Service Manual Working hydraulic

Function

Working hydraulic - Function

A. Neutral function Function schematic, see page 9/10

1. Pilot control
Pressurized oil supply from travel hydraulic "Replenishing" (see section 6.3) 92
check valve 52 P-distributor block 50 accumulator 55.
P-solenoid valve Y4.
After lowering the safety lever (solenoid valve Y4 shifted):
from solenoid valve Y4-B/distributor block 50-GP zu P-pilot control 115 regulating piston 116 bis 119
blocked.
test point ND.
The control lines from the pilot control 115 - outlets 1 to 4- are relieved via the regulating pistons 116 to 119 and
line connection T to the tank.

2. Working circuit - regulating pump 100

In resting position, the axial piston unit 101 of the regulating pump 100 is at maximum angle.
With the starting procedure of the Diesel engine, the pump starts to supply, LS-regulator 110 is moved
immediately against the spring and the axial piston unit 101 is moved to smallest angle = Qmin – flow by the
control cylinder 102.
A stand by pressure of 20+2 bar is retained in the system.

Current flow sequence:

Tank 80 shut off valve 81 regulating pump 100/axial piston unit 101
intern intermediate plate 111 P-solenoid valve Y28-A intermediate plate 111
regulator 105 (2x) pressure cut off valve106 /blocked.
(2x) LS-regulator 110 /shifted
restrictor 107 housing strainer 85 tank 80.
Pressure cut off valve106
restrictor 107 housing strainer 85 tank 80.
intermediate plate 111 control cylinder 102.

extern P-control valve block 130 PR valve131 /blocked.

outlet MP test point HD.
spool valve 140 /blocked.
spool valve 145 /blocked.
end plate 155
flushing valve 156/stage piston 157 (directional valve 158
shut off) tank line

In the branches of the tank line to the spool valve 140 and 145, pressure relief valve 131 and 142, plug 147 as well
LWT / Ausgabe / Edition / Edition / 02.2011

as solenoid valve Y3 and Y23, the oil is blocked. The control valve block 130 however is supplied with oil from both
sides and evenly warmed up.
Oil discharge via restrictor 107 ca. 3 l/min, via flushing valve 156 ca. 15 l/min.
The regulator connection X/test point LS (= LS signal) is relieved via two way check valve 149, spool valve 140
and end plate 155 spool valve 145 to the tank channel.

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Working hydraulic Service Manual
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3. Working circuits user – secondary relief

The supply and discharge lines of the user – hoist and tilt cylinder – are shut off. If necessary, these hydro
system parts are protected with secondary relief valves against overloads caused by external influences.
Hoist cylinder 170 – shut off by spool valve 140. Passage for pressurized oil on solenoid valve Y3 and Y5 is shut
off. The piston 161 for the quick drop unit 160 is held in neutral position (no passage). Secondary relief (290±10
bar) piston bottom side is provided via the pressure suction valve 142, suction on piston rod side (for piston
movement) is provided via solenoid valve Y5.
Tilt cylinder 175 – shut off by spool valve 145.

B. Constant operating function for certain components

- starting from neutral function as outlined in paragraph A.

1. Regulating pump 100

If a working function is actuated, the piston of the LS-regulator 110 is actuated on one side by the pressure
before the spool valve (= HD) and on the opposite side by the user side pressure (LS - connection X) and the
pressure spring. The pressure ratio on the piston determines its position and therefore the pressure actuation of
the control cylinders 102.
The pressure actuation of the control cylinder 102 against the return spring 103 bring the axial piston unit 101
constantly to the appropriate angle = on demand control for the required oil amount (given by the opening of the
spool valve 140/145).
The pressure on test point HD is 15+6 bar above the pressure on test point LS (HD-LS = p on the spool valve).
At maximum pump flow volume = max. opening of a spool valve, the p (HD-LS) is 13 bar.
The piston of the pressure cut off valve 106 is always actuated by the pressure on the pump side. If the (load)
pressure increases past the adjusted spring value = 260±5 bar, then the piston is moved against the spring. The
pressurized oil supply from the LS-regulator is shut off and the pressurized oil from the system is directed
directly via the pressure cut off to the control cylinder 102. The axial piston unit 101 is moved in direction Qmin,
until only the required amount to retain the maximum operating pressure is supplied = pressure cut off. HD = LS
= p 0 bar.
The oil which is constantly flowing off into the housing from the pump control via the restrictor 107 is used along
with the existing leak oil to flush the housing and flows via connection L strainer 85 to the tank.

1.1. Solenoid valve Y28 – Diesel engine overspeed safety

If the Diesel engine speed becomes excessive due to external influences, then the solenoid valve Y28 is shifted
by the electronic crawler control. The pressurized oil flow from the axial piston unit 101 to the regulator 105 is
shut off on solenoid valve Y28-P B.
The pressure existing in the pump control cylinder 102 is relieved via the intermediate plate 111 restrictor
107 and pressure cut off 106 LS-regulator 110 A-solenoid valve Y28-T to the housing / tank.
The control cylinder 102 has no control power, the return spring 103 sets the axial piston unit 101 to maximum
flow volume, independent of the current demand.
The excessive flow is discharge to the tank after corresponding pressure build up via the primary pressure relief
valve 131. This significantly increased power reduction (amount x pressure) acts as brake force and prevents
LWT / Ausgabe / Edition / Edition / 02.2011

the Diesel engine speed from increasing further.

2. Pilot control 115
The corresponding attachment function is controlled hydraulically by moving the pilot control in the appropriate
directions.
The pressure build up in the servo system and therefore the working speed increases with the deflection angle of
the lever.

Maximum servo pressure = 20+4 bar,

regulated servo pressure build up via regulating piston 116 to 119 = approx. 3,3 bar max.
By deflecting the lever diagonally, a tilt and lift cylinder function can be actuated at the same time.

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 Service Manual Working hydraulic
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3. Control valve block 130

Regulating range of the spool valve 140 und 145 = ca. 3,3 – 21,4 bar

3.1. Spool valve 140 and 145, check valve 141 and 146, two way check valve 149
When the spool valve opens, pressure available on the user side is directed to the two way check valve 149.
The higher pressure moves via the two way check valve to the LS-regulator of pump 100 (resulting in pump
movement in direction Qmax) and to the flushing valve 156 and closes it off.
The passage P user is shut off by the check valve 141/146 until the pressure required by the user has been
built up on the pump side (prevents the load from dropping).
The spool valve path and therefore the opening of the supply and discharge for the user (working speed)
depend on the servo pressure.

3.2. Pressure relief valve 131 – Primary relief

The valve protects the pump and the system from damage due to excessive pressure in case of problems or
incorrect adjustments of the pressure cut off valve. Adjustment value 315 bar.

3.3. Solenoid valve Y3/Y5 – Blade release

The existing pressurized oil moves via a restrictor bore in the stage piston to the spring side of the piston and is
blocked there by the solenoids, which are not energized. Pressure and spring force hold the valves closed.
The tank pressure constantly actuates the ring surface of the stage piston and can lift them in case of a vacuum
in the control valve block- channel A1 A1 (Y3) or B1 B1 (Y5) for suction.

3.4. Solenoid valve Y23 – Quick drop

The oil returning from the user via tank channel MT1 is slightly pretensioned before the stage piston of the
valve opens to the tank connection T. The oil which gets via the restrictor bore in the piston into the spring
chamber flows off via the open passage of the solenoid valve to connection T, without any action.

3.5. Flushing and relief valve 156

3.5.1 Flushing function
In neutral position, the stage piston 157 is lifted by the available pressurized oil, which is in stand by pressure.
A relatively small pump flow volume can now flow off to the tank channel in the control valve block 130 and on
to the tank. The control valve block 130 is thereby supplied with oil from both sides, evenly warmed up and
flushed out.
If a working function is actuated, the stage piston is held closed by the available LS pressure on the larger
surface against the pump flow and the complete pump flow is available for the working function.

The directional valve 158 remains closed / without function in both cases.
3.5.2 Relief function
If a workign function shuts off too quickly, pressure peaks can result in the system. If the pump side pressure
exceeds the still available LS pressure by the spring value of the directional valve 158, the valve piston is
moved by the pressure on the pump side against the spring. A part of the pressurized oil can now flow off into
the tank channel and the creation of pressure peaks is prevented.
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The stage piston 157 is normally closed / without function during the relief function.

4. Quick drop unit, complete 160

Pressurized oil in channel B B1 B1 flows around piston 161 and cannot act against its spring. The channel to
P-solenoid valve Y24 is blocked on A.
Pressurized oil in channel A A1 A1 actuates piston 161 on the front side and gets via a restrictor bore in the
piston into its spring chamber. At the same time, pressurized oil is directed via the intermediate plate 162 P-
solenoid valve Y24-B also into the spring chamber. The piston is actuated on both sides with the same
pressure and is held in neutral position by the higher, spring side force (large surface x pressure) = passage
A1 B1 remains closed.

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Working hydraulic Service Manual
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5. Lift cylinder 170 / End position valves 171

At pressure actuation, the pressure side check valves of the end position valves 171 open. However, the oil flow
is blocked by the second check valve, which acts in the opposite direction.
If the pistons in the lift cylinders reach an end position, the check valves which are blocked until now are
mechanically opened = the valve pistons are on the cylinder bottom / piston rod bearing, the cylinder pistons are
continued to be moved to the stop. The pressurized oil flows via the end position valves to the opposite side, the
system pressure does not increase further.

6. Oil pressure switch B18 – Return filter monitor

If the return filter insert was not replaced in time, the back pressure in the oil return flow increases due to the
filter contamination. Immediately before opening of the filter bypass valve 83, the electrical contact of the
pressure switch is closed (switch point 2.5 bar) and the indicator light on the instrument panel lights up.

C. Operating function – Working movement

- starting from neutral function as outlined in paragraph A and operating functions which remains the same, as
outlined in paragraph B.

1. Lifting the blade

1.1. Servo control

Servo pressure build up from regulating piston 117 to housing outlet 3 b1-control valve block 130
spool valve 140 /move against a1.

1.2. Working circuit

Pressurized oil flow from spool valve 140 zu control valve block - outlet-B1 A- quick drop unit 160
A1/A1
B1/B1- lift cylinder 170/piston rod side.
solenoid valve Y5.
In the lift cylinders, the piston / piston rod is pushed inward, the blade is raised.
Ölrücklauf von lift cylinder/piston bottom side zu B1/B1-quick drop unit 160-B
A1-control valve block 130 spool valve 140 tank line/connection T Rücklauffilter 82 Tank 80.

2. Lowering the blade

2.1. Servo control

Servo pressure build up <22 bar from regulating piston 116 to housing outlet 1
pressure switch ruckschalter B22
G3- distributor block 50 P-solenoid valve Y61-A distributor block 50-a1
a1-control valve block 130 spool valve 140 / move against b1.
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2.2. Working circuit

Pressurized oil flow from spool valve 140 to control valve block- outlet-A1 B- quick drop unit 160 B1/B1
A1/A1- lift cylinder 170/ piston bottom side.
pressure relief valve 142.
one way valve 150.
solenoid valve Y3.
On the lift cylinders, the piston / piston rod move outward, the blade is lowered, it is pulled down due to its own
weight to ground level load pressure build up in oil return, pushed from ground level on load pressure
build up in oil supply.
Oil return from lift cylinder/ piston rod side to A1/A1- quick drop unit 160-A
B1-control valve block 130 spool valve 140 tank line MT1
solenoid valve Y23 block connection T return filter 82 tank 80.

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 Service Manual Working hydraulic
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3. Lowering the blade quickly

3.1. Servo control

Servo pressure build up >22 bar from regulating piston 116 same as ”blade down” – paragraph 2.1,
Pressure switch B22 / electrical contact closed solenoid valve Y23 and Y24 energized / switched.
(see current flow plan 9.4.30 step 36)

3.2. Working circuit

Pressurized oil flow from spool valve 140 same as ”blade down” – paragraph 2.2, but in quick drop unit 160,
channel B1 B1 is connected via P B-solenoid valve Y24 with the spring chamber of piston 161.
Pump 100 / spool 140 provide maximum flow to lift cylinder 170/ piston bottom side.
Oil return flow from lift cylinder/ piston rod side to A1/A1- quick drop unit 160
T-solenoid valve Y24-A blocked.
Piston 161 channel B1 B1 A1- lift cylinder 170/ piston bottom side.
160-outlet A B1-control valve block 130 spool valve 140 tank line MT1
solenoid valve Y23 /blocked.
One way valve 150 oil supply A1 lift cylinder 170/ piston bottom side.
Blade drops to ground level at maximum speed.

4. Tilt blade to the left

4.1. Servo control

Servo pressure build up from regulating piston 118 to housing outlet 4 a2-control valve block 130
spool valve 145 / move against b2.

4.2. Working circuit

Pressurized oil flow from spool valve 145 zu control valve block-outlet A2 axle 173 block 176-B
tilt cylinder 175/piston bottom side.
In the tilt cylinder, the piston / piston rod is pushed outward, the left corner of the blade moves downward.
Oil return flow from tilt cylinder/ piston rod side to A-block 176 A-block 176 axle 173
B2-control valve block 130 spool valve 145 tank line/connection T return filter 82
tank 80.
Via the blade movement, the piston rod / piston is pulled out on the left and pushed in on the right by the lift
cylinder – and an oil flow is mechanically created in the lift cylinder hydraulic circuit (spool 140 remains
closed).

Oil flow at intermediate positions of lift cylinder piston:

Right lift cylinder/ piston bottom side B1-quick drop unit 160-B1
left lift cylinder/ piston bottom side.
Left lift cylinder/ piston rod side A1-quick drop unit 160-A1
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right lift cylinder/ piston rod side.

Oil flow at end position ”raised”:
Right lift cylinder piston – blocked in bottom side end position, end position valves one sided mechanically
opened.
Left lift cylinder piston / movement to piston rod side B1- pressure build up
A1-quick drop unit 160-A1 B1-right lift cylinder/ piston rod side end position valves 171
piston bottom side-A1 B1-quick drop unit 160-B1 A1-left lift cylinder/piston bottom side.
The missing oil volume (piston rod) is drawn via stage piston-solenoid valve Y3, one way valve 150 or the
suction function of the pressure relief valve 142 from the tank line.
Oil flow at end position ”lowered”:

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Working hydraulic Service Manual
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Left lift cylinder piston – blocked in rod side end position, end position valves one sided mechanically opened.
Right lift cylinder piston / movement to piston bottom side A1- pressure build up
B1-quick drop unit 160-B1 A1-left lift cylinder/ piston bottom side end position valves 171
piston rod side-B1 A1-quick drop unit 160-A1
B1-right lift cylinder/ piston rod side.
The excess oil volume (piston rod) is relieved via PR valve142 to the tank.

5. Tilt blade to the right

5.1. Servo control

Servo pressure build up from regulating piston 119 to housing outlet 2 b2-control valve block 130
spool valve 145 / move against a2.

5.2. Working circuit

Pressurized oil flow from spool valve 145 to control valve block-outlet B2 axle 173 block 176-A
block 177-A tilt cylinder 175 /piston rod side.
In the tilt cylinder, the piston / piston rod is pushed inward, the right corner of the blade moves down.
Oil return flow from tilt cylinder/ piston bottom side to B-block 177 B-block 176 axle 173 A2-control
valve block 130 spool valve 145 tank line MT1 solenoid valve Y23 block connection T return filter 82
tank 80.
Via the blade movement, the piston rod / piston is pulled out on the right and pushed in on the left by the lift
cylinder – and an oil flow is mechanically created in the lift cylinder hydraulic circuit (spool 140 remains
closed).
Oil flow intermediate positions of lift cylinder piston:
Left lift cylinder/piston bottom side B1-quick drop unit 160-B1 right lift cylinder/piston bottom side.
Right lift cylinder/piston rod side A1-quick drop unit 160-A1 left lift cylinder/piston rod side.
Oil flow at end position ”raised”
Left lift cylinder piston –blocked in bottom side end position, end position valves one sided mechanically
opened.
Right lift cylinder piston / movement to piston rod side B1-pressure build up A1-quick drop unit 160-A1
B1-linker lift cylinder/piston rod side end position valves 171 piston bottom side-A1 B1-quick drop
unit 160-B1 A1-right lift cylinder/piston bottom side.
The missing oil volume (piston rod) is drawn via stage piston-solenoid valve Y3, one way valve 150 or the
suction function of the pressure relief valve 142 from the tank line.
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 Service Manual Working hydraulic
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Oil flow at end position ”lowered”:

Right lift cylinder piston – blocked in rod side end position, end position valves one sided mechanically opened.
Left lift cylinder piston /movement to piston bottom side A1- pressure build up
B1-quick drop unit 160-B1 A1-right lift cylinder/piston bottom side end position valves 171
piston rod side-B1 A1-quick drop unit 160-A1
B1-linker lift cylinder/piston rod side.
The excess oil volume (piston rod) is relieved via pressure relief valve 142 to the tank.

6. Blade release ( float )

For electrical function, see current plan 9.4. – Steps 35,36

To activate the function blade release, press button S8 on the pilot control momentarily. The retaining solenoid
Y56 on the pilot control is energized via the step relay K7 and the indicator light H6 lights up. When the joystick
is deflected in „blade down“ direction to the stop, the oil pressure switch B22 switches to passage at a servo
pressure of 22 bar, and the solenoid valves Y3, Y5 and Y61 are energized via the relay K76 (PR754 F/N xxx-
6924 10343) or K64 (PR754 F/N xxx-10344 ). The joystick is held by the retaining magnet Y56 in the front
most position.
The solenoid valve Y61 (servo pressure shut off) is switched to diagonal passage, the pressurized oil supply
from the pilot control 115-1 to the spool valve 140-a1 is blocked and the control line is relieved to the tank. This
moves the spool valve via the spring force into neutral position and there is no pump side pressure build up in
the lift circuit.
The solenoid valves Y3 and Y5 are switched to switch position ”passage” and the spring chamber of the stage
piston is therefore relieved to the tank line.
If the blade is raised or lowered due to external influences, then, depending on the movement, a piston bottom of
piston rod side pressure is created in the lift cylinders / lines. This pressure lifts the stage piston of the
corresponding solenoid valves Y3/Y5 and the oil displaced by the blade movement flows off into the tank
channel.
The oil required for the movement on the opposite side of the lift cylinder piston is drawn via the second solenoid
valve from the tank channel. The piston bottom side is also supplied via the one way valve 150 and pressure
relief valve 142.
For detailed function description of valves, see section 8.7.
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Working hydraulic Service Manual
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50 Distributor block 130 Control valve block kpl.

52 Check valve (1 bar) 131 Pressure relief valve
- Primary relief 315 bar
55 Accumulator 140 Spool valve up/down
141 Check valve
60 Test console - test points 142 Pressure relief valve
ND Low pressure - Servo control working hydraulic - Secondary relief 290 bar
LS Load pressure - Load sensing 143 Plug
HD High pressure - working hydraulic 145 Spool valve Tilten
146 Check valve
80 Hydraulic tank 147 Plug
81 Shut off valve 148 Plug
82 Return filter 149 Two way check valve
83 Bypass valve (3 bar) 150 One way valve
85 Strainer 155 End plate
156 Flushing and relief valve
92 From TH. – Tandem gear pump - Replenishing 157 Stage piston
94 To TH. – Supply lines 158 Directional valve
95 To / from hand pump
96 To TH. - Tandemzahnradpumpe - Replenishing 160 Quick drop unit cpl.
97 From TH. – Return lines 161 Piston / installation valve
98 To TH. - Regulating pump – Fan drive 162 Intermediate plate

100 Regulating pump cpl. 170 Lift cylinder

101 Axial piston unit 171 End position valves
102 Control cylinder (Qmin)
103 Return spring (Qmax) 173 Support axle, right
105 Regulator cpl.
106 Pressure cut off valve(260 bar) 175 Tilt cylinder
107 Restrictor (0,6 mm) 176 Block
177 Block
110 Load Sensing regulator
111 Intermediate plate B5 Oil pressure switch – Brake release
B18 Oil pressure switch – Filter monitor (2.5 bar)
115 Pilot control B22 Oil pressure switch – Quick drop / blade release
116 Regulating piston – Blade down (22 bar)
117 Regulating piston – Blade up
118 Regulating piston – Tilt blade to the left Y3 Solenoid valve – Blade release (bottom side)
119 Regulating piston – Tilt blade to the right Y4 Solenoid valve – Safety control
Y5 Solenoid valve – Blade release (rod side)
Y13 Solenoid valve – Parking brake TH.
Y23 Solenoid valve – Quick drop (on control valve
block)
Y24 Solenoid valve – Quick drop (on quick drop unit)
Y28 Solenoid valve – Diesel engine -
Overspeed safety
Y56 Retaining magnet – Blade release
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Y61 Solenoid valve – Shut off servo pressure

Note: TH = Travel hydraulic

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 Service Manual Working hydraulic
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Working hydraulic Service Manual
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