At22 Hydraulic Secti

AT-20 Series III Hydraulic Circuit Components
Hydraulic Tank
• 10 micron Vented Breather Cap.

• Main Pump 90 micron Suction Strainer.
• Emergency Steering Pump 90 micron Suction Strainer.
• Tank top mounted Return Filter 10 micron absolute with magnetic particle
collection.
• Sight Level Indicator (check with all cylinders retracted).
Main Pump
• Eaton 420 Series Load Sensing 62.3cc/rev Variable Displacement Axial Piston,
overdriven 1.075 times on the PTO.
• 6 Ports :
• Suction Port
• Suction Port Test Point
• Pressure Port
• Pressure Port Test Point
• Load Sense Port
• Case Drain
• Pressure Compensator (Maximum Pressure) setting 250 Bar (larger adjuster -check
on Gauge Port G1 on manifold block whilst two blocking (hydraulically stalling)
winch up (in high speed mode) – check the rope spooling and that the rope does not
pull through the outer layer on the winch drum).
• Flow Compensator (Standby/Static Base Pressure) setting 30 Bar (smaller adjuster -
check on Gauge Port G1 on manifold block with engine idling and no functions
operational). If troubleshooting, before checking, it is best to remove the load sense
hose from the pump. Cap the hose or let it drain into a bucket, because the
hydraulic system does not use dynamic load sensing there should not be any oil
coming out of the hose when no functions are operational. Leave the load sense
port on the pump open, there should be no oil coming out of this port at any time
(just drip leakage).
• Load Sensing means that the pump will try to keep the pump outlet pressure at the
Standby Pressure Setting above the Pressure at the Load Sense Port. The pump
achieves this by varying the displacement (swash plate).
Emergency Steering Pump
• Barnes DC powered hydraulic pump.

• Fitted with relief valve set to 175 Bar (check on Gauge Port G1 with steering on full
lock or foot brakes fully applied - check with engine off, but ignition on, both park
brakes off).
Rev - 15/08/2008 Page 1 of 4

Inlet Cover
• Directly mounted on side of Mid Manifold

• Pressure reducing valve for pilot pressure to control spools set to 20 bar, safety relief of
50 bar, with filter to prevent contamination, relief valve to protect pilot circuit. Factory
set, but can be checked by putting ¼”BSPP test gauge into port V2. Check whilst
stalling a crane function, e.g. tele in.
• Filter to prevent contamination of the load sense circuit to the pump.
• Safety relief valve for protection if pump compensator fails, set to 270 Bar. To check;
adjust the pressure compensator (see main pump above) temporarily clockwise whilst
checking gauge port G1, the pressure should not exceed 270 Bar. Re-adjust pressure
compensator back to 250 Bar.
Mid Manifold Assembly
• Directly mounted between inlet cover and valve bank sections.

• Load Sensing Excess Flow Control Valve 1 (DPS2-16-P-F-0-160) to valve bank.
• Allowance for Dynamic Load Sense Bleed Orifice 5 for increased steering response
– function NOT used (M6 Plug).
• Damping Orifice 6 (M6 ↵0.8mm) for function smoothness.
• Pressure Switch (PSM 10 R14 AP T5D) for emergency steering pump 5 Bar (set
separately).
• Check Valve 3 (CV3-10-P-03) and 4 (CV1-16-P-0-5) for emergency steering pump
function.
• Shuttle Valve 2 (DSV2-8-B-0-0) senses the highest load sense pressure from steering
OS and crane functions OLS to send to the pump Load Sense Port.
Valve Bank
• Walvoil DPC130; 3 bank hydraulic closed centre, load sensing with electro-hydraulic
proportional spool control.
• Tele circuit is fitted with load sense pressure relief valve set to 210 Bar which limits
both Tele in and Tele out. Both work ports are open to tank (“motor” spool) in the
neutral position.
• Winch circuit has no port relief valves; hence maximum pressure when function stalled
is same as set by pump pressure compensator (250 Bar). Both work ports are open to
tank (“motor” spool) in the neutral position.
• Luff circuit is fitted with load sense pressure relief valve set to 220 Bar which limits
both Luff up & Luff down. The Luff down work port is closed to tank (“cylinder”
spool) in the neutral position, this stops the boom bouncing up after luffing down and
also whilst driving on the road. The Luff up work port is open to tank (“motor” spool)
in the neutral position.
End Cover
• Directly mounted on the end of the Valve Bank
Rev - 15/08/2008 Page 2 of 4

Luff Counterbalance Valve Manifold
• Mounted to the left of the valve bank manifold assembly.

• Counterbalance valve CBEA-LHN set to 210 Bar (needs to be set separately). The
valve controls the luff down function by ensuring the separate counterbalance valves
fitted to each Luff cylinder open first, hence allowing both cylinders to luff down
together evenly.
Orbital Steering Unit
• Eaton Dynamic Load Sensing, Non-reacting 460 cc/rev.

• Inlet Check Valve on P port to stop kick back on steering wheel.
• Shock Valves for L and R ports set to 262 Bar, shouldn’t ever need adjusting.
• Dynamic bleed down orifice integrated into rotary spool.
• LS Relief Valve – factory set to 158 Bar, actual reading on G3 is 220 Bar.
• 5 Ports
• P - Pressure Port, opens to L or R as below, closed when not turning.
• T - Tank Return, opens to L or R or LS as below.
• L - Opens to P when turning left, opens to T when turning right.
• R - Opens to P when turning right, opens to T when turning left.
• LS - Open to T when not turning, opens to L when turning left, opens to R when
turning right.
Tele Cylinder
• Bore 5 “, Rod 4 “, Stroke 4120 mm.

• Counterbalance Valves (CBGA-LHN) directly fitted to rod end.
• Extension set to 275 Bar (needs to set separately).
• Retract set to 70 Bar (needs to set separately).
Luff Cylinders
• Bore 5.5 “, Rod 3.5 “, Stroke 1580 mm.

• Counterbalance Valve (CAEG-LGN) directly fitted to barrel end for Extension set to
285 Bar (needs to set separately).
Steering Cylinders
• Bore 3”, Rod 1.5”, Stroke 446mm

• Hydraulic end stop cushioning
Rev - 15/08/2008 Page 3 of 4

Winch
• Brevini Two Speed 4.2 tonne Line Pull.

• Brevini Double Reduction Epicyclic gearbox.
• HP Two Speed Swash Plate Axial Piston Motor.
• Brevini Failsafe Spring applied Brake (Wet Brake).
• Counterbalance Valve fitted to winch up set to minimum of 330 Bar (needs to be set
separately).
• Shuttle Valve this takes the highest pressure of the up or down ports and uses it to
release the brake.
• Pressure Reducing Valve for 2 speed control pressure set to 18 Bar.
Orifice Troubleshooting Guide
• Hardpoint or slow steering

1. Check standby pressure.
2. Check load sense line is free flowing.
• Steering unstable - too responsive

1. Check orifice 5 is fitted with M6 plug.
Rev - 15/08/2008 Page 4 of 4

WLR 803 HOISTING WINCH
OPERATORS MANUAL
Part Number: 16C1522A
16C1522A 1
1 Introduction .................................................................................................... 3
2 Document symbols ........................................................................................ 4
2.1 Symbols relating to the “operator qualification level” .......................... 4
2.2 Symbols relating to “consulting the manual” ....................................... 4
2.3 Mandatory symbols relating to safety ................................................. 5
2.4 Danger symbols relating to safety ....................................................... 5
3 General Characteristics ................................................................................. 6
3.1 Permitted use ...................................................................................... 6
3.1.1 Prohibited uses............................................................................. 6
3.2 Main parts ........................................................................................... 8
3.3 Nameplate .......................................................................................... 9
3.4 Specifications.................................................................................... 11
3.4.1 Winch specifications ................................................................... 11
3.4.2 Airborne noise ............................................................................ 13
3.4.3 Vibrations ................................................................................... 13
4 Safety rules .................................................................................................. 14
4.1 Residual risks ................................................................................... 14
4.2 Workstation ....................................................................................... 15
5 Installation.................................................................................................... 16
5.1 General ............................................................................................. 16
5.2 Ambient conditions for use................................................................ 16
5.3 Assembly of the rope on the drum .................................................... 17
6 Commissioning ............................................................................................ 19
6.1 General warnings .............................................................................. 19
6.2 Trial operation ................................................................................... 19
6.3 Use ................................................................................................... 20
7 Maintenance ................................................................................................ 21
7.1 Service .............................................................................................. 21
7.2 Cleaning............................................................................................ 22
7.3 Routine maintenance ........................................................................ 23
7.3.1 Renewing lubricants / topping up ............................................... 23
7.3.2 Filling and vent plugs.................................................................. 23
7.3.3 Oil filling...................................................................................... 25
7.3.4 Recommended lubricant ............................................................ 25
7.4 Troubleshooting ................................................................................ 26
8 Spare parts .................................................................................................. 27
8.1 How to order spare parts .................................................................. 27
2 16C1522A
1 Introduction
Crane Owners and Operators:
Terex appreciates your choice of our product for your application. Our number
one priority is user safety which is best achieved by our joint efforts. We feel
that you make a major contribution to safety if you as equipment users and
operators:
1. Comply with OH&S, Federal, State and Local Regulations.

2. Read, Understand and Follow the instructions in this and other
manuals supplied with this product.
3. Use Good, Safe Work Practices in a common sense way.
4. Only have trained operators – directed by informed and
knowledgeable supervision – operating this product.
If there is anything in this manual that is not clear or which you believe should
be added, please send your comments to Terex Product Support.
Your safety is our priority.
16C1522A 3
2 Document symbols
2.1 Symbols relating to the “operator qualification level”
Machine operator: operator with no specific skills, capable of

performing simple tasks only, i.e. running the system with its controls.
Lifting and transport equipment operator: operator trained for

driving and using material and machine lifting and transport gear (the
instructions of the manufacturer of these must be scrupulously followed) in
accordance to the laws in force in the machine user's country.
Maintenance mechanic: qualified technician capable of running the

machine in normal conditions; running it with guards deactivated using a
deadman control; carrying out adjustments, maintenance or repair work on
mechanical components.
Manufacturer’s technician: qualified technician provided by the

manufacturer to carry out complicated operations in particular situations, as
established with the user. Specialised mechanical and/or electric and/or
software technicians are available according to need.
2.2 Symbols relating to “consulting the manual”
IMPORTANT
Texts highlighted by this symbol indicate a potential danger for the machine
and draw attention to the damage that such danger may cause to the machine
and/or to the operator.
4 16C1522A
TO SAFEGUARD THE ENVIRONMENT
Texts highlighted by this symbol contain warnings relating to the environment.
NOTE
Texts highlighted by this symbol contain additional information.
2.3 Mandatory symbols relating to safety
Always wear protective gauntlets:

this symbol means that operators should be wearing protective gauntlets for
electrical/thermal insulation.
Always wear accident-prevention footwear:

this symbol means that the operator must be wearing accident-prevention
footwear.
2.4 Danger symbols relating to safety
Danger of hand/arm and leg/foot crushing:

this symbol instructs operators to pay particular attention towards mechanical
components that could cause hand/arm and leg/foot crushing in the event of
unexpected movements or imprudent manoeuvres of the operators
themselves.
16C1522A 5
3 General Characteristics
3.1 Permitted use
 The WLR 803 winch has been designed and built for hoisting.
 The machine is designed for use in normal industrial environments.
 The machine must be run by persons that have been trained
concerning the characteristics of the same and that are familiar with the
contents of this manual.
 The machine is automatic since it does not call for the presence of an
operator during its work cycle.
3.1.1 Prohibited uses
The machine cannot be used either partially or totally:

 for lifting or towing people;
 without its guards and/or with its safety devices deactivated, out-of-
order or missing;
 unless it has been correctly installed;
 in dangerous conditions or when it is malfunctioning;
 improperly or by untrained personnel;
 for uses not complying with the specific standard;
 in the event of supply defects;
 if maintenance has been badly conducted;
 unless the appropriate personal protective equipment is worn;
 unless operators are suitably trained and informed, concerning
safety at work;
 after unauthorised modifications;
 with material and/or tools differing from those indicated for normal
machine operation;
 at an ambient temperature lower than –20°C or higher than 50°C;
 unless all instructions are observed.
The machine cannot be used in any of the following conditions:
 in environments where temperature is lower than -20°C and higher

than 50°C;
 in environments where relative humidity is lower than 10% or higher
than 85%;
 in submerged or semi-submerged places;
 in explosive or potentially explosive environments and areas
where there is a risk of fires.
6 16C1522A
 Any deviation from the above mentioned specifications calls for a
specific written authorisation by Terex Australia Pty Ltd.
 Any modification that has not been authorised by Terex, that
alters the functions of the machine and consequently modifies the
risks and/or generates additional ones, will be made at the
exclusive responsibility of the person/company making that
modification.
 Should these modifications be made without the manufacturer's
authorisation, any warranty issued by Terex Australia Pty Ltd will
be invalidated.
16C1522A 7
3.2 Main parts
A. Drum
B. Hydraulic motor
C. Motor support
D. Bearing support
E. Pressure roller
8 16C1522A
3.3 Nameplate
The machine's identification data can be found on the plate fastened to the
machine.
For no reason may the information printed on the plate be

altered.
Refer the "Serial Number" of the system every time you contact
Terex for information or spare parts.
16C1522A 9
The identifications plate bears the following information:
1) Serial Number
2) Item
3) Family/Out/i/In.
4) Bar code
5) Made in Italy
6) Rope diameter
7) Rope strength
8) F.E.M.
9) Info
10) kW
11) Volt
12) Hz
13) Weight
14) Max pressure
15) Max oil flow
16) Max line pull first layer
17) Max line pull top layer
18) Layer
19) Speed rope first layer
20) Speed rope top layer
21) Layer
10 16C1522A
3.4 Specifications
3.4.1 Winch specifications
16C1522A 11
12 16C1522A
3.4.2 Airborne noise
Sound pressure level: less than 70 db(A).
3.4.3 Vibrations
The machine does not create vibrations that put the health of operators at risk
or that disturb machines installed nearby.
IMPORTANT!
Increased shaking may indicate malfunctioning of the machine. In this
situation, stop the machine and perform the necessary checks.
16C1522A 13
4 Safety rules
IMPORTANT!
The machine is supplied without guards since it is usually incorporated
into a complex line.
The final manufacturer of the assembly is responsible for supplying and
installing all fixed and movable guards to prevent accidents in
dangerous positions, with the exception of those indicated in
"RESIDUAL RISKS": for example, the exit area from the rope drum.
These areas must be highlighted by applying safety labels that are easy
to understand.
4.1 Residual risks
A. Personal protective equipment (PPE)
Should it be necessary for operational or servicing reasons to work on the

system manually, operators must wear the necessary Personal Protective
Equipment, namely:
- Gloves resisting heat
- Non-slip footwear
B. Unexpected / accidental machine starting
The relevant risk is avoided by instructing the operator concerning the

practices to follow in this event:
- in the event of any maintenance work, inform the person in charge so as to
prevent any accidental starting of the machine.
C. Danger of entanglement / crushing
In the rope winding area, there is a risk of entanglement / crushing. Do not

approach this area during operation.
14 16C1522A
D. Danger of collision
When working in the rope towing area, there is a risk of rope failure. Keep at a
safe distance from the towing area during operation
4.2 Workstation
During operation, the operator must keep at a safe distance

from the winding and towing areas.
16C1522A 15
5 Installation
5.1 General
Machine installation is a complex operation that gives rise to various risks; this
operation is generally performed by Terex or by qualified technicians
authorised by the same. The installation of the winch to the crane boom can
require modification when installed on certain cranes. Please contact Terex
service, see section 7.1, for further information and procedures regarding your
winch installation.
Please be informed that installation of machines is not at the

care of Terex. Therefore, the latter refuses any liability in the event that
the instructions are not followed.
5.2 Ambient conditions for use
The machine has been designed and built for use in various climates, in non-
explosive environments or potentially explosive ones, with the following
temperature and humidity:
Temperature min. -20°C max. +50°C;
Humidity min. 10% max. 85%.
16 16C1522A
5.3 Assembly of the rope on the drum
The winch is generally supplied installed on a crane with rope

installed. If the winch is supplied as a spare part the rope will be
separated from its drum. Assembly of the rope must be performed by
the operator or by a qualified technician, following the instructions of
the rope manufacturer, after running the winch according to Section 6.2
Before mounting the rope, pull away the pressure roller from the drum and fix
it by means of two pins put into the proper holes “A”
16C1522A 17
Pass the end of the rope “A” outward through the slot on the drum plate, then
pass the rope under the two clamps “B” positioned by the two pins “D” in the
pocket “C”. Fix the rope with the two clamps “B” by tightening the four screws
“E” (M8, tool size 13 mm, tightening torque 25 Nm). The newer versions of the
winch use cap head screws “F” (M8, allen key 6 mm, tightening torque 25
Nm).
18 16C1522A
6 Commissioning
6.1 General warnings
Before starting up the machine, read this manual with care and
make sure to have understood its contents.
 For more information or explanations, contact Terex.

 Persons in charge of running and servicing the machine must possess
the specific competences described in this manual as well as the
psychological and physical abilities needed to use the machine.
 The following paragraphs provide instructions for putting the machine
into service.
Before putting the machine into service (only required if winch is installed as a
spare part for an existing crane):
 Check the level of lubricant.

 Check the tightness of all the nuts and bolts.
 Make sure that the hydraulic circuit has the features described in the
relative paragraph.
 Make sure the drum is turning in the right direction.
6.2 Trial operation
All information relating to pressure, oil flow rate and speed is

given in the winches' technical specifications tables.
Note the below is only required if winch is installed as a spare part for an
existing crane.
Before winding the rope around the installed winch, run the latter in both
directions for a few minutes. After winding the rope perform a trial lifting cycle
with a light load. Check correct operation of the brake of the load during its
upward movement. Make sure that the load is lowered in a smooth,
controllable and jerk-free manner.
16C1522A 19
6.3 Use
Before using the winch, make sure that the rope is in perfect
working order. If it is crushed or frayed, replace it immediately
Leave at least 2 coils of rope around the drum
Never use the winch beyond its maximum pulling capacity.
Unexpected breakage of the taut rope or any failure that causes

the hook to release the load will result in a particularly dangerous
"whiplash" action. For this reason, never stand in the operating radius
of the rope.
Never guide the rope with your hands while the winch is
running.
20 16C1522A
7 Maintenance
7.1 Service
Terex will service your winch at the standard service intervals of the crane it is
installed on. See section 7.3 for routine maintenance that can be carried out
by the customer.
Please contact the service department if you have any questions about your
winch. Please note the crane model number, crane serial number and winch
family (WLR803) in all your correspondence.
Service Centres
Brisbane
585 Curtin Avenue East
Eagle Farm, QLD 4009
P: (07) 3868 9600
New South Wales

114 Hassall Street
Wetherill Park, NSW 2164
P: (02) 8786 4444
Western Australia
39 Catalano Road
Canningvale, WA 6155
P: (08) 9232 0000
Victoria
187 Osborne Avenue
Clayton South, VIC 3169
P: (03) 9551 8644
16C1522A 21
7.2 Cleaning
Perform cleaning with the machine isolated from all energy

supplies. Never clean the machine and its components with solvents,
corrosive liquid or abrasive objects.
If you are using the winch in corrosive environments, containing rough
polluting particles and/or very fine dust, wash the winch with water and
suitable fluids to prevent dirt depositing and damaging important
components such as nuts and bolts, rings and washers.
Plan maintenance correctly so as to prevent excessive wear and tear of
the winch.
When using a high pressure washer for cleaning do not direct

water at the pressure rollers “A” and 2 speed solenoid connector “B”.
22 16C1522A
7.3 Routine maintenance
7.3.1 Renewing lubricants / topping up
REMOVAL OF ANY OIL INSIDE THE REDUCTION GEAR

SHOULD BE STORED IN APPROPRIATE CONTAINERS READY TO BE
HANDED OVER TO AUTHORISED WASTE DISPOSAL CENTRES, IN
ACCORDANCE TO THE LAWS IN FORCE.
For checking, topping up and renewing, use the special plugs provided (see
technical data sheet). Replace seals under the plugs every time you unscrew
them for inspections. For recommended lubricants see section 7.3.4
It is recommended to replace the lubricant when it is warm to prevent sludge

forming. When renewing oil, it is recommend to wash the reduction gear with
a suitable fluid, as indicated by the lubricant manufacturer.
Irrespective of the hours of work, the level of lubricant should be checked

every 20/30 calendar days.
Irrespective of the type of work, regularly check the winch, the condition and
level of lubricant and if necessary top up.
7.3.2 Filling and vent plugs
It is important to regularly check operation of the oil filling and

vent plugs to prevent vent clogging from causing pressure to rise in the
reduction gear and temperature of oil to increase.
16C1522A 23
A. Winch vent plug
B. Motor drain port
C. Winch oil level/filling plugs
D. Winch oil drain
Every time lubricant is renewed or topped up, push the inner section of the
plug with a pin until you overcome the resistance of the compression spring
on the closing diaphragm (max. 0.1-0.2 kg); to make sure that there are no
obstructions, blow compressed air (max. 0.5 bar) from the inner to the outer
side of the plug.
It is recommended to perform this operation regularly

irrespective of whether oil is renewed or not.
24 16C1522A
7.3.3 Oil filling
For oil filling follow the instructions below:

 Remove vent plug “A” and filling/level plugs “C”
 The winch may contain a small amount of protective oil. Remove it by
opening the drain plug “D”, then close the drain plug.
 Fill the winch with oil by a pump through one of the two plugs “C”. Fill
the winch until the oil comes out from the opposite plug “C”. Oil
quantity: about 4.5 litres.
 Remove the pump and close all the plugs.
After oil filling, remove the warning tag: “Fill the gearbox with
oil before use”
7.3.4 Recommended lubricant
Winch gearbox and brake – Castrol Alpha SP 320, 4.5 Litres
Note gearbox and brake are common.
16C1522A 25
7.4 Troubleshooting
If the winch is not working properly, check the troubleshooting

table to locate the cause and the solution, if any.
If the problem cannot be solved, contact Terex Technical Support,
National Free Call 24 / 7 PH: 1800 837 395 (1800TEREXL)
26 16C1522A
8 Spare parts
8.1 How to order spare parts
The Customer must purchase only original spare parts. Removal and refitting
must be performed in accordance to the manufacturer's instructions.
ORDERING SPARE PARTS

When ordering spare parts from Terex Australia Pty. Ltd., always indicate:
 CRANE SERIAL No e.g. 4000

 CRANE MODEL No e.g. AT-20
 WINCH FAMILY e.g. WLR803
 DESCRIPTION e.g. Seal kit
 QUANTITY e.g. 1
Winch spare part information can be found on the Docware electronic

catalogue (CD) included with your crane. If your winch was supplied
individually (i.e. not assembled to a crane) you will need to contact spare parts
for further information.
Enquiries and orders relating to spare parts should be made to:
Spare Parts
585 Curtin Avenue East
Eagle Farm, QLD 4009
P: (07) 3868 9600
16C1522A 27
PRESSURE COMPENSATED
PROPORTIONAL LOAD--SENSING
VALVE
Service and spare parts manual

DPC130 Service and spare parts manual
We wish to thank you for choosing this Walvoil Valve. Your valve is the product of Walvoil’s advanced engineering, exhaustive testing,
and continuous striving for superior reliabilty, safety, and performance.
The product must be used within the parameters shown in the technical catalogue.
To ensure a long, trouble--free life for your valve, give it the proper care and maintenance described in this manual.
Due to improvements in design and performance during production, in some cases there may be minor discrepancies between the
actual valve and the illustrations and text in this manual.
Before reading this manual
THIS PRODUCT HAS BEEN MANUFACTURED FOR USE IN A REASONABLE AND PRUDENT MANNER BY A QUALIFIED OPER-
ATOR; WALVOIL IS NOT RESPONSIBLE FOR ANY DAMAGE CAUSED BY AN INCORRECT USE OF THE PRODUCT.
Ogniqualvolta che appaiono i simboli mostrati sotto, osservare le istruzioni elencate! Eseguire sempre operazioni e manutenzione in
sicurezza.
This warning symbol identifies special This caution symbol identifies special
instructions or procedures which, if not instructions or procedures which, if not
correctly followed, could result in inju- strictly observed, could result in da-
ry. mage.
1st edition April 2005:

Questa edizione aggiorna tutte le precedenti.
2 DDM010E
Service and spare parts manual DPC130
Contents
Contents
1. Working conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Standard threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Dimensional data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5. General recommendations
5.1 Hydraulic recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 Electric recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6. Installation
6.1 Hydraulic circuit operating instructions . . . . . . . . . . . . . . . . . . . . . . . . 11
6.2 Electric circuit operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.3 8ZR3 electrohydraulic module connection . . . . . . . . . . . . . . . . . . . . . 13
6.4 8ZR3CB electrohydraulic module connection . . . . . . . . . . . . . . . . . . 15
6.5 8ZR4F electrohydraulic module connection . . . . . . . . . . . . . . . . . . . . 16
6.6 8ZR4P electrohydraulic module connection . . . . . . . . . . . . . . . . . . . . 19
6.7 8EZ3 electrohydraulic module connection . . . . . . . . . . . . . . . . . . . . . 21
6.8 8EZ4 electrohydraulic module connection . . . . . . . . . . . . . . . . . . . . . 23
6.7 Walvol Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7. Troubleshooting guide
7.1 Hydraulic circuit fault location tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.2 ZR electrohydraulic modules fault location tips . . . . . . . . . . . . . . . . . 28
8. Routine maintenance
8.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9. Extraordinary maintenance
9.1 General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.2 Valve in general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.3 BR -- BN inlet covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.4 BRS inlet cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.5 BRSO inlet cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.6 Working section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.7 Electrohydraulic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
10. Hydraulic circuit conversion
10.1 From Pressure Compensated to Load Sensing and vice versa . . . 48
10.2 Local compensation circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11. Storage
11.1 Recommended practices about hydraulic components . . . . . . . . . . 49
12. Spare parts list
12.1 Inlet cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
12.2 Working section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
12.3 Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
12.4 “A” side spool positioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
12.5 “B” side options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
12.6 End cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
12.7 Assembling parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
DDM010E 3
1. Working conditions
This manual shows technical specifications measured with mineral oil of 46 mm2/s -- 46 cSt viscosity at 40°C temperature.
Nominal flow rating on inlet port P 140 l/min

on ports A and B with compensator 100 l/min
on ports A and B without compensator 120 l/min
Operating pressure (maximum) on inlet port P and on ports A, B, LS 315 bar 4600 psi
Max. back pressure on outlet T 25 bar 360 psi
on drain L 2,5 bar 36 ps
∆p=100 bar -- 1450 psi
Internal leakage A(B)→T 10 cm3/min 0.61 in 3/min
fluid and valve at 40°C
Fluid Mineral base oil
Fluid temperature with NBR (BUNA--N) seals da --20° a 80°C
Viscosity coperating range da 15 a 75 mm2/s
minima 12 mm2/s 12 cSt
massima 400 mm2/s 400 cSt
Max level of contamination 18/15 -- ISO 4406
Ambient temperature da --40° a 60°C
NOTE -- For different conditions please contact Sales Dept.
2. Standard threads
REFERENCE STANDARDS
BSP UN--UNF
THREAD ISO 228/1 ISO 263
ACCORDING TO BS 2779 ANSI B1.1 unified
CAVITY ISO 1179 11926

ACCORDING TO SAE J2244
DIN 3852--2
shape X or Y
PORTS THREAD
MAIN PORTS BSP UN--UNF
IInlet P and outlet T G 3/4 1 1/16--12 (SAE 12)
Ports A and B G 1/2 7/8--14 (SAE 10)
PILOT PORTS
LS, M G 1/4 9/16--18 (SAE 6)
L, V1, V2 G 1/4 9/16--18 (SAE 6)
4 DDM010E
Dimensional data 3.
E
221.5
8.72 8 F
126 0.31
4.96 32 16 103
0.20
71.5 1.26 0.63 4.06
5
2.81
4
1
1
63
2
2.48
109
4.29
3
3
37.5 53
1.48 2.09
8.5
∅
8 9 10
7 65
8 9 10
7 65
0.31
8 0.33
21.5
0.85
0.75
19
41.5
1.63
P
12.72
43.5
1.71
323
Walvoil DPC130
100
3.94
1.30
Made in Italy
33
113020001
P000001
T
LS
53.5
2.11
41.5
1.63
21
0.83
95.5
3.76
3.66
93
Position 2
Position 0 36
1.42
Position 1 46
1.81
32 48 48 70 25
1.26 1.89 1.89 2.76 0.98
P : Inlet
T : Outlet
A/B : Ports
L : Drain for valve with electrohydraulic control
LS : Load Sensing signal port
V1 : Pilot pressure port (Pmax=20 bar / 290 psi) to supply hydraulic pilot control valves (P⇒OUT)
V2 : Pilot pressure port to supply pressure reducing valves of electrohydraulic controls (Pmax=315 bar / 4600 psi) (P⇒IN) or to
to connect pressure gauge: needs suitable joints.
E F Weight E F Weight
TYPE TYPE
mm in mm in kg lb mm in mm in kg lb
DPC130/1 200 7.87 184 7.24 12.4 27.3 DPC130/6 440 17.3 424 16.7 42.6 93.9
DPC130/2 248 9.76 232 9.13 19.4 42.8 DPC130/7 488 19.2 472 18.6 48.7 107
DPC130/3 296 11.7 280 11 25.3 55.8 DPC130/8 536 21.1 520 20.5 54.8 121
DPC130/4 344 13.5 328 12.9 31 68.3 DPC130/9 584 23 568 22.4 60.9 134
DPC130/5 392 15.4 376 14.8 36.5 80.5 DPC130/10 632 24.9 616 24.3 67 148
DDM010E 5
4. Hydraulic circuit
Fixed displacement pump application

With all spools in the neutral position pump flow is bypassed to tank by the inlet un--loader at stand--by pressure (9 bar / 130 psi).
With one or more valves sections active; load pressure is communicated to the inlet un--loader through shuttle valve logic. Excess
flow is bypassed by the inlet un--loader at load pressure plus stand by pressure (9 bar / 130 psi).
P T
B2 A2 B1 A1
V2
L V1
LS
LSAB LSAB
Description example: DPC130/2/BR11--S220--ELP/C10--18ZR3L0/C10--18ZR3L0/RF30--12VDC--<CVN>
Variable displacement Load-- Sensing pump application

With all spools in the neutral position the load sense shuttle valve logic vents to tank and pump pressure will be at pump stand--by
pressure.
With one or more valve sections active; load pressure is communicated through the shuttle valve logic to the Load--Sense control
located on the pump through the Load--Sense port located on the valve. In cases where the Load--Sense pressure exceeds the
Load--Sense relief valve setting located in the valve inlet; the flow will be relieved to tank.
B2 A2 B1 A1 P T
V2
L V1
LS
LSAB LSAB
Description example: DPC130/2/BR21--S220--ELP/C10--18ZR3L0/C10--18ZR3L0/RF30--12VDC--<CVN>
6 DDM010E
General recommendations 5.
5.1. Hydraulic recommendations

D Only highly qualified personnel must use the directional control valve. The high power created inside the hydrau-
lic circuit can cause damage to things and injury to people.
D Always wear adequate protective clothing, goggles, and use equipment suitable for preventing accidents, espe-
cially regarding hydraulic fluids.
D Always handle the valve using equipment that can guarantee the safety of personnel and that can safeguard
the valve from damage.
D Before carrying out installation and maintenance or replacing the hydraulic circuit, make sure that the system
or vehicle is off and that the pressure in the system has been released.
Place all of the actuators on standby (on the ground, at the lowest point, etc.), discharge all of the accumulators, and secure loads
whose accidental movement could cause damage or generate pressure.
D Do not touch the valve during operation. Its high temperature could cause quite serious burns.
5.1.1 Hydraulic fluid

The oil in the hydraulic circuit has the dual function of lubricating and transmitting power.
This is a vital factor in a hydraulic system and must be selected through the assistance of a qualified supplier: The DPC130 valve
requires hydraulic fluid with a viscosity of 15 to 75 mm2/s / 15 to 75 cSt.
Choosing the correct oil ensures long--lasting satisfactory operation of the system’s components, especially the valve. The oil cho-
sen for the operation of this hydraulic component is of course suitable for use with the pump, motor, and single--acting and double--
acting hydraulic cylinders.
D Water and hydraulic fluid must not be mixed together; water is considered a contaminating chemical agent.
5.1.2 Cleaning and filtration

D To ensure proper operation of the components, keep the hydraulic fluid at a filtration of 18/15 -- ISO4406 or better.
D Every time the oil is changed, filter the new fluid to prevent further contamination.
D Use continuous filtration on the circuit to eliminate dirt and products that corrode and wear, generated during system operation.
D Replace the fluid at regular intervals and remove waste from the circuit according to the operating conditions.
D Protect the circuit against pollutants transported by air by sealing the system and/or carrying out filtration of the breather valve.
D Before starting a new machine, clean (wash) the entire hydraulic system to make sure that paint residues, metal shavings, weld-
ing residues, etc., have been removed.
D Before installation, the directional control valve must always be thoroughly cleaned, especially after long periods of storage.
D Remove the plugs that protect the ports just before the valve is actually connected in order to prevent dirt and impurities from
penetrating inside.
D If the valve was stored in a cold place, remove any condensation that might have formed if moved into a warmer environment.
D The hydraulic circuits of systems and machines that are finished or are ready for shipping should be checked at random to ensure
that the level of fluid contamination corresponds to the recommended level: 18/15 -- ISO4406 or better.
DDM010E 7
5.1. Hydraulic recommendations

5.1.3 Hydraulic connections
D In the new system, all of the pipes must be carefully cleaned before installation in order to remove dirt, rust, and deposits.
The following cleaning procedures are recommended: Sanding, brushing, pickling, and flushing with a solvent to remove
contaminating particles.
D To reduce fluid resistance and the possibility of leaks, use the fewest number of fittings necessary for proper installation.
D Minimize the number of bends used to prevent excessive turbulence and friction of the fluid. The pipes must not have bends
with excessively acute angles. The minimum recommended radius is 3 times the internal diameter of the pipe. In high--pres-
sure systems (345 bar or higher), use steel elbows for curves in order to increase the circuit’s lifetime.
D The use of Teflon tape, hemp, or other ”fillers” for joints is PROHIBITED
D Verify that the pipes, fittings and connections are not subjected to mechanical stress.
D Make sure that the pipes are not wound and that there are no abrasions on the surface.
8 DDM010E
General recommendations 5.
5.2. Electrical recommendations

The DPC130 directional control valve may be equipped with proportional or ON/OFF electrohydraulic modules with or without on--
board electronics.
Keep to the listed recommendations regarding electrical connections, the laying of cables, the use of connectors, etc.
D Before installing, carrying out maintenance, or replacing the electrical circuit, make sure that the electrical power
to the circuit has been disconnected.
Place all of the actuators on standby (on the ground, at the lowest point, etc.), discharge all of the accumulators, and secure loads
whose accidental movement could cause damage or generate pressure.
D If possible, carry out welding operations on the machine’s chassis before installing the electronic components;
otherwise, the electrical system must be disconnected.
Always disconnect the negative cable from the battery first and then the positive cable.
The welder’s ground cable must be positioned as close to the welder itself as possible.
Avoid positioning the cables of the welding unit near the system’s electrical circuit.
D The system must always be equipped with an EMERGENCY STOP button that disconnects power to the circuit,
positioned at a point on the machine that can be easily accessed by the operator.
D The machine must be constructed so that it guarantees that power will be cut off to the circuit if the operator
leaves the control panel.
5.2.1 Wires
D According to experience, a high number of electrical and electronic malfunctions is due to problems with wiring
and electrical connections.
D Use cables with sheaths resistant to oils such as PUR (polyurethane) or PTFE (polytetrafluoroethylene).
D Avoid using cables or leads with cracked or worn insulating sheaths.
D Avoid positioning them near communication devices, antennas, generators, and other sources of high--frequency interference.
Separate the control circuit cables from any antenna cables.
D Separate the control circuit’s power supply from the communication circuit’s power supply.
D Ensure good contact with the battery’s negative terminal.
D If possible, pass the cables through the inside of the machine’s metal structures; alternatively, secure the cables in a corner be-
tween two metal surfaces or on a flat metal surface.
D Protect the cables from wear due to rubbing.
D Whenever possible, avoid positioning cables without securing them; any unfastened cables must be fitted so that they cannot
become wound and flattened.
D If the cables are in contact with sharp edges (eg: holes in sheet metal), protect them with plastic sheaths and conduits.
D Secure the cables using tape, clamps, glue, or other devices. If clips are used, do not secure them too tightly since the leads
inside the cable could be damaged.
The distance between the points at which the cables are secured must guarantee protection against vibrations produced by the
chassis.
D If movement is required, the length of the wires must permit bending. Avoid stretching and twisting the cables.
The minimum bending radius of the cables must not be less than 20 times the diameter.
DDM010E 9
5.2. Electrical recommendations
5.2.2 Connectors
A good electrical connection between the control circuit and the directional control valve’s electronics is fundamental to proper sys-
tem operation.
Properly attached connectors, accurately secured leads, and the right use and positioning of the seals ensure suitable contact, me-
chanical resistance, and insulation from external agents, necessary for preventing malfunctions and incorrect operation.
D Assembly of the cable inside the connector ensures two functions: Electrical contact and mechanical attachment.
A connector that is assembled and fitted incorrectly can cause sporadic malfunctioning that is difficult to identify.
D Always use brand--name connectors with technical characteristics (degree of protection, capacity, contact type
and material, etc.) that are compatible with similar devices present on the valves.
D Always use suitable tools: If the lead is not tightened into the connector with screws, a crimper (for securing the lead to the contact)
and an extraction tool (for removing the contacts from the connector) are generally necessary.
D The connector’s seals must be free of malformations and abrasions.
D The cable’s angle as regards the seal must not be excessive: Contact the supplier for suggested values.
10 DDM010E
Installation 6.
6.1. Hydraulic circuit operating instruction

D The directional control valve may be fitted in any position. To prevent deformation of the sections and consequent jamming
of the spools, check the cleanliness and regularity of the surface on which it sets.
D Attach the valve with suitable screws, using the provided brackets. After tightening, verify that it is securely and safety instal-
led.
D Verify the integrity of the surfaces of contact between the valve and the fittings and remove any foreign matter.
D Check the condition of the seals of the fittings.
D Connect the directional control valve correctly. In particular, make sure that ports P and T are not inverted and that the drain
line (port L) is connected directly to the tank.
D To determine the codes of the ports, see page 6.
D The directional control valve must only run under the operating conditions listed on page 4: in particular, the maximum al-
lowed back pressure is 25 bar / 360 psi for port T and 2.5 bar / 36 psi for port L.
D In circuits with fixed displacement pumps, port LS on the valve must be plugged. If the pump is a variable displacement
pump, port LS must be connected to the pump’s load--sensing signal.
D During startup, the temperature of the valve and the fluid differ over 20°C. The valve or the oil must be heated up through
no--load operation of the circuit.
D Initial startup: after 15 minutes of operation, stop the system and clean the circuit’s filters of impurities.
D The suggested tightening values for the fittings are reported below.
The tightening torque depends on various factors such as lubrication, coating, and surface finish: thesupplier must be con-
tacted.
In any case, to prevent deformation of the ports, do not exceed the reported values.
6.1.1 Tightening torques of fittings (Nm / lbft)
THREAD TYPE ports P and T ports A and B ports L and LS ports V1 and V2
BSP G 3/4 G 1/2 G 1/4 G 1/4
With O--ring seal 60 / 44.2 50 / 36.9 25 / 18.4 25 / 18.4
With copper washer 70 / 51.6 60 / 44.2 30 / 22.1 30 / 22.1
With steel and rubber washer 140 / 103 80 / 59 30 / 22.1 30 / 22.1
UN--UNF 1 1/16--12 SAE 12) 7/8--14 (SAE 10) 9/16--18 (SAE 6) 9/16--18 (SAE 6)
With O--ring seal 110 / 81.1 70 / 51.6 30 / 22.1 30 / 22.1
DDM010E 11
6. Installation
6.2. Electrical circuit operating instructions

If the valve is configured with electrically--controlled devices such as electrohydraulic modules and unloading valves, proceed with
connection, observing the following instructions.
6.2.1 Precautions
D Make sure that the machine is off and the electrical circuit is not powered.
D The machine’s motor must not be started until the electrical circuit is completely installed and checked.
6.2.2 Power supply

D Connect the positive power cable to the battery, observing the polarity.
D Make sure that the following components are present and functioning on the positive power cable: A fuse with adequate ca-
pacity -- ON/OFF button or key -- emergency stop button (one or more than one in series, in easily accessed positions).
D Connect the negative power cable to the battery and not to the machine’s chassis.
D Use a power cable that is independent from other electric circuits.
6.2.3 Electrohydraulic modules in general

D Check the integrity of the connectors on modules EZ and ZR.
D Connect the power cables and signal cables to the EZ and ZR modules, paying special attention to: Seals of connectors
(presence, integrity, correct assembly) -- position of cables (tension, contact with sharp edges or very hot parts, flattening due
to moving parts such as lids, hoods, and the like).
6.2.4 EZ electrohydraulic modules

D Connect the cables of the proportional solenoid to the switches or control units.
D Make sure that the wiring diagram is complied with.
D Verify the presence of free--wheeling diodes with adequate capacities, if not already provided for inside the control unit.
6.2.5 ZR electrohydraulic modules

D Connect the cables of the set--point signals to the joysticks or control units.
D Make sure that the wiring diagram is complied with.
D Make sure that the voltage of the ZR modules and the joysticks or control units are as equal to each other as possible and
that they are not influenced by the operation of other on--board electrical systems.
D Make sure that the range of the set--point signals corresponds to the range envisaged for the modules (under all machine
operation conditions, especially during activation of other on--board electrical systems).
D Make sure that there aren’t any free--wheeling diodes on the signal cables.
6.2.6 Startup
D Make sure people are not near the machine or within its range of operation at startup, placing themselves at risk.
D Verify the operation of the emergency stop buttons while the machine is not running.
D Start the machine at a low rpm or, in any case, a limited flow rate of oil.
D Activate, using caution, each of the directional control valve’s functions one at a time and verify their proper operation.
D Repeat the tests with gradually higher flow rates until the highest flow rate of oil is reached.
D Verify the operation of the emergency stop buttons while the machine is running.
D Verify machine behavior when the electrical system and motor are turned off.
12 DDM010E
Installation 6.
6.3. 8ZR3 connection example

6.3.1 One working section with sigle axis lever
Single axis lever

Type MDN142
Code: VJOY200001
Connector
Type C02 Emergency push--button
Code: 2X1001010 Code: VPUL110001
Fuse with fuse--holder

2A--19x20 DIN72581
Code: YW0102014
Working section
Type C10-- 1S8ZR3L1-- 12VDC
Battery
Code for BSP ports: 634110001
Code for SAE ports: 634110002
Electric wiring
Signal
Connector
2
4
yellow
3
1 brown
Battery voltage red
Battery Gnd orange
Emergency balck
light blue
bianco
Fuse Lever
- +
Battery
DDM010E 13
6. Installation
6.3. 8ZR3 connection example

6.3.2 Two working sections with double axis joystick
Connectors
Type C02
Code: 2X1001010 Emergency push--button
Code: VPUL110001
Joystick
Type MDT210
Code: 183520012

4A--19x20 DIN72581
Code: YW0102015
Working sections
Type C10-- 1S8ZR3L1-- 12VDC Battery
Electric wiring
Y axis signal
X axis signal
2 Connectors 2
4 4
3 3
1 1 Joystick
grey--black X axis output
red--black
Battery voltage Y axis output
white--black
battery voltage
Battery Gnd brown
Battery Gnd
Emergency pink
center tap
Fuse
- + Battery
14 DDM010E
Installation 6.
6.4. 8ZR3CB connection example

6.4.1 Two working section with double axis joystick
Connectors
Type C02
Emergency push--button
Code: 2X1001010
Code: VPUL110001
Joystick
Type MDT230
Code: 183520059

4A--19x20 DIN72581
Code: YW0102015
Working sections
Type C10-- 1S8ZR3CBL1-- 12VDC Battery
Electric wiring
CAN_High
2 2
BUS termination
Connectors
4 4
resitor
120 Ω
3 3
CAN_Low
1 1
brown CAN_High
Battery white
voltage CAN_Low
blue
Vcc
Battery Gnd black
battery Gnd
Emergency yellow--green Vcc return
Joystick
Fuse
- + Battery
DDM010E 15
6. Installation
6.5. 8ZR4F connection example

6.5.1 One section with single axis potentiometric handle
Connector
Type C25
Code: 5CON120037
Code: VPUL110001
Potentiometric handle
Working section Type HZB0
Type C10-- 1S8ZR4F2L1-- 12VDC Code: 2IM480000
Code for BSP ports: 634110036 2A--19x20 DIN72581
Code for SAE ports: 634110040 Code: YW0102014
Battery
Electric wiring
purple
signal
blue
battery voltage
Battery voltage
brown battery Gnd

Emergency
Battery Gnd
Handle potentiometer
Signal
1 2 3 4 Fuse
Connector
- +
Battery
16 DDM010E
Installation 6.

6.5.2 Two working sections with double axis potentiometric handle
Connectors
Type C25
Code: 5CON120037
Code: VPUL110001
Potentiometric handle
Type PZB0200A0
Fuse with fuse--holder Code: 2IM8510001
Working section 4A--19x20 DIN72581
Type C10-- 1S8ZR4F2L1-- 12VDC Code: YW0102015
Battery
Electric wiring
yellow
X axis signal
blue
battery voltage
brown
battery Gnd
Battery voltage
Battery voltage
Emergency purple
X axis signal
Y signal axis
Y axis signal
Battery Gnd
Battery Gnd
Handle potentiometers
Fuse
1 2 3 4 1 2 3 4
Connectors - +
Battery
DDM010E 17
6. Installation

6.5.3 Other devices to pilot the control module with segnal from 0,5 to 4,5 V
For two sections For three sections
MDZ double axis joys-

tick with HZ potentiomet-
MDZ double axis ric handle
joystick. Code: 183520072
Code: 183520071
grey grey
”dead man” ”dead man”
green switch green switch
purple Z axis output
whitw--blue X axis output blue
red--blue battery voltage
Y axis output brown
whitw--black battery Gnd
battery voltage white--blue
brown X axis voltage
battery Gnd red--blue
pink Y axis voltage
center valve white--black
battery voltage
brown
battery Gnd
pink
center valve
For four sections
grey
”dead man”
green switch
yellow MDZ double axis joys-
W axis signal
tick with PZ potentiomet-
purple Z axis signal ric handle.
blue battery voltage Code: 183520073
brown
battery Gnd
whitw--blue X axis signal
red--blue
Y axis signal
white--black
battery voltage
brown
battery Gnd
pink
center valve
18 DDM010E
Installation 6.
6.6. 8ZR4P connection example

6.6.1 One working section with single axis lever
Connector
Type C25
Code: 5CON120037
Code: VPUL110001
Lever
Type MDN142
Code: VJOY200001
Working section
Type C10-- 1S8ZR4P2L1-- 12VDC
2A--19x20 DIN72581
Code: YW0102014
Battery
Electric wiring
yellow
brown
Battery voltage
red
Emergency
Battery Gnd
orange
Signal
black
light blue
1 2 3 4 Fuse
white
Connector Joystick
- +
Battery
DDM010E 19
6. Installation
6.6. 8ZR4P connection example

6.6.2 Two working sections with double axis joystick
Connectors
Code: 5CON120037
Code: VPUL110001
Joystick
Type MDT210
Code: 183520012

4A--19x20 DIN72581
Code: YW0102015
Working sections
Type C10-- 1S8ZR4P2L1-- 12VDC
Battery Joystick
Code for SAE ports: 634110041 Type MDN231
Code: VJOY200003
Electric wiring
grey--black
X axis output
white--black
battery voltage
MDT joystick
brown
Tensione batteria
Tensione batteria
battery Gnd
Segnale asse X
Segnale asse Y
red--black
Gnd batteria
Gnd batteria
Y axis output
pink
Emergency Centre tap
1 2 3 4 1 2 3 4
battery Gnd yellow black
X axis output brown white

Connectors
Fuse battery voltage red
MDN joystick
orange
battery Gnd green

- +
Y axis output grey
Battery battery voltage purple
blue
20 DDM010E
Installation 6.
6.7. 8EZ3 connection example

6.7.1 One working section wirh ON/OFF control
Connector
Code: 2X1001010 Code: VPUL110001
2 positions selector
Type S3D
Code: VSEL200003

Working section 2A--19x20 DIN72581
Code: YW0102014
Type C10-- 1S8EZ3L1-- 12VDC
Code for SAE ports: 634110043 Battery
Electric wiring
Selector
3 3
3
4 4
2 1
Connector
Emergency
Fuse
- +
Battery
DDM010E 21
6. Installation

6.7.2 Two working sections with proportional control
Analog control unit

Type UGA
For configurations and codes
contact Sales Department
Code: VPUL110001
Double axis joystick

Type MDT210
Fuse with fuse--holder Code: 183520012
Working sections 4A--19x20 DIN72581
Type C10-- 1S8EZ3L1-- 12VDC Code: YW0102015
Battery
Electric wiring
Joystick
yellow
Control unit black
brown
Battery Gnd
Battery Gnd
purple
Port B
Port B
Port A
Port A
Emergency
3 3
2 1 2 1
4 4
Fuse
- + Battery
22 DDM010E
Installation 6.

6.8.1 One working section with ON/OFF control
Connector
Type C25
Code: 5CON120037 Emergency push--button
Code: VPUL110001
2 positions selector
Type S3D
Code: VSEL200003

2A--19x20 DIN72581
Code: YW0102014
Working section
Type C10-- 1S8EZ4L1-- 12VDC
Code for BSP ports: 634110038 Battery
Electric wiring
Selector
3 3
Connector
1 2 3 4 4 4
Emergency
Fuse
- +
Battery
DDM010E 23
6. Installation

6.8.2 Two working sections with proportional control
Analog control unit

Type UGA
For configurations and codes
contact Sales Department
Code: VPUL110001
Joystick a 2 assi
Tipo MDT210
Codice: 183520012
Working sections 4A--19x20 DIN72581
Type C10-- 1S8EZ4L1-- 12VDC Code: YW0102015
Battery
Electric wiring
Joystick
yellow
Control unit black
brown
Battery Gnd
Battery Gnd
purple
B port
B port
A port
A port
Emergency
1 2 3 4 1 2 3 4
Fuse
- + Battery
24 DDM010E
Installation 6.
6.9. Walvoil Service Tool

The ZR electrohydraulic modules with on--board electronics are supplied with standard programming of the operation parameters,
which satisfies most applications.
For special applications, the WST programming software allows some of the parameters for solenoid valve control to be modified
using a personal computer. For example, the minimum and maximum values of linear curves may be defined.
The special connection cable is required: VCAV600002 with a length of 3m or VCAV600003 with a length of 5m.
6.9.1 Minimum system requirements

D Windows 95 operating system or higher.
D 166 MHz Pentium processor.
D 32 Mb RAM.
D Connection through a standard RS232 serial port, DB9 connection; alternatively, a USB--RS232 converter can be used.
6.9.2 Program installation

The .WST_DPC130. software may be ordered from our Sales Department.
To install the WST software onto a personal computer, simply execute the file setup.exe.
6.9.3 Connection to the ZR electrohydraulic control

D Connect the personal computer’s serial port to the programming connector of the electrohydraulic module using the provided
programming cable.
D Make sure that the module is properly connected and powered (red or green LED’s on or blinking) and then execute the pro-
gram .WST_DPC130.exe.
Joystick and power

connector
Programming Programming cable

connector
DDM010E 25
7.1. Hydraulic circuit fault location tips
Hydraulic malfunction Cause Corrective action

1 Insufficient flow to 1.1 Insufficient pump flow rate Increase the motor’s speed.
th ports
the t 1.2 The mechanical stroke limiting device of Loosen the stroke limiting device until the correct flow rate is
the lever box is not properly adjusted. achieved.
1.3 The auxiliary valve on the ports is par- Remove the valve and clean the parts, proceeding as stated in
tially open. point 9.6.5 in the chapter entitled ”Extraordinary maintenance”.
1.4 The valves on the load--sensing signal Increase the valve’s calibration value as stated in points 9.6.4
(LSD and LSH) are set too low. and 9.3.1 in the chapter entitled ”Extraordinary maintenance”.
1.5 The valves on the load--sensing signal Dismantle the valve, clean it, and reassemble it as stated in
are partially open because of dirt. points 9.6.4 and 9.3.1 in the chapter entitled ”Extraordinary
maintenance”.
1.6 The valves on the load--sensing signal Dismantle the valve and check the poppet and seat as stated in
leak toward the tank. points 9.6.4 and 9.3.1 in the chapter entitled ”Extraordinary
maintenance”.
1.7 The section’s shuttle valve is not prop- Remove the valve, clean it, and check the condition of the seals
erly tightened because of dirt (all sec- as stated in point 9.6.3 in the chapter entitled ”Extraordinary
tions) or leaks due to worn seals. maintenance”.
1.8 The pressure reducing valves of the Remove the pressure reducing valve, clean it, and verify the
electrohydraulic controls do not carry condition as stated in point 9.7.2 in the chapter entitled ”Extraor-
out the entire necessary stroke be- dinary maintenance”.
cause of dirt.
1.9 Leakage from port LS in the lower part Act as stated in point 9.6.7 in the chapter entitled ”Extraordinary
of the working section (in the upper part maintenance”.
for sections C13 and C23)
1.10 The pilot solenoid valve of cover Check the conditions of the coil and solenoid valve as stated in
BRSO21 is jammed open. point 9.5.1 in the chapter entitled ”Extraordinary maintenance”.
1.11 The shut--off spool on cover BRSO21 Check the condition of the spool as stated in point 9.5.2 in the
does not carry out the entire stroke. chapter entitled ”Extraordinary maintenance”.
1.12 The damper of cover BRS is partially Remove and clean the damper as stated in point 9.4.3 and check
clogged and the load check valve is the condition of the valve as described in point 9.4.2 in the chap-
jammed. ter entitled ”Extraordinary maintenance”.
2 No flow 2.1 The pump is not working. Check coupling with the motor.
2.2 Low oil level in tank. Refill the tank with hydraulic oil to the indicated level.
2.3 Directional control valve not properly Verify proper connection of the ports.
connected to the hydraulic circuit.
2.4 Supply fittings damaged. Check and, if necessary, replace the fittings.
2.5 The unloading valve blanking plug on Remove the plug by proceeding as stated in point 9.3.2 in the
the inlet cover is damaged or incorrectly chapter entitled ”Extraordinary maintenance”.
tightened.
2.6 The unloading valve on the inlet cover Remove the valve by proceeding as stated in point 9.3.2 in the
does not close the circuit. chapter entitled ”Extraordinary maintenance”.
2.7 The restrictor valve or the filter of the LS Dismantle the valve and clean it as described in point 9.3.5 in the
joint on the inlet cover are completely chapter entitled ”Extraordinary maintenance”.
obstructed
2.8 The compensator on the inlet cover is Proceed as stated in point 9.3.3 in the chapter entitled ”Extraor-
jammed open due to dirt between the dinary maintenance”.
spool and the casing.
2.9 The pilot solenoid valve of cover Check the condition of the coil and the solenoid valve as stated
BRSO21 is jammed open. in point 9.5.1 in the chapter entitled ”Extraordinary mainte-
nance”.
2.10 The shut--off spool on cover BRSO21 Check the condition of the spool as stated in point 9.5.2 in the
does not slide. chapter entitled ”Extraordinary maintenance”.
2.11 The damper of cover BRS is completely Remove and clean the damper as stated in point 9.4.3 and check
clogged and the load check valve is the condition of the valve as described in point 9.4.2 in the chap-
jammed. ter entitled ”Extraordinary maintenance”.
26 DDM010E
Troubleshooting guide 7.
7.1. Hydraulic circuit fault location tips
Hydraulic malfunction Cause Corrective action

3 The pressure in a 3.1 The shuttle valve is dirty or leaks due to Simultaneously activate the concerned section with the following
section does not worn seals. one or the previous one and verify whether they both run correct-
reach the desired va- ly this way.
lue. If so, proceed as stated in point 9.6.3 in the chapter entitled ”Ex-
traordinary maintenance”.
3.2 Port LS in the lower part of the working Plug the port or connect it to a manometer.
section (in the upper part for sections
C13 and C23) is connected to auxiliary
devices.
3.3 The auxiliary valve on the port (type U) Remove the valve and check the poppet and seat as stated in
leaks toward the tank. point 9.6.5 in the chapter entitled ”Extraordinary maintenance”.
4 The pressure does 4.1 The pressure relief valve on the inlet Dismantle the valve, clean it, and reassemble it as stated in point
not reach the desired cover is jammed open due to dirt (during 9.3.1 in the chapter entitled ”Extraordinary maintenance”.
value in all of the sec- the valve’s pilot operated stage).
ti
tions. 4.2 The pressure relief valve on the inlet Dismantle the valve and check the poppet and seat as stated in
cover leaks. point 9.3.1 in the chapter entitled ”Extraordinary maintenance”.
4.3 The compensator on the inlet cover is Proceed as stated in point 9.3.3 in the chapter entitled ”Extraor-
jammed open due to dirt between the dinary maintenance”.
spool and the casing.
5 One or more sec- 5.1 The power connector of the control kit is Verify the integrity of the connector and its proper positioning.
tions onlyy operate
p disconnected or damaged.
manually
ll (for
(f elec-
l 5.2 The coil of the control kit is burned out. Replace the coil and check the voltage.
trohydraulic direc-
tional control 5.3 The pressure reducing valves of the Remove the pressure reducing valve, clean it, and verify the
valves). section are jammed shut. condition as stated in point 9.7.2 in the chapter entitled ”Extraor-
dinary maintenance”.
5.4 Obstruction of the pilot lines of the sec- Dismantle the directional control valve by proceeding as stated in
tion due to dirt. point 9.2.1 in the chapter entitled ”Extraordinary maintenance”.
6 The directional con- 6.1 No electrical power. Verify the position of the electrical circuit’s emergency button
trol valve onlyy works and, if necessary, check the battery’s voltage.
manuallyll (for
(f elec-
l 6.2 Port L of the drain line is plugged or par- Connect the port directly to the tank eliminating the obstruction, if
trohydraulic valves) tially obstructed. any.
6.3 The pressure reducing valve on the inlet Remove the valve and clean the parts as stated in point 9.3.4 in
cover is jammed shut due to dirt. the chapter entitled ”Extraordinary maintenance”.
7 When the pump is 7.1 The pressure reducing valves of the Remove the pressure reducing valve, clean it, and verify the
started, oil leaks section are jammed in the working posi- condition as stated in point 9.7.2 in the chapter entitled ”Extraor-
from one of the ports.
p tion. dinary maintenance”.
7.2 IThe spool does not slide. Check movement manually.
Remove the spool and follow the instructions in point 9.6.6 in the
chapter entitled ”Extraordinary maintenance”.
7.3 The coil of control kits EZ or ZR is al- Check the electrical circuit and make sure that the coil’s control
ready excited. kit is not jammed or accidentally activated.
8 Delay between ac- 8.1 For one section: The restrictor valve on Remove the restrictor valve and clean it by proceeding as stated
tivation of the spool the working section is partially obstruc- in point 9.6.8 in the chapter entitled ”Extraordinary mainte-
and the real move- ted. nance”.
mentt off the
th port’s
t’ ac- 8.2 For all sections: The restrictor valve or Proceed as stated in point 9.3.5 in the chapter entitled ”Extraor-
tuator the filter of the LS joint on the inlet cover dinary maintenance”.
are partially obstructed.
8.3 The Copy--Spool of cover BRS does not Remove the spool and verify the condition as described in point
switch over due to dirt. 9.4.1 in the chapter entitled ”Extraordinary maintenance”.
8.4 The Copy--Spool restrictor of cover Remove the restrictorl aand clean it by proceeding as stated in
BRS is obstructed. point 9.4.1 in the chapter entitled ”Extraordinary maintenance”.
8.5 The damper of cover BRS is clogged Remove and clean the damper as stated in point 9.4.3 in the
chapter entitled ”Extraordinary maintenance”.
8.6 The damper of cover BRS is too tight Adjust the damper as stated in point 9.4.3 in the chapter entitled
”Extraordinary maintenance”.
DDM010E 27
7.2. ZR electrohydraulic modules fault location tips

Malfunctioning of the control kit is signaled by the LED on the end cover, which blinks indicating the relative error code.
For example, error code 1 -- 5 indicates that the LED will blink, pause briefly, blink 5 times, pause for a long time, and then start again.
The number indicated in the reference column (Ref.) refers to page 32 where the type of malfunction is graphically represented.
Error
Visual signal Phase Ref. Cause of error Corrective action
code
1 Control kit not powered. Check the power circuit.
2 Power supply polarity inverted. Reset the correct polarity.
Turning on
LED damaged. NONE if the control kit is functioning.
LED spenti
p 0- 0 3 Control kit damaged. REPLACE THE CONTROL KIT.
(none)
1 Control kit not powered. Check the power circuit.
Regular
R l LED damaged. NONE if the control kit is operating.
operation
4 Control kit damaged. REPLACE THE CONTROL KIT.
Green LED Turning on Control kit in neutral position Control. NONE: Correct operation.
continuouslyy on 0- 0 Control kit in neutral position Control. NONE: Correct operation.
Funzionamento (none)
a regime LED damaged. NONE if the control kit is operating.
Manually adjust the sensor as stated in
Turning on 5 Electrical zero of LVDT incorrect. paragraph 9.7.1 in the section entitled ”Ex-
Blinking green 0- 0 traordinary maintenance”.
LED (none)
Regular
The spool is not in the neutral position. NONE: Correct operation.
operation
LED damaged. NONE if the control kit is operating.
Turning on
Red LED 0- 0 4 Control kit damaged. REPLACE THE CONTROL KIT.
continuously on Regular (none) LED damaged. NONE if the control kit is operating.
operation 4 Control kit damaged. REPLACE THE CONTROL KIT.
1- 5 3 Set--point signal NOT at neutral. Check the connection of the control de-
5- 3 3 Set--point signal low. vices (eg:
( g joystick)
j y ) and make sure theyy are
5- 4 3 Set--point signal high. i the
in th neutral
t l position.
iti
The spool does not reach the desired posi-

2- 6 6 Place the spool in the neutral position us-
tion within the set time.
ing the section’s lever.
lever
8- 2 6 The spool is not in the neutral position.
Check the electrical circuit and the bat-
3- 1 1 The voltage is too low.
tery’s voltage.
The solenoids are not electrically connec-
4- 2 7 REPLACE THE CONTROL KIT.
ted.
Reset the temperature through no--load
operation of the system.
Blinking red
LED T i on
Turning If the system’s temperature is within the
5- 1 The control kit’s temperature is low.
operation limits, there is a problem with the
card’s temperature sensor: REPLACE
THE CONTROL KIT.
Cool the system.
If the system’s temperature is within the
5- 2 The control kit’s temperature is too high. operation limits, there is a problem with the
THE CONTROL KIT.
Invalid CAN message received (only for Make sure that the output signal of the
1- 1 3
ZR3CB control kit). control device (eg: joystick) is correct.
Reset the default parameters and repeat
The parameters set on the module are not
5- 5 8 the settings procedure, modifying the inval-
valid.
id parameters.
28 DDM010E
Troubleshooting guide 7.
Error
Visual signal Phase Ref. Cause of error Corrective action
code
1- 5 3 Set--point signal NOT at neutral. Check the connection of the control de-
5- 3 3 Set--point signal low vices (eg:
( g joystick)
j y ) and make sure theyy are
5- 4 3 Set--point signal high i the
in th neutral
t l position.
iti
-- Make sure that the screws that limit the

stroke, located on the lever box, do not
hinder the spool’s stroke.
The spool does not reach the desired posi-
2- 6 6 -- Manually verify the spool’s movement: If
tion within the set time
there are obstructions, proceed as stated
in point 9.6.6 in the chapter entitled ”Ex-
traordinary maintenance”.
Place the spool in the neutral position us-
8- 2 6 The spool is NOT in the neutral position.
ing the section’s lever.
Check the electrical circuit and the bat-
3- 1 1 The battery’s voltage is low.
tery’s voltage
The solenoids are not electrically connec-
4- 2 7 REPLACE THE CONTROL KIT.
Blinking
g red Regular
g ted.
LED operation
ti Reset the temperature through no--load
operation of the system.
5- 1 The control kit’s temperature is low. If the system’s temperature is within the
operation limits, there is a problem with the
THE CONTROL KIT.
Cool the system.
f the system’s temperature is within the op-
5- 2 The control kit’s temperature is too high. eration limits, there is a problem with the
THE CONTROL KIT.
Invalid CAN message received (only for Make sure that the output signal of the
1- 1 3
ZR3CB control kit) control device (eg: joystick) is correct.
Reset the default parameters and repeat
The parameters set on the module are not
5- 5 8 the settings procedure, modifying the inval-
valid.
id parameters.
DDM010E 29
7.2.1 Error codes about supply circuit
Joystick
3
1 2
Wiring
Connectors Emergengy
2 push--button
1
1
Working Fuse with

section fuse--holder
Battery
1 2
7.2.2 Error codes about control kit
8 Walvoil Service Tool
30 DDM010E
Routine maintenance 8.
8.1. Inspection
Periodically checking the functions of the directional control valve, the system, the electrical circuit, and the condition of the fluid and
the fittings limits downtime due to malfunctions and, if necessary, replacement not normally necessary.
The following points should be given special attention:
8.1.1 Main checks

D All of the fittings must be properly tightened. Loose connections not only cause leaks, they also allow external air to pene-
trate into the system.
Air in the circuit causes noise and incorrect operation.
D The filters and tank must be periodically inspected to check for contaminating particles.
If there is excessive contamination, the system must be drained and cleaned. If necessary, replace the
filters.
D Periodically check proper assembly of the directional control valve. High vibrations could loosen the screws that secure it to
the work surface.
D Check the condition of the pipes and fittings; if corroded or worn, replace them
D Check for incorrect operations in the electrical control circuit.
D Check for error messages on control display, if present.
D Check for error signals on the electrohydraulic modules with on--board electronics (type ZR), if used.
D The cables and connectors must be intact and properly secured.
8.1.2 Topping up with hydraulic fluid

New hydraulic oil contains 50 m or more of contaminating particles. If added to the system, it must be filtered.
It is important that the oil be clean and free of all foreign substances.
A contaminated circuit can cause incorrect operation and excessive wear of system components.
DDM010E 31
Extraordinary maintenance is normally carried out to resolve the possible malfunctions listed in the ”Troubleshooting guide”, or
to remove or replace worn components.
All of the dismantling operations must be carried out by qualified personnel and must be done by meticulously following the general
rules reported below.
Again remember that proper filtration of the oil in the circuit is fundamental for guaranteeing proper operation of components and
for ensuring a long operational lifetime of the system.
9.1. General rules for removing and dismantling the directional control valve
D Immobilize the vehicle if it is on a slope in order to prevent uncontrolled movements.
D The maintenance operations must be carried out with the valve at room temperature.
D Before opening the hydraulic circuit, make sure that the system is off and that the pressure has been dis-
charged. Lower all of the vertical cylinders, discharge all of the accumulators, and secure loads whose movement could gen-
erate pressure.
D Before disconnecting the valve from the electrical circuit, make sure that the power is off.
D Cleanliness is of utmost importance when working with a hydraulic system: always work in a clean area.
The presence of dirt or foreign material in the system can cause serious damage or incorrect operation.
D When necessary, remove dirt from the electrical circuit cables using a clean cloth moistened with a soapy
solution: do not use solvents!
D Special tools are not required for normal dismantling.
D Before disconnecting the fittings, thoroughly clean the outside of the valve to prevent dirt from entering the ports.
D If the valve must be removed from the system, always make sure that the ports and pipes are properly plugged.
D All of the seals removed during dismantling should be thrown out and replaced.
32 DDM010E
Extraordinary maintenance 9.
9.2. Directional control valve in general

9.2.1 Dismantling working sections
A) -- REMOVAL
Nut
D Remove the directional control valve from the system.
D Rest the valve vertically on the inlet cover (as shown),
on a flat clean surface. Washer
D Unscrew the tie rods tightening nuts (wrench 13 -- 28

Nm / 20.1 lbft).
D Remove the bracket. Bracket
D Extract the end cover and then the working sections
with the relative seals.
B) -- CHECKS
D Proceed by cleaning the pilot lines with compressed air.
D Replace the seals between the sections.
C) -- ASSEMBLY
D Insert the seals into the housings.
D Clean the contact surfaces using a cloth that does not
leave behind fibers. PIlot lines
D Insert the sections one at a time into the tie rods.
CAUTION: Always check the proper positioning of the seals.
D Insert the end cover last.
D Insert the bracket and washers
D Lightly tighten the nuts enough to hold the valve toge-
ther.
D Turn the valve to horizontal, resting it on the side with
the brackets.
D Using a rubber hammer, hammer the sections until they
are correctly aligned. Make sure that the brackets rest
correctly on the surface.
D Securely tighten the nuts to the indicated value. Seals
Tie rods
DDM010E 33
9.3. BR -- BN inlet covers

9.3.1 LS pressure relief valve
A) -- ADJUSTING THE CALIBRATION C) -- CHECKS
Only LSH and LSD valves can be adjusted. Model LSZ, being D Thoroughly clean the parts and the seat.
protected against tampering, does not have this possibility. D Check the condition of poppet G and seat H: If dam-
D Remove nut A (only for LSD) and loosen B (wrench 10 aged, replace the entire valve.
-- 9.8 Nm / 7.2 lbft), holding screw C in place (allen D Check the condition of the seals, especially the front
wrench 3). one: If worn, replace them.
D To increase the valve setting, tighten screw C. To de- D Clean the housing on the cover and check its integrity.
crease, loosen it. If damaged, replace the cover’s body.
B) -- REMOVAL D) -- ASSEMBLY
D Remove valve body D (wrench 13 -- 42 Nm / 31 lbft), D Proceed in reverse as regards point A.
plate E, and spring F. Grease the spring and poppet using CASTROL
D Using a magnetic tool, extract poppet G. SPHEEROL TN grease, so that they remain inserted
D Using a socket wrench, extract seat H (wrench 7 -- 24 inside each other.
Nm / 17.7 lbf). Be careful not to lose the front seal.
LSZ
LSH LSD
C
A
B
O--ring seal 4GUA411421 D
11.4x2.1 VITON 75SH E
O--ring seal 4GUA406118 F
6.07x1.78 VITON 75SH G
Front O--ring seal

4GUA403515
3.5x1.5 VITON 75SH
34 DDM010E

9.3.2 Unloading valve
A) -- VALVE REMOVAL
D Remove the valve (wrench 24 -- 42 Nm / 31 lbft).
D Unscrew the ring nut that secures the coil and extract it
from the valve body. Valve blamking plug
4a -- VALVE BLANKING PLUG REMOVAL
O--ring seal 4GUA316422
D Unscrew the plug (wrench 10 -- 42 Nm / 31 lbft). 16.36x2.21
(Parker 3--908 N552--90)
B) -- CHECKS
D Clean the valve or plug. 9.25x1.78 NBR 70SH
D Check the condition of the seals of the valve or plug. If Ring 4ANE809912
9.91x1.5 (8--012)
worn, replace them.
D Clean the housing on the cover and check its integrity.
If damaged, replace the cover’s body. ELN valve
D Check the condition of the coil. If damaged, replace it
and verify proper voltage of the electrical circuit.
C) -- ASSEMBLY
D · Proceed in reverse as regards point A. 14x1.78 NBR 70SH
CAUTION: Insert the coil by positioning it with connector’s
ground pin facing the cover. 16.36x2.21
CAUTION: The coil’s ring nut must be manually tightened. (Parker 3--908 N552--90)
Use enough force so that it guarantees proper positioning of O--ring seal 4GUA109318
9.25x1.78 NBR 70SH
the coil without damaging the ring nut’s thread.
Ring 2S3AN6127110
9.9x12.7x1.1
ELP -- ELT valves

Ground pin
O--ring 4GUA118818
18.77x1.78 NBR 70SH
O--ring 4GUA316422
16.36x2.21
(Parker 3--908 N552--90)
O--ring 4GUA109318
9.25x1.78 NBR 70SH
Anello 4ANE909714
9.7x12.7x1.4
Valve body
Ring nut
Coil
DDM010E 35

9.3.3 Compensator
A) -- RIMOZIONE C) -- ASSEMBLY
D Remove the hexagonal plug (wrench 34 -- 42 Nm / 31 D Proceed in reverse as regards point A and tighten the
lbft). plugs to the indicated values.
D Extract the spring.
D Extract the spool.
D Remove the rear plug of the compensator (wrench 10 --
42 Nm / 31 lbft).
B) -- CHECKS
D Clean the spool and check the condition. If it appears to
be damaged, replace it.
D Verify spool movement inside the cavity, inserting it by
moving the screw. If it does not slide, replace it.
D Check the integrity of the compensator’s housing. If
damaged, replace the cover’s body.
D Clean the restrictor valve and the holes of the spool
using compressed air. If they remain obstructed, re-
place the entire spool.
D Check the condition of the seals of the plugs. If worn,
replace them.
Spool
Compressed air

19.3x2.4 NBR 90SH Compressed
air
Restrictort
Compressed air
Rear plug

26.64x2.62 NBR 90SH
Spool
Spring
Front plug
36 DDM010E

9.3.4 Pressure reducing valve 9.3.5 Load--Sensing joint
A) -- REMOVAL A) -- REMOVAL
D Remove the upper plugs (allen wrench 5 -- 24 Nm / 17.7 D Remove the joint (wrench 19 -- 24 Nm / 17.7 lbft).
lbft) and lower plugs (allen wrench 6 -- 30 Nm / 22.1 D Remove the restrictor valve (allen wrench 4 -- 24 Nm /
lbft). 17.7 lbft).
D Individually extract all of the parts, as shown. D Extract the joint’s filter
B) -- CHECKS B) -- CHECKS
D Thoroughly clean all of the parts in order to eliminate all D Clean the restrictor valve, eliminating foreign matter
traces of impurities. from the calibrated hole using compressed air.
D Check the poppet housing on the spool: If it appears D Clean the filter and, if necessary, replace it.
damaged, replace it.
D Check the condition of the joint’s seal. If worn, replace
D Check the condition and sliding of the spool in the cov- it.
er’s housing. If it appears damaged or does not slide,
C) -- ASSEMBLY
replace it.
D Proceed in reverse as regards point A and tighten the
D Check the integrity of the spool’s housing. If damaged,
restrictor valve and the joint to the indicated values.
replace the cover’s body.
D Check the condition of the seals of the plugs. If worn,
replace them.
D Clean the upper plug’s filter and check the condition. If
necessary, replace the entire plug.
C) -- ASSEMBLY
D Proceed in reverse as regards point A and tighten the
plugs to the indicated values.
CAUTION: Pay special attention to the spool’s position.
BSP thread
O--ring seal 4GUA113421 11.91x2.62 NBR 90SH
Upper 13.4x2.1 NBR 90SH SAE thread
plug O--ring seal 4GUA311920
O--ring seal 4GUA109318 Filter 4ACC218
11.89x1.98
9.25x1.78 NBR 70SH INOX AISI304 9x6x16
(Parker 3--906 N552--90)
Spool Filter
Spool
Joint
Restrictor
Poppet
housing
Poppet Restrictor
Side for insertion
Deflector in to the cover
Spring
Lower Compressed air

plug
11.3x2.4 NBR 90SH
DDM010E 37
9.4. BRS (Copy--Spool) inlet cover

This cover’s special characteristics are considered: For maintenance instructions on the ”LS pressure relief valve”, ”Pressure reduc-
ing valve”, ”Load--Sensing Joint”, ”Compensator”, and ”Unloading valve”, see the paragraphs on standard covers.
9.4.1 Copy--Spol 9.4.2 Load check valve

D Remove the plug (allen wrench 4 -- 6.6 Nm / 4.9 lbft). D Remove the plug (allen wrench 4 -- 6.6 Nm / 4.9 lbft).
D Extract the spring and spool. D Unscrew and extract the load check valve (wrench 5 --
D Unscrew and extract the restrictor valve (allen wrench 3 6.6 Nm / 4.9 lbft).
-- 6.6 Nm / 4.9 lbft ). B) -- CHECKS
B) -- CHECKS D Thoroughly clean the valve, making sure to eliminate all
D Thoroughly clean all of the parts in order to eliminate all traces of impurities from the holes on the two ends.
traces of impurities and dirt (especially from the restric- D Verify the return spring’s operation by pressing the ball
tor valve’s calibrated hole). with a pin punch on side A: If the ball is jammed or does
D Check the condition and sliding of the spool in the hous- not return into the housing, replace the valve.
ing. If it appears damaged or does not slide, replace it. D Verify the ball’s seal in the housing by blowing com-
D Check the integrity of the spool’s housing. If damaged, pressed air from hole B: If air exits the opposite end,
replace the cover’s body. replace the valve.
D Check the condition of the plug’s seal. If worn, replace D Check the condition of the plug’s seal. If worn, replace
it. it.
C) -- ASSEMBLY C) -- ASSEMBLY
D Proceed in reverse as regards point A and tighten the D Proceed in reverse as regards point A and tighten the
restrictor valve and plugs to the indicated values. plug to the indicated value.
Upper plug
Spring Load check valve
Compressed air
Copy--Spool O--ring seal 4GUA309318
9.25x1.78 NBR 90SH B
Restrictor
Load check valve
Plug
A
Pin punch

9.25x1.78 NBR 90SH
38 DDM010E
9.4. BRS (Copy-- Spool) inlet cover

9.4.3 Damper
A) -- REMOVAL C) -- ADJUSTMENT AND ASSEMBLY
D Loosen the attachment nut (wrench 16 -- 24 Nm / 17.7 D Screw the damper into the housing.
lbft) and remove the damper (allen wrench 6). D Start the hydraulic system.
B) -- CHECKS D Activate the port and verify movement.
D Clean the damper and make sure that the impurities D Since the damping effect occurs on the thread, it is nec-
and dirt inside of it are eliminated. essary to act as indicated below:
D Verify the return spring’s operation by pressing the ball -- if there is a response delay, slightly unscrew the dam-
with a pin punch on side A: If the ball is jammed or does per.
not return into the housing, replace the damper. -- if pitching and oscillations occur, slightly tighten the
D Verify the ball’s seal in the housing by blowing com- damper.
pressed air from the holes on side B: If air exits from D After adjusting, tighten the attachment nut to the indi-
end A, replace the valve. cated value.
D Check the condition of the seals. If worn, replace them.
Damper

Parback 4ANE808312
9.25x1.78 NBR 70SH
8.31x1.35 (8--011)
B
Pin punch
A
Compressed air
Damper
Attachment nut
Flow section for damping effect
DDM010E 39
9.5. BRSO (Shut--Off) inlet cover

The cover’s special characteristics are considered: For maintenance instructions on the ”LS pressure relief valve”, ”Pressure reduc-
ing valve”, and ”Load--Sensing Joint”, see the paragraphs on BR -- BN covers.
9.5.1 Pilot solenoid valve 9.5.2 Shut--Off spool

D Remove the solenoid valve (wrench 24 -- 42 Nm / 17.7 D Remove the front plug (allen wrench 10 -- 42 Nm / 31
lbft). lbft).
D Unscrew the upper ring nut and extract the coil. D Extract the spring.
B) -- CHECKS D Extract the spool.
D Check the condition of the valve’s seals. If worn, re- D Remove the spool’s rear plug (allen wrench 10 -- 42 Nm
place them. / 31 lbft).
D Check the sliding of the small internal rod by lightly B) -- CHECKS
shaking the valve. If nothing moves, replace the valve. D Clean the spool and check its condition. If it appears to
D Check the condition of the coil. If damaged, replace it be damaged, replace it.
and verify proper voltage of the circuit. D Verify spool movement inside the cavity, inserting it by
D Check the integrity of the cover’s housing. If damaged, moving the screw. If it does not slide, replace it.
replace the cover’s body. D Check the integrity of the spool’s housing. If damaged,
C) -- ASSEMBLY replace the cover’s body.
D Proceed in reverse as regards point A. D Check the condition of the seals of the plugs. If worn,
CAUTION: The coil’s ring nut must be manually tightened. replace them.
Use enough force so that it guarantees proper positioning of C) -- ASSEMBLY
the coil without damaging the ring nut’s thread. D Proceed in reverse as regards point A and tighten the
plug to the indicated value.
Solenoid valve Rear plug

Ring nut
Coil

19.3x2.40 NBR 90SH
Solenoid valve
Front plug
16.36x2.21
(Parker 3--908 N552--90)
Ring 2S3AN6159110 Rear plug
15.9x12.9x1.1 O--ring seal 4GUA326626
Ring 2S3AN6143110 26.64x2.62 NBR 90SH
14.3x11.3x1.1

10.82x1.78 NBR 70SH
12.42x1.78 NBR 70SH Spool
Spring
Front plug
40 DDM010E
9.6. Working section

9.6.1 Standard and VR compensator
A) -- REMOVAL C) -- ASSEMBLY
D Remove the compensator’s cartridge (wrench 27 -- 42 D Proceed in reverse as regards point A and tighten the
Nm / 31 lbft). plug to the indicated value.
D Extract the compensator kit.
B) -- CHECKS
D Clean the spool and check the condition of the cali-
brated hole. If the hole is clogged, replace the compen-
sator kit.
D Check the condition of the spool. If it appears to be
damaged, replace the compensator kit.
D Verify smooth movement of the spool in the housing,
inserting it by moving the screw. If it does not slide, re-
place the compensator kit.
D Check the integrity of the compensator’s housing. If
damaged, replace the section’s body.
D Check the condition of the plug’s seal. If worn, replace
it.

19.3x2.40 NBR 70SH Standard compensator kit
Compressed Compressed
air air
Restrictor Spool
VR compensator kit
Compressed Compressed
Cartridge
air air
Compensator kit
Restrictor Spool
DDM010E 41

9.6.2 Load check valve 9.6.3 Shuttle valve
D Remove the end plug (allen wrench 10 -- 42 Nm / 31 D Loosen the lever box’s screws (allen wrench 6 -- 9.8 Nm
lbft). / 7.2 lbft).
D Extract the spool and the spring. D Extract the lever box by moving it slightly in order to
B) -- CHECKS unhook it from the spool’s end.
D Clean the spool and check the condition: If worn, re- D Dismantle the valve (allen wrench 6 -- 24 Nm / 17.7 lbft).
place it. B) -- CHECKS
D Verify smooth movement of the spool in the housing, D Clean the seat and check its integrity. If damaged, re-
inserting it by moving the screw. If it does not slide, replace the section’s body.
place it. D Clean the valve and check the condition of the seals,
D Check the integrity of the load check valve’s seat. If especially the front one: If worn, replace them.
damaged, replace the section’s body. D Move the valve slightly to check if the ball moves
D Check the condition of the plug’s seal. If worn, replace smoothly. If it is jammed, replace the valve.
it. C) -- ASSEMBLY
C) -- ASSEMBLY D Reinsert the valve into the seat and tighten to the indi-
D Proceed in reverse as regards point A and tighten the cated value.
plug to the indicated value. CAUTION: Be careful not to lose the front seal.
D Correctly position the lever box, verifying that is properly
hooked onto the spool’s end.
CAUTION: Check proper positioning of the box’s seal.
D Tighten the screws to the indicated value.
O--ring 4GUA319324
19.3x2.40 NBR 90SH
Lever box
seal
Tappo
Cassetto
Molla

9x2 (Parker V1 0566 P5008)

12.42x1.78 (Parker V1 1200 P5008)
Front O--ring seal 4GUA306118
6.07x1.78 NBR 90SH
42 DDM010E

9.6.4 LS pressure relief valve 9.6.5 Auxiliary valves
See paragraph 9.3.1. A) -- REMOVAL
D Remove the valve from its seat on the section (13 -- 24
Nm wrench).
B) -- CHECKS
D Check the condition of the end plug’s seal. If worn, re-
place it.
LSH LSD LSZ
D Clean the valve and check the condition of the poppet:
If damaged, replace the valve.
D Clean the seat on the section and check its integrity: If
C) -- ASSEMBLY
D Insert the valve into the seat and tighten to the indicated
value.

15.60x1.78 NBR 90SH
Contact area
between poppet
and housing
Valve C Valve U
DDM010E 43

9.6.6 Spool
D Loosen the box’s screws (allen wrench 6 -- 9.8 Nm / 7.2 D Assemble the bushings, spring, and ring on the spool.
lbft). D Insert the spool into the housing.
D Extract the lever box by moving it slightly in order to D Proceed by assembling the lever box, checking for
unhook it from the spool’s end. proper positioning of the box’s seal.
D Carefully extract the spool. D Tighten the screws of the box to the indicated value.
D Remove the open ring and extract the spring and the
two half--bushings.
B) -- CHECKS
D If necessary, thoroughly clean the spool in order to elim-
inate impurities.
D Check the condition of the spool. If it appears to be
damaged, replace it.
D Verify manual spool movement inside the housing, in-
serting it by moving the screw. If it does not slide, re-
place it.
D Clean the spool hole and check its integrity. If dam-
aged, replace the section’s body.
Half--bushing
Spring
Lever box
seal
Half--bushing
Open spring
44 DDM010E

9.6.7 LS ports
D Remove the plug from the section’s housings (allen D Screw the plug into the housing and tighten to the indi-
wrench 6 -- 24 Nm / 17.7 lbft). cated value.
B) -- CHECKS
D Eliminate any impurities on the plug and in the housing.
D Check the seal. If worn, replace it.
Execution with Execution with upper

lower port and lower ports
Plug with BSP thread Plug with SAE thread
O--ring seal 4GUA311926 O--ring seal 4GUA311920

11.91x2.62 NBR 90SH 11.89x1.98
(Parker 3--906 N552--90)
DDM010E 45
9.6. Working section 9.7. Electrohydraulic modules

9.6.8 Restrictor valve on LS signal 9.7.1 LVDT sensor calibration
A) -- REMOVAL Calibration of the LVDT transducer is carried out at Walvoil
D Remove the restrictor valve from the seat in the lower during the control kit’s test procedure.
part of the section (allen wrench 4 -- 6.6 Nm / 4.9 lbft). Further calibration is generally not required, but sometimes
small adjustments can become necessary due to external
B) -- CHECKS
stress.
D Eliminate any dirt in the restrictor valve’s calibrated hole The error signal that indicates this event is shown by the blink-
by blowing compressed air into each hole. ing green LED when the system is turned on.
D If necessary, clean the outside of the restrictor valve
and the seat. A) -- ADJUSTMENT
Adjustments must be carried out with the hydraulic circuit dis-
D Check the seal. If worn, replace it.
connected and the electrical circuit powered.
D Clean the seat on the section and check its integrity: If
D Remove the module’s rear end plug 1 (wrench 8 -- 6.6
Nm / 4.9 lbft).
C) -- ASSEMBLY
D Using an 8 socket wrench, adjust nut 2 until the blinking
D Screw the part into the seat and tighten to the indicated green LED stays on continuously.
value.
D Retighten the rear plug to the indicated value.
B) -- CHECKS
D Temporarily disconnect the directional control valve
from the electrical circuit.
D Make sure that the levers of the sections are in the neu-
tral position and remove any fittings on the concerned
section.
D Activate the hydraulic circuit and make sure that the
ports do not leak oil.

2.57x1.78 NBR 70SH
Compressed
air
Compressed
air
LVDT Transducer
1 2
46 DDM010E
9.7. Electrohydraulic modules

9.7.2 Pressure reducing valves
A) -- REMOVAL on EZ control kit B) -- CHECKS
D Loosen the solenoid’s screws (allen wrench 4 -- 6.6 Nm D Carefully extract the small center rod from the body and
/ 4.9 lbft). clean it of impurities.
D Remove the magnet. D Check the condition of the small rod. If damaged, re-
D Remove the upper seals. place the entire valve.
D Using a pliers, extract the pressure reducing valves by D Check the condition of the seals. If worn, replace them.
carefully gripping them by the seat of the upper seal. D Check the seats of the valves on the control kit’s body.
CAUTION: Do not damage the seats. If damaged, replace the entire control kit.
3a -- REMOVAL on ZR control kit C) -- ASSEMBLY
D Loosen the solenoid’s screws (allen wrench 4 -- 6.6 Nm D Reinsert the valves into the seats.
/ 4.9 lbft). CAUTION: Check proper positioning of the upper seal.
D Remove the end cover. D Assemble by following the instructions at point A in re-
D Lift the card--magnet block slightly and rest it on the verse.
upper part of the control kit’s body so that it doesn’t in-
terfere when removing the pressure reducing valves.
CAUTION: Do not subject connection wires to mechani-
cal stress.
D Remove the upper seals.
D Using a pliers, extract the pressure reducing valves by
carefully gripping them by the seat of the upper seal.
CAUTION: Do not damage the seats.
Upper seal
Upper seal seat
Small rod Card--magnet unit

O--ring seal 4GUA107718 Connection wires
7.66x1.78 NBR 70SH
5.28x1.78 NBR 70SH Upper seal
EZ Control kit ZR Control kit
DDM010E 47
10. Hydraulic circuit conversion
10.1. From Pressure Compensated to Load Sensing and vice versa

The directional control valve may be converted from an open circuit to a closed circuit and vice versa.
The procedures are limited to replacing certain parts on the inlet cover by ordering special kits.
The codes of the kits are: 5KIT130300 (for going from an open to a closed circuit) and 5KIT130310 (for changing from a closed to
an open circuit).
For component dismantling and replacement instructions, see paragraphs 9.3.3 and 9.3.5 in the section entitled, ”Extraordinary
maintenance”.
Kit 5KIT130300
Ref. Code Description Q.ty
1 3VIT208061 M8x1x6 restrictor 1
2 9CUR126182 Compensator spool for closed entre circuit 1
M5x10 restrictor with metering hole = 0.5
1 3 9STR105101
mm / 0.02 in
1
Kit 5KIT130310
3
2 Ref. Code Description Q.ty
M8x1x6 restrictor with metering hole = 1 mm
1 3VIT208060
/ 0.039 in
1
2 9CUR126181 Compensator spool for open centre circuit 1

M5x10 restrictor with metering hole = 0.5
3 9STR105101
mm / 0.02 in
1
10.2. Local compensation circuit

The working sections of the DPC130 are designed so that they may be converted from C--type sections (or F) with a standard com-
pensator to CV--type sections (or FV) with a load check valve or to CC--type sections (or FC) with a VR compensator or vice versa.
The necessary operations are limited to replacing the kit (for example, compensator) located on the section with the chosen one (for
example, load check valve).
For dismantling instructions, see paragraphs 9.6.1 and 9.6.2 in the section entitled, ”Extraordinary maintenance”.
Ref. Code Description

1 5COM130 Standard compensator kit
2 5CAS3180436 Load check valve kit
3 5COM131 VR compensator kit
1 For the codes of the individual components of the kits, see para-
graphs 12.2.1 -- 12.2.3 -- 12.2.5 in the section entitled ”Spare
parts list”.
48 DDM010E
Storage 11.
11.1. Recommended practices about hydraulic components

The lifetime of each hydraulic system is directly related to its cleaning.
Contaminating chemical particles are one of the worst enemies of a hydraulic system and every effort must be made to prevent this
type of contamination.
The following instructions represent a list of rules that should be followed in order to reduce or eliminate any contamination during
storage and handling of hydraulic components.
D The protective plugs must be left on the directional control valve and pipes until just before use.
D Carefully remove the plugs on the ports so that plastic residues are not left on the threads.
D Do not paint too heavily near the ports, in order to prevent particles from entering the valve.
D The boring or area near the ports is a seal area and must be protected against dings and pollutants
D Pipes and fittings must be washed, lubricated, and plugged until they are used.
D The plastic plugs used for the ports must always be clean.
D The tanks must be pickled, treated with rust--proofing, and closed until use.
The protective rust--proofing must be removed with thorough washing just before use.
D If the hydraulic components were stored in a cold place, remove any condensation that could have formed when the compo-
nents became warmer.
D If stored for a long time the component could require rust--proofing (eg: lubricating oil).
DDM010E 49
[1.69]
420 Mobile Piston Pump

Technical Bulletin ADU041
ADU049
ADU062
Model Codes
ADU 062 R 08 AB 1 0 A 43 14 00 A 1 AB 1 00 CD 0 A
1 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
1 2 3 Pump Series 10 11 Main Ports 15 16Pressure Control 23 24 Auxiliary Rear Mount
ADU – 420 Family Open AA – Rear Ports, 4 Bolt Flange Setting Code 00 – No Rear Mount
Circuit Piston 2” Inlet; 1” Outlet 28 – 206.8-213.7 bar AA – 9T No Coupling Needed
(Code 61) [3000-3100 lbf/in2] AB – SAE A 2 bolt with
4 5 6 Pump Displacement AB – Side Ports, 4 Bolt Flange 43 – 275.8-282.7 bar 11T Coupling
041 – 41.0 cm3/r [2.50 in3/r] 2” Inlet; 1” Outlet [4000-4100 lbf/in2] AC – SAE B 2 bolt with
049 – 49.2 cm3/r [3.00 in3/r] (Code 61) 13T Coupling
17 18Flow Control
062 – 62.3 cm3/r [3.80 in3/r] 25
12 Drain Ports Setting Code Shaft Seal
7 Pump Rotation 1 – .875-14 UNF-2B O-Ring 00 – No Flow Control Setting 0 – No Shaft Seal
R – Right Hand (Clockwise) Port on Top 14 – 12.41-15.17 bar 1 – Polyacrylate (standard)
Right Side Suction; Left 2 – .875-14 UNF-2B O-Ring [180-220 lbf/in2] 2 – Fluorocarbon
Side Pressure Port Port on Bottom 24 – 22.75-25.51 bar 3 – Double Fluorocarbon
L – Left Hand [330-370 lbf/in2] 26 27
(Counter-clockwise) 13 Diagnostic Ports Pump Special
Left Side Suction; Right 0 – No Diagnostic Ports 19 20Secondary Features
Side Pressure Port Pressure Setting 00 – No Special Features
14 Control Type 00 – No Pressure Setting 28 29
8 9 Front Mount and Shaft A – Pressure/Flow Paint
02 – 2 Bolt B with straight Compensator With 21Control Special Features 00 – No Paint
keyed shaft, 25.4mm SAE O-Ring Port 0 – No Special Features CD – Blue Primer
(1.00 in.) dia. B – Pressure/Flow A – Load Sense Bleed 30 Identification
05 – 2 Bolt B with 13T spline Compensator With Metric Down Orifice
shaft, 22.2mm (.88in.) dia. O-Ring Port 0 – Standard
08 – 2 Bolt B with 15T spline C – Pressure 22Displacement Option
shaft, 25.4mm Compensator Only 31 Design Level
1 – Standard Displacement
(1.00 in.) dia. 2 – External Manual A – First Design
Stroke Adjust
Features Pump Performance Data

- SAE B-B, 2 Bolt Mount, - Standard SAE splined DISPLACEMENT 041 049 062
Cradle Swashplate and keyed shaft options (cc/rev) 41.0 49.2 62.3
(in/rev) 2.50 3.00 3.80
- Clockwise and Counter- - End and Side Ports PRESSURE (BAR)
Clockwise rotation in Tube and Flange styles
Continuous 280 280 280
Intermittent 320 320 320
- Pressure Compensator & - Optional diagnostic ports Peak 350 350 350
Pressure/Flow Comp.
SPEED CAPABILITY
pump control types - Alternate Drain Port
locations Rated 2750 2650 2600
Standby 3600 3600 3600
- Auxiliary thru-drive pad Minimum 600 600 600
for multiple pump use
INLET CONDITIONS
(RATED SPEED)
7.4 psig (1.5 bar) 2950 2850 2800
0 psig (1.0 bar) 2750 2650 2600
5" Hg (.85 bar) absolute 2550 2450 2400
DYNAMIC RESPONSE
(MSEC)
Response (off stroke) 25 25 30
Recovery (on stroke) 90 90 100
Load Sense Recovery 100 100 120
STANDBY POWER
LOSS (HP) 4.5 4.5 5
DRY WEIGHT (LBF) 46 46 48
2 EATON Hydraulics 420 Mobile Piston Pump E-PUPI-TB001-E January 2003

Pump
Installation –
Rear Ported Case Drain Top
122.7
7/8-14 UNF-2B SAE
420 Mobile Piston Pump (M22 X 1.5 Metric Optional) [4.83]
O-Ring Port
(Shown Plugged)
42.9
[1.69]
2X 13.6
ATTENTION: [.54]
Removal of the pressure
adjustment screw cover may
void the warranty on this For compensator
assembly configuration see
26.19 42.88 separate compensator
[1.031] [1.688] installation drawing
Pressure
port -C For shaft configuration
1.00 SAE see separate shaft
4 bolt installation
Suction drawing
split flange port -D
port standard 2.00 SAE 4
pressure bolt split flange
series port standard
(code 61) pressure series
(code 61)
52.37
[2.062] 77.77
[3.062]
101.57±0.02
4X .500-13 UNC-2B [3.999±.001]
41.1
[1.62] 38.1 19.6 MIN 9.4
[8.58]
4X .375-16 UNC-2B [1.50] [.77] [.37]
(M10 X 1.5-6H optional)
14 MIN
[.55]
97.3
[3.83]
119.1
[4.69]
2X Ø14.2 79.2
77.5 [.56] [3.12]
[3.05] (case drain)
73.9
73.8 72.1 [2.91]
[2.91] [2.84]
(case drain)
Case Drain Bottom 7/8-14 UNF-2B SAE

(M22 X 1.5 Metric Optional) [5.75]
O-Ring Port (Shown Plugged)
EATON CORPORATION Hydraulics 420 Mobile Piston Pump E-PUPI-TB001-E January 2003 3
Pump
Installation –
Case Drain Top
Side Ported 7/8-14 UNF-2B SAE
420 Mobile Piston Pump (M22 X 1.5 Metric Optional)
O-Ring Port 122.7
(Shown Plugged) [4.83]
73.8
[2.91] 42.9
74.7
[2.94]
ATTENTION:
adjustment screw cover may 2X 13.7
void the warranty on this [.54]
assembly
Suction For compensator
port -D configuration see
2.00 SAE 4 separate compensator
bolt split installation drawing
flange
port For shaft configuration
standard see separate shaft
pressure installation 119.1
series drawing [4.69]
(code 61) 79.2
[3.12]
(case drain)
77.77
[3.062]
72.1 74.7
2X Ø14.2 [2.84] [2.94]
[.56] (case drain)
[8.59] 146.1
42.88 [5.75]
[1.688]
4X .500-13 UNC-2B
(M12 X 2.5-6H optional)
19.6
[.77] MIN Pressure
port -C
256.2 1.00 SAE
[10.09] 4 bolt
97.3 9.4 split flange
[3.83] [.37] port standard
pressure
(code 61)
71.4
[2.81]
52.37
[2.062]
71.4 [3.999±.001]
[2.81]
240.9
[9.49] [8.34] 26.19
[1.03] 4X .375-16 UNC-2B
Case Drain Bottom 7/8-14 UNF-2B SAE (M10 X 1.5-6H optional)
(M22 X 1.5 Metric Optional) 14
O-Ring Port (Shown Plugged) MIN
[.55]

Pump
Installation –
Thru-drive
SAE A Option Case Drain Top
420 Mobile Piston Pump 7/8-14 UNF-2B
(M22 X 1.5 Metric Optional)
O-Ring Port 122.7
74.7
[2.94]
ATTENTION:
Removal of the pressure adjustment
screw cover may void the warranty
on this assembly
For compensator
configuration see
A separate compensator
Suction installation drawing
Port -D 2.00
SAE 4 Bolt 119.1
Standard [4.69]
Pressure 79.2
Series 2X Ø 14.2
[.56] [3.12]
(Code 61) (case
77.77
[3.062] 72.1
[2.84]
(case drain)
A
42.88 [8.59] For shaft [5.75]
[1.688] configuration
4X .500-13 UNC-2B see separate shaft
(M12 X 1.75-6H optional) installation drawing
19.6 MIN
[.77]
Ø ±0.02
±0.01] .375-16 UNC-2B
7.9 19 MIN
[.31] ]
287.3 Groove to accept
[11.31] 2 X 13.6 9.4 an AS 568A size 042
[.54] [.37] (1/16 X 3-1/4 ID)
O-Ring
3X .375-16
71.4 UNC-2B
[2.81] THRU
106.38
172.7 57 ±0.02 [4.188]
[6.80] ±.001] 86.4
[3.40]
71.4
[2.81]
106.38
1
[4.188]
Case Drain Bottom 97.3 For output shaft
7/8-14 UNF-2B SAE [3.83] configuration see VIEW A-A
(M22 X 1.5 Metric Optional) separate output
O-Ring Port (Shown Plugged) shaft installation drawing
EATON CORPORATION Hydraulics 420 Mobile Piston Pump E-PUPI-TB001-E January 2003 5
Pump
Installation – Case Drain Top
7/8-14 UNF-2B SAE
Thru-drive (M22 X 1.5 Metric Optional)
SAE B Option O-Ring Port 122.7
[4.83]
74.7
[2.94]
ATTENTION:
adjustment screw cover may
void the warranty on this
assembly
For compensator
A configuration see
Suction port -D separate compensator
2.00 SAE 4 installation drawing
bolt split
flange port 119.1
standard [4.69]
pressure
series
(code 61) 2X Ø14.2 79.2
[.56] [3.12]
(case
77.77
[3.062]
72.1
[2.84]
218.2
A 42.88 [8.59]
For shaft 146.1
[1.688] configuration see [5.75]
4X .500-13 UNC-2B separate shaft
(M12 X 1.75-6H optional) installation
19.6 MIN drawing
[.77]
Ø101.68±0.02
[4.003±.001]
10.4
287.3 [.41]
[11.31] 2X 13.6 9.4
[.37] Groove to accept
an AS 568A size
045 (1/16 X 4 ID)
71.4 O-Ring
[2.81] 4X .500-13
UNC-2B THRU
172.7 ±0.02 146.1
[6.80] 9±.001] [5.75]
71.4 86.4
[2.81] [3.40]
Case Drain Bottom 97.3 For output shaft

7/8-14 UNF-2B SAE [3.83] configuration see 146.1
(M22 X 1.5 Metric Optional) separate output shaft [5.75]
O-Ring Port (Shown Plugged) installation drawing VIEW A-A

Pump Control
Installation
Load Sense Port

7/16-20 UNF-2B SAE
(M14 X 1.5 Metric Optional)
O-Ring Port 74.7
96.6 [2.94]
[3.81]
139.5
122.2 [5.49]
[4.81] 94.5
[3.72]
163.9
[6.45]
229.3 [9.03]
.03]
210 bar [[3000
3000 psi]
or less
251.5 [9.90]
210 bar [3000 psi]
or greater
6.31±.04
[.248 -.002 ]
Shaft Installation Key width
08 Code 05 Code 02 Code 46.0

(1.81)
46.0 41.3
(1.81) (1.62)
(1.12)
3(.12)
+.11
28.16 -.12
[1.108 +.005
-.004 ]
+.007
ø25.393
3-.006
[.9998 +.0002 ]
-.0003
ø 24.912 [.9808] 15 Tooth 30° ø 21.737 [.8558] 13 Tooth 30°

Flat Root Side Fit 16/32 Flat Root Side Fit
Class 5 Spline 16/32 Class 5 Spline per
per ANSI B92.1 (Modified) Fits
Fits 15 Tooth 30° 13 Tooth 30°
Flat Root Side Fit Fit 16/32 Internal Splines per
16/32 Internal Splines SAE J498b Class 1 or
per SAE J498b Class 1 ANSI B92.1 Class 5
or ANSI B92.1 Class 5
EATON Hydraulics 420 Mobile Piston Pump E-PUPI-TB001-E January 2003 7

Eaton Eaton Eaton
14615 Lone Oak Road 20 Rosamond Road 46 New Lane, Havant
Eden Prairie, MN 55344 Footscray Hampshire PO9 2NB
USA Victoria 3011 England
Tel: 952 937-9800 Australia Tel: (44) 23 92 486 451
Fax: 952 974-7722 Tel: (61) 3 9319 8222 Fax: (44) 23 92 487 110
www.hydraulics.eaton.com Fax: (61) 3 9318 5714
© 2003 Eaton Corporation

All Rights Reserved
Printed in USA
Document No. E-PUPI-TB001-E
January 2003
ABN : 86 010 671 048
ACN : 010 671 048
E-Mail : info@terex.com.au
Internet : www.terex.com.au
Terex Lifting Australia Pty. Ltd.

(QF112G.2)
SERVICE BULLETIN SB0124
DATE: 08/04/2008 REVISION: -

MODEL(S): AT-20 Series III
SUBJECT: Eaton STC® hydraulic fittings
EFFECTIVE: AT-20 S/N 3950, 4000, 4060, 4080, 4100 onwards
Issue:
To improve the installation and serviceability of the valve bank and associated
components, Eaton STC® Connectors have been introduced on the AT-20 Series III
cranes. STC connectors use an o-ring to seal and latching ring to retain the connector.
These connectors greatly reduce the time taken to assemble and disassemble hoses from
components.
The manifold on the valve bank and the steering orbitrol are directly ported with STC and
other components use adaptors. Hoses with STC have a male connector and simply push
into the port. A special tool is used to release the connection. STC does not lock the hose
into a specific orientation and therefore not all hoses are STC. These hoses will generally
use JIC fittings.
Action:
Refer to Eaton Service Bulletin JA535 for information on assembly and inspection. Please
be aware that if access is limited, other hoses may need to be removed first, but with STC
this is a very quick and easy process.
Part numbers for tools and adaptors which are supplied with each crane are as follows:
PP2340500 TOOL RELEASE STC -06

PP2342700 ADAPTOR 9/16”M JIC x 06M STC
PP2342800 ADAPTOR 3/4”M JIC x 08M STC
PP2342900 ADAPTOR 1.1/16”M JIC x 12M STC
If a hose reaches the end of its service life, then replacements can be ordered via
TEREX|CRANES spare parts. For emergency field repairs, the JIC to STC adaptors
(supplied with each new crane) can be used with conventional JIC hoses – ensure the
hose has the correct working pressure rating.
QLD (Head Office) N.S.W. W.A.

585 Curtin Avenue East 114 Hassall Street 93 Poole Street
P.O. Box 1396 Wetherill Park, NSW 2164 Welshpool, WA 6106
Eagle Farm QLD 4009 PH: (+61) 2 8786 4444 PH: (+61) 8 9358 9806
PH: (+61) 7 3868 9600 Fax: (+61) 2 8786 4455 Fax: (+61) 8 9358 9851
Fax: (+61) 7 32682489
Simple, available and cost effective ™

FRANNA • LORAIN •P&H •RO STINGER •PPM •BENDINI •AMERICAN •PEINER •COMEDIL • DEMAG
Terex Lifting Australia Pty. Ltd.
In addition, the following plug and caps may be purchased as an aid when performing
specialised service or diagnostic work.
PP2343000 PLUG 06M STC

PP2343300 CAP 06F STC
Should you have and questions or comments concerning this bulletin, please contact
Terex Lifting Australia Pty Ltd Product Support Department on (07) 3868 9600.
Simple, available and cost effective ™

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AT-20 Series III Hydraulic Circuit Components

• 10 micron Vented Breather Cap.

Emergency Steering Pump

• Barnes DC powered hydraulic pump.

Rev - 15/08/2008 Page 1 of 4

• Directly mounted on side of Mid Manifold

Mid Manifold Assembly

• Directly mounted between inlet cover and valve bank sections.

• Directly mounted on the end of the Valve Bank

Rev - 15/08/2008 Page 2 of 4

• Mounted to the left of the valve bank manifold assembly.

Orbital Steering Unit

• Eaton Dynamic Load Sensing, Non-reacting 460 cc/rev.

• Bore 5 “, Rod 4 “, Stroke 4120 mm.

• Bore 5.5 “, Rod 3.5 “, Stroke 1580 mm.

• Bore 3”, Rod 1.5”, Stroke 446mm

Rev - 15/08/2008 Page 3 of 4

• Brevini Two Speed 4.2 tonne Line Pull.

Orifice Troubleshooting Guide

• Hardpoint or slow steering

• Steering unstable - too responsive

Rev - 15/08/2008 Page 4 of 4

1. Comply with OH&S, Federal, State and Local Regulations.

Your safety is our priority.

2.1 Symbols relating to the “operator qualification level”

Machine operator: operator with no specific skills, capable of

Lifting and transport equipment operator: operator trained for

Maintenance mechanic: qualified technician capable of running the

Manufacturer’s technician: qualified technician provided by the

2.2 Symbols relating to “consulting the manual”

2.3 Mandatory symbols relating to safety

Always wear protective gauntlets:

Always wear accident-prevention footwear:

2.4 Danger symbols relating to safety

Danger of hand/arm and leg/foot crushing:

3.1 Permitted use

3.1.1 Prohibited uses

The machine cannot be used either partially or totally:

The machine cannot be used in any of the following conditions:

 in environments where temperature is lower than -20°C and higher

For no reason may the information printed on the plate be

3.4.1 Winch specifications

4.1 Residual risks

A. Personal protective equipment (PPE)

Should it be necessary for operational or servicing reasons to work on the

B. Unexpected / accidental machine starting

The relevant risk is avoided by instructing the operator concerning the

C. Danger of entanglement / crushing

In the rope winding area, there is a risk of entanglement / crushing. Do not

During operation, the operator must keep at a safe distance

Please be informed that installation of machines is not at the

5.2 Ambient conditions for use

The winch is generally supplied installed on a crane with rope

6.1 General warnings

 For more information or explanations, contact Terex.

 Check the level of lubricant.

6.2 Trial operation

All information relating to pressure, oil flow rate and speed is

Leave at least 2 coils of rope around the drum

Never use the winch beyond its maximum pulling capacity.

Unexpected breakage of the taut rope or any failure that causes

New South Wales