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Electro - Hydraulic System

29.6 - 29.6LP & 35.7

DF05_J06_ Updated: 18- January - 2010

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Hydraulic tank
1)Increased capacity = 120 lts..
2)Larger top opening for improved access.
3)Removable inner baffle plate.
4)Cleaned and treated in production

REMOVABLE BAFFLE
PLATE

REMOVABLE BAFFLE
PLATE

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Two versions of hydraulic system

GEAR PUMP VERSION

P/N 0.900.1305.9 LS type

CONTROL VALVE with
DUMP VALVE

PISTON PUMP VERSION

P/N 0.900.1308.2 LS type CONTROL VALVE

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Two types of main valve block

TELESCOPIC

TILT + COMP.
EXIT BLOCK

AUXILIARY

INLET BLOCK
BOOM LIFT
GEAR PUMP VERSION: 0.900.1305.9

PISTON PUMP VERSION: 0.900.1308.2

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Main valve block– Schematics Gear pump version

INLET BOOM LIFT AUX TELE EXIT

TILT
BLOCK BLOCK

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Main valve block– Schematics Piston pump version

INLET BLOCK BOOM LIFT TILT AUX TELE

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GEAR PUMP
VERSION

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Implement pump – GEAR

Casappa Pump 45cc

1

4
3 Delivery port
3
4 Suction port
4 3

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Oil supply to control valve

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Main control valve – Inlet block

LS relief

Steering priority valve

LS Bleed

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Main control valve ( GEAR PUMP ) – Inlet block connections

PORT D – Oil supply to
steer orbital unit ( after
PRIORITY valve) PORT LS –
pressure port
fitted T

PORT T – Oil return

to tank

PORT P - Oil delivery

from implement pump
P

PORT DLS – LS signal

from steer orbital unit

PORT M – Pressure gauge

M
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Main control valve (GEAR PUMP) Steer priority valve

LS Relief

L.S. Bleed

T
P
D
M

Priority valve spool

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Main control valve – LS Bleed

After controls have returned to

neutral, the residual pressure in
the LS line, is quickly discharged
through the calibrated orifice of
the LS bleed valve.

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Main control valve – LS relief

When pressure in the LS line

reaches 2 bar , LS relief valve
opens to tank, limiting the max
pressure in the system.

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Main control valve – Spool section

SPOOL

COMPENSATOR

SPOOL

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Main control valve – Compensated flow

2 simultaneous movements: M1 and M2 ; M1 is demanding more pressure than M2 ( P1 is higher than P2)

M2 P2 M1
P1

P1 Higher than P2
Q1 Higher than Q2

Q = Flow ( lts/min)
P = Pressure ( bar )
PILOT PRESSURE LS

LOW PRESSURE

HIGH PRESSURE

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Main control valve ( GEAR PUMP) – End block DUMP

VALVE

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Main control valve – operation of dump valve

( only Gear pump )

With controls and spools in neutral position, When a spool is moved as a consequence of a
the dump valve opens as a consequence of the commanded movement, the pilot pressure in
stand by pressure ( at least 22 bar needed ) in the LS line, locks the dump valve in closed
the system and dumps oil to tank. The control position. Oil is therefore available for the
valve works as an open center. function.

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LS relief pressure – Dump valve function

M = 250 bar
LS = 225 bar

LS relief valve limiting

the LS pressure LS line LS port P ( bar ) = 225
P line main pressure M port P ( bar ) = 250
T return to tank Dump valve balanced opens
passage to tank.
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Main control valve - Exit block

DUMP VALVE

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Main control valve (GEAR PUMP) – End block connections

IMPORTANT NOTE: In
absence of CHARGE
pressure servo controls
are non operational !!!

PORT Pr – CHARGE pressure from G port hydrostatic pump

To Pr
Tpr

Pr PORT Tpr –
Pilot oil
G port TANK
return to
tank

Hydrostatic pump 21
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Pressure check points (Gear pump)

Located on main control valve. Accessible from rear

chassis opening.

PORT D

MAIN
IMPLEMENT
+ STEERING
PRESSURE

PORT M

PORT LS
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PISTON PUMP
VERSION

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Implement pump - LS

LS Pilot

SUCTION

DELIVERY
CASE DRAIN

PUMP CONNECTIONS

45 cc Max displacement

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Main control valve (PISTON PUMP) – Inlet block connections

PORT D – Oil supply to
steer orbital unit ( after
PRIORITY valve) PORT LS –
connected to
port X on T
Piston pump

PORT T – Oil return

to tank

PORT P - Oil
delivery from
implement P
pump

PORT DLS – LS signal

from steer orbital unit

PORT M – Pressure gauge

M
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Main control valve – LS Bleed

After controls have returned to

neutral, the residual pressure in
the LS line, is quickly discharged
through the calibrated orifice of
the LS bleed valve.

26
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Main control valve (PISTON PUMP) – Steer priority valve

LS Relief

L.S. Bleed

T
P
D
M

Priority valve spool

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Main control valve – LS relief

When pressure in the LS line

reaches 2 bar , LS relief valve
opens to tank, limiting the max
pressure in the system.

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Main control valve ( PISTON PUMP) – End block connections

IMPORTANT NOTE: In
absence of CHARGE
pressure servo controls
are non operational !!!

PORT Pr – CHARGE pressure from G port hydrostatic pump

To Pr
Tpr

Pr PORT Tpr –
Pilot oil
G port TANK
return to
tank

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Pressure check points (Piston pump)

Located on main control valve. Accessible from rear
chassis opening.

MAIN
IMPLEMENT
+ STEERING
PRESSURE

PORT M

PORT LS
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Main return line and filter

Filter
Breather

Return Filter

31
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Hydraulic return filter

Filter breather

32
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Hydraulic filter clogging indicator switch

ERROR CODE
2332 -
HYDRAULIC
FILTER
RESTRICTION

UGM

J2(24)

Normally the contacts of the switch are closed ( Input is grounded) to indicate filter is
clean. When the filter differential pressure rises above 1,2 bar the pressure switch
contact will open indicating a filter restriction.
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ELECTRO
HYDRAULIC
SYSTEM

34
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Joystick
P/N 0.900.1321.4

+
XG ( 8 )

Power from fuse F22 After ignition

J7 CAN 1

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Joystick switches

AUXILIARY ELECTRIC

AUXILIARY SWITCH
CONTINOUS
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Servo controls electric circuit

X2

37
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Servo controls
MAX CURRENT : 1.7 A ( 1700 mA)
Coil resistance at 20°C = 3.5 Ohms
Integrated protection diode = NONE

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Lift Cylinder

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P Return
Lift Up
2)

DIAGNOSTICS / CABIN FUNCTIONS /

)

(
11

J3

MAIN LIFT COMMANDED: 1500 mA

(
J2

MAIN LIFT ACTUAL :1500 mA

UGM

CAN - BUS

JOYSTICK
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2)
Lift Down
(
J3
)
22
(
J2

DIAGNOSTICS / CABIN FUNCTIONS /

UGM MAIN LIFT COMMANDED: 1500 mA
MAIN LIFT ACTUAL:1500 mA

CAN - BUS

JOYSTICK P Return
41
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Boom angle sensor

Lowest position Highest position

42
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Boom angle sensor installation 29.6

43
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Boom angle sensor installation 35.7

44
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Telescopic cylinder

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JOYSTICK Telescopic extend

CAN - BUS

UGM
)
4)

35
(
J3

(
J2

DIAGNOSTICS / CABIN FUNCTIONS /

TELESCOPE COMMANDED: 1500 mA
TELESCOPE ACTUAL :1500 mA

P Return
46
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P Return
Telescopic retract
DIAGNOSTICS / CABIN FUNCTIONS /
TELESCOPE COMMANDED: 1500 mA
TELESCOPE ACTUAL :1500 mA
4)
(
J3
)
34
(
J2

UGM

CAN - BUS

47
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JOYSTICK
Tilt Up
CAN - BUS
COMP
CYLINDER

DIAGNOSTICS / CABIN
FUNCTIONS /
TILT COMMANDED: 1500 mA
TILT ACTUAL:1500 mA TILT
CYLINDER

UGM
8)
6)

(
J2
(
J3

P Return
48
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JOYSTICK
Tilt Down
CAN - BUS COMP
CYLINDER

DIAGNOSTICS / CABIN
FUNCTIONS /
TILT COMMANDED: 1500 mA
TILT ACTUAL:1500 mA
TILT
CYLINDER

UGM
6)

)
19
(
J3

(
J2

P Return
49
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Compensation circuit

Kg
0 Degrees

Kg
0 Degrees

COMPENSATION

Compensation cylinder on side of boom connected to tilt cylinder through main control valve,
works to maintain level of forks all along the boom lift and lower arc.

50
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Compensation cylinder
Improved boom hinge fixation. Two
bolts on a mobile plate. Fixation moved
on right side of boom ( opposite to the
compensation cylinder.

One compensation cylinder on left side of boom.

51
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Anti kick valve

Anti kick valve helps to reduce stress on boom

base while the tilt circuit is operating at high
pressure ( example = bucket work ).

52
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Compensation – Boom Lift Up

Boom Lift Up results in the

Comp cylinder extending, there
fore pressurizing its rod side.

Oil is transferred to the TILT cylinder

rod side, resulting in the same to
retract ( TILT DOWN).

Lines connected to Port A2 on main control

valve are pressurized. TILT Spool remains in
neutral position ( closing A2 and B2 ports).
Overpressure is discharged through port relief
valve set at 280 bar.
53
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Port relief valve A2

Pressure relief at 280 bar

54
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Compensation – Boom Lift Down

Boom Lift Down results in the

Comp cylinder retracting, there
fore pressurizing its piston side.

Oil is transferred to the TILT cylinder

piston side, resulting in the same to
extend ( TILT UP).

Lines connected to Port B2 on main control

valve are pressurized. TILT Spool remains in
neutral position ( closing A2 and B2 ports).
Overpressure is discharged through port relief
valve set at 280 bar.
55
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Port relief valve B2

Pressure relief at 280 bar

56
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Operation of the anti kick valve

TILT CYLINDER

COMPENSATION
ANTI KICK CYLINDER
VALVE

During heavy bucket work, pressure in the piston side of the tilt cylinder operates almost
constantly to the maximum spec ( 250 bar ) with possible peaks of higher pressure. The Anti
kick valve isolates the piston side of the COMPENSATION cylinder in order to reduce stress
transferred to the boom base.
57
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Operation of the Anti kick valve_2

TILT CYLINDER BOOM LIFT UP

COMPENSATION
ANTI KICK CYLINDER
VALVE

Example shows compensation circuit at work when the boom is LIFT UP. The anti kick
valve is piloted open to allow flow of oil from the tilt cylinder piston side to the
compensation cylinder piston side.

58
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Front auxiliary

CLOSE CENTER FUNCTION. When

command is released, residual
pressure can be discharged by
using the CONTINOUS AUXILIARY
SWITCH ( see next page).

2nd auxiliary hydraulic + electric

( Option ) shown here.

59
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JOYSTICK Aux B

CAN - BUS DIAGNOSTICS / CABIN FUNCTIONS /

AUXILIARY COMMANDED: 1500 mA
AUXILIARY ACTUAL:1500 mA

UGM
)
14
(

)
J3

20
(
J2

P Return
60
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JOYSTICK
Aux A

CAN - BUS
DIAGNOSTICS / CABIN FUNCTIONS /
AUXILIARY COMMANDED: 1500 mA
AUXILIARY ACTUAL:1500 mA

UGM
)
14
(

9)
J3

(
J2

P Return
61
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Auxiliary residual pressure dump

In order to dump any residual pressure trapped in the auxiliary lines, the operator has to:
-Push and release two times the shown switch
-Then push and hold for at least 30 seconds until the pressure is released.
• IMPORTANT: Engine must be running
P (Bar)
250

T ( sec)

HOLD
Minimum 30 seconds

PUSH Release PUSH Release PUSH Release

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STEERING

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Orbital – steering pump

ORBITAL CONNECTIONS

LS Pilot line to DLS

port on entry block

From priority valve – Entry

block port D

Steering pressure switch Return to tank

Left Right

L R

Bar 170
+/- 10
P
T

R
L
P T
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Steer pressure switch

ERROR CODE - 8638 –
LOW STEER PRESSURE

Steer pressure J1(35)

switch Setting
5 Bar

Under normal conditions pressure switch contact is closed ( input is grounded).

If steer pressure drops below 5 bar, contact will open, indicating low steer pressure.

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Steering priority valve

Steering priority
valve

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Delivery to port P of Steering orbitrol unit

Pilot signal
form
Orbitrol

Less than Less than

12 bar 12 bar

Pilot signal to pump

Phase 1 –
Delivery from
LS PUMP
engine starting – no
steering
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Delivery to port P of Steering orbitrol unit

Pilot signal
form
Orbitrol

12 bar 20 bar

Pilot signal to pump

Phase 2 –
Delivery from
LS PUMP
engine started – no steering -
stand by pressure
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Delivery to port P of Steering orbitrol unit

Pilot signal
form
Orbitrol

P= More
P – 12 bar than 20 bar

Pilot signal to pump

Delivery from
LS PUMP

Phase 3 – boom movement

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Delivery to port P of Steering orbitrol unit

Pilot signal
form
Orbitrol

More than More than

20 bar 20 bar

Pilot signal to pump

Delivery from
LS PUMP Phase 4 - steering
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Steer select valve

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2 Wheel steer

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4 Wheel steer

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Crab Steer

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Complete hydraulic schematics – Gear pump

DWG.1001109615
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Complete hydraulic schematics – Piston pump

DWG.1001110010
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PRESSURE
CHECKS AND
ADJUSTMENTS

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Stand by pressure check ( GEAR PUMP )

1) Fit 0- 40 bar range pressure gauge fitted on port M of main control valve.

When controls are left in NEUTRAL,

DUMP VALVE begins to open at 20-22
bar allowing oil flow to tank.

Port M

2) Start engine, low idle, all controls in NEUTRAL.

3) Pressure should be 20-22 bar

DUMP
VALVE

MAIN CONTROL VALVE

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Stand by pressure check ( PISTON PUMP)

1) Fit 0-40 bar range pressure gauge fitted on port M of main control valve

This valve block is NOT fitted

28-30 bar with a dump valve, therefore
the circuit is closed ( closed
center spools)

Port M

2) Start engine, low idle, all controls in NEUTRAL.

3) Pressure should be 28- 30 bar

Stand by pressure can be adjusted

here. Turn clockwise to increase MAIN CONTROL VALVE
pressure.
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Max Implement pressure check (GEAR & PISTON PUMP)

1) Connect a 0- 600 bar range pressure gauge to port M of Main control valve.
2) Start engine, low idle, in this example, engaging TELE IN function to end stroke.

3) Max pressure should be 260 bar.

To LIFT cylinder

Port M

PUMP

MAIN CONTROL VALVE

LS Relief valve

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Max steer pressure check ( GEAR & PISTON PUMP)

1) Connect gauge on port D, Engine running , low idle, leave joystick controls in NEUTRAL,
activate steering full stroke.

NOTE: 2WS mode shown here.

180 - 190 bar

MAIN
CONTROL
STEER ORBITAL
VALVE
UNIT PRIORITY
VALVE
PUMP

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RESUME OF PRESSURE CHECKS

Valid only for GEAR pump version.

Engine =
DEUTZ Low Idle speed = 950 rpm High Idle speed = 2350 rpm
TCD2012
HYDRAULIC PRESSURE READINGS ( Bar )
Low Idle Neutral High Idle Neutral Steer to end stroke Low Idle Steer to end stroke High Idle Tele IN Low Idle Tele IN High Idle
Port M 22 29 185 194 250 250
Port D 18 18.5 180 180 21 22
Port LS 5.5 6 168 168 225 225

D
LS

M
Ports M & D Port LS

Use 0- 40 bar gauge for pressure checks in NEUTRAL.

Change to 0- 600 bar gauge for checks while commanding a function.
Alternatively use a digital pressure gauge ( 0- 700 bar range).

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RESUME OF PRESSURE CHECKS

Valid only for PISTON pump version.

Engine =
DEUTZ Low Idle speed = 950 rpm High Idle speed = 2350 rpm
TCD2012
HYDRAULIC PRESSURE READINGS ( Bar )
Low Idle Neutral High Idle Neutral Steer to end stroke Low Idle Steer to end stroke High Idle Tele IN Low Idle Tele IN High Idle
Port M 28-30 28-30 200 200 260 260
Port D 20-22 20-22 190 190 20-22 20-22
Port LS 8-9 8-9 175 175 240 240

D
LS

M
Ports M & D Port LS

Use 0- 40 bar gauge for pressure checks in NEUTRAL.

Change to 0- 600 bar gauge for checks while commanding a function.
Alternatively use a digital pressure gauge ( 0- 700 bar range).

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HYDRAULIC STALL TEST

1) Start engine, accelerate to high idle ( 2350 rpm).
2) Stall each hydraulic function (end stroke) and note the engine
rpm drop.
3) Compare the results to the standard.

GEAR PUMP VERSION PISTON PUMP VERSION

Hydraulic stall test Hydraulic stall test

Throttle set ( rpm ) Throttle set ( rpm )
Function STD Function STD
NEUTRAL 2350 NEUTRAL 2350
Boom lift up 2300 Boom lift up 2325
Boom lift down 2250 Boom lift down 2325
Tele in 2250 Tele in 2325
Tele out 2250 Tele out 2325
Combined Tele in + Boom lift down 2250 Combined Tele in + Boom lift down 2325
Combined Tele out + Boom lift up 2250 Combined Tele out + Boom lift up 2325
Tilt up 2250 Tilt up 2325
Tilt down 2250 Tilt down 2325
Aux A 2250 Aux A 2325
Aux B 2250 Aux B 2325
Steer left 2WS 2275 Steer left 2WS 2325
Steer right 2WS 2275 Steer right 2WS 2325
Steer left 4WS 2275 Steer left 4WS 2325
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