"LOAD SENSING - SEMI-COMPENSATED"

HYDRAULIC CIRCUIT
for ROTO IMS and ROTO MCSS

MAHYROTO.01
 INDEX

INTRODUCTION ......................................................................................................................... 1
HYDRAULIC SYSTEM DIAGRAM............................................................................................... 2
SYSTEM COMPONENTS AND CONNECTIONS........................................................................ 3
DISMANTLING AND SERVICE OF THE COMPONENTS .......................................................... 4
 1 - INTRODUCTION

This manual provides the information necessary for a correct and safe way to carry out maintenance works
not included in the INSTRUCTION HANDBOOK FOR OPERATING AND MAINTENANCE; it is addressed to
qualified fitters, who know enough about mechanical components and the functioning of hydraulic and
electrical systems for the machine on which it is operating.
The action necessary to implement and enforce the policies related to the Environment and Health and
Safety procedures are left to the responsability of the workshop manager.

This is the symbol used to identify the size of the spanner used for operations described in this
handbook. The spanner type will be advised only if it is different from the standard.

HYDROSTATIC OIL

ESSO HVI 46
Viscosity (ISO 3448) = 46.
Classification to DIN 51524,2 = HLP 46.

If a different brand of oil is used, ensure that is has the caracteristics equal to the specified ESSO products.
Should you wish to change the product brand, the system must be flushed clean of the original oil.
The use of oils with characteristics different to the above ESSO product will bring to the automatic withdrawal
of the warranty on all components of the hydrostatic system.

Check oil level daily.

Replace oil and cartridge filter (86) at the intervals shown in the INSTRUCTION HANDBOOK.

CHECK INSTRUMENTS
It is advisable to use the following pressure gauges (glycerine immersed) and instruments:

- 2 pressure gauges, scale end 600 bar (one of them is already assembled in the vehicle cab)
- 1 pressure gauge, scale end 40 bar.
- 1 R.P.M. counter, scale end 5000 RPM.
- 1 thermometer, scale end 100° C.
- 1 tester : current I = 1,5 A (scale end) / voltage V = 30 V (scale end).

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2 - HYDRAULIC SYSTEM DIAGRAM

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 2 - HYDRAULIC SYSTEM DIAGRAM

13 Reduction brake for fifth wheel rotation

14 Slew lock valve
15 Damping check valve
17 Power steering
23 Main directional control valve
24 Telescoping ram lock valve
25 Lifting ram
27 Telescoping ram
29 Slew motor
30 Compensation valve
31 Compensation ram
32 Carriage ram lock valve
33 Carriage ram
36 Front quick couplings
42 Female quick coupling
45 Emergency electro-pump
48 Piloted opening lock valve
58 Cab inclination control panel
59 Valve for slowing down the boom lowering movement
67 Tac-lock ram
68 Lifting ram lock valve
72 Cab lifting ram
75 Solenoid valve for boom retraction in case of emergency
85 Servo/brake
92 Steering pressure switch
93 Steering accumulator
94 Accumulator (50 bar)
118 Return line manifold
119 Rotating hydraulic coupling
161 Control management block

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2 - HYDRAULIC SYSTEM DIAGRAM

2-3
 2 - HYDRAULIC SYSTEM DIAGRAM

1 Suction line filter

2 Return line filter
3 Variable delivery pump
4 Diesel engine
12 Volume recovery valve
18 Power steering solenoid valve manifold
19 Steering rams
20 Vertical stabilizers solenoid valves manifold
22 Pressure gauge
35 Stabilizer engaging electro-valve
39 Stabilizer electro-valve block
41 Pressure switch
63 Vertical stabilizer ram lock valves
64 Vertical stabilizer ram
90 Pressure check plug
96 Accumulator (100 bar)
97 Suspensions rams
102 Damping check valves
106 Accumulators (70 bar)
108 Suspension rams lock valves
109 Rear suspension delivery manifold
111 Stabilizers arms solenoid valves manifold
112 Stabilizers arms rams lock valves
113 Stabilizers arms rams
119 Rotating hydraulic coupling

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 3 - SYSTEM COMPONENTS AND CONNECTIONS

INDEX

MAIN COMPONENTS............................................................................................ 2

POWER SUPPLY OF AN HYDRAULIC SYSTEM DIAGRAM ................................................... 3

LS PUMP (Load Sensing) and "DFR" (3)...................................................................... 4

THE DISTRIBUTOR (23) ........................................................................................ 6

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 3 - SYSTEM COMPONENTS AND CONNECTIONS

MAIN COMPONENTS

WARNING!!! This is only an example of a hydraulic system. It is intended purely as an illustration

and for didactic purposes. When carrying out a maintenance operation, ALWAYS refer to the hydraulic
system diagram present in the machine's "Operator's Manual".

(3) THE LS PUMP (Load Sensing) and the "DFR

(23) THE DISTRIBUTOR

3-2
 3 - SYSTEM COMPONENTS AND CONNECTIONS

POWER SUPPLY OF AN HYDRAULIC SYSTEM DIAGRAM

WARNING!!! This is just an extract from a generic hydraulic system diagram. It is intended purely
as an illustration and for didactic purposes. When carrying out maintenance operations ALWAYS refer to
the hydraulic system diagram present in the machine's "Operator's manual".

1 Suction line filter 4) Diesel engine

2 Return line filter 23) Main directional control valve
3 Pump

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 3 - SYSTEM COMPONENTS AND CONNECTIONS

LS PUMP (Load Sensing) and "DFR" (3)

Pump diagram

S) Suction from tank L1) Pump stopper

L) Casing drainage to tank DFR) DFR apparatus
X) Piloting signal of circuit VLS) Stand-by pressure register
B) Supply to circuit VP) Pump maximum pressure register
L) Tank drainage 90) Pressure testing point

Functioning of the pump

The LS pump is a variable piston pump, so, has variable delivery. Variable delivery is obtained using a system of
axle pistons which, turning in a drum, slide on a plate (flat) that can be inclined at various angles. Modifying
the angle of the plate changes the course of the pistons, producing a different delivery. The main
characteristic of this pump is that it has a variable delivery that depends on the demands of the system, always
following the formula:

P = pxQ

where:
P = Power
p = Pressure
Q = Flow

In other words, the pump works at constant power, reducing the delivery when the circuit demands a higher
pressure. When there is no demand for oil, the pump positions itself at its minimum delivery and, the circuit
pressure, remains on stand-by with a value that, in this application, is about 35 bar (stand-by pressure).
When the operator acts on the machine's hydraulic controls, a pressure signal reaches the pump from the
distributors via the piloting line and the pump increases its delivery. The piloting line gives a signal of retro-
action to the pump and, the pump regulates its delivery depending on the pressure demands at that moment.
The regulating apparatus of the pump is the DFR.

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 3 - SYSTEM COMPONENTS AND CONNECTIONS

On the DFR apparatus there are two regulators:

Stand-by pressure regulator (VLS)

The stand-by pressure is the pressure that permanently pressurises the circuit, when hydraulic manoeuvres
are not being carried out. The stand-by pressure retroactively returns to the pump non appena as soon as
the operator decides to carry out a hydraulic manoeuvre.

Pump maximum pressure regulator (VP)

When the circuit pressure reaches the input value, this mechanism causes the pump plate to turn towards
its minimum angle, progressively reducing the capacity.

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 3 - SYSTEM COMPONENTS AND CONNECTIONS

THE DISTRIBUTOR (23)

Main components

S1) Mechanically controlled sections.

S2) Logic element.
S3) Servo controlled sections.

A) Electro-hydraulically controlled cursor.

B) Compensated flow limiting valve.
C) Compensator.
D) Maximum pressure valve (hydraulic pump).
D1) Maximum pressure valve (emergency pump).
E) Solenoid valve for movement release.
F) Hydrostat.
G) Servo controls pressure reducing valve.
G1) Servo controls solenoid valve
H) Metal filter for servo controls
I) Calibrated hole (1 mm).
L) Non return valve.
M) Fall preventing valve.
N) Non return valve on the "Load sensing" circuit
(two balls inside each sensor).
O) Rotation compensator
P) Single-acting valve (controlled by the LS
signal).
Q) Check valve.
R) Check valve.
S) Check valve.

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3 - SYSTEM COMPONENTS AND CONNECTIONS

3-7
 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

LOAD SENSING PUMP SERVICE

WARNING!!! Service of the pump is considerably difficult and must be carried out by competent
technicians. Therefore it will not be dealt with in this manual.

"DFR" REGULATOR SERVICE

WARNING!!! When carrying out the following operations on the machine, a certain amount of
hydraulic oil could leak from the system. Prepare a suitable collection system to avoid polluting the earth
and unnecessary waste.

NB!!! These operations can be carried out without removing the DFR from the pump and without
altering the settings.

Service of regulation system for stand-by pressure

(1) Slider (4) Washer

(2) Spring guiding pin (5) Regulation group
(3) Spring

- Unscrew the stand-by pressure regulation group

(5).

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

- Remove the stand-by pressure regulation group (5); with the aid of a magnet extract in order, the spring
guide (2) and the internal slider (1).

Service of the pump maximum pressure regulation system

(1) Slider (4) Spring

(2) Spring guide (5) Washer
(3) Spring (6) Regulation group

- Unscrew the regulation group (6).

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

- Remove the regulation group (6); with the aid of a magnet extract in order, the spring guide (2) and the
internal slider (1).

Removal of the DFR from the pump

- Disconnect the pilot hose (A) from the DFR, and

the four securing screws (B) of the pump.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

DISTRIBUTOR SERVICE

1) Servo controls 5) Rotation control section

2) Head 6) Logic element
3) Head 7 Cursors
4) Sections

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

REMOVAL OF SECTIONS FROM THE LOGIC ELEMENT (S2)

1) Unscrew the four nuts that secure the head on the right side of the two sections; remove the head from the
sections.

2) Use a screwdriver to fully extract the two sections from the supports on the right side and to remove them
from the logic element.

3) Unscrew the four nuts that secure the head on the left side; use a screwdriver to fully extract the head.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

4) Finally remove the three servo controlled sections on the right side from the logic element.

CAUTION!!! While removing the sections

from the logic element, take care not to damage
the four copper washers placed between the
"extraction/retraction" section and the "turret
slew" section.

SERVICE OF THE SERVO CONTROLLED TURRET SLEW SECTION

5) Unscrew the 4 screws that secure the servo control to its corresponding section; remove the electrical part
and unscrew the 2 screws that secure the hydraulic element to the section.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

6) Unscrew the 4 screws that secure the compensating block in place (See "O" - Chapter 3, paragraph "THE
DISTRIBUTOR (23)").

7) Remove the various components from the turret slew section.

8) Fasten the turret slew section in a vice, then remove the single-acting valve to check its condition (See "N"
- Chapter 3, paragraph "THE DISTRIBUTOR (23)").

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

SERVO CONTROLLED SECTION SERVICE

9) Unscrew the four screws fastening the servo control to the corresponding section; remove the components.

10) Remove the entire servo controlled component; extract the bush/valve group.

11) Extract the valve (2) from the bush (1).

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

12) With the help of a screwdriver, extract the two valves of the servo control.

13) Check the state of the o-ring seals.

14) Unscrew the two screws fastening the block to the main section.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

15) Unscrew screw "x" on the hydraulic section side and check that the metal filter is clean.

16) Extract the block, unscrew the two screws fastening the cursor manual control to the main section.

17) Extract the cursor manual control.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

18) Remove the indicated gasket (1).

19) On the centering spring side, extract completely the bar (3) and the gasket (2).

20) If you wish to disassemble the components on

the bar, it is recommended to measure the
calibration with a gauge while the grindstone is
in compression (as indicated in the picture)
before starting the operation.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

21) Remove the fall preventing valve, check the condition of the O-rings, the spring and the cursor seating (See
"M" - Chapter 3, paragraph "THE DISTRIBUTOR (23)").

MECHANICALLY CONTROLLED SECTION SERVICE

(it only applies to ROTO IMS without factory-fitted wiring for radio control and platform)

1) Extract the rubber protection.

2) Unscrew the levers of the cursor mechanic control.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

3) Rotate to one side (see picture) the section and procede to the removal of the indicated screws.

4) On the opposite side, unscrew the fastening screws of the centering spring cap; remove the cap.

5) Extract the cursor from its seating. The two sections are now separated.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

6) If you wish to disassemble and replace the spring on the cursor, make sure to measure the compression
height of the screw (as indicated in the picture) before proceeding.

LOGIC ELEMENT SERVICE

1) Unscrew the 8 screws fastening the aluminium block and extract this from its seating on the main block.

2) Extract the two compensators from their seatings by pulling them to the outside (See "C" - Chapter 3,
paragraph "THE DISTRIBUTOR (23)").

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

3) Check the O-rings.

4) Unscrew the check nut and extract the solenoid from the servo controls solenoid valve (See "G1" - Chapter
3, paragraph "THE DISTRIBUTOR (23)").

5) Unscrew and remove the solenoid valve.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

6) Use a screwdriver to remove the metal filter

placed under the servo controls solenoid valve
(See "H" - Chapter 3, paragraph "THE
DISTRIBUTOR (23)").

7) Unscrew the check nut and extract the solenoid from the movement release solenoid valve (See "E" -
Chapter 3, paragraph "THE DISTRIBUTOR (23)").

8) Unscrew and remove the solenoid valve.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

9) Remove the plug, then the single-acting valve (See "Q" - Chapter 3, paragraph "THE DISTRIBUTOR (23)").

10) Use Seeger ring pliers to unscrew the single-acting valve placed on input block PI of the logic element (See
"L" - Chapter 3, paragraph "THE DISTRIBUTOR (23)").

11) Remove the servo controls pressure reducing valve; check the O-rings and the mesh filter (See "G" - Chapter
3, paragraph "THE DISTRIBUTOR (23)").

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

12) Unscrew and remove the maximum pressure valve installed on the emergency pump line (See "D1" - Chapter
3, paragraph "THE DISTRIBUTOR (23)").

13) Use an Allen wrench to remove the plugs, so that you can access the single-acting valves (A and B) (See "R" -
Chapter 3, paragraph "THE DISTRIBUTOR (23)").

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

14) Remove the hydrostat with its spring; use a wrench to extract the bar (See "F" - Chapter 3, paragraph "THE
DISTRIBUTOR (23)").

a) Hydrostat b) Spring
c) Bar

15) Remove the top and then the setscrew (See "I" - Chapter 3, paragraph "THE DISTRIBUTOR (23)").

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

16) Check that the 1 mm hole on the setscrew is

free from any debris.

17) Unscrew and remove from its seating the maximum pressure valve (See "D" - Chapter 3, paragraph "THE
DISTRIBUTOR (23)").

18) Also remove the basket left inside the hole. (a) electro-valve body - (b) gasket.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

19) Remove the top and then, with the help of a screwdriver, uncrew the non return valve (See "P" - Chapter 3,
paragraph "THE DISTRIBUTOR (23)").

REVISION OF PILOT SYSTEM BLOCK

1) Begin disassembling the block "A" fastened to the distributor.

2) After a.m. disassembling, remove all block hoses in order to get free access to the inner components.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

3) See below the hydraulic system related to the pilot system block.

4) Start disassembling the valves so as to enable a proper check of correct operation and soundness of each
one. Using a screwdriver remove the 1l/min compensated flow control valve from “T” line

5) Using a screwdriver remove the 0,3l/min compensated flow control valve from "LSI2" line.

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 4 - DISMANTLING AND SERVICE OF THE COMPONENTS

6) Using a screwdriver, remove the 1l/min compensated flow control valve from "LS" line

7) Using a 3mm Allen wrench, remove the single-acting valve from "LSI1" line.

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