MANITOU MLT 845 MERCEDES BENZ 647182EN_Group 70 (Hydraulic)

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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Values indicative only

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1

Values for information purposes only.


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.

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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.

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1



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.

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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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3



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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1HYDRAULIC CHARACTERISTICS

AND SPECIFICATIONS


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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1HYDRAULIC CHARACTERISTICS AND

SPECIFICATIONS


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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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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SPECIFICATIONS


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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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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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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1HYDRAULIC SPECIFICATIONS AND

CHARACTERISTICS


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


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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SPECIFICATIONS


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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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)

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CHARACTERISTICS


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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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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CHARACTERISTICS


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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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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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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CHARACTERISTICS


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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TprPrEF

D

The hydraulic pressure arrives at the entry module with pump stand-by pressure.

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CHARACTERISTICS


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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CHARACTERISTICS


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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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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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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CHARACTERISTICS


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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ANDSPECIFICATIONS


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


Description

Notes: ___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Arrival of distributor signal

Flow regulator FR

Flow regulator DR

Proportional electrovalve

Control cylinder

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ANDSPECIFICATIONS


Flow of fl uids

Position of machine in stop mode or:

Governing faultGoverning deactivated

Notes: ___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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Flow of fl uids

Small displacement position 60%

Notes: ___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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ANDSPECIFICATIONS


Flow of fl uids

Large displacement position 100%

Notes: ___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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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

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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.


70

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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




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



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


(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


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


(26/09/2012)70-03-M209EN

704


D

MDLSS

TddTdd

4

TP3

12

TprPr

T

P

LS

FEMS

A

MA

VCI

PD

D

P

N

R

CA

FR


(26/09/2012) 70-03-M209EN

70


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


3 HYDRAULIC BOOM CIRCUIT


VI

VT

CSP

CSP

PAAV

(26/09/2012) 70-03-M209EN

70


LOCATION

4 BOOM COMPENSATION HYDRAULIC CIRCUIT


D

VC

VC

VIP-VC

VIT-VC

(26/09/2012)70-03-M209EN

708


M

DLS

Tdd

D

D

PD

SC

D3

M

DLS

Tdd

D

D

PD

D3

5 STEERING HYDRAULIC CIRCUIT



(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

(26/09/2012) 70-04-M209EN

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


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


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


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


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


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)

(26/09/2012) 70-04-M209EN

70


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.

(26/09/2012)70-04-M209EN


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.

(26/09/2012) 70-04-M209EN

70


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


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).


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


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.


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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3HYDRAULIC COMPONENTS REMOVAL

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 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.


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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5HYDRAULIC COMPONENTS REMOVAL

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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3HYDRAULIC COMPONENTS REFIT

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.


11

11

11

13

13

13

12

1415

19

17181718

181717 18

168816

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5HYDRAULIC COMPONENTS REFIT


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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COFFRET MANOMTRES DE BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

COFFRET MANOMTRE DIGITAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

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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

MANITOU MLT 845 MERCEDES BENZ 647182EN_Group 70 (Hydraulic)

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Transcript of MANITOU MLT 845 MERCEDES BENZ 647182EN_Group 70 (Hydraulic)