HYDRAULICS

- HYDRAULIC CHARACTERISTICS AND

SPECIFICATIONS

- HYDRAULIC SCHEMATIC DIAGRAMS

- HYDRAULIC COMPONENTS LOCATION

- HYDRAULIC CONTROL AND

ADJUSTEMENT

- HYDRAULIC SPECIFIC TOOLING

70
 HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS

HYDRAULIC COMPONENTS DATA SHEETS

– STEERING PUMP
– COUNTER BALANCE VALVE
– SLOPE CORRECTION VALVE
– DOUBLE EXTENSION BALANCING VALVE
– DISCHARGE VALVE

70

(24/05/2011) 70-01-M153EN
70

70-01-M153EN (24/05/2011)
 Hydraulic characteristics and 1
specifications

STEERING PUMP/DIRECTIONAL BLOCK OSPC 200 LS

Values for information purposes only.

T
P
Role:
L - Direct and dose the flow in order to supply the
steering circuit.
R
- It is a rotating valve.

LS

R L

1. Secondary relief valve.

1 2. Pump valve.

2 3. Main pressure relief valve.

70
200 cm³/tr

LS - P : Pressure.
- T : Return to tank.
- R : Exit towards the right side.
- L : Exit towards the left side.
- LS : Pilot line.
T P

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________

(03/09/2008) F70-3-0003EN
 2 Hydraulic characteristics and
specifications

Values for information purposes only.

R L

When the driver turns the steering wheel towards the right, he
passes the flowrate from P to R and sends pilot pressure towards
the divisor to get priority.
LS

T P

R L

When there is an impact on a wheel, the pressure increases in the

line. This pressure opens the valve which enables the resulting
pressure to be evacuated and therefore protects the hydraulic
and mechanical steering components.
LS

T P

R L
70

When the wheels are locked to a maximum, the steering circuit

increases in pressure, the LS line activates the relief valve and
enables flow to the tank.
LS

T P

What use do the two valves that are located opposite each other on the top part of the diagram
have?

What is the maximum pressure permitted in the steering circuit?

What is the LS line, without actions, connected to on the steering wheel?

F70-3-0003EN (03/09/2008)
 Hydraulic characteristics and 1
specifications

COUNTER BALANCE VALVE d1

Values for information purposes only.

Role:
- Insulates the cylinder in case of hose breakage.

- Cylinder movement requires the starting of the I.C.

V1 engine.

- Limits max. pressure due to impacts.

V2

70
C1 C2
1 3
1. Temporization screws.
2
2. By-pass valve.
4
3. Slide with max. adjustment screw.

V1 V2 4. Non-return valve.

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(03/09/2008) F70-3-0008EN
 2 Hydraulic characteristics and
specifications

Values for information purposes only.

C1 C2

V1 V2

Return control during cylinder descent.

C1 C2

V1 V2
70

When a position is secured, no component is able to exert sufficient pressure to open the
valve.

Only a pressure peak due to an impact can open it.

C1 C2

V1 V2

When the cylinder is pushed, the supply (no-return valve to pass) and return are free.

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
F70-3-0008EN (03/09/2008)
 Hydraulic characteristics and 3
specifications

Values for information purposes only.

What is the valve opening pressure on the diagram?

What happens when the non-return valve starts to leak?

70
If the temporization screw is either screwed or unscrewed, what effect does it have
on movement?

(03/09/2008) F70-3-0008EN
 4 Hydraulic characteristics and
specifications
70

F70-3-0008EN (03/09/2008)
 Hydraulic characteristics and 1
specifications

DUMP CORRECTION VALVE

Values for information purposes only.

V2

V1

C2 C1

V2 V1

70

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(03/09/2008) F70-3-0009EN
 2 Hydraulic characteristics and
specifications

Values for information purposes only.

70

F70-3-0009EN (03/09/2008)
 Hydraulic characteristics and 1
specifications

DOUBLE EXTENSION BALANCING VALVE bf2,3

Values for information purposes only.

Role:

- Insulates the cylinder in case of hose breakage.

C1

C2 - Cylinder movement requires the starting of the I.C.

engine.

V1 - Limits max. pressure due to impacts.

V2

70
C1 C2
300b 1 1 300b 1. Balancing valve.

2. By-pass ring.
2 2

3 3. Temporization screws.
V1 3 V2

Maximum pressure (bar) 350

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(01/02/2011) F70-3-0015EN
 2 Hydraulic characteristics and
specifications
70

F70-3-0015EN (01/02/2011)
 Hydraulic characteristics and 1
specifications

DISCHARGE VALVE Bf1

Values for information purposes only.

c Role:
- Discharge or accumulative flow from two different
hydraulic lines.
T
P

1. Non-return valve

70
2. Tank slide.

3. Pilot electrovalve.
3
C VD

Ø0,7

P T
2
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(03/05/2011) F70-3-0044EN
 2 Hydraulic characteristics and
specifications
70

F70-3-0044EN (03/05/2011)
 HYDRAULIC SCHEMATIC DIAGRAMS

Pages
Series D - Series 4:
– MLT 630/731 T Series D-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– MLT 634 120 LSU + PS Series D-E3
– MLT 735/741 120 LSU + PS Series 4-E3 . . . . . . . . . . . . . . . . . . . . . . . 6
– MLT 634/731 T LSU Series D-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– MLT 742 T Series 4-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– MT 732/932 Series D-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
– MT 1030 S/ST Series 4-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

70
– MLT 1035 LT LSU Series 4-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
– MLT 742 H T LSU Series 4-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
– MT 1033 H L Series 4-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Series E - Series 5:
– MLT 731 T Series E-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
– MLT 634 -120 LSU + PS Series E-E3
MLT 735 -120 LSU + PS Series E-E3
MLT 741 -120 LSU + PS Series 5-E3 . . . . . . . . . . . . . . . . . . . . . . . . . 24
– MLT 634 T LSU Series E-E3
MLT 735 T LSU Series 5-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
– MLT 1035 LT LSU Series 5-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

(16/05/2011) 70-02-M153EN
 2
Hydraulic schematic diagrams
70

70-02-M153EN (16/05/2011)
 3
MLT 630 T Series D-E3 Hydraulic schematic diagrams
MLT 731 T Series D-E3

Keys and diagrams

HYDRAULIC DIAGRAM KEY

Position on
Item Designation Characteristics (Options)
diagram
BA Feed block + accumulator E21
CA Suction strainer S6
CSP Counterbalance valve K27/I27/M40
CR(O) Trailer hook (option) I40
D 4 or 5 component valve (option) S38
EE Inlet section S25
EA(O) Attachment component (option) S27
EL Lifting component S29
EI Tilt component S31
EA Optional equipment component S33
ET Telescoping component S36
EF Closing component S38
D3 3 position steering valve A14
Position 1: short steering
Position 2: front wheel steering
Position 3: crab position
EVTF(O) Boom head electrovalve (option) E30
FDAV Front disc brake 3
FDAR Rear disc brake K15
FR Return filter Q13
M Turbo i.c. engine Q7 1104d-44ta
Idle speed 930 rpm
Nominal loaded speed 2200 rpm

70
Full speed unladen 2400 rpm
MC Master cylinder C6
N Level S4
P Pump equipment Q4
PAAV Front attachment plug C28
PAAV(O) Front attachment plug (option) E27
PAAR(O) Rear attachment plug (option) G38
PD Steering pump C13
PP Pressure port O21
PFR(O) Trailer brake plug integrated in the VAFR (option) G10
PRF(O) Leakage return plug (option) A27
R Hydraulic tank S5
RLF Brake fluid tank A3
SC Circuit selector n°1 C10
SCFR(O) Circuit selector n° 2 (trailer brake option) E9
S2F Selector 2 functions K20
VC Compensation cylinder DE K29 100x50 c310
VI Tilt cylinder DE I29 120x60 c445/130x65 c380
VDAV Front steering cylinder DE K5 90x45 c80x2
VD Discharge valve O9
VDAR Rear steering cylinder DE K13 90x45 c80x2
VL Lifting cylinder DE I25 130x70 c720/140x70 c720

(16/05/2011) 70-02-M153EN
 4
Hydraulic schematic diagrams MLT 630 T Series D-E3
MLT 731 T Series D-E3

HYDRAULIC DIAGRAM KEY

Position on
Item Designation Characteristics (Options)
diagram
VT DE telescoping cylinder K39 70x50 c2100/70x50 c2750
VAFR(O) Trailer brake valve (option) G9
VVT(O) Ts locking cylinder DE (option) A29 60x45 c183
VAI Insulation valve A33
VACM(O) Movement cut-off valve (option) Q19

NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
speed.
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
70

70-02-M153EN (16/05/2011)
 5
MLT 630 T Series D-E3 Hydraulic schematic diagrams
MLT 731 T Series D-E3
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 32 33 34 35 36 37 38 39 40 41 42

PRF
BL L 2
3 1
RLF N A B T
A A
AV AR 3 2 1 VVT(O)
3 2 1
D3
B1 P VAI
MC R L
P
PD 200b 200b

C C

200 cm3 /tr

PAAV

SC
V1 V2 C2
C4
LS 140b PAAV(O)
S C1 C3
SCFR(O)
V1 V2 0,7 L.
E T P E
13 b
Ø1 S P1
35b
BA
U EVTF(O)
P T P1 P2
45±5B

Y
VAFR(O)
G N LS P2 T G
PFR Ø 0.7
B OPTION FREINAGE REMORQUE
PAAR(O)
(1 ou 2 PRISES)
T P
M4 S2F

TELESCOPAGE
M2
VI CR(O)
S2
B1
I VL I
A1
S1
C1 C2
M3 CSP 315b +15
0
M1

ACCESSOIRES
S2
B2
110b
A2 V1 V2 VT

70
S1
K FDAV VDAV FDAR K
VDAR
VC
C1 C2
335b CSP
ES. AR.
ES. AV.

C1 C2
335b CSP
30b
M V1 V2 M

N°226111
30b
V1 V2

O O
P P A1 B1 A2 B2 A3 B3 X1 A4 B4 X2 A5 B5 T
C VD 280b 280b 190b 190b

EF CF OUT P1 PP
FR
6b
5b
BA
LS
Q M VACM(O) M3 M4 Q
P
21.99 cm3/tr IN 10 μm absolu 1ère monte
21.99 cm3/tr 15 μm absolu PR.
P T
M1 M2
250b
CA
Niveau moyen: N 125 μm
S 104L absolu EE EA(O) EL EI EA ET EF S

R Capacité 128 litres Réserve direction

Y1 Y2 D

(16/05/2011) 70-02-M153EN
 6
Hydraulic schematic diagrams MLT 634 120 LSU + PS
Series D-E3
MLT 735 120 LSU + PS
MLT 741 120 LSU + PS
Series 4-E3
HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY
Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
BA Feed block + accumulator E17 VAI Isolation valve A21
CA Breather filter S11 VAFR(O) Trailer brake valve (option) I10
CR(O) Trailer hook (option) C41 VC Compensation cylinder DE C26 110x55 c310
CSP Counterbalance valve A26/C33/E30 VDAR Rear steering cylinder E8
D Control Valve K18 VDAV Front steering cylinder E4
EE Inlet section K20 VI Tilt cylinder DE A28 140x70 c388
EA Attachment component K23 VL Lifting cylinder DE A31 150x70 c716
EA(O) Attachment component (option) K35 VT DE telescoping cylinder A24 75x55 c2700
EL Lifting component K32 VVT(O) Carriage locking cylinder (option) DE A17 60x45 c183
EI Tilt component K29
ET Telescoping section K25
EF Closing component K37
D3 3 position steering valve A10
Position 1: short steering NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
speed.
Position 2: front wheel steering
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
Position 3: crab steering
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
EVAA(O) Rear attachment electrovalve (option) E38
EVTF(O) Jib head electrovalve (option) E20
EV5E(O) 5th component electrovalve (option) M34
FDAR Rear brake disc E9
FDAV Front brake E2
FEMS Ems head filter M20
FR Return filter O17
M Turbo i.c. engine Q12 1104d-e44ta
70

Idle speed 930 rpm +20/0

Nominal loaded speed 2200 rpm
Full speed unladen 2360 rpm
MA Manipulator O20
MC Master cylinder M9
N Level S5
P Pump equipment Q8
PAAV Front attachment plug A16
PAAV(O) Front attachment plug (option) C16
PAAR(O) Rear attachment plug (option) A39/C39
PCR Cooler circuit pump Q3
PD Steering pump E13
PFR(O) Trailer brake plug integrated in the VAFR (option) K11
PP Pressure port G19
PRF(O) Leakage return plug (option) C16
R Hydraulic tank S7
RF Cooler O5
RLF Brake fluid tank K8
SC Circuit selector G9
SCFR(O) Trailer brake circuit selector (option) G8
VACM(O) Movement cut-off valve (option) K18

70-02-M153EN (16/05/2011)
 7
MLT 634 120 LSU + PS Series D-E3 Hydraulic schematic diagrams
MLT 735/741/120 LSU + PS Series 4-E3
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 32 33 34 35 36 37 38 39 40 41 42

VVT(O) VT VI VL x
VAI
1
A 2 A B T PAAR(O) A
3 1 (1 ou 2 PRISES)
2
3 2 1 C1 C2 C1 C2
PAAV 335b CSP 300b CSP
AV AR D3 3
3 2 1 PAAR(O)
P
4 (2 PRISES)
C2 30b
C4 V1 V2
PAAV(O) V1 V2 C1 C2 CR(O)
C C1 C3 335b CSP C
VC
PRF(O)
C3
30b C2

ES. AR.
ES. AV.

V1 V2

x
EVTF(O) P1 P2
EVAA(O)
0,7 L. C4 C1
E FDAV VDAV VDAR FDAR R L 13 b E
200b 200b PD P1
BA
35b CSP M
U C1 C2

x
200 cm3/tr 45±5b
P2 P1
200b
SC

x
V1 V2
V1 V2 P2 T
G LS 140b G
S
PP
SCFR(O)

x
V1 V2 T P
M LS D B1 A1 B2 A2 b B3 A3 b B4 A4 b B5 A5
S
DLS

OPTION FREINAGE REMORQUE

I P T I
P

Y
VAFR(O) 22,5 bar
N LS
PFR
B 270 bar
T

70
K T T T T T K
B B A B
EE EA ET 200 bar 190b 280b EI 280 bar EL EA(O) EF
RLF D
Y pst a a a
VACM(O)
B2 L N
2 4

M MC M
P FEMS EV5E(O)
10 μm 3 1

MA P T

O O
B 1 3 2 4

RF FR
6b
5b
P 63 cm3/tr M
PCR 10 μm absolu
Q 14 cm3/tr (1ère monte) MA Q
15 μm absolu
L L1 L2 S (pièce rechange)

CA
N Niveau moyen :
125 μm
absolu
S 104 litres S

R Capacité 128 litres Réserve direction

(16/05/2011) 70-02-M153EN
 8
Hydraulic schematic diagrams MLT 634 T LSU Series D-E3
MLT 731 T LSU Series D-E3

HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY

Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
BA Feed block + accumulator E20 VDAR Rear steering cylinder DE K13 90x45 c80x2
CA Suction strainer S6 VL Lifting cylinder DE I33 130x70 c720
CSP Counterbalance valve E27/K30/M33 VT DE telescoping cylinder I29 70x50 c2100/140x70 c720
CR(O) Trailer hook (option) C41 VAFR(O) Trailer brake valve (option) DE G9 70x50 c2700
D 4 or 5 component valve (option) O38 VVT(O) Ts locking cylinder DE (option) A32 60x45 c183
EE Inlet section S24 VAI Insulation valve A36
EA(O) Attachment component (option) S35 VACM(O) Movement cut-off valve (option) E24
EL Lifting component S34
EI Tilt component S32
EA Optional equipment component S27
ET Telescoping component S29
EF Closing component S37
D3 3 position steering valve C13
NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
speed.
Position 1: short steering
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
Position 2: front wheel steering 3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
Position 3: crab position
EVHAR(O) Electrovalve (rear hydraulic option) K18
EVTF(O) Boom head electrovalve (option) E33
FDAV Front disc brake K5
FDAR Rear disc brake K15
FEMS ems head filter G20
FR Return filter Q11
70

M Turbo i.c. engine Q7 1104d-44ta

Idle speed 930 rpm
Nominal loaded speed 2200 rpm
Full speed unladen 2400 rpm
MA Manipulator G21/G24
MC Master cylinder C5
N Level S4
P Pump equipment Q4
PAAV Front attachment plug C31
PAAV(O) Front attachment plug (option) C31
PAAR(O) Rear attachment plug (option) C40
PD Steering pump C12
PFR(O) Trailer brake plug integrated in the vafr (option) I10
PP Pressure port O19
PRF(O) Leakage return plug (option) A23
R Hydraulic tank S5
RLF Brake fluid tank A2
SC Circuit selector E10
SCFR(O) Circuit selector (trailer brake option) E9
SCHAR(O) Circuit selector (rear hydraulic option) K39
VC Compensation cylinder DE E28 100x50 c310
VI Tilt cylinder DE C28 120x60 c445
VDAV Front steering cylinder DE K7 90x45 c80x2/130x65 c380

70-02-M153EN (16/05/2011)
 9
MLT 634 T LSU Series D-E3 Hydraulic schematic diagrams
MLT 731 T LSU Series D-E3
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 32 33 34 35 36 37 38 39 40 41 42

VVT(O)
B L
RLF
N PRF(O)
A VAI A

2 A B T
3 1

B1
3 2 1 2
MC AV AR
PAAV PAAR(O)
D3 1 (1 ou 2 PRISES)
3 2 1
P P
C C2
C
C4
R L VI PAAV(O)
PD 200b 200b 0,7 L. C1 C3
13 b
CR(O)
P1
35b BA VACM C1 C2
200 cm3/tr U CSP 300b
SC 45±5b EVTF(O)
E V1 V2 P1 P2
E
LS 140b
V1 V2
S
P2 T
3 4
SCFR(O)
V1 V2 VC
T P

S FEMS
MA
OPTION 10 μm
G FREINAGE G
REMORQUE
P T
P T

Y
MA
VAFR(O) 2 C4
N LS
PFR 1 C1
B 1 2 3 4 C2
VL
C3
I I

VT

SCHAR(O)
P1 P2

70
K
FDAV FDAR K
VDAV VDAR C1 C2 C1 C2
335b CSP CSP 335b
EVHAR(O)
ES. AR.
ES. AV.

3 2
30b 30b
1 4 V1 V2 V1 V2
M C1
M
C2
CSP 70b

V1 V2
PP

O P O
X

M LS D B1 A1 B2 A2 b B3 A3 b B4 A4 b B5 A5
D
B FR DLS
6b b b
5b

Q P Q
P 45 cm3/tr M
10 μm absolu 1ère monte 22,5 b
15 μm absolu PR.
LS a a
L L1 L2 S

T T T
T 270 b T B B A B
EI
CA EE EA ET 200 b 190 b 280 b 280 b EL EA(O) EF
Niveau moyen: N 125 μm y pst a a a
S 104L absolu S

R Réserve direction

(16/05/2011) 70-02-M153EN
 10
Hydraulic schematic diagrams MLT 742 T Series 4-E3

HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY

Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
BA Feed block + accumulator G20 VAFR(O) Trailer brake valve (option) I8
CA Suction strainer S6 VVT(O) Ts locking cylinder DE (option) A26 60x45 c183
CSP Counterbalance valve M22/I25/M41 VAI Insulation valve A30
CR(O) Trailer hook (option) I38 VACM(O) Movement cut-off valve (option) O18
D 4 or 5 component valve (option) S35
EE Inlet section S22
EA(O) Attachment component (option) S24
EL Lifting component S26
EI Tilt component S28
EA Optional equipment component S30
ET Telescoping component S33
EF Closing component S35
D3 3 position steering valve C13
Position 1: short steering
Position 2: front wheel steering NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
speed.
Position 3: crab position
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
EVTF(O) Boom head electrovalve (option) E27
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
FDAV Front disc brake K3
FDAR Rear disc brake K15
FR Return filter O13
M Turbo i.c. engine Q6 1104d-44ta
Idle speed 930 rpm
Nominal loaded speed 2200 rpm
Full speed unladen 2400 rpm
70

MC Master cylinder C5
N Level S3
P Pump equipment Q3
PAAV Front attachment plug C25
PAAV(O) Front attachment plug (option) C24
PAAR(O) Rear attachment plug (option) G36
PD Steering pump C12
PP Pressure port O21
PFR(O) Trailer brake plug integrated in the vafr (option) I9
PRF(O) Leakage return plug (option) A23
R Hydraulic tank S4
RLF Brake fluid tank A3
SC Circuit selector n°1 E9
SCFR(O) Circuit selector n°2 (trailer brake option) G8
VC Compensation cylinder DE K26 110x55 c310
VI Tilt cylinder DE I26 140x70 c388
VD Discharge valve O9
VDAV Front steering cylinder DE K5 90x45 c80x2
VDAR Rear steering cylinder DE K13 90x45 c80x2
VL Lifting cylinder DE I23 150x70 c716
VT DE telescoping cylinder K40 75x55 c2700

70-02-M153EN (16/05/2011)
 11
Hydraulic schematic diagrams
MLT 742 T Series 4-E3

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 32 33 34 35 36 37 38 39 40 41 42

B L VVT(O)
A RLF N PRF A
VAI

2 A B T
3 1
B1
3 2 1
MC
AV AR D3
P PAAV
3 2 1
C P C

C2
R L C4
PD PAAV(O)
200b 200b
C1 C3

200 cm3/tr
E E
SC EVTF(O)
V1 V2 P1 P2
LS 140b
S
SCFR(O)
V1 V2 T P 0,7L.
13 b
S P1
Ø1
G OPTION 35b BA G
FREINAGE U
REMORQUE
P T
45±5b
PAAR(O)
(1 ou 2 PRISES)
Y
VAFR(O) P2 T
N LS VI CR(O)
PFR Ø 0.7
I B I

C1 C2
VL 315b +15
0
CSP
110b
V1 V2 VT

70
FDAV VDAV FDAR
K VDAR VC K

C1 C2
ES. AR.

CSP
ES. AV.

315b +15
0
C1 C2
335b CSP
110b
M V1 V2 M

30b
V1 V2

O O
C P

P1
VD VACM(O)
EF CF OUT
PP P A1 B1 A2 B2 A3 B3 A4 B4 A5 B5 T
FR 280b 280b 190b 190b
6b
5b
LS
M
P
Q IN
Q
21.99 cm3/tr 10 μm absolu 1ère monte
21.99 cm3/tr 15 μm absolu PR.
P T

CA
Niveau moyen: N 125 μm
104L 270b
S absolu S
EE EA(O) EL EI EA ET EF
R Capacité 128 litres Réserve direction
D

(16/05/2011) 70-02-M153EN
 12
Hydraulic schematic diagrams MT 732 Series D-E3
MT 932 Series D-E3

HYDRAULIC DIAGRAM KEY

Position on
Item Designation Characteristics (Options)
diagram
CA Suction strainer S6
CSP Counterbalance valve I24/I34/G37
CSD Double counter balance valve K37
D 4 component valve O35
EE Inlet section S24
EA(O) Attachment component S25
EL Lifting component S28
EI Tilt component S30
ET Telescoping component S32
EF Closing component S34
D3 3 position steering valve A12
Position 1: short steering
Position 2: front wheel steering
Position 3: crab position
FDAV Front disc brake K3
FR Return filter O15
M Turbo i.c. engine Q7 1104d-44t/1104d-44ta
Idle speed 930 rpm
Nominal loaded speed 2200 rpm
Full speed unladen 2380 rpm (1104d-44t)
Full speed unladen 2400 rpm (1104d-44 ta)
MC Master cylinder E4
N Level S4
P Pump equipment Q4
70

PAAV(O) Front attachment plug (option) E22

PD Steering pump C11
PP Pressure port O24
R Hydraulic tank S5
RLF Brake fluid tank A5
VC Compensation cylinder DE I28 110x55 c310 (mt 7 and 9)
VI Tilt cylinder DE E28 120x60 c416 (mt 7 and 9)
VD Discharge valve O10
VDAV Front steering cylinder DE K5 90x45 c80x2
VDAR Rear steering cylinder DE K11 90x45 c80x2
VL Lifting cylinder DE G24 140x70 c720 (mt 7 and 9)
VT DE telescoping cylinder I33 70x50 c2700 (mt 7)
VT1 DE telescoping cylinder I38 100x60 c2600 (mt 9)
VT2 DE telescoping cylinder G38 80x50 c2600 (mt 9)
VACM Movement cut-off valve Q18

NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
speed.
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.

70-02-M153EN (16/05/2011)
 13
MT 732 Series D-E3 Hydraulic schematic diagrams
MT 932 Series D-E3
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 32 33 34 35 36 37 38 39 40 41 42

2 A B T
A 3 1 A

3 2 1
RLF AV AR
D3
3 2 1
P

R L
C B2 B1 PD 200b 200b C

200 cm3/tr
MC

LS 140b
E E

T P
VI
PAAV(O)
VT2
C1 C2
VL CSP 315b +15
0
G G
C1 C2
110b CSP 315b +15
0
V1 V2

110b
VC VT V1 V2

I C1 C2 VT1 I
CSP 335b
C1 C2
335b CSP
C1 C2
FDAV VDAV VDAR CSD
30b 300b 300b
V1 V2

70
K 30b K
V1 V2 V1 V2
ES. AR.
ES. AV.

Télescopage MT 7 Télescopage MT 9

M M

En série pour MT 728 / 928

En option pour MT 732 / 932 T (A)

PP
C P A1 B1 A2 B2 A3 B3 A4 B4 T
O VD 280b 280b
190b 190b D O
EF CF OUT P1 FR
6b
5b

LS VACM
M
P 10 μm absolu 1ère monte
21.99 cm3/tr IN 15 μm absolu PR.
Q 21.99 cm3/tr Q
P T

250b

CA EE EA(O) EL EI ET EF
Niveau moyen: N 125 μm
104L absolu
S S
R Capacité 128 litres Réserve direction

(16/05/2011) 70-02-M153EN
 14
Hydraulic schematic diagrams MT 1030 S Series 4-E3
MT 1030 ST Series 4-E3

HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY

Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
CA Suction strainer S9 VDAV Front steering cylinder DE K4 90x45 c80x2
CSP Counterbalance valve I32/C34/I39 VI Tilt cylinder DE A34 120x60 c416
CSD Double counter balance valve K38 VL Lifting cylinder DE G33 140x70 c720
CPD Double counterbalance valve I28 VSD Right stabilizer cylinder DE I26 125x60 c200
D 6 component valve O38 VSG Left stabilizer cylinder DE I30 125x60 c200
EE Inlet section S23 VT1 DE telescoping cylinder I40 100x60 c2850
EA Optional equipment component S25 VT2 DE telescoping cylinder G40 80x50 c2850
ESD Right stabilizer section S27 VVT(O) Ts locking cylinder DE (option) A22 60x45 c183
ESG Left stabilizer section S29
EL Lifting component S31
EI Tilt component S34
ET Telescoping component S36
EF Closing component S38
D3 3 position steering valve A13
Position 1: short steering NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
speed.
Position 2: front wheel steering
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
Position 3: crab position
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
EVTF(O) Boom head electrovalve (option) E23
FDAV Front disc brake K2
FDAR Rear disc brake K14
FR Return filter O15
M Turbo i.c. engine Q9 1104d-44t/1104d-44ta
Idle speed 930 rpm
Nominal loaded speed 2200 rpm
70

Full unladen speed (1104d-44t) 2380rpm

Full unladen speed (1104d-44ta) 2400 rpm
MC Master cylinder E3
N Level S6
P Pump equipment Q6
PAAV Front attachment plug C21
PAAV(O) Front attachment plug (option) C20
PD Steering pump C12
PFR(O) Trailer brake plug integrated in the vafr (option) G9
PRF(O) Leakage return plug (option) E17
PP Pressure port O22
R Hydraulic tank S7
RLF Brake fluid tank C4
SCFR(O) Circuit selector (trailer brake option) E8
VACM(O) Movement cut-off valve (option) O17
VAFR(O) Trailer brake valve (option) G8
VAI Insulation valve A26
VASS Stabilizer safety valve K28
VC Compensation cylinder DE E34 110x55 c310
VD Discharge valve O12
VDAR Rear steering cylinder DE K12 90x45 c80x2

70-02-M153EN (16/05/2011)
 15
MT 1030 S Series 4-E3 Hydraulic schematic diagrams
MT 1030 ST Series 4-E3
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 32 33 34 35 36 37 38 39 40 41 42

VVT(O)
2 A B T
3 1 VAI
A A
3 2 1 VI
AV AR
D3
3 2 1
P
C1 C2
PAAV
CSP 315b
+15
0
R L
PD 200b 200b
C C2 C
C4
110b
RLF PAAV(O)
C1 C3 V1 V2
200 cm3/tr
VC

LS 140b
B2 B1
SCFR(O) PRF(O) EVTF(O)
E P1 P2 E
V1 V2
T P
S
MC Ø1
OPTION
FREINAGE
REMORQUE P T

G Y VL VT2 G
VAFR(O)
N LS
PFR Ø 0.7
B C1 C2
CSP 315b +15
0

VSD VSG
C1 C2 C1 C2 C1 C2
110b
I 280b 100b 100b 280b CSP 335b I
V1 V2
CPD
V1 V2 V1 V2 VT1
VASS 30b
FDAV VDAV FDAR B B
VDAR V1 V2

70
A A C1 C2
K CSD 300b 300b K
ES. AR.
ES. AV.

V1 V2

M M

PP
C VD
O VACM(O) P A1 B1 A2 B2 A3 B3 A4 B4 A5 B5 A6 B6 T O
P1 FR D
280b 280b 190b 190b
EF CF OUT
6b
5b

LS
M 10 μm absolu 1ère monte
P
15 μm absolu PR.
IN
Q 21.99 cm3/tr Q
21.99 cm3/tr P T

250b

CA
Niveau moyen: N 125 μm EE EA ESD ESG EL EI ET EF
S 104L absolu S

R Capacité 128 litres Réserve direction

(16/05/2011) 70-02-M153EN
 16
Hydraulic schematic diagrams MLT 1035 LT LSU
Series 4-E3

HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY

Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
BA Feed block + accumulator C19 VC Compensation cylinder DE E25 110x55 c310
CA Suction strainer S8 VCD Roll corrector cylinder C37 110 x 50 c165
CSD Double counter balance valve E37/M28 VI Tilt cylinder DE C25 120x60 c416
CSP Counterbalance valve C24/M32/K34 VDAV Front steering cylinder DE K5 90x45 c80x2
CR(O) Trailer hook (option) G39 VDAR Rear steering cylinder DE K12 90x45 c80x2
D 5 component valve O36 VL Lifting cylinder DE G32 140x70 c720
EE Inlet section S21 VT1 DE telescoping cylinder K26 100 x 60 c2850
ECD Slope control component S33 VT2 DE telescoping cylinder G26 80 x 50 c2850
EL Lifting component S31 VAFR(O) Trailer brake valve (option) I7
EI Tilt component S29 VVT(O) Ts locking cylinder A29
EA Optional equipment component S25 VAI Insulation valve A33
ET Telescoping component S26 VACM Movement cut-off valve C22
EF Closing component S34
D3 3 position steering valve C12
Position 1: short steering NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
speed.
Position 2: front wheel steering
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
Position 3: crab position
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
EVSC(O) Circuit selector electrovalve (option) K38
EVTF(O) Boom head electrovalve (option) E30
FDAV Front disc brake K2
FDAR Rear disc brake K14
FEMS Ems head filter E19
FR Return filter Q13
M Turbo i.c. engine Q9 1104d-44 ta
70

Idle speed 930 rpm

Nominal loaded speed 2200 rpm
Full speed unladen 2400 rpm
MA Manipulator G20
MC Master cylinder C4
N Level S4
P Pump equipment Q6
PAAV Front attachment plug C28
PAAV(O) Front attachment plug (option) C28
PAAR(O) Rear attachment plug (option) G37
PCR Cooling circuit pump Q2
PD Steering pump C11
PFR(O) Trailer brake plug integrated in the vafr (option) I8
PP Pressure port O18
PRF(O) Leakage return plug (option) A20
R Hydraulic tank S6
RF Cooler Q3
RLF Brake fluid tank A3
SC Circuit selector E8
SCFR(O) Circuit selector (trailer brake option) E7
S1F Selector 1 function K18

70-02-M153EN (16/05/2011)
 17
Hydraulic schematic diagrams
MLT 1035 L T LSU Series 4-E3

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 32 33 34 35 36 37 38 39 40 41 42

PRF(O) VVT(O)
B L
A RLF N A
VAI

2 A B T
3 1

3 2 1
VI
MC AV AR
D3 PAAV
3 2 1 0,7 L.
P P
C 13 b C
P1
C1 C2
VACM
C2 Gicleur VCD
R L 35b BA CSP 300b C4 Ø 0.9
U PAAV(O)
PD 200b 200b C1 C3
45±5B 1
2 V1 V2
3 Gicleur
200 cm3/tr Ø 0.9
P2 T
E SC E
EVTF(O) C2 C1
V1 V2 VC P1 P2 325b 325b
LS 140b
S FEMS
SCFR(O) CSD
10 μm V2 V1
V1 V2
T P

S P T PAAR(O) CR(O)
(1 ou 2 PRISES)
OPTION
MA
G G
FREINAGE
REMORQUE
P T
1 2 3 4 VT2 VL
Y
VAFR(O)
N LS
PFR C2 C1
B
I 315b +15
0
CSP I
C4

C2
110b
V2 V1 C1 C2 C1 C3
335b CSP

70
VT1
K K
FDAV VDAV VDAR FDAR 30b
V1 V2
EVSC(O)
P1 P2

S1F
C2 C1
M5 C1 C2
ES. AR.

DEVERS

CSD
ES. AV.

M6 300b 300b
S2
CSP 70b
3 2
M M
1 4
S1 V2 V1 V1 V2

MA
PP

P
O O
X
M LS D B1 A1 B2 A2 b B3 A3 b B4 A4 b B5 A5
D
DLS b b
B FR
6b
RF 5b
P
Q Q
22,5 bar
P 45 cm3/tr M
PCR a a
10 μm absolu 1ère monte LS
15 μm absolu PR.

N°272035
14 cm3/tr
L L1 L2 S T T
T
T EE 270b T T B B A B
EI 280 bar
200b
EA ET 190b 280b EL ECD EF
CA y pst a a a
Niveau moyen: N 125 μm
S 104L absolu S

R Capacité 128 litres Réserve direction

(16/05/2011) 70-02-M153EN
 18
Hydraulic schematic diagrams MLT 742 H T LSU Series 4-E3

HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY

Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
A Accumulator I10 R Hydraulic tank S9
BT Transfer box E13 RF Cooler Q13
CA Breather filter S10 RAD Radiator O4
CAR Non-return valve O12/O15 RLF Brake fluid tank I17
CR(O) Towing hook C41 (OPTION) RPI Inching pressure reducer (th7) K20
CSP Counterbalance valve E31/E33/E36 SCFR(O) Trailer brake circuit selector G19 (OPTION)
D Control Valve I25 VACM(O) Movement cut-off valve K25 (OPTION)
EE Inlet section I27 VAI Isolation valve A28
EA Attachment component I29 VAFR(O) Trailer brake valve (option) I20
EA(O) Attachment component I37 (OPTION) VC Compensating cylinder E31 DE 100x55 C310
EL Lifting component I35 VDAR Rear steering cylinder I15
EI Tilt component I33 VDAV Front steering cylinder I4
ET Telescoping section I31 VI Tilting cylinder C32 DE 140x70 C388
EF Closing component I38 VL Lifting cylinder C35 DE 150x70 C716
D3 3 position steering valve E20 VPV Gear change cylinder I12
Position 1: short steering VT Telescoping cylinder C30 DE 75x55 C2700
Position 2: front wheel steering VVT(O) Carriage locking cylinder (option) A25 DE 60x45 C183
Position 3: crab steering
EVAA(O) Rear attachment electrovalve E39 (OPTION)
EVTF(O) Boom head electrovalve E27 (OPTION)
EV5E(O) 5th component electrovalve K37 (OPTION) NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
speed.
EVPV Gear change solenoid valve K13
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
FDAR Rear brake disc I16
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
FDAV Front brake I2
70

FEMS Ems head filter K26

FR Return filter O18
FT Transmission filter K6
M Perkins diesel engine M15 1104D-44T
Idle speed 930 rpm +20/0
Nominal loaded speed 2200 rpm
Full speed unladen 2400 rpm
MA Manipulator K27
MC Master cylinder K17
MH Hydrostatic motor E5
N Level S8
P Pump equipment M6
PAAV Front attachment plug C23
PAAV(O) Front attachment plug C23 (OPTION)
PAAR(O) Rear attachment plug A40 (OPTION)
PCR Cooler circuit pump Q11
PD Steering pump E20
PFR(O) Trailer brake plug integrated in the vafr I20 (OPTION)
PH Hydrostatic pump O15
PP Pressure port G26
PRF(O) Leak return plug E24 (OPTION)

70-02-M153EN (16/05/2011)
 19
Hydraulic schematic diagrams
MLT 742 H T LSU Series 4-E3

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 32 33 34 35 36 37 38 39 40 41 42

A A

VVT(O) x
1
VAI PAAR(O)
2 (1 ou 2 PRISES)

3
VL PAAR(O)
4 (2 PRISES)
PAAV
C VT VI CR(O) C
C2
C4
PAAV(O)
C1 C3 C1 C2 C1 C2 C3
C1 C2

x
2 A B T 335b 300b 315b +15 C2
3 1
PRF(O)

x
0
3 2 1

AV AR D3 30b CSP CSP 110b CSP EVAA(O)

V1 V2 V1 V2 V1 V2 C4 C1
3 2 1 P P1 P2
E R L EVTF(O) VC E
M1 B T U BT CSP
PD 200b 200b
x

x
MH C1 C2 M

x
a P2 P1
200 cm3/tr 200b

x
OPTION V1 V2
FREINAGE REMORQUE
SCFR(O) LS 140b
b V1 V2 PP

x
G G
P M LS D B1 A1 B2 A2 b B3 A3 b B4 A4 b B5 A5
S T
DLS
x

T G X1 X3 A

ES. AR.
ES. AV.

P T P

Y 22,5
FDAV VDAV VDAR FDAR VAFR(O) bar
N LS
I PFR B T 270 bar I
VPV RLF T T T T T
B B A B
B2 L N D EE EA ET EI EL EA(O) EF
A

x
Y pst 200 bar a 190 bar 280 bar a 280 bar a
0,7 L A B
13 b Gicleur Ø1 VACM(O) 2 4
EVPV T P
MC
FT P T P
B A
RPI

70
A
FEMS EV5E(O)
K 15 μm 10μm 3 1 K
absolu
MA P T

X Y
1 3 2 4
MB Fe Fa Fa1 PS a b T1
B
x

M B
M

MA
P 63 cm3/tr M

L L1 L2 S PH
A
O O
x
x

MA Fs S MH G X2 X1 T2
CAR CAR FR
RAD 0.5 bar 2 bar 6b
5b
10 μm absolu (1ère monte)
15 μm absolu (pièce rechange)
RF

Q PCR 14 cm3/tr
Q

N CA
125 μm
Niveau moyen : absolu
104 litres
S S
R Capacité 128 litres Réserve direction

(16/05/2011) 70-02-M153EN
 20
Hydraulic schematic diagrams MT 1033 H L

HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY

Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
BT Transfer box K12 VAI Insulation valve A30
CA Suction strainer S17 VAP Control valve E32
CAR Non-return valve Q24 VC Compensating cylinder C35 De 110x55 C310
CPD Double counterbalance valve E32 VCD Slope corrector cylinder C34 De 110x50 C165
CSD Double counter balance valve I37 VDAR Rear steering cylinder Q15 De 90x45 C80x2
CSP Counterbalance valve G37/G36/A34 VDAV Front steering cylinder Q6 De 90x45 C80x2
D 4 or 5 component valve K40 (Option) VI Tilting cylinder A35 De 120x60 C416
EE Inlet section M31 VL Lifting cylinder E34 De 140x70 C720
EA Optional equipment component M32 VPV Gear change cylinder Q11
ECD Slope corrector component M33 VT1 Telescoping cylinder G38 De 100x60 C2850
EL Lifting component M35 VT2 Telescoping cylinder E38 De 80x50 C2850
EI Tilt component M36 VVT(O) Ts locking cylinder A27 De 60x45 C183 (Optional)
ET Telescoping component M38
EF Closing component M39
D3 3 position steering valve C23
Position 1: short steering NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
Position 2: front wheel steering
speed.
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
Position 3: crab position
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
EVPV Gear change solenoid valve Q12
EVTF(O) Boom head electrovalve C28 (Option)
FDAV Front disc brake Q5
FR Return filter Q27
FT Transmission filter K18
M Perkins engine M24 1104d-44t
70

Idle speed 930 rpm (+20/0)

Nominal loaded speed 2380 rpm
Full speed unladen 2400 rpm
MC Master cylinder I26
MH Hydrostatic motor K4
N Level S15
P Pump equipment M16
PAAV Front attachment plug A27
PAAV(O) Front attachment plug C26 (Option)
PD Steering pump C22
PFR(O) Trailer brake connector G29 (Option)
PH Hydrostatic pump O23
PP Pressure port K30
PRF(O) By-pass return connector G29 (Option)
R Hydraulic tank S19
RH Hydraulic cooler S15
RLF Brake fluid tank G17
RPI Inching pressure reducer (th7) I18
SCFR(O) Circuit selector E21 Trailer brake option
VACM(O) Movement cut-off valve K28 (Option)
VAFR(O) Trailer brake valve G20 (Option)

70-02-M153EN (16/05/2011)
 21
MT 1033 H L Hydraulic schematic diagrams

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 32 33 34 35 36 37 38 39 40 41 42

2
3 1 VVT(O) VI

AV AR VAI
A 3 2 1 C1 C2 A
+15
315b 0
A B T

3 2 1 PAAV CSP 110b

D3 V1 V2
P C2
C4 VC
PAAV(O)
R L C1 C3
PD 200b 200b
VCD
C C

200 cm3/tr EVTF(O)

P1 P2 C1 C2
325b 325b
LS 140b
SCFR(O)
Gicleur Ø1 V1 V2
CPD
V1 V2
T P Ø1
S
E Gicleur Ø1
VL VT2 E

P T B
VAP C1 C2
+15
A 315b 0
Y
VAFR(O)
OPTION FREINAGE REMORQUE N B
PRF(O) CSP 110b
V1 V2
C1 C2
G RLF VT1 G
335b
PFR(O)
B2 B1
C1 C2
30b CSP 300b 300b
Gicleur Ø1 V1 V2

MC T P CSD
V1 V2

I I
RPI
A

PP
P A1 B1 A2 B2 A3 B3 A4 B4 A5 B5 T
D

70
190b 190b
K BT 280b 280b
K
M1 T B U VACM(O)
MH FT
a 15 μm Y
absolu

a b
MB Fe Fa1 Fa PS T1
LS CF EF B 250b
M b M
EE EA ECD EL EI ET EF

T G X1 X3 A P
43,77 cm3/tr M
PH
ES. AV.

A
O O
MA Fs S MH G X2 X1 T2
ES. AR.

FDAV VDAV VDAR

VPV CAR
2b

Q A B Q
EVPV
P T
FR
6b
5b

10 μm absolu (1ère monte)

RH 15 μm absolu (pièce rechange)

S N CA S
Niveau moyen : 125 μm
104 litres absolu
R Capacité 128 litres Réserve direction

(16/05/2011) 70-02-M153EN
 22
Hydraulic schematic diagrams
MLT 731 T Series E-E3

HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY

Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
BA Feed block + accumulator E21 VT DE telescoping cylinder K39 70x50 c2100/70x50 c2750
CA Suction strainer S6 VAFR(O) Trailer brake valve (option) G9
CSP Counterbalance valve K27/I29/M40 VVT(O) Ts locking cylinder DE (option) A29 60x45 c183
CR(O) Trailer hook (option) I40 VAI Insulation valve A33
D 4 or 5 component valve (option) S38 VACM(O) Movement cut-off valve (option) Q19
EE Inlet section S25
EA(O) Attachment component (option) S27
EL Lifting component S29
EI Tilt component S31
EA Optional equipment component S33
ET Telescoping component S36
EF Closing component S38
D3 3 position steering valve A14
Position 1: short steering
Position 2: front wheel steering NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
Position 3: crab position
speed.
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
EVTF(O) Boom head electrovalve (option) E30
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
FDAV Front disc brake K3
FDAR Rear disc brake K15
FR Return filter Q13
M Turbo i.c. engine Q7 1104d-44ta
Idle speed 930 rpm
Nominal loaded speed 2200 rpm
Full speed unladen 2400 rpm
70

MC Master cylinder C6
N Level S4
P Pump equipment Q4
PAAV Front attachment plug C28
PAAV(O) Front attachment plug (option) E27
PAAR(O) Rear attachment plug (option) G38
PD Steering pump C13
PP Pressure port O21
PFR(O) Trailer brake plug integrated in the vafr (option) G10
PRF(O) Leakage return plug (option) A27
R Hydraulic tank S5
RLF Brake fluid tank A3
SC Circuit selector n°1 C10
SCFR(O) Circuit selector n°2 (trailer brake option) E9
S2F Selector 2 functions K20
VC Compensation cylinder DE K29 100x50 c310
VI Tilt cylinder DE I29 120x60 c445/130x65 c380
VDAV Front steering cylinder DE K5 90x45 c80x2
VD Discharge valve O9
VDAR Rear steering cylinder DE K13 90x45 c80x2
VL Lifting cylinder DE I25 130x70 c720/140x70 c720

70-02-M153EN (16/05/2011)
 23
Hydraulic schematic diagrams
MLT 731 T Series E-E3
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 32 33 34 35 36 37 38 39 40 41 42

PRF
BL L 2
3 1
RLF N A B T
A A
AV AR 3 2 1 VVT(O)
3 2 1
D3
B1 P VAI
MC R L
P
PD 200b 200b

C C

200 cm3 /tr

PAAV

SC
V1 V2 C2
C4
LS 140b PAAV(O)
S C1 C3
SCFR
V1 V2 0,7 L.
E T P E
13 b
Ø1 S P1
35b
BA
U EVTF(O)
P T P1 P2
45±5B
Y
VAFR
G N LS P2 T G
PFR Ø 0.7
B FREINAGE REMORQUE
PAAR(O)
(1 ou 2 PRISES)
T P
M4

TELESCOPAGE
M2
VI CR(O)
S2
B1
I VL I
A1
S1
C1 C2
M3 CSP 315b +15
0
M1

ACCESSOIRES
S2
B2
110b

S1
A2 V1 V2 VT
FDAR S2F

70
K FDAV VDAV VDAR K
VC
C1 C2
335b CSP
ES. AR.
ES. AV.

C1 C2
335b CSP
30b
M V1 V2 M

N°226111
30b
V1 V2

O O
P P A1 B1 A2 B2 A3 B3 X1 A4 B4 X2 A5 B5 T
C VD 280b 280b 190b 190b

EF CF OUT P1 PP
FR
6b
5b
BA
LS
Q M VACM(O) M3 M4 Q
P
21.99 cm3/tr IN 10 μm absolu 1ère monte
21.99 cm3/tr 15 μm absolu PR.
P T
M1 M2
250b
CA
Niveau moyen: N 125 μm
S 110L absolu EE EA(O) EL EI EA ET EF S

R Capacité 135 litres Réserve direction

Y1 Y2 D

(16/05/2011) 70-02-M153EN
 24
Hydraulic schematic diagrams MLT 634 -120 LSU + PS
Series E-E3
MLT 735 -120 LSU + PS
MLT 741 -120 LSU + PS
Series 5-E3
HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY
Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
BA Feed block + accumulator E17 VACM(O) Movement cut-off valve (option) K18
CA Breather filter S11 VAI Isolation valve A21
CR(O) Trailer hook (option) C41 VAFR(O) Trailer brake valve (option) I10
CSP Counterbalance valve A26/A30/C33/ VC Compensation cylinder DE C26 110x55 c310
E30
VDAR Rear steering cylinder E8
D Control Valve K18
VDAV Front steering cylinder E4
EE Inlet section K20
VI Tilt cylinder DE A28 140x70 c388
EA Attachment component K23
VL Lifting cylinder DE A31 150x70 c716
EA(O) Attachment component (option) K35
VT DE telescoping cylinder A24 75x55 c2700
EL Lifting component K32
VVT(O) Carriage locking cylinder (option) DE A17 60x45 c183
EI Tilt component K29
ET Telescoping section K25
EF Closing component K37
D3 3 position steering valve A10
Position 1: short steering NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
Position 2: front wheel steering speed.
Position 3: crab steering 2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
EVAA(O) Rear attachment electrovalve (option) E38
EVTF(O) Jib head electrovalve (option) E20
EV5E(O) 5th component electrovalve (option) M34
FDAR Rear brake disc E9
FDAV Front brake E2
FEMS Ems head filter M20
FR Return filter O17
70

M Turbo i.c. engine Q12 1104d-e44ta

Idle speed 930 rpm +20/0
Nominal loaded speed 2200 rpm
Full speed unladen 2360 rpm
MA Manipulator O20
MC Master cylinder M9
N Level S5
P Pump equipment Q8
PAAV Front attachment plug A16
PAAV(O) Front attachment plug (option) C16
PAAR(O) Rear attachment plug (option) A39/C39
PCR Cooler circuit pump Q3
PD Steering pump E13
PFR(O) Trailer brake plug integrated in the VAFR (option) K11
PP Pressure port G19
PRF(O) Leakage return plug (option) C16
R Hydraulic tank S7
RF Cooler O5
RLF Brake fluid tank K8
SC Circuit selector G9
SCFR(O) Trailer brake circuit selector (option) G8

70-02-M153EN (16/05/2011)
 25
MLT 634 -120 LSU + PS Series E-E3 Hydraulic schematic diagrams
MLT 735 -120 LSU + PS - MLT 741 -120 LSU + PS Series 5-E3
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 32 33 34 35 36 37 38 39 40 41 42

VVT(O) VT VI VL x
VAI
1
A 2 A B T PAAR(O) A
3 1 (1 ou 2 PRISES)
2
3 2 1 C1 C2 C1 C2
PAAV 335b CSP 300b CSP
AV AR D3 3
3 2 1 PAAR(O)
P
4 (2 PRISES)
C2 30b
C4 V1 V2
PAAV(O) V1 V2 C1 C2 CR(O)
C C1 C3 335b CSP C
VC
PRF(O)
C3
30b C2

ES. AR.
ES. AV.

V1 V2

x
EVTF(O) P1 P2
EVAA(O)
0,7 L. C4 C1
E FDAV VDAV VDAR FDAR R L 13 b E
200b 200b PD P1
BA
35b CSP M
U C1 C2

x
200 cm3/tr 45±5b
P2 P1
200b
SC

x
V1 V2
V1 V2 P2 T
G LS 140b G
S
PP
SCFR

x
V1 V2 T P
M LS D B1 A1 B2 A2 b B3 A3 b B4 A4 b B5 A5
S
DLS

FREINAGE REMORQUE
I P T I
P

Y
VAFR 22,5 bar
N LS
PFR
B 270 bar
T

70
K T T T T T K
B B A B
EE EA ET 200 bar 190b 280b EI 280 bar EL EA(O) EF
RLF D
Y pst a a a
VACM(O)
B2 L N
2 4

M MC M
P FEMS EV5E(O)
10 μm 3 1

MA P T

O O
B 1 3 2 4

RF FR
6b
5b
P 63 cm3/tr M
PCR 10 μm absolu
Q 14 cm3/tr (1ère monte) MA Q
15 μm absolu
L L1 L2 S (pièce rechange)

CA
N Niveau moyen :
125 μm
absolu
S 110 litres S

R Capacité 135 litres Réserve direction

(16/05/2011) 70-02-M153EN
 26
Hydraulic schematic diagrams
MLT 634 T LSU Series E-E3

MLT 735 T LSU Series 5-E3

HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY

Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
BA Feed block + accumulator E20 VDAV Front steering cylinder DE K7 90x45 c80x2
CA Suction strainer S6 VDAR Rear steering cylinder DE K13 90x45 c80x2
CSP Counterbalance valve E27/K30/K32/ VL Lifting cylinder DE I33 130x70 c720/140x70 c720
M33
VT DE telescoping cylinder I29 70x50 c2100/70x50 c2700
CR(O) Trailer hook (option) C41
VAFR Trailer brake valve G9
D 4 or 5 component valve (option) O38
VVT(O) Ts locking cylinder DE (option) A32 60x45 c183
EE Inlet section S24 VAI Insulation valve A36
EA(O) Attachment component (option) S35 VACM(O) Movement cut-off valve (option) E24
EL Lifting component S34
EI Tilt component S32
EA Optional equipment component S27
ET Telescoping component S29
EF Closing component S37
D3 3 position steering valve C13 NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
Position 1: short steering speed.
Position 2: front wheel steering 2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
Position 3: crab position
EVHAR(O) Electrovalve (rear hydraulic option) K18
EVTF(O) Boom head electrovalve (Option) E33
FDAV Front disc brake K5
FDAR Rear disc brake K15
FEMS Ems head filter G20
FR Return filter Q11
M Turbo i.c. engine Q7 1104d-44ta
70

Idle speed 930 rpm

Nominal loaded speed 2200 rpm
Full speed unladen 2400 rpm
MA Manipulator G21/G24
MC Master cylinder C5
N Level S3
P Pump equipment Q4
PAAV Front attachment plug C31
PAAV(O) Front attachment plug (option) C31
PAAR(O) Rear attachment plug (option) C40
PD Steering pump C12
PFR Trailer brake plug integrated in the vafr I10
PP Pressure port O19
PRF(O) Leakage return plug (option) A23
R Hydraulic tank S4
RLF Brake fluid tank A2
SC Circuit selector E10
SCFR Circuit selector E9
SCHAR(O) Circuit selector (rear hydraulic option) I39
VC Compensation cylinder DE E28 100x50 c310
VI Tilt cylinder DE C28 120x60 c445/130x65 c380

70-02-M153EN (16/05/2011)
 27
MLT 634 T LSU Series E-E3 Hydraulic schematic diagrams
MLT 735 T LSU Series 5-E3
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 32 33 34 35 36 37 38 39 40 41 42

VVT(O)
B L
RLF
N PRF(O)
A VAI A

2 A B T
3 1

B1
3 2 1 2
MC AV AR
PAAV PAAR(O)
D3 1 (1 ou 2 PRISES)
3 2 1
P P
C C2
C
C4
R L VI PAAV(O)
PD 200b 200b 0,7 L. C1 C3
13 b
CR(O)
P1
35b BA VACM C1 C2
200 cm3/tr U CSP 300b
SC 45±5b EVTF(O)
E V1 V2 P1 P2
E
LS 140b
V1 V2
S
P2 T
3 4
SCFR
V1 V2 VC
T P

S FEMS
MA
10 μm
G FREINAGE G
REMORQUE
P T
P T

Y
MA
VAFR C4
2
N LS
C1
PFR 4
1 C2
B 1 2 3
VL
C3
I SCHAR(O) I

VT

P1 P2

FDAR

70
K K
FDAV VDAV VDAR C1 C2 C1 C2
335b CSP CSP 335b
EVHAR(O)
ES. AR.
ES. AV.

3 2
30b 30b
1 4 V1 V2 V1 V2
M C1
M
C2
CSP 70b

V1 V2
PP

O P O
X

M LS D B1 A1 B2 A2 b B3 A3 b B4 A4 b B5 A5
D
B FR DLS
6b b b
5b

Q P Q
P 45 cm3/tr M
10 μm absolu 1ère monte 22,5 b
15 μm absolu PR.
LS a a
L L1 L2 S

T T T T
T 270 b T B B A B
EI
CA EE EA ET 200 b 190 b 280 b 280 b EL EA(O) EF
Niveau moyen: N 125 μm y pst a a a
S 110L absolu S

R Capacité 135 litres Réserve direction

(16/05/2011) 70-02-M153EN
 28
Hydraulic schematic diagrams
MLT 1035 LT LSU
Series 5-E3

HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY

Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
BA Feed block + accumulator C19 S1F Selector 1 function K18
CA Suction strainer S8 VC Compensation cylinder DE E25 110x55 c310
CSD Double counter balance valve E37/M28 VCD Roll corrector cylinder C37 110 x 50 c165
CSP Counterbalance valve C24/I27/M32/ VI Tilt cylinder DE C25 120x60 c416
K34
VDAV Front steering cylinder DE K5 90x45 c80x2
CR(O) Trailer hook (option) G39
VDAR Rear steering cylinder DE K12 90x45 c80x2
D 5 component valve O36
VL Lifting cylinder DE G32 140x70 c720
EE Inlet section S21
VT1 DE telescoping cylinder K26 100 x 60 c2850
ECD Slope control component S33
VT2 DE telescoping cylinder G26 80 x 50 c2850
EL Lifting component S31
VAFR Trailer brake valve I7
EI Tilt component S29
VVT(O) Ts locking cylinder A29
EA Optional equipment component S25
VAI Insulation valve A33
ET Telescoping component S26
VACM Movement cut-off valve C22
EF Closing component S34
D3 3 position steering valve C12
Position 1: short steering NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
Position 2: front wheel steering speed.
Position 3: crab position 2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
EVSC(O) Circuit selector electrovalve (option) K38
EVTF(O) Boom head electrovalve (option) E30
FDAV Front disc brake K2
FDAR Rear disc brake K14
FEMS Ems head filter E19
FR Return filter Q13
70

M Turbo i.c. engine Q9 1104d-44 ta

Idle speed 930 rpm
Nominal loaded speed 2200 rpm
Full speed unladen 2400 rpm
MA Manipulator G20
MC Master cylinder C4
N Level S4
P Pump equipment Q6
PAAV Front attachment plug C28
PAAV(O) Front attachment plug (option) C28
PAAR(O) Rear attachment plug (option) G37
PCR Cooling circuit pump Q2
PD Steering pump C11
PFR Trailer brake plug integrated within vaf I8
PP Pressure port O18
PRF(O) Leakage return plug (option) A20
R Hydraulic tank S6
RF Cooler Q3
RLF Brake fluid tank A3
SC Circuit selector E8
SCFR Circuit selector E7

70-02-M153EN (16/05/2011)
 29
MLT 1035 LT LSU Hydraulic schematic diagrams
Series 5-E3
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 32 33 34 35 36 37 38 39 40 41 42

PRF(O) VVT(O)
B L
A RLF N A
VAI

2 A B T
3 1

3 2 1
VI
MC AV AR
D3 PAAV
3 2 1 0,7 L.
P P
C 13 b C
P1
C1 C2
VACM
C2 Gicleur VCD
R L 35b BA CSP 300b C4 Ø 0.9
U PAAV(O)
PD 200b 200b C1 C3
45±5B 1
2 V1 V2
3 Gicleur
200 cm3/tr Ø 0.9
P2 T
E SC E
EVTF(O) C2 C1
V1 V2 VC P1 P2 325b 325b
LS 140b
S FEMS
SCFR CSD
10 μm V2 V1
V1 V2
T P

S P T PAAR(O) CR(O)
(1 ou 2 PRISES)
MA
G G
FREINAGE REMORQUE
P T
1 2 3 4 VT2 VL
Y
VAFR
N LS
PFR C2 C1
B
I 315b +15
0
CSP I
C4

C2
110b
V2 V1 C1 C2 C1 C3
335b CSP

VT1

70
K K
FDAV VDAV VDAR FDAR 30b
V1 V2
EVSC(O)
P1 P2

S1F
C2 C1
M5 C1 C2
ES. AR.

DEVERS
CSD
ES. AV.

M6 300b 300b
S2
CSP 70b
3 2
M M
1 4
S1 V2 V1 V1 V2

MA
PP

P
O O
X
M LS D B1 A1 B2 A2 b B3 A3 b B4 A4 b B5 A5
D
DLS b b
B FR
6b
RF 5b
P
Q Q
22,5 bar
P 45 cm3/tr M
PCR a a
10 μm absolu 1ère monte LS
15 μm absolu PR.

N°272035
14 cm3/tr
L L1 L2 S T T
T
T EE 270b T T B B A B
EI 280 bar
200b
EA ET 190b 280b EL ECD EF
CA y pst a a a
Niveau moyen: N 125 μm
S 110L absolu S

R Capacité 128 litres Réserve direction

(16/05/2011) 70-02-M153EN
 30
Hydraulic schematic diagrams
70

70-02-M153EN (16/05/2011)
 HYDRAULIC COMPONENTS LOCATION

pages
Hydraulic circuits key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2
1 - Main hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3
2 - Telescoping lift hydraulic circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5
3 - Boom hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7
4 - Boom compensation hydraulic circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . .A9
5 - Slope correction hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A11
6 - Steering hydraulic circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A12

70

(26/05/2011) 70-03-M153EN
 A2
Hydraulic components location

HYDRAULIC CIRCUITS KEY

Hydraulic circuits:
1 - Main 4 - Jib supply compensation
2 - Telescoping lift 5 - Tilting corrector
3 - Jib 6 - Steering

Representation on circuit Electric

Item Designation code
1 2 3 4 5 6 equivalence
BA FEED BLOCK + ACCUMULATOR x x x
CA SUCTION STRAINER x
CPD DOUBLE PILOT VALVE (Slope corrector cylinder) x
CPD DOUBLE PILOT VALVE (Right hand and left hand x
stabilizer cylinders)
CSD DOUBLE COUNTER-BALANCE VALVE (VT1) x
CSP COUNTER BALANCE VALVE (Lift cylinder) x x
CSP COUNTER BALANCE VALVE (Tilt cylinder) x x
CSP COUNTER BALANCE VALVE (VT2) x x
D 7 COMPONENT VALVE x x x x x
D3 3 POSITION STEERING VALVE x
Fdar REAR BRAKE DISC
Fdav FRONT BRAKE
FP NEGATIVE BRAKE
FR RETURN FILTER x
JSM HYDRAULIC CONTROL LEVER x x
70

MC MASTER CYLINDER
MR COOLER MOTOR x x
P HYDRAULIC PUMP x x
PD STEERING PUMP x
R HYDRAULIC TANK x
RDU UNDIRECTIONAL FLOWRATE REDUCTOR GEAR
RF OIL COOLER x
RLF BRAKE FLUID TANK
VC COMPENSATING CYLINDER x x
VCD SLOPE CORRECTOR CYLINDER x
Vdar REAR STEERING CYLINDER x
Vdav FRONT STEERING CYLINDER x
VI TILT CYLINDER x x
VIC COMPENSATION INSULATION VALVE x
VL LIFT CYLINDER x
VSD RIGHT HAND STABILIZER CYLINDER x
VSG LEFT HAND STABILIZER CYLINDER x
VT1 1 TELESCOPING CYLINDER x
VT2 2 TELESCOPING CYLINDER x

70-03-M153EN (26/05/2011)
 A3
Hydraulic components location

1 - MAIN HYDRAULIC CIRCUIT

MLT 634-LSU Turbo S.E-E3 /MLT 735-LSU Turbo S.5-E3 /MLT 1035L-LSU Turbo S.5-E3
MLT 634-120LSU S.E-E3 /MLT 735-120LSU S.5-E3 /MLT 741-120LSU S.5-E3
MLT 634-120LSU PS S.E-E3 /MLT 735-120LSU PS S.5-E3 /MLT 741-120LSU PS S.5-E3

MA

MA

IN
T 4 T
1 P OU
2 3
FEMS

Pst

Y 2
1
VACM(O)
3

D U

BA

70
PP

P
LS

D
N

T
P1

BA

L1
X
P
B
R

S
CA

FR

(26/05/2011) 70-03-M153EN
 A4
Hydraulic components location

MLT 731 Turbo S.E-E3

B
A2 2
S2F T

B
A1 1

PP MA

D P

T P1

U
T

BA
70

PP C

D VD
N P

U P1
T

BA
OUT
LS
EF
F
C

P
IN

CA FR

70-03-M153EN (26/05/2011)
 A5
Hydraulic components location

2 - TELESCOPING LIFT HYDRAULIC CIRCUIT

MLT 731 Turbo S.E-E3

D B1
A1

B4
A4

VT

VL

V1
V1
V2 CSP
V2 CSP

MLT 634-LSU Turbo S.E-E3 /MLT 735-LSU Turbo S.5-E3

MLT 634-120LSU S.E-E3 /MLT 735-120LSU S.5-E3 /MLT 741-120LSU S.5-E3
MLT 634-120LSU PS S.E-E3 /MLT 735-120LSU PS S.5-E3 /MLT 741-120LSU PS S.5-E3

70
A2

B2

A4
D
B4

CSP V1

V1

V2

V2

VT

VL

V1
V1
V2
V2 CSP CSP

(26/05/2011) 70-03-M153EN
 A6
Hydraulic components location

MLT 1035L-LSU Turbo S.5-E3

V2 CSP VT1
V1

CSP VT2

V1

V2
70

B2

A2
D A4

B4

CSP
V1
V1
V2
V2

VT1

VL

V2

V1
V1

V2
CSP

70-03-M153EN (26/05/2011)
 A7
Hydraulic components location

3 - BOOM HYDRAULIC CIRCUIT

MLT 731 Turbo S.E-E3/MLT 735-LSU Turbo S.5-E3

MLT 735-120LSU S.5-E3/MLT 735-120LSU PS S.5-E3

PAAV

D C
VI

B1
A1

V1
B3
CSP
V2
A3

70
MLT 634-LSU Turbo S.E-E3/MLT 634-120LSU S.E-E3/MLT 634-120LSU PS S.E-E3

PAAV

D C

VI

V1
A
CSP V2
B1 B
A1

B3 A

A3

(26/05/2011) 70-03-M153EN
 A8
Hydraulic components location

MLT 1035L-LSU Turbo S.5-E3

PAAV

A
B
D C
V1
B A
V2

B1
A1 CSP
VI

B3
A3
70

MLT 741-120LSU S.5-E3/MLT 741-120LSU PS S.5-E3

PAAV

D C
VI

B1
A1

V1
B3
CSP
V2
A3

70-03-M153EN (26/05/2011)
 A9
Hydraulic components location

4 - BOOM COMPENSATION HYDRAULIC CIRCUIT

MLT 731 Turbo S.E-E3

B3
A3
B1

D A1

B1 1
A

B3 3
A

VC

MLT 634-LSU Turbo S.E-E3 /MLT 735-LSU Turbo S.5-E3

MLT 634-120LSU S.E-E3 /MLT 735-120LSU S.5-E3 /MLT 741-120LSU S.5-E3

70
MLT 634-120LSU PS S.E-E3 /MLT 735-120LSU PS S.5-E3 /MLT 741-120LSU PS S.5-E3

A1

D B1

A3

B3
B1 1
A

B3 3
A

VC

(26/05/2011) 70-03-M153EN
 A10
Hydraulic components location

MLT 1035L-LSU Turbo S.5-E3

A1

B1
A3

B3

B1 1
A

B3 3
A

VC
70

70-03-M153EN (26/05/2011)
 A11
Hydraulic components location

5 - SLOPE CORRECTION HYDRAULIC CIRCUIT

MLT 1035L-LSU Turbo S.5-E3

S1F
3

2
4
1

2
CSD

3
a D
VCD V1
VACM V2

T
U
A5

B5
BA
b

70

(26/05/2011) 70-03-M153EN
 A12
Hydraulic components location

6 - STEERING HYDRAULIC CIRCUIT

MLT 634-LSU Turbo S.E-E3/MLT 634-120LSU S.E-E3/MLT 634-120LSU PS S.E-E3

LS
PD L
R
T
ES. AV

A T

R P D3 VDAV

SC
S
V2
SCFR V2

VDAR D S
D

S
DL

ES. AR
70

MLT 731 Turbo S.E-E3

LS
PD
L

T
R
ES. AV

T
A

R P D3 VDAV

SC
S
SCFR V2
V2

VDAR
S
LS

ES. AR P

70-03-M153EN (26/05/2011)
 A13
Hydraulic components location

MLT 735-LSU Turbo S.5-E3/MLT 735-120LSU S.5-E3/MLT 735-120LSU PS S.5-E3

MLT 741-120LSU S.5-E3/MLT 741-120LSU PS S.5-E3

LS
PD L
R
T
ES. AV

T
A
B

R P D3 VDAV

SC
S
SCFR V2
V2

VDAR D S
D

S
DL

ES. AR

70
MLT 1035L-LSU Turbo S.5-E3

ES. AV

LS
PD
L
R
T

P
VDAV

T
A
B

R P D3

SC
S
SCFR V2
V2

D
VDAR S

S
DL

ES. AR

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Hydraulic components location
70

70-03-M153EN (26/05/2011)
 HYDRAULIC CONTROL AND ADJUSTMENT

Pages

Hydraulic pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3

EMS module operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1
Control block operation (DDIC system). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C1
Control block removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1
Cylinder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1

70
KAPPA hydraulic pump removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1
AA10VO hydraulic pump removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G1

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Hydraulic control and adjustment
70

70-04-M153EN (10/09/2010)
 A3
Hydraulic control and adjustment

HYDRAULIC PRESSURE CONTROL

Pages

Hydraulic pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5

– 1 - Main circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
– 2 - Steering circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7
– 3 - Power assisted braking circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8
LSU circuit hydraulic pressure control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9
– 1 - Main circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9

70
– 2 - Steering circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13
– 3 - Power assisted braking and joystick circuit . . . . . . . . . . . . . . . . . . . . . . . . A14

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70

70-04-M153EN (10/09/2010)
 A5
Hydraulic control and adjustment

HYDRAULIC PRESSURE CONTROL

1 - MAIN CIRCUIT

Parts required

- 1 Manometer 0/400 bar 549 885

or 1 digital manometer (0-600 bar) 554 118
- 1 Connector 213 536
- 1 test hose 549 888
A
- 1 test plug 72 339

Procedure

- Check hydraulic oil level.

- Remove the trim panel 1 (Fig. A) to the rear of the cab to gain
access to the control block.
1
- Bring the oil up to operating temperature (50°C) by carrying out
hydraulic movements.

Checking and adjusting the pressure relief valve is carried out

with full flow and the engine at maximum revolutions.
Checking and adjusting the anti-shock valves is carried out with B
minimum flow and the engine operating at 1000 rpm.

70
Checking and adjusting the main pressure relief valve.

3
- Connect the pressure gauge to the test port.
- With the engine at maximum revolutions, activate the accessory 2
1
circuit control and read the pressure shown on the gauge. 4
- Main pressure relief valve: 240 bar (MT 732/932)
250 bar (MLT 630/731).

Checking and adjusting anti-shock valves.

- Prior to carrying out these procedures it is necessary to increase

the setting on the main limiter 4 (Fig. B) by 50 bar.
- Connect the pressure gauge to the pressure port.
- Keep the relevant cylinder at the end of its travel and read the pressure shown on the gauge
(See table of values).
- When adjustment operations have been completed, return the main limiter to:
240 bar (MT 732/932)
250 bar (MLT 630/731).

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Hydraulic control and adjustment

Table of values

Cylinder rod side

MT 732
Key hydraulic MT 932
MLT 630 Turbo
circuit diagram MLT 731 Turbo

Crowd compensation EI piston side 280 bar

anti-shock valve EI rod side 190 bar
Piston side Elevation anti-shock EL piston side 280 bar
valve
Boom extension ET piston side 190 bar
anti-shock valve
70

70-04-M153EN (10/09/2010)
 A7
Hydraulic control and adjustment

2 - STEERING CIRCUIT

Parts required

- 1 Manometer 0/400 bar 549 885

or 1 digital manometer (0-600 bar) 554 118
- 1 test hose 549 888
- 1 connector 173 567
- 1 test point 58 181 A

STEERING
Procedure PUMP

- Using a T connector connect the pressure

gauge to the pressure out pipe on the main
pump (port P).

- With the engine operating at maximum

revolutions, move the steering on to full
lock and, holding that position, read the
pressure on the pressure gauge.
- Steering pressure: 140 bar

70
MAIN PUMP

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Hydraulic control and adjustment

3 - POWER ASSISTED BRAKING CIRCUIT

A
Parts required MT ...

- 1 Manometer 0/60 bar 549 884

or 1 digital manometer (0-600 bar) 554 118
- 1 test hose 549 888
- 1 connector 211 689
- 1 test plug 58 181
MASTER CYLINDER

Procedure

- With the motor off, press the brake pedal approximately 20

times to depressurize the braking circuit.
- Using a T connector connect the pressure gauge to the feed
block outlet for MT models… (Fig. A) and between the feed
block and the valveblock for MLT…Turbo (Fig. B).
- Operate the engine at maximum revolutions.
- Turn the steering wheel in order to activate the pump spool.
- Adjust the screw on the feed block to 35 bar.

FEED BLOCK
70

Checking adjustment
B
- With the motor off, press the brake pedal approximately
20 times to depressurize the braking circuit. MLT ... Turbo
- Operate the engine at maximum revolutions.
- Turn the steering wheel.
- Brake power assistance pressure: 35 bar

Before removing the T-piece with the gauge, decompress the

circuit by pressing the brake pedal with the engine stopped. MASTER
CYLINDER

Checking the accumulator and the feed block non-return

valve.
VALVE
- After checking the brake power assistance circuit pressure, BLOCK
leave the pressure gauge and connector on the hydraulic
circuit.
- Stop the engine.
- There is then braking capacity for at least 5 presses on the
pedal before pressure drops to zero.
- If, on the other hand, the pressure drops to zero after the FEED
engine is stopped, either the accumulator or the non-return BLOCK
valve is faulty.
70-04-M153EN (10/09/2010)
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Hydraulic control and adjustment

CHECKING LSU CIRCUIT PRESSURES

1 - MAIN CIRCUIT

Parts required

- 1 Digital manometer (0-600 bar) 554 118

- 1 test hose 549 888
- 1 Rev counter 490 165
A
Procedure
2
- Check hydraulic oil level.
- Remove the covers 1 and 2 (Fig. A).
- Remove control block cover plate 3 (Fig. B) inside the cab.
- Bring the oil up to operating temperature (50°C) by carrying out
hydraulic movements.
1

1-1 Checking and adjusting stand-by pressure (the same as B

adjusting the FR regulator)

- Connect the digital pressure gauge (0-600 bar) to the control block
test port (Fig. C).

70
- Connect the tachometer.
- Start the engine and leave it at idle.
- Without making any hydraulic movement, measure the stand-by
pressure : 19 bar ± 1.
- If the stand-by pressure is not correct turn the adjustment screw 3
FR 1 (Fig. D) on the main pump. Screw in to increase pressure
and screw out to decrease pressure. (Tip: 1 turn equals approx.
16 bar)

NOTE: If it proves impossible to correctly set the pressure using this

technique, refer to page 11.

- Using the tachometer ensure the engine is idling at 930 +20

0 rpm.
- Carry out adjustments if necessary.
C D

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Hydraulic control and adjustment

1-2 Checking the DR valve pressure (LS main pump maximum

pressure)

NOTE: In the DDIC system maximum hydraulic circuit pressure limiting

is carried out using the LS limiter on the SX14 control block.
Do not decalibrate the pump regulator DR.
H

- Connect the 0-600 bar pressure gauge to the test port (Fig. H).
- With the engine at maximum revolutions, activate the press button
(accessory circuit) on the joystick.
- Tighten the adjusting screw 1 (Fig. H) to over-rate the main control
block limiter.
- There must be 290 bar showing on the manometer.
- If not, turn the adjustment screw 2 (Fig. I) on the main pump. 1
- Screw in to increase the DR and screw out to decrease the DR. (Tip:
one turn equals approx. 50 bar)
- When finished, reset the main pressure relief valve 1 (Fig. H) to 270
bar ± 5. I

1-3 Checking and adjusting the control block anti-shock

valves

- Before commencing this procedure over-rate the main limiter 1

70

(Fig. H) to 290 bar, following the instructions below.

- Connect the 0-600 bar pressure gauge to the test port (Fig. H).
- With the engine at maximum revolutions, activate the press button
(accessory circuit) on the joystick.
- Set the pressure to 290 bar by tightening the adjustment screw on
the main control block 1 (Fig. H) limiter.
- Screw in to increase the DR and screw out to decrease the DR. (Tip:
one turn equals approx. 50 bar)

When over-rating is complete, check the anti-shock valves.

- Engine at 1500 rpm.

- Have the relevant cylinder at the end of its travel and read the
pressure on the gauge (see table of values) below.
- If the pressures are not correct, turn the anti-shock valve adjustment J
screw (Fig. J).
2
1 - Crowd anti-shock valve, rod side
2 - Crowd anti-shock valve, piston side
3 - Elevation anti-shock valve, piston side
4 - Boom extension anti-shock valve, piston side

- When operations are complete, re-set the pressure relief valve to

270 bar ± 5. 3
1
4
70-04-M153EN (10/09/2010)
 A11
Hydraulic control and adjustment

Table of values
Key hydraulic circuit MLT 630 120 LSU
Cylinder rod side MLT 634 Turbo LSU
diagram MLT 634 120 LSU
MLT 634 120 LSU POWERSHIFT
MLT 731 Turbo LSU

Crowd compensation EI piston side 280 bar

+9
0
anti-shock valve EI rod side 190 bar
+9
0

Elevation anti-shock EL piston side 280 bar +9

0
Piston side valve
Boom extension ET piston side 200 bar +9
0
anti-shock valve

1-4 Checking and adjusting the main limiter K

- Connect the 0-600 bar pressure gauge to the test port (Fig. K).
- With the engine at maximum revolutions, activate the press
button (accessory circuit) on the joystick and read the pressure
on the gauge.
- Main limiter pressure: 270 bar ± 5.

70
- If the pressure is not correct, turn the adjusting screw 1 (Fig. K)
on the main limiter.
1

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Hydraulic control and adjustment

Troubleshooting

STAND-BY PRESSURE IMPOSSIBLE TO SET CORRECTLY TO 19 BAR

± 1 (PAGE 8).
- Connect the pressure gauge to the main LS pump.

There are 2 possible solutions. (A or B)

K
A - Remove the plug 1 (Fig. K) and put in its place a test port (Ref.:
58 187) and then connect a pressure gauge.
- With the engine at idle and no hydraulic movement, check the
pressure.
- The pressure should be 0. If there is some residual pressure or
check the flow regulator 3 (Fig. L) for possible seize or
blockage.
2

B - Connect a T connector (Ref.: 211 689) between the two connectors

2 (Fig. K), fit a test port (Ref.: 58 181) and connect the pressure FR 1
gauge.
- With the engine at idle and no hydraulic movement, check the
L
pressure.
- The pressure should be 0. If there is some residual pressure
in the LS line check the flow regulator 3 (Fig. L) on the control 3
block.
70

NOTE:
- If stand-by pressure is 19 bar, the pump’s flow rate is at the
minimum of 2 liters per minute.
- If pressure is below 19 bar, the pump is pumping.
- If there is a leak between the pump outlet and the reservoir (e.g.
leaking anti-shock valve) the pump attempts to compensate the
leak and can cause an idling engine to stall.
- A lack of flow at the pump can be caused by a leak in the LS circuit
(loss of pressure in the LS line).

70-04-M153EN (10/09/2010)
 A13
Hydraulic control and adjustment

2 - STEERING CIRCUIT

Parts required

- 1 Manometer 0/400 bar 549 885

or 1 digital manometer (0-600 bar) 554 118
- 1 test hose 549 888

Procedure
A
- Remove the control block cover 1 (Fig. A).

B
- Connect the pressure gauge to the control block test port (Fig. B).

70
- With the engine operating at maximum revolutions, move the
steering on to full lock and, holding that position, read the pressure
on the pressure gauge.
- Steering pressure : 140 bar

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Hydraulic control and adjustment

3 - POWER ASSISTED BRAKING AND JOYSTICK CIRCUIT

Parts required

- 1 Manometer 0/60 bar 549 884

or 1 digital manometer (0-600 bar) 554 118
- 1 test hose 549 888
- 1 Connector 211 689
- 1 test point 58 181

Procedure
A
- With the engine switched off, press the brake pedal approximately
20 times to remove the accumulator pressure.
- Connect a pressure gauge with a T connector between the two
connectors 1 (Fig. A).
- Operate the engine at maximum revolutions. 1
- Turn the steering wheel in order to activate the pump spool.
- Read the pressure shown on the gauge.
- Power assisted braking circuit pressure : 35 bar.
70

- If pressure is not correct, remove the pressure reducer to check for

contamination and, if necessary, change the block and accumulator
assembly.

Before removing the T-piece and the pressure gauge, depressurize

the circuit by pressing the brake pedal with the engine stopped.

NOTE: If you find that pressure falls just after the engine is switched
off, refer to the “Troubleshooting” chapter.

70-04-M153EN (10/09/2010)
 B1
Hydraulic control and adjustment

EMS MODULE OPERATION

Pages

Overview of the EMS electrohydraulic control module . . . . . . . . . . . . . . . . . . . . . . . . B3

– 1 - Component positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
– 2 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4
Operation and cross-section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5
EMS as fitted to telehandler - hydraulic schematic . . . . . . . . . . . . . . . . . . . . . . . . . . B6
– 1 - Hydraulic characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6

70
– 2 - Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7
Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7
– 1 - Electrical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8
– 2 - Curve characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8
Zero adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B9
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B10
Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11
– 1 - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11
– 2 - Proportional controller troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . B12
– 3 - Basic principles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13
– 4 - Electrohydraulic controller removal and fitting . . . . . . . . . . . . . . . . . . . . . . B14
– 5 - Connection block and filter removal and fitting . . . . . . . . . . . . . . . . . . . . . . B20
– 6 - Neutral position setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B21
– 7 - Procedure for putting a new module into service . . . . . . . . . . . . . . . . . . . . B22

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70

70-04-M153EN (10/09/2010)
 B3
Hydraulic control and adjustment

EMS ELECTROHYDRAULIC CONTROL MODULE OVERVIEW

1 - LOCATION OF COMPONENTS

EMS Modules

LS

P
T

70

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 B4
Hydraulic control and adjustment

2 - LAYOUT

T 4
1 P
2
70

Pilot pressure 35 bar

Interface
MA = 15 Nm
Control unit

Inlet block
MA = 10 Nm

MA = 11 Nm

Return Filter

70-04-M153EN (10/09/2010)
 B5
Hydraulic control and adjustment

OPERATION AND CROSS SECTION

5 3 7 12 8

14

1 2 11 4 6 10 9 13

The electrohydraulic control module is composed of an electronics unit (1), an electrohydraulic

transformation stage (2) and a mechanical interface (4).

The analog electronic card (5) modulates the current sent to the proportional electrohydraulic valves

70
(3) so that the position of the control piston (6) measured by the linear sensor (7) corresponds
to the control signal received. The sensor (7) is adjustable using a screw and LED (14) (see
page 11). Each electrohydraulic valve (3) is in contact with a control piston chamber (8). The
amount of hydraulic fluid it sends moves the control piston the amount required by the controller.
The pressure of the fluid in the control piston chamber (8) depends on the external force opposing
the movement of the piston (6).

The mechanical interface (4) connects the control module to the side of the hydraulic control block.
It is centered by the collar (9) and held in place by two fixing bolts. The transverse oil-way (11)
supplies hydraulic fluid to the electrohydraulic valves, the oil-way (12) provides system drainage.
A connection block on the side of the first module provides a means of connection for all the inter-
connected modules to the external low pressure source. The bolt (10) connects the control piston
(6) and the valve spool.

The return mechanism (13) ensures that all moving parts return to neutral.

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Hydraulic control and adjustment

EMS AS FITTED TO TELEHANDLER - HYDRAULIC SCHEMATIC

Analog
Input signal
microcontroller
5
Hall Effect position
PWM Driver sensor

8
SX14 13
10
SP
7
TP VPB V PA 9
6

3 3

Tp Pp

RPM
12 11

Pressure
reducer
70

1 - HYDRAULIC CHARACTERISTICS

Oil consumption:
at end of travel: 3,6 cc at 46 cSt

Maximum feed pressure: 35 bar

Maximum return pressure: 1,5 bar

Fluid temperature range: -20 to +80°C

Viscosity range: 10 to 380 mm2/sec

Maximum permitted fluid contamination: NAS1638 Class 9

Type of fluid: Manitou hydraulic ISO 46

70-04-M153EN (10/09/2010)
 B7
Hydraulic control and adjustment

2 - HYDRAULIC DIAGRAM

P Pump
A, B Cylinder
T Reservoir
LS Load Sensing
A
Pst Low pressure
B
Y Hydraulic control drain

Y
Pst

P LS T

CABLING

70
HALL
– +
EFFECT
Sensor
+5 – Telehandler + 12 V
battery
signal
blue
yellow/green
1
2
5V supply black 4

brown 3

0,5V - 4,5V signal

5V generator

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 B8
Hydraulic control and adjustment

1 - ELECTRICAL CHARACTERISTICS

Supply voltage: 12

Amperage: 0,6 A

Power used: 8W

Controller supply voltage: 5V

Controller amperage: 7 mA

Input impedance: 40 kOhm

Protection:
supply: Polarity inversion to ISO 7637
controller: Short circuit, open circuit, overvoltage

CEM: to ISO 7637

2 - CURVE CHARACTERISTICS

- Control block spool travel as a function of the signal sent by the Joystick thumb wheel
100% = 5 V
50% = 2,5 V
0% = 0 V
70

10

Maximum safety
4 threshold: protection
against short
2 circuits between the
regulated supply
Input voltage (%) Input voltage (%)
0 line and the control
0 10 20 30 40 50 60 70 80 90 100 line
-2

-4
Initial jump to
overcome spring
-6 resistance and
spool overlap
-8

-10

Neutral position dead zone

Minimum safety threshold:
protection against short circuits
between the signal line and earth

70-04-M153EN (10/09/2010)
 B9
Hydraulic control and adjustment

ZERO-SETTING

0 bar

Adjustment
screw

Green LED

This screw is adjusted to tell the electronic control card the

neutral position of the control block spool and, therefore,
the zero position of the status sensor

The zero position of the status sensor can be adjusted using

an adjustment screw.

Green LED Adjustment method: The LED situated next to the adjustment
screw must be lit when the spool is at neutral.

Caution: it is essential that the 35 bar supply pressure is

decompressed.

70
Essential precautions

Useful information:

Once zero-setting has been carried out the green LED will not necessarily illuminate every time
the spool returns to neutral. This is because the electronic precision of a return to neutral is
considerably more precise than that obtained with the mechanical return to neutral system.

Essential precautions:

- Never directly aim a jet wash at the EMS module.

- If electric welding is carried out, disconnect all electronic connections.
- Never handle the block by its electrohydraulic (EMS) modules.
- Protect the modules from any possible physical shock when handling them and when they are
in use.

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Hydraulic control and adjustment

TROUBLESHOOTING

1 - Take note of the telehandler serial number.

2 - Take note of the control block serial number.
3 - Take note of the module serial number.
4 - Check if the LED is lit when the joystick is in its neutral (middle) position.
NB: The LED is used only for adjustment purposes.
5- If the LED is lit, go to 7 below.
6- If the LED is not lit:
- Disconnect the module power supply
- Slowly and carefully adjust the zero point until the LED lights up. Take note of the
number of turns needed.
7- Check the presence of 12 V battery voltage on the EMS terminals.
8- Check the regulated 5 V on the EMS module. In the case of no voltage, replace the module.
9- Check the minimum set voltage of 0,9 V on the EMS.
10 - Check the minimum set voltage of 2,5 V (half the regulated voltage) on the EMS when the
thumbwheel is at the end of travel in one direction.
11 - Check the minimum set voltage of 4,1 V at the EMS when the thumbwheel is at the end of
travel in the opposite direction.
12 - If any one of the three voltages (positions 9, 10, 11) replace the handle. If all is correct see
13 below.
13 - Check the supply pressure P to the EMS (35 bar max.).
14 - Check the return pressure Y from the EMS (1,5 bar max.).
15 - Check operation.
16 - If it is still inoperational:
70

- Remove the complete module and mechanically slide the SX14 spool in both
directions, testing operation speed in both directions.
- If spool speeds are correct when operated manually, change the module.

70-04-M153EN (10/09/2010)
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Hydraulic control and adjustment

MAINTENANCE INSTRUCTIONS

1 - INTRODUCTION

1-1 Foreword

Only competent persons can install, connect

or maintain this device. All operations must
comply with current technical and cleanliness
standards specific to this type of installation.

To ensure optimal performance and safety

during maintenance operations, you are
strongly advised to READ THIS MANUAL
EMS electrohydraulic control module
WITH CLOSE ATTENTION.

All the information, illustrations and characteristics in this document are based on the most recent
information available at the time of publication. In order to assure the high quality of its products,
MANITOU reserves the right to make modifications to the conception or technical aspects of this
product without notice.

70
1-2 Safety Notice

Pay particular attention to the safety alert markers and special instructions markers in this
manual.

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Hydraulic control and adjustment

2 - PROPORTIONAL CONTROL TROUBLESHOOTING

Problem(s) Likely cause Additional checks Solutions

No movement for any 1. Insufficient supply Check the minimum
proportional operation voltage supply voltage of 9 V
at the proportional
controller terminals.

2. Insufficient pilot Check the supply

pressure pressure in the
proportional controller
pilot circuit blocks
minimum 15 bar.
3. Proportional control Clean the filter. Remove the hydraulic
protection filter supply block filter.
blocked.

Absence of or faulty 1. Absence of proportional Check the signal from Check the wiring
movement on one control signal at the the joystick to the connections and loom
proportional operation. control block. proportional control between the proportional
units. control unit and the
Value = 2,5 V if the joystick.
joystick thumbwheel is If connections and wiring
at neutral. are good, change the
joystick.
2. Faulty proportional Check for a signal voltage If the value is out of range,
70

control signal at the of between 1 and 4 change the joystick.

control block. volts, using the joystick
thumbwheel.

3. Insufficient control Check for a 5 V control If the voltage is zero or

voltage at the control voltage from the insufficient, replace the
block proportional proportional control units proportional control unit.
control units. towards the joystick.

Untimely movement with Faulty signal from the Check the signal from Check the wiring
the joystick proportional joystick proportional the joystick to the connections and loom
controller at neutral. controls. proportional control between the proportional
units. control unit and the
Value = 2,5 V if the joystick.
joystick thumbwheel is If connections and wiring
at neutral. are good, change the
joystick.
Jerky or irregular Protection filter partially Clean the filter. Remove the hydraulic
movements on all blocked. supply block filter.
proportional operations.

Jerky or irregular Blockage or seizing of Replace the proportional

movements on one that proportional control control unit.
proportional operation. unit’s position sensor.

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Hydraulic control and adjustment

Problem(s) Likely cause Additional checks Solutions

Jerky or irregular Blockage or seizing of Replace the proportional
movement in one the pilot spool of the control unit.
direction only, on one proportional control unit
proportional operation. in question.
Asymmetric response Position sensor neutral Adjust the neutral
to control of one mis-calibrated. position on the position
proportional operation. sensor.
Oil leak between two Defective sealing in Change seals.
proportional control the pilot circuit oilways
units. between units.
Oil leak at electrohydraulic 1. Damaged seal. Change the seals.
and mechanical interface
on the proportional
control units. 2. Excessive pilot Check that the supply
pressure. pressure in the pilot
circuit does not exceed
35 bar.

3 - BASIC RULES

General points concerning the connection of the electrohydraulic control module

Hydraulic system

70
When removing the electrohydraulic control module, all openings must be immediately covered to
avoid any possible contamination of the hydraulic system.
Check the hydraulic system’s oil quality and filtration capacity as part of all repair and maintenance
tasks on the system.
When replacing the electrohydraulic control module, do not remove the plastic plugs on openings
and pipework until just before making connections.
Do not tighten connectors to a higher torque than that shown in the fitting instructions.
PTFE tape, hemp or jointing compound must not be used.
Hydraulic pipes and connectors must in no case be under any strain.

Electrical system

Throughout all operations, take care not to damage the cables and electrical connections.
Ensure that there is no residual voltage in the electrical cables and connections.

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4 - REMOVAL AND INSTALLATION OF THE ELECTROHYDRAULIC CONTROL MODULE

4-1 General recommendations

CAUTION: BEFORE REMOVING THE ELECTROHYDRAULIC CONTROL MODULE FROM THE

TELEHANDLER BOTH THE ECM ITSELF AND ITS SURROUNDINGS MUST BE CAREFULLY CLEANED.
(N.B. NEVER AIM HIGH PRESSURE LIQUID FROM A JET WASH DIRECTLY AT THE ECM).

THE HYDRAULIC SYSTEM MUST BE KEPT TOTALLY CLEAN OF ALL IMPURITIES. PLASTIC PLUGS
MUST BE FITTED ONTO OILWAYS AND OPENINGS AS SOON AS THEY ARE EXPOSED.

Be sure to wear appropriate protective clothing and to use correct equipment to avoid accidents,
particularly with hydraulic oil.

Use the lifting eyes and correct maintenance equipment.

Put all controls connected to the telehandler in neutral (on the ground, as low as they will go
etc.) to avoid possible accidents from uncontrolled movements of parts of the machine when the
hydraulic system is disconnected.

When the machine is stopped, remove all residual pressure from the system by working all the
distribution coils. For this, move the joystick in every direction.

4-2 Removal of a simple electrohydraulic control module

70

Telehandler switched off:

- Place all parts of the machine connected to the control unit into their rest position.
- Remove all accumulated pressure by activating all the coils. To do this, move the
joystick in every direction.

NOTE: Fit a vacuum pump to the hydraulic fluid reservoir to limit oil escapes when connections are
broken.
Fit protective plugs as soon as you have disconnected the hydraulic connections on
the electrohydraulic control module. Be sure to collect any oil spills in an appropriate
recipient.

Unscrew the fixing bolts with a M5 Allen key.

Re-fitting: torque to 15 ± 1 N.m

Pull the electrohydraulic control module

backwards, parallel to the coil, to free the piston.

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Hydraulic control and adjustment

Remove the cover from the pre-set return spool

system, on the opposite side from the coil.

Unscrew the positioning piston from the

distribution coil using a 19 mm spanner on the
piston side and a M5 Allen key on the spring
side.

Re-fitting: Apply 2 drops of Loctite 242 to the

piston thread.
Torque: 10 ± 1 N.m

70
Remove and replace the sealing ring between the
controller and the control valve.

Remove the alignment ring.

NOTE: Do not remove the coil from the control

valve.

To re-fit, carry out the above procedure in reverse

order.
Adjust the neutral position.
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4-3 Removal of one or more electrohydraulic control modules mounted together

Telehandler switched off:

- Place all parts of the machine connected to the control unit into their rest position.
- Remove all accumulated pressure by activating all the coils. To do this, move the
joystick in every direction.

NOTE: Fit a vacuum pump to the hydraulic fluid reservoir to limit oil escapes when connections are
broken.
Fit protective plugs as soon as you have disconnected the hydraulic connections on
the electrohydraulic control module. Be sure to collect any oil spills in an appropriate
recipient.

To remove either an intermediate or an end

electrohydraulic control module, it is necessary
to remove the entire module.

Remove all the fixing bolts from every

electrohydraulic control module using a M5 Allen
key (cf. § 4.2).

Re-fitting: torque to 15 ± 1 N.m

70

Pull the electrohydraulic control module

backwards, parallel to the coil, to free the piston.

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Hydraulic control and adjustment

Place the modules on a clean and uncluttered

surface to keep them separate one from
another.

Re-fitting:
- Remove and replace the connection pipes
between defective modules.
- Replace the defective electrohydraulic control
module.
- Replace all sealing rings between controls and
their control valve.
- Re-assembly is carried out in the reverse order.
- Adjust the neutral position.

70
4-4 Assembled electrohydraulic control module

Ensure that all mating surfaces are clean before re-assembling.

Re-fit any connecting pipes that have been removed.
Replace the O-ring between the electrohydraulic control module and the control valve component.
Re-fit the module following the instructions described in paragraphs 4.2 and 4.3 in reverse order.

Once it is installed the unit can be used:

- check the condition of all seals on hydraulic connectors
- check the condition of electric wiring
- make the hydraulic connections to the unit, following the connection diagram and tightening to
specified torques (see the table on the data sheet)
- ensure that pipes are not kinked and to not rub anywhere.

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4-5 Removal an Disassembly of control unit

NOTE: The electrohydraulic control module should not be removed for this operation.

Telehandler switched off:

- Place all parts of the machine connected to the control unit into their rest position.
- Remove all accumulated pressure by activating all the coils. To do this, move the
joystick in every direction.

NOTE: Fit a vacuum pump to the hydraulic fluid reservoir to limit oil escapes when connections are
broken.
Fit protective plugs as soon as you have disconnected the hydraulic connections on
the electrohydraulic control module. Be sure to collect any oil spills in an appropriate
recipient.

Remove the 4 mounting screws with a M3 Allen

key.

Re-fitting: torque to 3 to 3,5 N.m

70

Remove the electrohydraulic control module by

pulling it gently backwards, parallel to the coil,
until the position sensor stem is fully out.

NOTE: Removing the 4 mounting screws from

the control module releases the circuit
board protective cover. When carrying out
this operation be sure to avoid any risk of
contamination, damp or physical impact to
the electronic and hydraulic components.

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Hydraulic control and adjustment

Remove one or two electrohydraulic valves.

NOTE: This operation should only be carried out

if there is an externally visible oil leak
around the seal between the valve and its
housing.

Re-fitting:
- replace the external valve sealing rings
- put the valve(s) in its housing

Sealing rings

70
Replace the external sealing ring on the stem
(or the sensor O-ring).

NOTE: Before re-fitting, position the sensor O-ring

in its groove on the side of the mechanical
interface.

Re-fit the electrohydraulic control module by

following the instructions in reverse order.

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5 - REMOVAL AND RE-FITTING OF THE CONNECTION BLOCK AND THE FILTER

Telehandler switched off:

- Place all parts of the machine connected to the control unit into their rest position.
- Remove all accumulated pressure by activating all the coils. To do this, move the
joystick in every direction.

NOTE: Fit a vacuum pump to the hydraulic fluid reservoir to limit oil escapes when connections are
broken.
Fit protective plugs as soon as you have disconnected the hydraulic connections on
the electrohydraulic control module. Be sure to collect any oil spills in an appropriate
recipient.

5-1 Removal and refitting of connection block

Remove the two fixing screws with a M5 Allen

key.

Re-fitting: torque to 11 ± 1 N.m

70

Remove the connection block. Pull the block

backwards, parallel to the bolt hole, in such a
way as to pull the connecting pipes out of their
corresponding sockets.

Re-fitting:
- Put the connecting pipes in position
- Re-fit the components in reverse order

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Hydraulic control and adjustment

5.2 - Replacement of the filter

Unscrew the filter from port P using a straight

screwdriver.

Re-fitting: screw the filter into port P by hand.

6 - NEUTRAL POSITION ADJUSTMENT

NOTE: To carry out this operation it is not necessary to remove either the control unit from the
telehandler or the electrohydraulic control module from the control valve.

Telehandler switched off:

- Place all parts of the machine connected to the control unit into their rest position.
- Remove all accumulated pressure by activating all the coils. To do this, move the
joystick in every direction.

70
Take note of and remove the inspection plug
located on the underside of the rear cover of the
control module.
Switch on the ignition.
It is absolutely essential that the 35 bar control
pressure is decompressed.

Note the internal adjustment device and the

green LED located underneath.
The green LED lights when the “mechanical zero
point” on the coil matches the “electrical zero
point” on the electronic installation.

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Using a small straight screwdriver, turn the

adjustment screw clockwise or anti-clockwise
until the green LED lights.

7 - COMMISSIONING A NEW MODULE

Telehandler switched off:

- Place all parts of the machine connected to the control unit into their rest position.
- Remove accumulated pressure by activating all the coils.

Start the engine and load the accumulator by turning the steering wheel.

CAUTION

THE electrohydraulic PROPORTIONAL SYSTEM IS DESIGNED AND BUILT TO WORK DOWN TO -40°C.
FOR OIL TEMPERATURES LOWER THAN 15°C IT IS POSSIBLE THAT CONTROL MOVEMENTS MAY
INITIALLY BE SLOW AND JERKY. WE STRONGLY RECOMMEND YOU FOLLOW APPROPRIATE OIL
70

WARMING PROCEDURES WHEN STARTING IN COLD WEATHER.

Engage the joystick and slowly vary the control signals, checking that there are no obstacles in the
vicinity of the telehandler that could be struck if there is an accidental movement.

In response to a variable signal from the joystick, the selected function on the telehandler should
accelerate or slow down smoothly according to the signal, indicating good stability.

When just one joystick command is chosen, its corresponding function should be the only one to
respond and all other functions should remain at rest.

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HYDRAULIC CONTROL BLOCK SYSTEM (DDIC SYSTEM)

Pages

Operation of the DDIC (Load independent flow distribution) system . . . . . . . . . . . . . . C3

– 1 - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3
– 2 - Inlet component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4
– 3 - Distribution element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5
– 4 - End element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7

70

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70

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Hydraulic control and adjustment

OPERATION OF THE DDIC SYSTEM

(LOAD INDEPENDENT FLOW DISTRIBUTION)

1 - INTRODUCTION

The Rexroth control block can control up to three

simultaneous movements.

The SX14 control block is made up of:

- An inlet/outlet element
- distribution elements
- an end element

Complete SX14 control block

R L
200b 200b PD

200 cm3/tr

V2
LS 140b
S

T P
M LS D B2 A2 b B3 A3 b B4 A4 b B5 A5
DLS

70
P T P

Y
VAFR 22,5 bar
N LS
PFR
B 270 bar
T

T T T T T
B B A B
EE ET 200 bar 190b 280b EI 280 bar EL EA(O) EF
D
a a a

Inlet component Distribution elements End

element

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Hydraulic control and adjustment

2 - INLET ELEMENT

The inlet element contains:

- a flow divider
The flow divider controls supply to the control block and to the steering system, with the
steering having priority.
- an LS pressure relief valve
The function of the LS pressure relief valve is to limit the maximum pressure in the circuit
by limiting the pump pilot pressure.
It pre-empts the action of the DR spool of the pump and reduces cavitation.
- a flow regulator
The flow regulator ensures the depressurization of the LS pilot line.

R L
200b 200b PD

200 cm3/tr

V2
LS 140b
S

T P
M LS D
DLS

P T P
70

Y
VAFR
N LS
PFR
B 270 bar
T

EE
D

T
P LS T P
LS

DLS M
LS
D

T
LS Pressure P
relief valve T
Flow regulator and
filter

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Hydraulic control and adjustment

3 - DISTRIBUTION ELEMENT

Each SX directional valve element is made up of a body 1, a spool 2, two load hold check valves 3,
a pressure compensator 4 and cavities for secondary relief and anti-cavitation valves 5.

B2 A2 b B3 A3 b B4 A4 b B5 A5

T T T T T
B B A B
ET 200 bar 190b 280b EI 280 bar EL EA(O)
a a a

A B
LS

70
T P T

Pressure compensator
Load hold check valve

Secondary or anti-cavitation valve

Main spool Hydraulic control

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Hydraulic control and adjustment

The maximum flow for each hydraulic function is determined by the shape of the spool:

Function PISTON side ROD side

Lifting 100 l/mm 100 l/mm
Tilting 100 l/mm 100 l/mm
Telescoping 90 l/mm 50 l/mm
Jib accessory 100 l/mm 100 l/mm
Double action rear accessory 100 l/mm 100 l/mm
Single action rear accessory 100 l/mm

Pressure compensator

- It ensures communication between the main pressure line through the control block and supply
to the actuator.
- It captures pressure information at the actuator and transmits it to the pump.

There is a priority between the actuator supply function and sending pressure information, so as
to prevent a rapid increase in pressure due to any delay in the compensator opening relative to
pump control.
70

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Hydraulic control and adjustment

4 - THE END ELEMENT

The end element contains a flushing valve whose function is

to prevent pressure spike phenomena due to the premature
closing of the main spool in one of the distribution elements
before the pump returns to minimum output.
22,5 bar

EF

Flushing valve

LS

70
End element

P
T

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70

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CONTROL BLOCK DIS-ASSEMBLY

Pages

1 - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2
2 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3
3 - Essential rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4
4 - SX14 control block removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . D5
5 - SX14 repair procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6

70
6 - Tightening torques MLT...LSU + MLT...120 LSU . . . . . . . . . . . . . . . . . . . . . . . . . . D12
7 - Tightening torque MLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13
8 - Tightening torque MT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D14

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CONTROL BLOCK DIS-ASSEMBLY

1 - INTRODUCTION

1-1 Preface

This manual provides the instructions for servicing and

maintenance operations for the SX14 control block. For
the inspection and servicing operations associated with
the hydraulic system of the machine to which the block
is connected, it is essential to consult the corresponding
chapters in this manual.

The fitting, connecting and maintenance of this device must

be carried out only by a qualified technician, paying full
regard to current technical standards and the cleanliness
rules specific to this type of installation.

All information, illustrations, instructions and characteristics contained in this publication are based
on the latest product information available at the date of publication. Further to its aim to improve
quality, MANITOU reserves the right to make modifications at any time with no further notification or
obligation from its side.

1-2 Safety instructions

70

The safety instructions and important notes to which you must pay particular attention appear in
this manual in the following manner:

Instructions to be followed without fail in order to ensure your safety and avoid the risk of
material damage in the course of maintenance or repair operations.

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Hydraulic control and adjustment

2 - TROUBLESHOOTING

Before working through any of these troubleshooting steps or removing the control block,
carry out a prior inspection of the telehandler’s hydraulic circuit in order to eliminate all
possible malfunctions arising from causes external to the SX14 control block.

Abnormal operation of the actuators connected to the control block.

Malfunction observed Probable cause Additional checks Solutions

Lack of power at all - LS pressure relief valve Take a pressure - Replace the LS pressure
actuators defective measurement relief valve (cf. § 5.1)
(see chapter 70 - 02) - Adjust the LS pressure
- LS pressure relief valve relief valve
out of adjustment
Lack of power on one - Secondary pressure - Re-set to nominal
actuator only relief or anticavitation pressure (see
valve out of adjustment chapter 70 - 02)
- Secondary pressure
relief valve jammed - Replace the secondary
“open” (return to tank) pressure relief valve
(cf. § 5.5)
Lack of speed in the Spool piloting fault Check control pressure Remedy
performance of one or all (see chapter 70 - 02)
movements

70
Lack of speed in just one - Spool stroke incorrect or Check piston movement If movement is incorrect,
movement spool not moving freely change housing and
- Individual compensator piston assembly
pressure blocked (cf. § 5.7 and 5.6).
Change housing and
pressure compensator
(cf. § 5.7)
Steering abnormally hard Flow divider adjustment - Adjusting piston sliding - Replace control sub-
problem freely system (cf. § 5.3)
- Adjusting piston - Replace housing and
jammed control sub-system
(cf. § 5.7 and 5.3)
Simultaneous - Individual compensator - Remove and clean
movement malfunction orifice blocked individual compensator
(cf. § 5.7)
- Individual compensator - Replace housing and
pressure blocked pressure compensator
assembly
- LS line leakage - Replace LS flow
regulator (cf. § 5.2)

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Abnormal machine operation.

Malfunction observed Probable cause Additional checks Solutions

Engine remains under Flow regulator blocked Check the ΔP at neutral Replace the flow regulator
load after spools have (see chapter 70 - 02) (cf. § 5.2)
returned to neutral

Abnormal control block operation.

Malfunction observed Probable cause Additional checks Solutions

Increased force on Control block assembly Check tightening torque Loosen and tighten to
controls or spool return tie rods too tight correct torque: (cf. § 6)
defective
Before commencing,
remove the control
block from its
mounting
Replace the spool seals
Spool seals worn out (cf. § 5.6)

Visual defects.

Malfunction observed Probable cause Additional checks Solutions

Spool leaking oil Spool seals defective Change spool seals
(cf. § 5.6)
70

Oil leaks at pressure Defective seals Remove the pressure

relief valves and plugs relief valve or plug and
replace the seals
Oil leakage between Defective seals between Remove the distribution
elements elements elements and change
the seals (cf. § 5.7)

3 - ESSENTIAL RULES

General points concerning the control block connection

- When the block is removed all openings must be plugged immediately to avoid any contamination
of the hydraulic circuit.
- When re-fitting the block remove the plastic plugs from openings just before re-making
connections.
- Do not tighten connectors to a torque greater than that specified in the assembly instructions.
- Check the quality of the hydraulic oil and the filtration capacity during all maintenance or repair
operations.
- The use of PTFE tape, hemp and jointing compound is forbidden.
- Hydraulic lines and connections must be under not strain of any kind.

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4 - SX14 CONTROL BLOCK REMOVAL AND RE-FITTING

4.1 General recommendations

Before removing the SX14 control block from the telehandler it is essential to thoroughly
clean the control block and its surroundings using a jet wash.
No impurity must enter the hydraulic circuit. Fit plastic plugs on all lines and openings as
soon as they are exposed.
Wear protective clothing and use suitable equipment to avoid any accident, particularly
with hydraulic fluid.
Use the lifting eyes and appropriate handling equipment.
Set all actuators attached to the control block in their rest position (on the ground, at
their lower limit etc.) to avoid accidents arising from uncontrolled movements when the
hydraulic circuit is disconnected.
With the machine switched off, release any pressure stored in the system by moving all
the distribution spools.

4.2 SX14 Control block removal

- Fit a vacuum pump to the tank to limit oil leakage when connections are broken.
- As soon as lines are disconnected from the control block, plug all openings.
- Be sure to catch any escaped oil in an appropriate recipient.
- Unscrew the mounting screws and remove the control block.

4.3 Re-fitting the SX 14 control block

70
- Ensure all mating faces are perfectly clean.
- Check the mating face onto the telehandler for flatness (Tolerance 0,5 mm).
- Check the condition of all seals on line connectors.
- Clean the block if it has been in prolonged storage.
- Correctly offer the block up to the telehandler and fix it in place with bolts.
- Connect the lines to the block as per the connecting diagram and the specified torques.
- Ensure that hoses are deployed so that are not twisted or rubbing on anything.
- When fitting has been correctly carried out the device can be put into use:
- Decalibrate the LS pressure relief valve before putting the telehandler into service.
- Move the distribution spools.
- Adjust the maximum pressure using the LS pressure relief valve while keeping one receiver
at the end of its stroke.

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5 - SX14 CONTROL BLOCK REPAIR PROCEDURES

5.1 LS pressure relief valve replacement

NOTE: There is no need to remove the control block from

the telehandler for this operation.

Telehandler switched off:

- Place all actuators connected to the control block in
their rest position.
- Release stored pressures by moving all the distribution
spools.

NOTE : Collect any oil leaks in an appropriate recipient.

- On the inlet element, unscrew the LS pressure relief valve (17 mm spanner).

Reassembly: tightening torque: cf. § 6.

5.2 Flow regulator replacement

NOTE: There is no need to remove the control block from

the telehandler for this operation.
70

Telehandler switched off:

- Place all actuators connected to the control block in
their rest position.
- Release stored pressures by moving all the distribution
spools.

NOTE: Catch any escaped oil in an appropriate

container.

- On the inlet element, unscrew the flow regulator (22 mm spanner).

Reassembly: tightening torque: cf. § 6.

REMOVAL AND REPLACEMENT OF FILTER

- Using pliers, take the filter out of the flow regulator.

Strainer

Take care not to damage the O-ring at the end of

the regulator.

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5.3 Flow divider sub-assembly dis-assembly

NOTE: It is not necessary to remove the control block from the telehandler for this operation.

Telehandler switched off:

- Place all actuators connected to the control block in their rest position.
- Release stored pressures by moving all the distribution spools.

NOTE:
- Fit a vacuum pump to the fluid reservoir in order to limit
any possible oil leaks during this operation.
- Catch any oil leaks in an appropriate recipient.

- Unscrew the plug (12 mm Allen key).

- Remove the stop and the spring.

Reassembly: tightening torque: cf. § 6.

- Replace any defective parts.

- Replace the O-rings on the plugs.
- Re-assembly is the reverse of dis-assembly.

Plug

70
Stop
Spring

Piston assembly

5.4 Flushing valve disassembly

NOTE: There is no need to remove the control block from

the telehandler for this operation.

Telehandler switched off:

- Place all actuators connected to the control
block in their rest position.
- Release stored pressures by moving all the
distribution spools.

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- On the outlet element, unscrew the flushing valve plug

Plug (12 mm Allen key).

Re-fitting:
Shim
- Replace the plug O-ring.
- Tightening torque: cf. § 6.
Spring

- Remove: - the shim,

Ring
- the spring,
Piston - the ring,
- the piston.

- Re-assembly is the reverse of dis-assembly.

5.5 Replacement of secondary pressure relief valve

NOTE: There is no need to remove the control block

from the telehandler for this operation.
70

Telehandler switched off:

- Place all actuators connected to the control
block in their rest position.
- Release stored pressures by moving all the
distribution spools.

NOTE: Catch any escaped oil in an appropriate container.

On the distribution element in question, unscrew the secondary pressure relief valve (24 mm open
ended spanner).

Re-fitting:
- Set the pressure relief valve to the specified value.
- Fit the secondary pressure relief valve on the distribution element. For torque: cf. § 6.
- Fit a new appropriate locking cover.

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Hydraulic control and adjustment

5.6 Removal of a spool

NOTE: There is no need to remove the control block

from the telehandler for this operation.

Telehandler switched off:

- Place all actuators connected to the control
block in their rest position.
- Release stored pressures by moving all the
distribution spools.

NOTE:
- Fit a vacuum pump to the fluid reservoir in order to
limit any possible oil leaks during this operation.
- Catch any oil leaks in an appropriate recipient.

- Remove the cover fixing screws (5 mm Allen key).

Reassembly: tightening torque: cf. § 6.

70
- Remove the cup and spring.
- Remove the O-ring from the cover.
- Extract the spool from the distribution element.

Re-fitting: Grease new seals when fitting.

Spool fitting direction.

5.7 Dis-assembly and re-assembly of control block

PRELIMINARY OPERATIONS:

- Remove the control block from the telehandler (cf. § 4).

- Remove the 3 assembly nuts (13 mm socket).

Reassembly: tightening torque: cf. § 6.

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Hydraulic control and adjustment

- Remove the outlet element.

- Separate the distribution elements from the input
element.
- Replace the O-rings between the distribution
elements, the input element and the output element.
- If the input element is to be replaced, remove the
tie rods.
- Assembly is the opposite of dis-assembly, ensuring
that tie rods are torqued to the correct torque.
- Before commencing, ensure that mating faces on
the elements are clean.

Individual pressure compensator removal

- Unscrew the plug (7 mm Allen key).

70

- Remove the compensator piston.

- Clean the piston’s nozzle with compressed air.
- Check the condition of the bore in the body.

Re-assembly: replace the O-ring and the anti-extrusion

ring in the plug.

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Hydraulic control and adjustment

Disassembly of a load check valve

- Unscrew the plug (5 mm Allen key).

- Remove the spring and the poppet.

- Visually inspect the parts for condition.
- If necessary, replace any defective parts.

Re-fitting:
- Replace the plug O-ring.
- Tightening torque: cf. § 6.

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(24/05/2011) 70-04-M153EN
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Hydraulic control and adjustment

6 - TIGHTENING TORQUE MLT...LSU + MLT...120 LSU

Torques given in N.m ± 10%.

ref. torque Nm ref. torque Nm

Input element:
1 LS pressure relief valve: 45 Distribution element:
2 LS flow regulator: 20 7 Non-return valve: 30
3 DLS/LS selector: 20 8 Pressure compensator plug: 60
4 Priority valve seat: 10 9 Secondary pressure relief valve: 70
5 Priority valve plug: 100 10 Hydraulic control unit: 10
6 Tie rods: 30 11 Return spring housing: 10
12 EMS control module control piston: 10
Output element: 13 EMS Module: 15
14 Flushing valve plug: 100
15 Tie rod nuts: 42

6 15 14

9
70

11

8
10
5
12

3
7

13

1
4

70-04-M153EN (24/05/2011)
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Hydraulic control and adjustment

7 - TIGHTENING TORQUES MLT

F2

F1

C
H G D1
J D2
C
I
C K F

A
C

D
A

E2 E
E
C
E1

70
Ref Designation Number Size (mm) tightening torque
(N.m)
A M8 bolt 2 5 9,8
B M5X12 bolt 4 4 6,6
Change the seals M5X16 bolt 24 4 6,6
D Complete pressure relief valve 1 27 42
D1 1 27 42
Complete pressure relief valve (detail)
D2 1 13 24
E Poppet 2 24 42
E1 2 24 42
Complete pressure relief valve (detail)
E2 2 17 24
F Cartridge 2 24 42
F1 2 24 42
Complete pressure relief valve (detail)
F2 2 22 24
G Valve 4 8 24
H Plug 1 8 42
I Plug 2 12 42
J Bolt 1 6 24
K Bolt 1 6 24

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Hydraulic control and adjustment

8 - TIGHTENING TORQUES MT
N2 J1
J2

N1

R P O Q
M

J
N

B
A
Q H
B

A A G
K B D
N H
G

H D
C
G L
K2 E D
F

C I

K1
C
I
S

Ref Designation Number Size (mm) tightening torque

(N.m)
Shouldered bolt 3 5 24
70

A
B M10 nut 3 17 24
Change the seals Brake nut 5 13 24
D M12x20 bolt 3 18 24
E M5x12 screw 2 4 6,6
F M5x14 screw 8 4 6,6
G M5x18 screw 6 4 6,6
H M5x25 screw 3 4 6,6
I M8x25 screw 5 6 24
J Complete pressure relief valve 1 27 42
J1 1 27 42
Complete pressure relief valve (detail)
J2 1 13 24
K Complete pressure relief valve 2 24 42
K1 2 24 42
Complete pressure relief valve (detail)
K2 2 17 24
L M12x200 lever 2 19 42
M Cover screw 24 4 6,6
N Complete pressure relief valve 2 24 42
N1 2 24 42
Complete pressure relief valve (detail)
N2 2 22 24
O Valve 6 8 42
P Plug 1 8 42
Q Plug 2 12 42
R Bolt 6 6 24
S Lever 1 19 42
T Lever 1 19 42
70-04-M153EN (24/05/2011)
 E1
Hydraulic control and adjustment

CYLINDER DISASSEMBLY

Pages

Cylinder disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3
– 1 - Hydraulic lifting systems standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3
– 2 - Dis-assembly and re-assembly of the complete rod . . . . . . . . . . . . . . . . . . E4
– 3 - Disassembly and re-assembly of piston and cylinder head . . . . . . . . . . . . . E7
– 4 - Dis-assembly and re-assembly of piston seals . . . . . . . . . . . . . . . . . . . . . . E9
– 5 - Dis-assembly and re-assembly of cylinder head seals. . . . . . . . . . . . . . . . . E10
– 6 - Application of thread locking compound . . . . . . . . . . . . . . . . . . . . . . . . . . E11

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70

70-04-M153EN (03/05/2010)
 E3
Hydraulic control and adjustment

CYLINDER DISASSEMBLY

1 - HYDRAULIC LIFTING SYSTEMS STANDARDS

Extracts from Standard Pr EN 1459 - 1997

5.5.2 Hydraulic lifting system

5.5.2.1 Load retention

The lowering of a load due to a leak in the hydraulic system must not exceed 150mm
in 10 minutes with the boom positioned in its least favorable position and the oil at
its normal working temperature.

The average speed of tilt forward caused by oil leaks must not exceed half a degree
per minute.

6.3.3 Static load - leak test (elevation, tilt)

Load lowering measurements due to hydraulic leaks (see 5.5.2.1) must be carried
out with a test using the effective capacity, the telescoping boom completely
extended and the maximum elevation angle. Load lowering and fork clamp tilt must
be measured at the heel of the fork lift mast or close nearby.

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Hydraulic control and adjustment

2 - DIS-ASSEMBLY AND RE-ASSEMBLY OF THE COMPLETE ROD

A1
Dis-assembly

- Place the cylinder in a vice fitted with soft jaws.

Rod 1 Body 3
- Tighten the vice moderately only to avoid deforming the
cylinder body.
- Loosen the cylinder head 2 (Fig. A1) with a hook wrench.
- If you have difficulty loosening the cylinder head consult the
paragraph “Dis-assembly” in chapter 6.
- Completely unscrew the cylinder head 2 (Fig. A1).
Cylinder head 2 Piston 4
- Remove the entire rod from the cylinder body.

NOTE: FOR LONG CYLINDERS

- Pull the rod out by 200 mm maximum.

A2
- Unscrew the cylinder head half of one turn (Carry out this
operation very progressively, without any abrupt movements).
- Pull the rod out by some 2500 mm.
- Support the rod by its end to reduce stress on the cylinder
head (Fig. A2).
- Continue to unscrew the cylinder head. If resistance is felt
raise and lower the rod to reduce friction.
70

Never force the cylinder head to unscrew it as this

might cause it to seize.

Inspection

- De-grease and clean the cylinder interior.

- Carry out a visual inspection of the cylinder body. It should be
free of scrapes, burrs, rust etc.

Re-fitting

- Use a brush to apply hydraulic oil to the piston seals.

- Replace the complete rod in the cylinder body 3 (Fig. A1).
- Take care not to damage the piston seals when taking them
past the thread on the piston body.

NOTE: Tightening the cylinder head is different depending on

if the cylinder body has a flange or not (Fig. A4). Follow
the following instructions.

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Hydraulic control and adjustment

CYLINDER WITHOUT FLANGE

A3
- Apply hydraulic oil to the external sealing rings of the cylinder
Thread head.
Cylinder locking - Apply Loctite 222 thread locking compound (see chapter 6)
head compound
Rod to the cylinder head (Fig. A3).
- Screw the cylinder head on.
- Tighten using a hook wrench and torque wrench (see
torque, Fig. A4) or use the procedure of tightening by angle
(Fig. A4).
- Turn the rod one rotation to ensure the seals are correctly in
place.
Seal
FLANGED CYLINDER

- Apply hydraulic oil to the seals and the thread of the cylinder
head.
- Screw the cylinder head on.
- Tighten using a hook wrench and torque wrench (see
torque, Fig. A4) or use the procedure of tightening by angle
(Fig. A4).
- Turn the rod one rotation to ensure the seals are correctly in
place.

Comments

70
- We recommend testing the cylinder before re-fitting it to the
telehandler.
- Move the rod in and out several times.

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Hydraulic control and adjustment

A4
A4-1
Procedure for tightening the cylinder head using the angle method.

- Tighten the cylinder head until it is in contact with the

cylinder body.
X - Put a mark 1 (Fig. A4-1) on the cylinder body and on the
cylinder head.
- Further tighten the cylinder head over the distance X (Fig. A4-2).
1 - Engage the flange with one of the nocks on the cylinder
1 head.

Tightening torques for cylinder head

flange
70

A4-2
THREAD A Ø BORE B Ø FLANGE C TIGHTENING TORQUE DISTANCE X
M43 x 200 40 51 200 to 250 N.m
M48 x 200 45 56 200 to 250 N.m
M53 x 200 50 61 200 to 250 N.m
M58 x 200 55 66 250 to 300 N.m
M63 x 200 60 72 250 to 300 N.m
M66 x 200 63 75 250 to 300 N.m
M68 x 200 65 78 250 to 300 N.m
M73 x 200 70 82 300 to 350 N.m
M78 x 200 75 89 300 to 350 N.m
M83 x 200 80 94 350 to 400 N.m
M88 x 200 85 99 350 to 400 N.m
M93 x 200 90 107 350 to 400 N.m
M98 x 200 95 109 400 to 450 N.m
M104 x 200 100 119 400 to 450 N.m
M109 x 200 105 124 400 to 450 N.m
M114 x 200 110 129 450 to 500 N.m
M124 x 200 120 139 450 to 500 N.m
M129 x 200 125 139 450 to 500 N.m
M134 x 200 130 149 450 to 500 N.m 8 to 9 mm
140 450 to 500 N.m 8,5 to 9,7 mm
150 450 to 500 N.m 9,2 to 10,5 mm
70-04-M153EN (03/05/2010)
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Hydraulic control and adjustment

3 - DISASSEMBLY AND RE-ASSEMBLY OF PISTON AND CYLINDER HEAD

B1 Dis-assembly
Cylinder head 2
Piston 7
- Place the rod in a vice fitted with soft jaws.
Rod 1 Piston 4 Set
Nut 5 screw 6
- Tighten sufficiently to stop the assembly rotating.
- Loosen the nut 5 (Fig. B1) and completely
unscrew it using a ring spanner. Or, depending
on model, remove the set screw 6 (Fig. 1) with an
Allen key.

NOTE: The set screw 6 (Fig. B1) is fitted with Loctite

and it is locked by striking it with a cold
B2 chisel.
Cylinder head 2
- Dis-assemble the piston 4 (Fig. B2) by pulling it
Rod 1 Piston 4
manually or, depending on model, by unscrewing
the piston 7 (Fig. B1) with a hook wrench.

B3

70
Cylinder head 2 - Remove the cylinder head 2 (Fig. B3) by sliding it
Rod 1
along the rod.

B4
Inspection

Cylinder head 2 - Check the rod for straightness using a dial gauge
Rod 1 along its entire length (Fig. B4).
- Check for flaking, corrosion or scraping on the rod.

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Hydraulic control and adjustment

Re-fitting
B5
- Re-fit the cylinder head 2 (Fig. B5) over the rod 1
Cylinder head 2 (Fig. B5).
- Re-fit the piston 4 (Fig. B1) onto the rod.
Rod 1
- Screw on and tighten the nut 5 (Fig. B1) using a
ring spanner and a torque wrench (Fig. B6). Or,
depending on model, re-screw the piston 7 (Fig. B1)
using a hook wrench (see torque Fig. B6) and secure
it with the set screw 6 (Fig. B1).

NOTE: B6
• The set screw must be secured with Loctite 243,
PISTON TIGHTENING TORQUE see chapter 6.
1400 • Set screw torque = 20 N.m.
1200 • Use a cold chisel to knock the metal back over the
1000
set screw.
Torque (N.m)

800

600

400

200

0
M20 M30 M40 M50 M60 M70
Thread
70

70-04-M153EN (03/05/2010)
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Hydraulic control and adjustment

4 - DIS-ASSEMBLY AND RE-ASSEMBLY OF PISTON SEALS

C1
NOTE:
Sealing rings Never use sharp or cutting tools (screwdrivers, blades etc.)
for fitting or removing seals. It is recommended to work on
workbenches free of swarf.

Dis-assembly

- Remove the piston seals (Fig. C1 or C2).

- Caution, ensure you do not damage the edges or bottom of
the seal grooves.
O-ring
Inspection

C2 - Degrease and clean the piston.

Seal
- Inspect bottoms and sides of the seal grooves for
smoothness and the absence of scrapes.
- The grooves must be clear of foreign bodies.

Re-fitting

- Position the seals as per Fig. C1 or C2.

- When fitting outside seals, expand them sufficiently to slide
them into their grooves, taking care not to break them.
- The inside seal must be fitted by hand.

70
O-ring

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Hydraulic control and adjustment

5 - DIS-ASSEMBLY AND RE-ASSEMBLY OF CYLINDER HEAD SEALS

D1
NOTE:
Anti-extrusion seal 2
O-ring 3 O-ring 1
Never use sharp or cutting tools (screwdrivers, blades etc.)
for fitting or removing seals. It is recommended to work on
workbenches free of swarf.

Dis-assembly

- Remove the seals from the cylinder head.

- Caution, ensure you do not damage the edges or bottom
Oil scraper 4 of the seal grooves.

Rod seal 5 Inspection

- Degrease and clean the cylinder head.

D2 - Inspect bottoms and sides of the seal grooves for
smoothness and the absence of scrapes.
Seal
- The grooves must be clear of foreign bodies.
- Slide the bare cylinder head over and along the piston
rod. Slide it all the way along the rod.
- The clearance should not be too great, but neither should
it jam.

Re-fitting
Plug 1
70

- Place the seals as per Fig. D1. The lips on the rod seal
should face the pressure side.
- When fitting the rod seal, start by engaging it in the
groove while holding it in place, possibly with your
D3 thumb or possibly with a plug 1 (Fig. D2) with no sharp
Drift 2 edges.
- Push it into its groove with the other hand or with a
smooth drift 2 (Fig. D3). If it proves difficult to fit, soak it
in hydraulic oil at 50°C before fitting.

Seal - Fit the oil scraper ring 4 (Fig. D1) using a mallet and a
pad. The O-rings 1 and 3 (Fig. D1) and the anti-extrusion
seal Ref. 2 (Fig. D1) are fitted by hand.

Plug 1

70-04-M153EN (03/05/2010)
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Hydraulic control and adjustment

6 - APPLICATION OF THREAD LOCKING COMPOUND

Characteristics

Loctite 222 low strength threadlocker

Application to cylinder head threads

No activator
Fixture time 10 - 30 min.
Cure time 3 - 6 hours
(Pressurizing the cylinder)
With Loctite N Activator
Fixture time 10 - 20 min.
Cure time 2 - 4 hours
(Pressurizing the cylinder)
Shear strength 1,5 - 4 N/mm2

Loctite 243 medium strength threadlocker

Applied to M8 bolts for securing pistons.

No activator
Fixture time 10 - 20 min.
Cure time 3 - 6 hours
(Pressurizing the cylinder)

70
With Loctite N Activator
Fixture time 5 - 15 min.
Cure time 2 - 4 hours
(Pressurizing the cylinder)
Shear strength 5 - 7,5 N/mm2

Dis-assembly

If parts fitted with threadlocker cannot be undone with normal tools, it is recommended to heat the
threadlocked zone to 250°C. For this a hot air gun is recommended, rather than a gas torch.

Note

If the temperature is close to 0°C when parts are fitted, it is recommended to use Loctite Activator.
This brings with it the added benefit of a reduction in cure time.

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Hydraulic control and adjustment
70

70-04-M153EN (03/05/2010)
 F1
Hydraulic control and adjustment

DIS-ASSEMBLY OF KAPPA HYDRAULIC PUMP

Pages

Dis-assembly of KAPPA main hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3

– 1 - General recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3
– 2 - Kappa 30 load sensing pump - replacement of seals . . . . . . . . . . . . . . . . . F4
– 3 - Main pump diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F12

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(10/09/2010) 70-04-M153EN
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Hydraulic control and adjustment
70

70-04-M153EN (10/09/2010)
 F3
Hydraulic control and adjustment

DIS-ASSEMBLY OF KAPPA MAIN HYDRAULIC PUMP

1 - GENERAL RECOMMENDATIONS

70
Check that components have not been damaged in transit. Always work in a clean environment.
Except for seals, clean all parts with solvent and blow them with clean dry air before re-assembling.
Take care not to damage seals. Avoid any careless handling or other damage to machined surfaces.
Components must be assembled without the use of force. If resistance is encountered, this means
incorrect assembly or the pieces which have been assembled are not perfectly aligned with other
components. If hand pressure is insufficient to completely position a component use a rubber
mallet. Never use a metal mallet or hammer. Be sure to use the correct tightening torques taken
from the values shown in the correct tables.

List of tools:

- Vice
- Special tool for installing the shaft seal
- Vertical press
- Special tool for protecting the shaft seal when fitting the front cover
- Special tool for carrying out pump rotation test after assembly
- Torque wrench
- Oil and grease
- Emery cloth

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Hydraulic control and adjustment

2 - KAPPA 30 LOAD SENSING PUMP - REPLACEMENT OF SEALS

- Fit soft jaws made of aluminum or similar to the vice

in order not to damage the machined surfaces of the
pump.

- Place the pump vertically with the end drive shaft facing
the floor, then tighten the vice. Be sure not to damage
machined parts when tightening.

- Mark the pump with a marker pen to help ensure correct

re-assembly.

- Remove the fixing bolts with a spanner.

70

- Remove the rear cover and the bolts.

- Remove the flexible seal.

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Hydraulic control and adjustment

- Remove the fixing bolts with a spanner.

- Remove the screws.

- Turn the pump round and place it in the vice with the end

70
drive shaft facing the ceiling.

- Remove the front cover with a rubber mallet.

- Mark the thrust plate and the body with a marker pen to
ensure correct re-assembly.

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Hydraulic control and adjustment

- Remove the thrust plate.

- Remove the drive gear and the driven gear.

- Remove the lower thrust plate and mark it and the body
70

with marker pen to ensure correct re-assembly.

- Remove the flexible seal.

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Hydraulic control and adjustment

- Remove the thrust plate and anti-extrusion seals and

replace with new ones, using grease, on both thrust
plates.

- Very carefully place the lower thrust plate in the body

until it is touching the body. The seal must be facing
down.

NOTE: The marker pen mark mad earlier on the thrust

plate and the body will be used at this point to
ensure the thrust plate is re-fitted in the correct
orientation with no possibility of error.

- Engage the drive gear and driven gear in the pump body,

70
until they are resting on the lower thrust plate.

- Take care not to inadvertently swap the gears round. Put

them back in their original positions.

- Very carefully place the upper thrust washer in the

body until it is touching the gears. The seal must face
upwards.

NOTE: The marker pen mark mad earlier on the thrust

plate and the body will be used at this point to
ensure the thrust plate is re-fitted in the correct
orientation with no possibility of error.

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Hydraulic control and adjustment

- Place the cover on the workbench and remove the ring

with pliers.

- Turn the cover over. Remove the shaft seal with a tool.
Take care not to damage machined parts.

- Apply a thin coating of grease to the shaft seal to ease

70

fitting. Now use the special shaft seal fitting tool and
push it into its housing until the ring seat is visible.

- Use pliers to engage the ring.

70-04-M153EN (10/09/2010)
 F9
Hydraulic control and adjustment

- Lubricate the tool for protecting the shaft seal when

fitting the front cover with clean grease or oil and engage
it in the drive gear.

- Fit the front cover without damaging the seal lip, ensuring
the guides are correctly housed.

- Place the pump vertically with the end drive shaft facing
the floor, then tighten the vice. Be sure not to damage
machined parts when tightening.

- Tighten the screws with a torque wrench set to a torque

of 140 N.m. Tighten the screws in diagonal sequence.

- Use grease to put the seal in place.

70
- Place the rear cover in the vice.

- Unscrew the plug with a spanner.

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Hydraulic control and adjustment

- Remove the sealing ring from the plug and fit a

new one.

- Using a torque wrench tighten the spring-carrier plug to

50 N.m.

- Unscrew the plug with a spanner.

70

- Remove the sealing ring from the plug and fit a

new one.

70-04-M153EN (10/09/2010)
 F11
Hydraulic control and adjustment

- Using a torque wrench tighten the plug to 50 N.m.

- Position the pump vertically with the drive shaft facing

downwards, then tighten the vice. Take care not to
damage the machined parts when tightening.

- Assemble by hand-tightening screws.

NOTE: The mark made earlier on the pump body and cover
will be used to ensure error-free assembly.

- Use a torque wrench to tighten the screws to a torque of

70
70 N.m, using a diagonal tightening sequence.

- Check the rotational torque by turning the drive gear,

ensuring that it moves freely and that no mistakes have
been made when assembling.

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Hydraulic control and adjustment

3 - MAIN PUMP DIAGRAM

1 – Plug
2 – Cup
3 – Reducer
4 – Valve spring
5 – Drive gear
6 – Cover
7 – Circlip
8 – Shaft seal
9 – Ring
10 – O-ring
11 – Thrust plate
12 – Driven gear
13 – O-ring
14 – Anti-extrusion ring
15 – Body
16 – Rear cover
17 – Screw
18 – Washer
19 – Screw
70

20 – Washer
21 – Sleeve
23 – Plug
24 – Screw
25 – O-ring
26 – Filter
27 – Plug
28 – Reducer
29 – Spool
30 – O-ring

70-04-M153EN (10/09/2010)
 G1
Hydraulic control and adjustment

DIS-ASSEMBLY OF THE AA10VO HYDRAULIC PUMP

Pages

Dis-assembly of the AA10VO main hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . G3

– 1 - Dis-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3
– 2 - Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G8

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Hydraulic control and adjustment
70

70-04-M153EN (10/09/2010)
 G3
Hydraulic control and adjustment

DIS-ASSEMBLY OF THE AA10VO MAIN HYDRAULIC PUMP

1 - DIS-ASSEMBLY

70
- Remove the regulator.

When re-assembling, ensure the regulator adjustable

throttle is correctly oriented, with the slot aligned
with the oil circulation drillings.

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Hydraulic control and adjustment

- Position the pump vertically.

- Take a note of its position and remove the end cover.

- Remove the end cover, keeping the port plate in

position.

- Remove the sealing rings.

70

- Remove the taper roller bearing at the end of the shaft.

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Hydraulic control and adjustment

- Remove the shim.

- Place the pump horizontally.

- Remove the rotating group while keeping the pistons
and support plate in place.

- Remove the control piston end stop.

70
- Remove the piston from the control cylinder.
- Swivel the swashplate to facilitate the removal of the
piston.

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Hydraulic control and adjustment

- Remove the control piston rod.

NOTE: As the head of the rod has a particular shape, it

may be necessary to manoeuver the swashplate
to remove the rod.

- Remove the swashplate.

- Remove the swashplate return spring.

70

- Remove the gear shaft and lower bearing assembly.

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Hydraulic control and adjustment

- Remove the swashplate shell bearings.

Grub
screws

- Remove the end circlip.

- Screw self-tapping screws through the shaft seal

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recess.
- Remove the shaft seal by pulling on the screws using
pliers.

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Hydraulic control and adjustment

2 - RE-FITTING

- Carry out the operations described above in reverse

order, incorporating the instructions given below:

- Use a spacer to fit a new shaft seal.

- Refit the end circlip.

- Ensure the port plate (cut-out) lines up correctly with the

end cover (tongue).

Cut-out
Tongue
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- Carefully reposition the end cover seal.

- If the end cover position was not marked at the time of

dis-assembly, use the oil circulation drillings to correctly
align the end cover with the pump body.

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Hydraulic control and adjustment

- Ensure the control piston rod correctly engages in its

housing on the swashplate. Swivel the swashplate to
ensure the rod is correctly located.

- Bearing pre-load: This must be 0 to 0,05 mm.

- Use the shim 1 to ensure correct adjustment.

Fill the pump body with hydraulic oil after work is

done on it.

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Hydraulic control and adjustment

STANDARD TIGHTENING TORQUE TO BE USED WHEN NOT SPECIFICALLY MENTIONED IN

REMOVAL AND RE-FITTING PROCEDURES.

TIGHTENING TORQUE IN N.m (*)

Thread Class 5.6 Class 5.8 Class 8.8 Class 10.9 Class 12.9
diameter
M3 0,54 0,76 1,16 1,7 2
M4 1,24 1,74 2,66 3,91 4,57
M5 2,47 3,46 5,2 7,7 9
M6 4,29 6 9,1 13,4 15,7
M8 10,4 14,6 22 32 38
M10 20 28 44 64 75
M12 35 49 76 111 130
M14 57 79 121 178 209
M16 88 124 189 278 325
M18 122 171 261 384 449
M20 173 243 370 544 637
M22 238 334 509 748 875
M24 298 418 637 936 1095
M27 442 619 944 1386 1622
M30 600 840 1280 1880 2200

(*) - Tightening torques are given for black or zinc-plated fasteners with light lubrication.
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- Tightening torques are given for automatic slip and reset torque wrenches and direct read
dial torque wrenches.
- For more information consult French Standard NF E25-030.

DSR Valve

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 HYDRAULIC SPECIFIC TOOLING

pages

BASIC MANOMETER BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

DIGITAL MANOMETER BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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BASIC MANOMETER BOX

This box contains all the components required for

measuring pressure on all Manitou products.

1 2 3 3 4 5 5 6
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8 7

Basic manometer box .................................................................................549671

Consisting of:

1. 1 Manometer 1/9 bar ..............................................................549882

2. 1 Manometer 0/40 bar ............................................................549883
3. 2 Manometers 0/60 bar ..........................................................549884
4. 1 Manometer 0/400 bar ..........................................................549885
5. 2 Manometers 0/600 bar ........................................................549886
6. 4 Standard hoses ....................................................................549887
7. 2 Hoses for Maniscopic ...........................................................549888
8. 7 Manometer ports ..................................................................549889

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DIGITAL MANOMETER BOX

FUNCTIONS:

• Mano Function: the following combinations can be

displayed:

- Temperature upstream to +/- 2°C

- Pressure upstream P1 with its min. and max. (700 bar
in class 0.1)
- Pressure downstream P2 with its min. and max. (700
bar in class 0.1)
- Differential pressure dP=P1-P

• Hold Function: the operator is able to freeze the display

panel so that he can take notes whenever he wishes

• Unit Function: the operator can change the measurement

unit whenever he wishes (bar, psi, kPa, mCe).

• Tare Function: enables offset to zero

• Leakage test Function: enables the pressure variation to

be measured over a programmed time period

• Recording Function: A max. of 16000 values may be

recorded. The sampling period can be configured.

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• Zero Function: zero is carried out on 2 sensors

Digital Manometer box ...............................................................................662187

Consisting of:

1. 1 dP HP 700 bar Mano digital manometer

2. 1 measurement hose DN2 1215/1620, L = 1,5m, 630 bar
3. 2 measurement hoses DN2 1620/1620, L = 1,5m, 630 bar
4. 2 1620 Manometer adaptors

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70-09-M153EN (11/05/2011)