the 4 coils for accessory and boom movements.
JSMX36
123456
121110987
18
1420 7
131926
X56
1101826 9
172534
X57
Y7 Y6 Y8 Y9
X36
+12V (APC)ATTACHEMENT (S1)BOOM HEAD VALVE GND
SAFETY VALVE GROUDBOOM LOWERING VALVE GROUDMICRO RELAIS SUPLYANALOG SENSOR ANGLE 2
EASY CONNECT SYSTEMMOVENTS FORCINGROLLER 1IN TIMER ECU +12V APCATTACHEMENT (S2)TRANSMISION CUTHYDRAULIC MOVENTS INHIBITIONSEAT MICROSWITCH (NO)JSM ROLLER 1
GROUD+12VdcOIL FLOW CONTINUOUSPARKING BRAKE INFO
ANALOG SENSOR ANGLE 1GROUD
CAN HCAN LSPU +APCSPU +APCEV. SENS+ TELECOPEBOOM LOWERING PROP. VALVESAFETY VALVE+12V APC+12V APC
BP1 ev TDF
GEAR INFOANALOG SENSOR (N.O.) BOOM RETRACTIONJSM ROLLER 2TRANSMISSION CUT
ATTACHM. LOCKFAN PROP. VALVE
GEAR INFOANALOG SENSOR (N.F.) BOOM RETRACTIONROLLER 2FAN PROP. VALVE
CAN GNDTELECOPIC BOOM PROP. OUTFAN INVERSIONANALOG SENSORS GNDVCI VALVEOIL FLOW CONTINUOUS SIGN. LAMPGROUD
SPU1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
X56
X571
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
HYDRAULICDISTRIBUTOR GND
123456
121110987
X87
(26/09/2012)70-04-M209EN
704 HYDRAULIC CONTROL AND ADJUSTMENT
50 60
70
80
90
100 125
130 140
15
SPU
JSM
Rexroth SX 14 S control block
(26/09/2012) 70-04-M209EN
70
5HYDRAULIC CONTROL AND ADJUSTMENT
DANGEROUS MOVEMENTS CUT-OFF OPERATING PRINCIPLES
Movement cut-off is activated by the VRP/SPU or VCI at 105% gauge signal.If gauge signal exceeds 112%, the VS also cuts out.(These fi gures can change, depending on the jib angle)
VS cut-out occurs 7% after proportional cut-out, to cater for the eventuality of the SPU taking longer to carry out a proportional cut-out. The VS will then cut out all movements at 112%.
1
2
321
4b A
T
4 3 12
P
4b3
1 2
A
A4B4
VS
a
14V
Tdd
LSM
DLS
P
D
LS
TT
Tpr
b
a
EE
270bar
Pr
B1 A1
280 bar
190 bar
a
b
TAT B
A2B2
200
a
b
BT
bar
B3 A3
280
23
b
bar
T B
barb
PRES
MA
PRES
EAEI ET
D
EFEL
VCI
1
2
3
1 - Tilt cut-out valve (VCI).2 - Movement cut-out valve (VS).3 - Control Regulation Valve (VRP).
(26/09/2012)70-04-M209EN
706 HYDRAULIC CONTROL AND ADJUSTMENT
REMOVAL OF SX 14 S DISTRIBUTOR
1 SAFETY INSTRUCTIONS
Safety instructions and important notices which you must closely observe are shown in this chapter in the following way:
b Instructions to be scrupulously followed to guarantee your safety and avoid the risk of damage to the telehandler in the course of maintenance operations.
50
60
70
80
90
100 125
130
140
15
(26/09/2012) 70-04-M209EN
70
7HYDRAULIC CONTROL AND ADJUSTMENT
2 TROUBLESHOOTING
bBefore carrying out any of the fault-fi nding procedures to detect the cause of the breakdown or before removing the distribution unit, it is essential to fi rst carry out an examination of the machines hydraulic circuit in order to eliminate any breakdown resulting from causes external to the SX 14 S distributor unit.
Faults arising from malfunction of receivers linked to the distribution unit.
Results noted Probable causes Additional checks SolutionsLack of power at all receivers
- LS Limiter defective
- LS limiter out of adjustment
Measure pressure (see unit specifi cations)
- Change the LS limiter (cf. 5.1)
- Adjust
Lack of power at just one receiver
- Secondary suppression limiter out of adjustment
- Secondary limiter stuck open (return to tank)
- Reset to design pressure (see unit specifi cations)
- Change the secondary limiter (cf. 5.5)
Lack of speed in one or all movements
For SX 14 S fi tted with open center inlet: Open center piston stuck in position P towards T
Change the body + piston assembly
Lack of speed in one movement
- Incorrect slide movement
- Adjustable hydraulic control stop out of adjustment
- Individual pressure balance stuck
Manual control: measure slide movement.Direct electrical control: check the coil resistance (R: 2.5 Ohm at 25C)
- If movement is incorrect, change the body + slide assembly. If the resistance is incorrect change the coil.
- Adjust- Change the body
+ pressure balance assembly
Failure to maintain pressure
- Load hold check valve faulty
- Excessive play between the body and the slide
- Change the body + valve assembly
- Change the body + slide assembly
Steering abnormally hard Flow divider poorly adjusted
- Regulating piston sliding freely
- Regulating piston stuck
- Change regulation sub-assembly (cf. 5.3)
- Change body + regulation assembly (cf. 5.7 et 5.3)
Excessive delay in response to steering
Flow Divider regulation piston fi lter clogged
Change the fi lter
(26/09/2012)70-04-M209EN
708 HYDRAULIC CONTROL AND ADJUSTMENT
Results noted Probable causes Additional checks SolutionsClamps faulty (SX14S fi tted on loading shovel)
- Output coil defective- Output ball valve
malfunction - 2 way valve defective
- Check coil resistance (R: 6 Ohm at 20C)
If resistance is incorrect, change the coil.Change the ball valveChange the 2 way valve
Simultaneous movement fault
- Individual balance jet blocked
- Individual pressure balance stuck
- LS line leak
- Remove and clean the individual balance (cf. 5.7)
- Change the body + pressure balance assembly
- Change the LS fl ow regulator (cf. 5.2)
Faults manifesting as machine malfunction.
Results noted Probable causes Additional checks SolutionsDiesel engine remains under load after slides returned to neutral
- Flow regulator blocked- Regulator fi lter blocked
- Change the fl ow regulator (cf. 5.2)
- Change the fi lter
Defects manifesting as malfunction of distribution unit controls.
Results noted Probable causes Additional checks SolutionsCoupling fault - Mechanical defect
- Defective coil- Check coil resistance (R:
16.5 Ohm at 20C)- Change the
latchmechanical- If resistance is incorrect,
change the coilIncreased effort to use controls or lack of return
Distribution unit tie bolts too tight
Slide unions worn out
Check tightening torque Loosen and adjust to tightening torque 42 10% Nm. b Before commencing free
the distribution unit from its fi xing points
Change the slide connectors (cf. 5.6)
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Faults found upon visual inspection.
Results noted Probable causes Additional checks SolutionsSlide oil leaks Defective slide seals Change slide connectors
(cf. 5.6)Oil leaks at limiters and stoppers
Defective seals Remove the limiter or stopper and change the seals
Oil leaks between modules
Defective seals between modules
Remove distribution modules and change seals (cf. 5.7)
Hydraulic controller oil leaks
- Defective seal between unit and housing
- Defective adjustable stop nut seal
Change the seal
Damaged joystick control bellows
Change the bellow
3 ESSENTIAL RULES
GENERAL NOTES CONCERNING CONNECTING UP THE DISTRIBUTION UNIT
When the unit is removed seal all openings immediately to avoid any possible contamination to the hydraulic circuit.
When re-fi tting the unit, remove the plastic stoppers from openings and pipes just before making connections.
Do not tighten unions to a torque greater than that shown in the assembly instructions. Whenever work is done, check the quality of the oil and the level of fi ltration. The use of PTFE, hemp or sealing compound is forbidden. Pipework and unions must be under no mechanical strain.
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4 REMOVAL AND RE-FITTING OF THE SX 14 S UNIT
4.1 GENERAL GUIDANCE
bBefore removing the SX 14 S distribution unit it is essential to fully clean the unit and its surroundings. (Do not apply the output from a pressure washer directly to the unit).It is essential that the hydraulic circuit is kept clean of all dirt or foreign objects. Use plastic plugs on openings and pipes as soon as they are removed.Wear protective clothing and use correct equipment to avoid any accident, particularly with the fl uid.Use the lifting eye-bolts and appropriate maintenance equipment.Place all the machines receivers attached to the distribution unit in their rest positions (resting on the ground, at the bottom of their movement etc.) to avoid any accident arising from unplanned movements as a result of disconnecting the hydraulic circuit.With the machine stopped, release all stored pressure by moving the distribution slides.
4.2 REMOVAL OF THE SX 14 S UNIT
e HYDRAULIC COMPONENTS REMOVAL Attach a vacuum pump to the tank to limit the escape of oil when unions are unfastened. Insert the plastic plugs immediately after disconnecting the pipes from the unit. Take care to catch any oil spills in an appropriate container. Unscrew the fi xing bolts and remove the distribution unit.
4.3 RE-FITTING THE SX 14 S UNIT
e HYDRAULIC COMPONENTS REMOVAL Ensure mating faces are perfectly clean. Check the mating surface of the unit with the machine for fl atness (tolerance 0.5 mm). Check the condition of all the seals on the pipework unions. If the unit has been stored for an extended period, clean it. Off er the distribution unit up to the machine and secure it with bolts. Connect the pipework to the unit, in accordance with the connection diagram and the recommended
torque settings. Ensure that fl exible hoses have clearance; they must not be twisted or rubbing on anything. When assembly is complete the machine can be put back into operation:
Turn down the LS pressure limiter before starting up the machine. Keep one of the distributor lines activated after the hydraulic cylinder connected to it reaches
its end stop.
bOn the distribution line in question, the value of the secondary pressure limiter must be greater than that to be set with the LS limiter. Adjust the maximum pressure measured in M at the LS pressure limiter. Retighten the locknut on the adjusting screw to torque: 20 10% Nm.
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5 SX 14 S unit REPAIR PROCEDURES
5.1 CHANGING THE LS LIMITER
NOTE: It is not necessary to remove the distribution unit from the machine to change the limiter.
b With the machine stopped: Put all the machines receivers connected to the distribution unit in their rest positions.
- With the machine stopped, release all stored pressure by moving the distribution slides.
NOTE: Catch any leaked oil in an appropriate container.
On the inlet, unbolt the LS limiter (17 mm spanner).
Refi tting: tightening torque: cf. 6.
5.2 CHANGING THE FLOW REGULATOR
NOTE: It is not necessary to remove the distribution unit from the machine to change the limiter.
b With the machine stopped: Put all the machines receivers connected to the distribution unit in their rest positions.
- With the machine stopped, release all stored pressure by moving the distribution slides.
NOTE: Catch any leaked oil in an appropriate container.
On the inlet, unbolt the LS limiter (22 mm spanner).
Refi tting: tightening torque: cf. 6.
Filter removal and replacement
Using fl at-nosed pliers, remove the fi lter from the regulator.
b Take care not to damage the O-ring at the end of the regulator.Filter
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5.3 DIS-ASSEMBLY OF FLOW DIVIDER REGULATION SUB-ASSEMBLY
NOTE: It is not necessary to remove the distribution unit from the machine to change the limiter.
b With the machine stopped: Put all the machines receivers connected to the distribution unit in their rest positions. With the machine stopped, release all stored pressure by moving the distribution slides.
NOTE: Attach a vacuum pump to the tank to limit the escape of oil during this operation.
Catch any leaked oil in an appropriate container.
Remove the plug (12 mm Allen key) Remove the stop and the spring.
Refi tting: tightening torque: cf. 6.
Replace any defective parts. Replace the O-rings on the plugs. Re-assembly is the reverse of dis-assembly.
5.4 FLUSHING VALVE REMOVAL
NOTE: There is no need to remove the control block from the telehandler for this operation.
b Telehandler switched off : - Place all actuators connected to the control block
in their rest position. - Release all stored pressure by moving the distribution
slides.
Piston kit
O-ringsBall
Sealing kit
Selector kit
Priorityfl ow divider
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- On the outlet element, unscrew the fl ushing valve plug (12 mm Allen key).
Re-fi tting: Replace the plug O-ring. Tightening torque: cf. 6.
Remove: - the shim,- the spring,- the ring,- the piston.
Re-assembly is the reverse of dis-assembly.
5.5 SLIDE REMOVAL
NOTE: There is no need to remove the control block from the telehandler for this operation.
b Telehandler switched off : - Place all actuators connected to the control block in their rest position.
- Release all stored pressure by moving the distribution slides.
NOTE: Fit a vacuum pump to the fl uid reservoir in order to limit
any possible oil leaks during this operation. Catch any oil leaks in an appropriate recipient.
Remove the cover fi xing screws (5 mm Allen key).
Reassembly: tightening torque: cf. 6.
Remove the cup and spring. Remove the O-ring from the cover. Extract the spool from the distribution element.
Re-fi tting: Grease new seals when fi tting.
b Spool fi tting direction.
T3
Piston
Shims
Spring
O-ring
Plug
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1
2
3
5.6 DIS-ASSEMBLY AND RE-ASSEMBLY OF CONTROL BLOCK
Preliminary operations:
Remove the control block from the telehandler (cf. 4).
Remove the 3 assembly nuts (13 mm socket).
Reassembly: tightening torque: cf. 6.
Remove the outlet (1). Separate the distribution units (2) from the inlet (3). Replace the O-rings between the distribution elements,
the input element and the output element. If the input element is to be replaced, remove the tie rods. Assembly is the opposite of dis-assembly, ensuring that
tie rods are torqued to the correct torque. Before commencing, ensure that mating faces on the
elements are clean.
Individual pressure compensator removal
Unscrew the plug (7 mm Allen key).
Remove the compensator piston.
Clean the pistons nozzle with compressed air.
Check the condition of the bore in the body.
Re-assembly: replace the O-ring and the anti-extrusion ring in the plug.
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Load hold check valve disassembly
Unscrew the plug (5 mm Allen key).
Remove the spring and the poppet.
Visually inspect the parts for condition.
If necessary, replace any defective parts.
Re-fi tting: Replace the plug O-ring. Tightening torque: cf. 6.
6 SPECIFIC TIGHTENING TORQUE
Tightening torques given in Nm 10%.
Ref. torque N.m Inlet component:1 LS pressure relief valve: 452 LS Flow regulator: 3,53 DLS/LS selector: 204 Priority valve seat: 105 Priority valve plug: 100
Distribution module6 Non-Return Valve: 30 to 357 Balance plug: 608 Hydraulic Control Housing: 109 Return housing: 1010 EMS module control piston: 1011 EMS module: 15
Output module12 Flushing valve plug: 10013 Tie-bolt nuts: 42
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5 N.m1 N.m
5 N.m
20 N.m
100 N.m
10 N.m Loctite 542
20 N.mLoctite 542
45 N.m 6 N.m
3,5 N.m 0,5 N.m
45 N.m20 N.m
10 N.m
10 N.m
30-35 N.m60 N.m
30-35 N.m
T3
100 N.m
42 N.m
1 - Pressure limiter2 - Flow controller3 - DLS/LS Selector4 - Priority valve seat5 - Priority valve plug6 - Non-return valve7 - Balance plug
8 - Hydraulic control housing9 - Return housing
10 - EMS module control piston11 - EMS module12 - Flushing valve plug13 - Tie-bolt nuts
1
2
3
5
4
7
6
10 11
8
9
12
13
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DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
PREPARATION AND SAFETY INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DISTRIBUTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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50 60 70 80 90
100 125 130 140 15
DISTRIBUTOR
Key:
A - Distributor
PREPARATION AND SAFETY INSTRUCTIONS
Stabilise the machine on a horizontal fl oor above a pit. Lift the boom. Deactivate the battery power supply using a battery cut-off .
A
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DISTRIBUTOR REMOVAL
Place the two safety systems (Item 1) on the compensation cylinders and operate the battery cut-out.
Remove the cover plate (Item 2) on the cab.
Place a container under the carriage at the level of the distributor.
Remove the hose (Item 3) using a 41 mm spanner.
Remove the T+hose (Item 4) using a 46 mm spanner.
Remove the hose (Item 5) using a 46 mm spanner.
Remove the hose (Item 6) using a 19 mm spanner.
Remove the four hoses (Item 7) using a 30 mm spanner, mark them to make refi tting them easier.
Remove the four hoses (Item 8) using a 36 mm spanner, mark them to make refi tting them easier.
Remove the two hoses (Item 9) using a 19 mm spanner, mark them to make refi tting them easier.
1
2
3
4
5
6
8787
788 7
9889
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Disconnect the two connectors X29 (Item 10) and X35 (Item 11) and mark them to make refi tting them easier.
Remove the three hoses (Item 12) using a 19 mm spanner, mark them to make refi tting them easier.
Remove the hose (Item 13) using a 30 mm spanner.
In the cab, remove the two cover plates (Item 14 and 15) (sixscrews) using a 4 mm hexagonal spanner.
Disconnect the emergency stop connector (Item 16).
Remove the three hoses (Item 17) using a 19 mm spanner, mark them to make refi tting them easier.
15
14
16
17
17
17
12
12
12
13
1012
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Remove the hose (Item 18) using a 19 mm spanner, mark it to make refi tting it easier.
Disconnect the three connectors X28 (Item 19), X34 (Item 20) and X92 (Item 21), mark them to make refi tting them easier.
Disconnect the connector X23 (Item 22) and the ground X105 (Item 23).
Remove the retaining screw (Item 24) from the distributor support bracket using a 19 mm spanner.
Remove the retaining screw (Item 25) from the distributor support bracket using a 19 mm spanner.
19 20 21
18
22
23
24
25
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Remove the distributor (Item 26).
26
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DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
PREPARATION AND SAFETY INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DISTRIBUTOR REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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50 60 70 80 90
100 125 130 140 15
DISTRIBUTOR
Key:
A - Distributor
PREPARATION AND SAFETY INSTRUCTIONS
Stabilise the machine on a horizontal fl oor above a pit. Lift the boom. Deactivate the battery power supply using a battery cut-off .
A
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DISTRIBUTOR REFIT
Raise the distributor (Item 1), tighten the retaining screw (Item 2) using a 19 mm spanner.
In the cab, tighten the retaining screw (Item 3) on the distributor support bracket using a 19 mm spanner.
Connect the ground X105 (Item 4) and the connector X23 (Item 5) in the plug (Item 6).
Connect the three connectors X28 (Item 7), X34 (Item 8) and X92 (Item 9) by following the markings.
Fasten the hose (Item 10) using a 19 mm spanner by following the markings.
3
21
5
4
6
7 8 9
10
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Fasten the three hoses (Item 11) using a 19 mm spanner by following the markings.
Fasten the hose (Item 12) using a 30 mm spanner.
Fasten the three hoses (Item 13) using a 19 mm spanner by following the markings.
Disconnect the two connectors X29 (Item 14) and X35 (Item 15) by following the markings.
Fasten the two hoses (Item 16) using a 19 mm spanner by following the markings.
Fasten the four hoses (Item 17) using a 36 mm spanner by following the markings.
Fasten the four hoses (Item 18) using a 30 mm spanner by following the markings.
Fasten the hose (Item 19) using a 19 mm spanner.
11
11
11
13
13
13
12
1415
19
17181718
181717 18
168816
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Fasten the hose (Item 20) using a 46 mm spanner.
Fasten the T+hose (Item 21) using a 46 mm spanner.
Fasten the hose (Item 22) to the T (Item 21) using a 41 mm spanner.
In the cab, connect the emergency stop connector (Item 23).
Position and fasten the two cover plates (Item 24 and 25) (sixscrews) using a 4 mm hexagonal spanner.
Position and fasten the cover plate (Item 26) to the cab.
Remove the two safety systems (Item 27).
Turn the current back on by means of the battery cut-out.
Top up with hydraulic oil.
22
21
20
24
25
23
27
26
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HYDRAULIC SPECIFIC TOOLING
pages
COFFRET MANOMTRES DE BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
COFFRET MANOMTRE DIGITAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
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1 2 3 3 4 5 5 6
78
Basic manometer kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .549671
Consisting of:
1. 1 Manometer 1-9 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549882 2. 1 Manometer 0-40 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549883 3. 2 Manometers 0-60 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549884 4. 1 Manometer 0-400 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549885 5. 2 Manometers 0-600 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549886 6. 4 Standard hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549887 7. 2 Hoses for Maniscopic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549888 8. 7 Manometer connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549889
This box contains all the components required for measuring pressure on all Manitou products.
BASIC MANOMETER KIT
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Digital Manometer box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .662187
Consisting of:
1. 1 dP HP 700 bar Mano digital manometer 2. 1 measurement hose DN2 1215/1620, L = 1,5 m, 630 bar 3. 2 measurement hoses DN2 1620/1620, L = 1,5 m, 630 bar 4. 2 1620 Manometer adaptors
FUNCTIONS :
Manometer functions: the screen can display all the following items:
- Temperature upstream to +/- 2C - Upstream pressure P1 showing minimum and maximum
(700 bar class 0.1) - Downstream pressure P2 showing minimum and maximum
(700 bar class 0.1) - Diff erential pressure dP=P1-P
Hold Function: the operator is able to freeze the display to take notes at will
Unit Function: the operator can change the measurement unit at will (bar, psi, kPa, mCe).
Tare Function: enables taring
Leakage Test Function: enables pressure variations to be measured over a set time period
Recording Function: a max. of 16000 values may be recorded. The sampling period can be confi gured.
Zero Function: zero is carried out on 2 sensors
DIGITAL MANOMETER BOX
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TABLE OF CONTENTS 70HYDRAULIC CHARACTERISTICS ANDSPECIFICATIONSSTEERING PUMP/DIRECTIONAL BLOCK OSPC 200 LSCOUNTER BALANCE VALVEBOOM SUSPENSION ELECTROVALVE (OPTION)ACCUMULATOR BLOCKMASTER CYLINDER WITH ASSISTANCESX 14 S DISTRIBUTOR (INLET)SX 14 S DISTRIBUTOR (TILT)SX 14 S DISTRIBUTOR (TELESCOPING - ACCESSORY)SX 14 S DISTRIBUTOR (ELEVATION)SX 14 S DISTRIBUTOR (CLOSING)TILT CUT-OFF VALVE (VCI)STEERING SELECTORCASAPPA MVP 60 PUMPHYDRAULIC PUMP A10VO EK1
HYDRAULIC SCHEMATIC DIAGRAMSHYDRAULIC COMPONENTS LOCATIONHYDRAULIC CONTROL AND ADJUSTMENTHYDRAULIC COMPONENTS REMOVALHYDRAULIC COMPONENTS REFITHYDRAULIC SPECIFIC TOOLING
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