10 10 Common hydraulics ~ 10.4.2 Axial piston pump with variable displacement ‘Axial piston pump with variable displacement he aK ni de ho = 6 10 14 14 i Pos | Explanation Signal description | Reference + | Control vave it and extension sends | See pressure pate Sewo | Tab 7 Load handing, roup 7.2 Litingon- load signal when a function is activated. | pressurelitandextension | ering (on lft frame member. 2 | Control signal goes to the shuttle valve that sends load signal on to hydraulc oil ump no. 3 and no. 4 ‘See pressure plate Servo pressure it anc extension ‘n lft frame member. ‘Shuttle valve, description page 19 3 | Hydraute of! pump no. 8 and no. 4 in- crease the flow. ‘See pressure plate Max. pressure hydraulic oll ‘pumps on left frame mem- ber. ‘Axial piston pump with variable aisplace- ‘ment, description page 9 4 | Solenoid valve, unloading main pump (76062) leads load signal on to hydrau lic ol pump no. 1 and the shuttle valve (Position 5). ‘See pressure plate Servo pressurelittand extension ‘on left frame member. ‘Tab 7 Load handling, group 7.3.9 Valve ‘block pump unloading ‘5 | Theshutle valve sends load signal onto hydraulic oll pump no. 2. ‘See pressure plate Servo pressureliftandextension (n lft ame member. ‘Shute valve, description page 19 6 | Hydraulic oll pump no. 1 andno.2in- | See pressure plate Max. | Axia piston pump with variable alsplace- crease the flow. pressure hydraulic ol | ment, description page 9 ‘pumps on lef frame mem- ber. ‘voRFoso1a0 ‘Workshop manual DRF400~45010 Common hydraulics ~ 10.4.2 Axial piston pump with variable displacement " Pos | Explanation Signal description | Reference 7 | Wany anachment uncon sacwvated, | U=28V Tab 11 Common secre group 175.88 then conto unt frame rear (O787-R) Conte und tame rear activates soenoi valve top hyraues Diagnostic menu, see secon 8 Conta sye- (8003). tom group 8.4.5.6 HYD, menu 6 @ | Solenad valve top hyerauis (Y6008) “ab 7 Load handing, coup 742 Valve controls an unloaded constant pressure boc opt hycaulee tohycraule oi pump, 2 hs nctons as aload signal @ | The shutievave sndsicadsignatonto | - Shut valve, descrpton page 18 yao pump no. 2 10 | Hyctauic ot pump no. 2 increases the | Seo pressure plate Max flow. pressure hydraulic ol ‘pumps on ef frame mem- ber. ‘Axia piston pump with variable displace ‘ment, description page 9 11 | When solenoid vaive top hydraulics | - ‘Tab 7 Load handling, group 7.42 Valve (76003) isnot activated, the unloaded block top it hyrauios pressure is directed to tank. 12 | The steering valve sends oad signal | - ‘Tab 5 Steering, group 5.2.8 Steering valve when the steering wheel is tured, 18 ‘The shuttle valve senda load signalonto hydraulic oll pump no. 8 and no. 4 ‘Shuttle valve, description page 19 4 Hydraulic oll pump no. 8 and no. 4 in- crease the flow. ‘See pressure plate Steer- Ing pressure, onletirame member. ‘Axial piston pump with variable displace- ‘ment, description page 9 Priority valve directs pressure from ‘pumps to steering valve. ‘See pressure plate Steer- Ing pressure, onteft frame member. Tab 5 Steering, group 5.22 Prionty valve 16 ‘At boom in, Control unit frame rear (0787-R) activates Solenoid valve, ‘pump unloading (¥6062). Us24v Tab 11 Common electric, group 11.5.3.9 Control unit fame rear Diagnostic menu, see heading & Control ‘and monitoring system , group 8.4.8.2 BOOM, menu 2 7 Solenoid valve pump unloading (¥6062) leads the pressure from the control valve to tank, ‘Tab 7 Load handling, group 7.3.9 Valve ‘lock pump unloading Workshop manual DRF400—450, ‘vorFroaoreoe 10 Common hydraulics ~ 10.4.2 Axial piston pump with variable displacement Hydra NOTE Read the safety instructions fo ol before work, see tab B Safety. oil pump, checking 1. Operate and warm up the machine so that the hydraulic ol reach- 8 operating temperature, approx. 50°C. Tum off the engine. Connect pressure gauge to test outlet on hydraulic ol pump 1 Start the engine and let itil. CCheck the stand-by pressure forone pump ata time in the fllow= ing order: Hydraulle ol pump 1: 1.8 MPa Hydraulic ol pump 2: 2.1 MPa Hydraulic oll pump 9:2.9 MPa Hydraulic oil pump 4:3.1 MPa ‘The settings apply to standard machine, certain machines can 11. Hydraulic of! pump 1 hhave higher stand-by pressure. For correct stand-by pressure, 2. Hydraulic ofl pump 2 ‘see pressure plate. However, the ilference in pressure between 3. Hydraulic i! pump 3 the different pumps must aways be maintained. 4. Hydraulic oll pump 4 6 Increase engine speed to approx. 1100 r/min and run extension function against end:-position (overflow). Fun out the boom to max. and continue to request max. exten- sion with the control lever. This results in overflowing of the ex tension function. 7 Check max. pressure on hydrauite oll pump 1, the pressure ‘should match the value on the pressure plat. ‘All pumps shal give the same pressure. The order between the pumps is of no importance. 8 Tum off the engine 8 Transfer the pressure gauge to the next pump and repeat steps 3-8 on all four pumps, ‘vorreo1ce Workshop manual DRF400-45010 Common hydraulics - 10.5 Hoses, pipes and valves Ci. line for measuring hose length 10.5 Hoses, pipes and valves 10.5.1 Pipes and hoses Pipes and hoses, general Hoses with ORFS-couplings are used almost exclusively. For max- ‘mum service lfe and function, the folowing should be observed when ‘replacing hoses. 1. Toavoid stresses in the connection, there should be a length of straight hose after the connection. 2. The hose may not be twisted. (A twist of 7% reduces service lite by 80%.) Minimize the number of bends by using correct couplings. A. Avoid sharp bends. Keep the hoses clean intemal. Leave the plugs in place as long 1a possible when instaling, ‘6. Check the postion of the O-rings and tighten tothe correcttorque, seetab F Technical data. NOTE ‘Straight coupling requires counterhold wrench so that the O- ‘ing isnot damaged. 7. O-tings shall not be lubeated with ol when insted Hose length Hose length s measured on a liout hose between the sealing su- faces. On angled connections, measure from the sealing surfaces Cente ne [Ci] according othe figure Cleanliness “The function and service feof hydraulic components depend oa ‘reat extent on how clean the hydraulic oil's. Therefore, itis very im- Portant to prevent dit from entering the brake and hydraulic system, ‘Some simple advice to keep the hydraulic system clean. ‘+ Atways clean the area around a component before stating to work. *+ Plug hose connections immediately after disconnecting. if possi- ble, use correc plugs fr the connection type. hugs are missing, use clean plastic bags and cable ties or tape to seal the connec- tion. ‘+ Never reuse oll that has been drained from the machine. ‘+f possibe, titer the oil before pouring it into the machine, ol ba- ts often contain impurties. When filing hydraulic ol ft through the caps atthe hydraulic oil fitrs inthe tank so thatthe oils fitered. Vorroao1es ‘Workshop manual DRF400-45010 Common hydraulics - 10.5.2 Prity valve 18 1. Shuttle valve attachment 2. Shuttle valve control 3. Shuttle valve, mini-wheel or lever steering (&) 4. Shuttle valve, option rame @®) 10.5.2 Priority valve Priority valve, description See section 5 Steering, group 5.2.2 Prony valve. 10.5.3 Shuttle valve Shuttle valve, description A shultle valve chooses between two pressure signals and sends the strongest. Shuttle valves are used to send oad signals tothe hydraulic cl pumps. This results in control of the pumps by the function that r= Auires the highest pressure if several functions are activated atthe same time, ‘Depending on options, there are two to four shuttle valves. The shuttle valves are located on a bracket foro fling between the engine and transmission, ‘The shuttle valves choose between the following contol signals: 1. Chooses between load signal from the contro valve fori, lower and extension as wel as the contol signal from the control valve {or attachment, The shut valve sends contol signals onto main pump 4, see Axial piston pump with variable displacement, de- scription page 8. 2. Chooses between the load signal from the control valve fori, lower and extension as well as the contol pressure from the con trol valve. The shuttle valve sends the control signal onto control hydraulic pump 2, see Axial piston pump with variable dsplace- ‘ment, description page 9. @ ‘Chooses between the load signal from shuttle valve (position 4) ‘oF restriction to hydraulic ol pump 3 and 4, see Axial piston pump with variable displacement, description page 9. “This shuttle valve is found ifthe machine is equipped with joystick ‘steering oF min-wheel. 4 @ ‘Chooses between the load signal trom shuttle valve (position 2) ‘or control valve option frame to hydraulic ol pump 2, see Axia pis- ton pump with variable displacement, description page 9, “This shuitle valve is found ithe machine is equipped with support Jacks, hydraulic sing cab or cab lit and lowering. Workshop manual DRF400—450 vorFoa.o10820 10 Common hydraulics ~ 10.6.4 Collection black titered return 10.5.4 Collection block filtered return Multiblock, filtered return lines, description ‘The mulliblock receives severalretum lines irom different components nd routes them back tothe tank through the tank fiers ‘The block is located on top ofthe hoisting beam in front ofthe trans- mission. 1. Muitiblock,unfitered retum lines 2, Mutblock fitered return fines 10.5.5 Collection block unfiltered return Multiblock, unfiltered return lines, description ‘The multblock receives several retum rain ines trom diferent valves and routes them straight hack tothe tank “The drain ines are highly sensitive to counterpressure. If pressure bulids up inthe drain lines the valves wall nat work property. ‘The block is mounted on the side ofthe hoisting beam in front ofthe transmission 1. Multiblock, unfitered retum lines 2. Muliblock fitered retum lines ‘vorris0%08 ‘Workshop manual DRF400-450E Schematics ~ 10 Common hydraulics Hydraulic diagram basic machine coer ec vorroaoree Workshop manual ORF 400-450E Schematics ~ 10 Common hydraulios 1", 2 19, 14 18. 16. 7. 18 18, |. Breather fier brake oll tank a. 23. 24. Lit eyinder Valve block it oylinder Extension cylinder Valve block extension cylinder Lin eyinder ‘Valve block Wt cylinder ‘Accumulator brake pressure Brake valve Parking brake caliper Brake oylinder Wheel brake Drive axle block Make-contact dectutch Make-contact brake light Make-contact parking brake ‘Accumulator charging valve Breaking contact brake pressure Cooler brake oll ‘Thermal by-pass valve Brake oll tank Breather fiter hydraulic ol tank ‘Steering valve ‘Steering cylinder 25. Olt return from attachment 26. Brake olfiter 27. Hydraulic ol fiter 28. Cooler hydraulic oll 29. By-pass valve hydraulic ol cooler 80, Fine fiter hydraulic oi! 31, Priory valve Pump cooling and fitering of hydraulic oll Non-return valve Pressure feed to attachment 5. Hydraulic oll pump S and 4 Shuttle valve BREBR 37. Pump brake system Valve block top it hycraulles ‘Shuttle valve Unloading valve attachment 41. Hydraulic ol pump 1 and 2 42, Pressure limiting valve 3. Valve block pump unloading 888 Pressure reducer 45, Accumulator servo pressure 46, Servo iter 47, Control valve Ef and lower as well as extension Workshop manual DAF 400450 VoRFo30108Schematics ~ 10 Common hydaules Hydraulic diagram top lift vorroaores: Workshop manual DRF 400-450E Schematics ~ 10 Common hydraulics Titoylinder Damping block Rotation motor unit Valve block rotation motor ‘Sideshit cylinders ‘Spreader motor Valve block spreader mator “Twistlock cylinders Control valve attachment Filter hydraulic ot Filter hydraulic oil (bigh pressure titer) CE) Solenoid valve engagement hydraulic pressure Shuttle valve Hydraulic of pump 1 and 2 Workshop manual DAF 400-450 voRF0s.0168ee ee Hydraulic diagram top lift, tilt lock and controllable tilt vorroso1cs. Workshop manual DRF 400-450Schematics — 10 Common hydraulics 10. 12, 13, 14 Tittoylinder Damping block Rotation motor unit, Valve block rotation motor Sideshift cylinders ‘Spreader motor Valve block spreader motor Twistlock oylinders Control valve attachment Fer hydraulic oi Filter hydraulic oil (high pressure fiter) GE) Solenoid valve engagement hydraulic pressure ‘Shuttle valve Hydraulic ol pump 1 and 2 Workshop manual DRF 400450 vorreao1es10 Schematics ~ 10 Common hydraulics Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic levelling ‘vorraso1ee ‘Workshop manual DRF 400-450E Schematics ~ 10 Common hydraulics " Tit oyinder Damping biock Fotation motor unit Valve block rotation motor Sideshit cylinders ‘Spreader motor Valve block spreader motor “Twistlock cylinders ‘Solenoid valve engagement hydraulic pressure Shuttle valve . Hydraulic o fiter Hydraulic ol pump 1 and 2 |. Leveling cyinders 3. Valve block leveling cylinders. Over-centre valve leveling Workshop manual ORF 400-450 vorres.1682 E Schematics ~ 10 Common hydraulics Hydraulic diagram joystick steering ‘voRFaao1a8 ‘Workshop manual DRF 400-450Schematics ~ 10 Common hydraulics 13 Control valve option frame Priority vatve Shuttle valve ‘Shuttle valve joystick steering Hydraulic ol pumps 3 and 4 Workshop manual DRF 400-450 voRrono1aa4 E Schematics ~ 10 Common hydraulics, Hydraulic diagram sliding cab oO cane ons o86 =) Vvorroaoiaa Workshop manual DRF 400-450E Schematics ~ 10 Common hydraulics 18 1. Control valve option frame Hydraulle motor sliding cab Solenoid valve engagement hydraulic pressure ‘Shute valve Shuttle valve option Hydraulic oll pump t and 2 Workshop manual DRF 400-450 VvoRFen 0168,16 E Schematics ~ 10 Common hydraulics Hydraulic diagram cab lift and support jacks ow pesaacnoe i) vorroso1a8 Workshop manual DRF 400-450Schematics ~ 10 Common hydraulics 7 Control valve option frame ‘Accumulator Hydraulic cylinder suppor jacks Valve block support jacks ‘Load control valve Hydraulic cyfinder cab itviowering Restriction Valve block top it hydraulics 8, Shuttle valve 10. Shuttle valve option frame 111. Hydraulic oll pump 1 and 2 Workshop manual DRF 400-450 ‘voRFoa.016818 E Schematics ~ 10 Common hydraulics Hydraulic diagram sliding cab and support jacks 2! vorreacraa Workshop manual ORF 400-450Schematics ~ 10 Common hydraulles Ty Control valve option frame Hydraulic cylinder suppor jacks (Over-centre valve suppor jacks Hydraulic motor siding cab Restriction ‘Solenoid valve engagement hydraulic pressure Shuttle valve Shuttle valve option Hydraute oii pump 1 and 2 Workshop manual DRF 400-450 ‘voRFcs 016820 E Schematics ~ 10 Common hydraulics Hydraulic diagram combi attachment (part 1 of 3) : 3 ; 01205 TaN T ‘vorroa.0108 Workshop manual DRF 400-450E Schomatics ~ 10 Common hydraullos at 11 12, 13, 14, 18, Tit cylinder Damping block Rotation motor unit Valve block rotation motor Sideshit cylinders Spreader motor Valve block spreader motor Twistlock cylinders Valve block leveling cylinders Over-centre valve leveling Leveling cylinders Control valve attachment ‘Solenoid valve engagement hydraulic pressure ‘Shuttle valve Hydraute oi! pump 1 and 2 Workshop manual DRF 400-450 vorros.o108Schematics ~ 10 Common hydraulics Hydraulic diagram combi attachment (part 2 of 3) 001205: conse enter 2p) ‘oRFea 0108 Workshop manual DRF 400-450Schematics ~ 10 Common hydraulics 2 Control valve lit eg lett Lowering cylinder front it log Valve block lowering front it leg Valve block lowering front it leg Clamping cylinder tront it leg Valve block operating positon front it leg Clamping cyinder rear it eg Valve block lowering rear lit leg Valve block lowering rear lit leg 10. Lowering cylinder rear it tog Workshop manual DF 400-450 vorFosoras,24 (001205:D. Schematics ~ 10 Common hydraulics Hydraulic diagram combi attachment (part 3 of 3) eto err ott 1 -pna) ‘Workshop manual DRF 400-450E Schematics ~ 10 Common hydraulics 25 2 3 4, 5. 6 7. a 8. Control valve lit leg right Lowering cylinder front it eg Valve block lowering front it leg Valve block lowering front it leg Clamping cylinder trot it log \Valve block operating positon front it leg Clamping cylinder rear it eg Valve block lowering rea i leg Valve block lowering rear it leg 10. Lowering ylinder roar it eg Workshop manual DAF 400-450 vores o168