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Hydraulic oil General hydraulics 1

Hydraulic oils meeting DIN 51524 -3 (HVLP) or ISO 6743-4 HV can be used

Hydraulic temperatures during normal operation.

40 - 50 °C ISO VG 32
50 - 60 °C ISO VG 46
60 - 80 °C ISO VG 68
70 - 90 °C ISO VG 100

Viscosity (cold start)

above –15 °C ISO VG 32
above + 0 °C ISO VG 46
above + 5 °C ISO VG 68
above +15 °C ISO VG 100

Filling capacity
appr. 240 l hydraulic oil tank.
appr. 75 l brake hydraulic oil tank.

Factory filling oil

Shell Tellus T 68

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Hydraulic tank
•The vehicle has two separate hydraulic systems with two
independent hydraulic tanks. One system does the
loading and steering. The other system takes care of the
brake system.
•The machine is equipped with a 240 l hydraulic oil tank
and 75 l brake hydraulic oil tank.
•The hydraulic oil tank has 40 kPa (0,4 bar) overpressure to
prevent cavitation. The brake oil tank is vented to operate at
atmospheric pressure.
•Suction pipes and replaceable return filters for hydraulics
and brake flushing are inside the tanks.
•The return filters back pressures are monitored by pressure
transducers. If filter restriction reaches a critical level, the
“filter clogged” light will warn the operator..
•Two sight glasses in the hydraulic tank front make the
checking of oil level easy. The oil level must be between the
sight glasses when bucket is on ground when the oil is cold.
•At operating temperatures the oil level must be seen in
upper sight glass. The brake hydraulic oil level should be
between the sight glasses when the oil is cold and brakes
engaged.

Note! Before performing any maintenance work on hydraulic

system, the hydraulic oil tank must be de-pressurized.
Pressure is released by using the directional valve on top
of the hydraulic oil tank.

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Hydraulic tank

A hoses with drain taps (2, 3) are installed to the tank

bottom tomake the oil draining easier and cleaner.
To clean the oil tanks, the top covers (15, 17) and
inspection hole cover (1) must be removed.

1. Inspection hole cover

2. Hydraulic oil tank drain tap
3. Brake hydraulic oil tank drain tap
4. Brake hydraulic oil temperature sensor B368
5. Hydraulic oil temperature sensor B301
6. Brake hydraulic oil level (alarm) limit switch S3103
7. Hydraulic oil level (alarm) limit switch S312
8. Brake hydraulic oil level (warning) limit switch S3104
9. Hydraulic oil level (warning) limit switch S356
10. Hydraulic oil return filter Z308
11. Return filter pressure sensor S377
12. Brake hydraulic oil pressure sensor S376
13. Brake hydraulic sight glasses
14. Main hydraulic sight glasses
15. Hydraulic oil tank cover
16. Hydraulic oil tank breather filter
17. Brake hydraulic oil tank cover
18. Hydraulic oil tank pressure relief valve
19. Brake hydraulic oil return filter Z307
20. Brake hydraulic oil tank breather
21. Oil filling valve
22. Hydraulic oil tank pressure gauge

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Functional description of Return filter

Return filter Z308 (1.)

The return filter cleans the hydraulic oil
returning to the receiver. Filtering
capacity β10=75. The return filter is
equipped with a magnetic filtration.
Magnetic filtration is effective on full flow,
even during by-pass.

Spring-loaded non-return valve (1.)

Non-return valve allows the hydraulic oil
returning to the tank past the filter when
the pressure on the primary side of the
filter is more than 1,4 bar greater than
the pressure on the secondary side. If
the hydraulic oil is cold, viscosity is
higher and by-pass valve may open at
lower pressure.

Filter limit switch S377 (2.)

Limit switch S377 indicates blockage of
the filter.

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Limit swithes + temperature sensor

Limit sensors S3104 (3.)

The limit sensor indicates low level in the brake oil tank.

Limit sensors S356 (4.)

The limit sensor indicates low level in the hydraulic oil tank.

Temperature sensors B301 (5.)

The temperature sensors measures the temperature of the
hydraulic oil.

Temperature sensors B368 (6.)

The temperature sensors measures the temperature of the
brake oil.

Limit sensors S312 (7.)

The limit sensor indicates critical low level in the hydraulic oil
tank.

Limit sensors S3103 (8.)

The limit sensor indicates too critical low level in the brake
oil tank.

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Suction lines

•Suction lines consist of hoses, main

suction pipe and suction connection.
The main suction pipe leads the oil
from bottom of the tank to the suction
connection and forward to pumps
through the hoses.
•Brake circuit has separate suction
pipe which leads the oil from the
brake hydraulic tank to suction side of
the brake pump.
•Brake release pump unit (option) and
emergency steering pump unit
(option) has separate suction pipes
which are separately connected to the
tanks.
•Always bleed the air from the suction
line when the line has been opened or
the pump has been replaced. Bleed
the air from the suction lines by
opening the bleeding plug.

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Priority block

Priority block V315 (1.)

Priority block contains piloted
pressure relief valve, shuttle valve,
on/off valve and pressure
accumulator.
Piloted pressure relief valve
The piloted pressure relief valve
directs oil flow from pump P301 to
steering valve and boom and bucket
valve. Priority is at steering.
Shuttle valve
The shuttle valve compares
pressures coming from the steering
valve (LS-pressure) and from the
pump P303 outlet. The bigger
pressure is directed to the pump
P301’s controller. Pressure accumulator (2.)
On/off valve Y367 The pressure accumulator stores oil from the pilot pressure line and if the
The on/off valve (Y367) is a pressure falls in the line, the accumulator discharges the hydraulic oil it has
solenoid valve, which drains the stored, hence pressure remains more constant in the line. Pressure
pressure accumulator and whole accumulator volume is 1,4 liter and the pre-charge pressure is 12 bars. When
pilot pressure line. the external pressure in the line is more than 12 bars, accumulator charges,
in other words stores hydraulic energy. If the external pressure falls in the
line, the accumulator discharges the hydraulic oil it has stored.

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Pressure measuring points

Max 280 bar

150-200 bar

121 bar

121 bar

150-200 bar

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Pressure measuring points

285 bar

<1 bar

<1 bar

285 bar 285 bar 285 bar

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Pressure measuring points

280 bar

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Pressure measuring points

35 bar
285 bar
210 bar
210 bar when steering used
280 bar when bucket used

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Pressure measuring points

285 bar
100 bar

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Pressure measuring points

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Pressure measuring points

12,4-15,2 bar

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Pressure measuring points

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Pressure measuring points

210 bar

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Marking of hydraulic hoses

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Hydraulic oil coolers system description

The hydraulic oil is cooled with two cooling cell.

There are two separate cooler sections in a
cooler. Pump P302 produces pressure to the oil
coolers hydraulic motors and air condition unit.
Brake hydraulic oil is cooled on the right side
cooler. Steering and bucket hydraulic oil is
cooled on the left side cooler. Transmission oil
is cooled on second sections
of both cooling cells. If hydraulic oil flow to
coolers suddenly stops and cooling fans
rotation continues, oil circulates through the
cooler motors until the motors stops.
Sequence valve V306 controls the hydraulic
flow to the cooler fan motors. From the fan
motors brake hydraulic oil flows through the air
conditioning unit and the cooler core. From the
hydraulic cooler core brake hydraulic oil flows
through brake flushing back to tank.
The hydraulic oil flows through the engine
cooler fan motor to the cooler core and back to
tank.

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Functional description General hydraulics 19

Oil coolers A306

The hydraulic oil flow rotates the coolings fan, which produces air flow to cool the oil in the coolers.

Thermostatic bypass valve

Oil cooler contains two thermostatic bypass valves. If oil temperature is below 50 °C, valve directs o il flow past
the cell. Between temperatures 55 °C - 65°Cvalve dir ect flow partly past the cell and partly through it. If oil is
warmer than 65 °C, all the flow goes through the co oler cell.

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Functional description General hydraulics 20

Non-return valve
Non-return valve prevents oil flow passing the cooler motors in normal working situation. If hydraulic oil flow to
coolers suddenly stops and cooling fans rotation continues, oil circulates through the cooler motors until the
motors stops.

Sequence valve V306

Functional description of the sequence valve V306 is presented in chapter “Brake system”.

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Cooler circuit

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Pumps

There are 4 pumps in the hydraulic circuit. One double

piston pump and two piston pumps produce the hydraulic
flow needed for all hydraulic accessories.

Piston type double pump P301

The capacity of the block 1 is used for steering and pilot
control and block 2 is used for engine cooler.

Piston type pump P302

The capacity of the pump is used in brake hydraulics.

Piston type pump P303

The capacity of the pump is used in boom / bucket system.

Transmission pump
The capacity of the pump is used in transmission and
converter.

Safety interlocks
The system prevents controlling pump in the following situations:
- Emergency stop is activated
- The engine is not running
- During engine cranking
- Boom floating is on (bucket pump control)

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Piston type double pump P301 General hydraulics 23

Pump P301 is a piston type double pump.

The double pump produces hydraulic
pressure and flow needed in the hydraulic
systems. The pump has two blocks on the
same shaft. Shaft speed is approximately
2270 rpm when the engine is running at
2150 rpm.

Block 1
Block 1 produces the hydraulic flow for steering and pilot control. The pressure produced is also used for boom
and bucket hydraulics. The volume flow produced by the pump block is hydraulically adjusted according to the
needs of the hydraulic system. The pump block outlet is equipped with a non-return valve, which prevents the
hydraulic flow from returning to the pressure side of the pump block.
Block 2
Block 2 produces the hydraulic flow for engine cooler. The volume flow produced by the pump block is electrically
adjusted according to the needs of the engine cooling capacity.

See the separate pump manufacturers service instructions manual for

dismantling, assembly and inspection information.

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Piston type pump P302

Pump P302 produces the hydraulic pressure needed (max 280 bar) for brake hydraulics, oil coolers and air
condition. The volume flow produced by the pump block (max 45 l/min) is hydraulically adjusted according to
the needs of the hydraulic system.

See the separate pump manufacturers service instructions manual for

dismantling, assembly and inspection information.

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Piston type pump P303

Pump P303 produces the hydraulic pressure needed (max 285 bar) for the boom and bucket hydraulics. The
pressure produced by the pump block (max 155 l/min) is electrically adjusted according to the joystick
movements. Less the Control system feeds current to the proportional valve, the greater the pump output is. The
pump is also adjusted hydraulically according to the needs of the hydraulic system. The pump
block outlet is equipped with a non-return valve, which prevents the hydraulic flow from returning to the pressure
side of the pump.

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Starting new pumps
Do not start the engine without priming pumps first!

1. Make sure that the entire hydraulic system is clean.

2. Fill tank to proper level with recommended grade of hydraulic oil.
3. Open the hydraulic hose connection. Prime all variable displacement type pumps case drains with hydraulic oil.
When the pumps are primed attach all the hoses that where removed from the pumps.

4. Bleed the air from the suction lines by opening the bleeding plug (A) first from the suction connection. When
all air is bled through the plug close the plug. Note! Use the compressed air if necessary.

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Starting new pumps General hydraulics 27

5. Bleed the air from the suction side of the bucket hydraulic
pump by opening the bleeding plug. Pressurise hydraulic
tanks if necessary. When all air is bled through the plug
close the plug.

6. Adjust pump pressure to default setting. Pump pressure

adjustment is presented in section Checking and adjusting.

7. A new pump and system should not be started and

immediately operated at full speed or pressure. The
recommended procedure is to gradually speed up to
approximately one-half operational speed or amaximumof
1000 rpm. at minimum pressure. Preliminary circuit checks
for air entrapment, leaks, etc., may be made at this point.
When the recommended operation viscosity and
temperature has been achieved,
load may be alternatively applied up to check for satisfactory
operation of all circuit components.

Do not start the engine without priming pumps first!

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Checking the pilot pressure General hydraulics 28

General
•The hydraulic oil temperature should be 60...80 °C .
•Connect and disconnect pressure gauge(s) only
when the circuit is not pressurized.
•Use only special couplings for pressure testing.
•Do not overtighten couplings. When special
couplings are used, finger tight is adequate.
Over tightening causes harmful leakage.
•Use hose(s) long enough to read the gauge(s) while
sitting in the cabin.

Pilot pressure test

1. Connect a pressure gauge to the quick-disconnect
fitting.
2. Run the engine at low idle.
3. Pressure should be 35 bar
(3.5 MPa).

Only perform maintenance work when the machine is parked. Use the appropriate tools for
the task. Replace or repair faulty tools and equipment. When performing maintenance and
repair work, make sure there are no unauthorised persons in the working area.

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Sequence valve pressure check

Brake charging volume flow rate is adjusted from the

sequence valve.

1. Ensure that the machine is on an even surface, the

parking brake is applied and movement in the driving is
prevented by, for example, wheel chocks.

2. Install the frame locking pin.

3. Screw the sequence valve adjustment screw to fully open

position and then 1/4 turn back.

Only perform maintenance work when the machine is parked. Use the
appropriate tools for the task. Replace or repair faulty tools and
equipment. When performing maintenance and repair work, make sure
there are no unauthorised persons in the working area.

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Symbols for hydraulic drawings General hydraulics 30

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Symbols for hydraulic drawings General hydraulics 31

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Symbols for hydraulic drawings

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Symbols for hydraulic drawings General hydraulics 33

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Symbols for hydraulic drawings

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Symbols for hydraulic drawings

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Symbols for hydraulic drawings

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